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BACKGROUND OF THE INVENTION
[0001] The present invention relates to precision approach path indicator systems (PAPIS) used in airports to provide approach slope guidance for aircraft approaching an airport runway, and light assemblies useful in such systems. More particularly, the present invention relates to PAPIs and light assemblies for use therein which provide substantial and important advantages and/or benefits relative to the prior art systems and assemblies.
[0002] Precision approach path indicator systems (PAPIs) are known airport lighting aids. As commonly employed, PAPIs use a single row of either two or four light units including halogen or similar lamps. The row of either two or four identical light units is placed on one side of the runway in a line perpendicular to the runway centerline to define the visual glide path angle. The light units each have a white segment in an upper part of the beam and red segment in a lower part of the beam separated by a pink transition zone. In the two-light system, for example, a Type L-881 system, the lights are positioned and aimed to produce a signal presentation wherein a pilot on or close to the established approach path sees the light unit nearest the runway as red and the other light unit as white. When above the approach path the pilot sees both light units as white; and when below the approach path the pilot sees both light units as red.
[0003] In the four-light system, for example, Type L-880, PAPI system, the signal presentation is such that a pilot on or close to the established approach path sees the two light units nearest the runway as red and the two light units farthest from the runway as white. When above the approach path the pilot sees the light unit nearest the runway as red and the three light units farthest from the runway as white; and when further above the approach path the pilot sees all the light units as white. When below the approach path the pilot sees the three light units nearest the runway as red and the light unit farthest from the runway as white; and when further below the approach path the pilot sees all light units as red.
[0004] The visual glide path angle provided by the PAPI is the center of the on-course zone, and is normally 3degrees (of an arc) when measured from the horizontal, but may vary, for example, if jet aircraft are supported by the airport, if obstacles to flight are located at the airport, or if elevated terrain affects the approach to the airport. Other considerations in siting the PAPIs indicator lights include whether the terrain drops off rapidly near the approach threshold, and whether severe turbulence is experienced on approach. On short runways, the PAPI system indicator lights are located as near the threshold as possible to provide the maximum amount of runway for braking after landing. Thus, the PAPI system indicator lights are often positioned and aimed to produce a minimum Threshold Crossing Height (TCH), which is the height of the lowest on-course signal at a point directly above the intersection of the runway centerline and the threshold, and clearance over obstacles in the approach area.
[0005] PAPIs are very useful in providing approach slope guidance to aircraft approaching an airport. However, certain problems do exist. For example, the halogen or similar lamps used in the prior art PAPIs are relatively costly to operate and, in addition, have a relatively limited useful life. Although the lighting assemblies of such PAPIs are structured to facilitate relatively rapid lamp replacement, the cost of maintenance, particularly the cost and inconvenience of closing an airport runway in order to change lamps, represents a significant disadvantage to using such PAPIs. In addition, since providing accurate approach path guidance is very important in maintaining the safety of airport operation, lamps which become ineffective after relatively short periods of operation, even if they are relatively easy to replace, can create a significant detriment to airport safety.
[0006] There is a need for new PAPIs, for example. new PAPIs which address one or more of the problems or disadvantages of the prior art PAPIs.
Summary of the Invention
[0007] New precision approach path indicator systems or PAPIs and new light assemblies useful in PAPIs have been discovered. The new PAPIs and light assemblies are relatively straightforward in construction; and meet or exceed substantially all the regulatory requirements and specifications, for example, imposed by the U.S. Federal Aviation Administration (FAA), on the operation and structure of PAPIs and light assemblies used therein. Moreover and advantageously, the present PAPIs and light assemblies are less costly to install and/or operate and/or maintain relative to the prior art PAPIs, and/or are more reliable in operation relative to the prior art PAPIs.
[0008] In one broad aspect of the present invention, precision approach path indicator systems (PAPIs) effective in providing approach slope guidance for aircraft approaching an airport runway are provided. Such PAPIs comprise a plurality of light assemblies positioned on or in proximity to an airport runway and structured or configured to be effective in providing approach slope guidance light signals to a pilot of an aircraft approaching a runway. In a preferred embodiment of the invention, each light assembly includes a first and second light source; particularly preferably such light source comprises light emitting diodes (LEDs), for example, at least one first LED and at least one second LED, such as a first array of LEDs and a second array of LEDs. The first array of LEDs includes at least one first LED, and preferably a plurality of first LEDs. Similarly, the second array of LEDs includes at least one second LED, preferably a plurality of second LEDs. As indicated above, the present invention contemplates the use of light sources, and assemblies comprising light sources, other than LEDs that share one or more of the advantages thereof: for example, without limitation, a low power requirement (thus resulting in reduced costs of operation); high efficiency conversion of electric to radiant energy; and long and reliable operation with minimal maintenance.
[0009] The present PAPIs may be advantageously located and used in substantial accordance with the procedures used to locate and use the prior art PAPIs, for example as described elsewhere herein and/or is commonly understood by those of ordinary skill in the art. Importantly, in a preferred embodiment the present PAPIs include light assemblies comprising LEDs. Such LEDs are very effective in providing the required light for operation of the present PAPIs in a cost effective and reliable manner. In particular, PAPIs and light assemblies that include LED-containing and similar light sources may often be operated at reduced cost and/or increased reliability relative to the halogen lamps employed in prior art PAPIS, for example, PAPIs including halogen lamps.
[0010] In a further broad preferred aspect of the present invention, assemblies, for example light assemblies for use in an airport approach path indicator system, for example, the present PAPIs, are provided. Such light assemblies comprise a mirror component including first and second, preferably substantially planar, mirrored surfaces positioned to meet at an angle of about 90°. In this preferred embodiment, first and second spaced apart light emitting diodes (LEDs) are located so that the at least one first LED emits light reflected by the first mirrored surface and the at least one second LED emits light reflected by the second mirrored surface. A projection lens is provided and is positioned to allow light reflected by the first and second mirrored surfaces to pass therethrough.
[0011] It will be apparent to one of ordinary skill in the art that the mirrored surfaces, while preferably substantially planar, may be somewhat curved in certain embodiments of the present invention. For a single element projection lens, the best focus occurs on a curved surface; thus in such other embodiments of the invention the mirrored surfaces may have a slight curve.
[0012] In addition, while the preferred embodiment comprises mirrored surfaces positioned at angles of about 90° to each other, those of ordinary skill in the art will appreciate that any geometry in which light from the first and second light source is reflected from the first and second mirrored surfaces, respectively, toward the projection lens is within the ambit of the present invention so long as substantially no light from the first light source is reflected from the second mirrored surface toward the projection lens, or vice versa.
[0013] The first and second mirrored surfaces preferably meet at a substantially straight edge. The mirror component is advantageously positioned relative to the first and second LEDs so that the first mirrored surface and the second mirrored surface reflects light emitted from substantially only the first LED or LEDs and the second LED or LEDs, respectively. It is possible to make a PAPI device according to the present invention such that substantially all the light emitted by the one or more light source located near each of the mirrored surfaces is reflected by that mirrored surface, with little if any light missing the mirrored surface. However, to make such a device would require quite high tolerances. In other embodiments, a portion of the light emitted by said one or more light source may be directed past the mirror without being reflected thereby into the projection lens. It is preferably that the amount of such light be minimized.
[0014] A “substantially straight edge” includes an edge that is substantially perpendicular to the direction of the light reflected toward the projection lens. In one embodiment of the present invention, the intersection of the two mirrored surfaces may form a somewhat curved or rounded edge rather than a sharp edge.
[0015] In one embodiment, the mirror component is positioned relative to the first and second light sources so that light emitted by the first light source or assembly contacts the first mirrored surface at an angle of about 45° relative to the first mirrored surface, and light emitted from the second light source or assembly contacts the second mirrored surface at an angle of about 45° relative to the second mirrored surface. Preferably the light source or assemblies comprise one or more LED, more particularly a plurality of LEDs.
[0016] A substantially sharp angular cutoff between the light projected from the first and second mirrored surfaces may be created when the substantially straight edge is placed proximal to the focal plane of the projection lens such that the first light source illuminates a portion of the first mirrored surface that includes the substantially straight edge, and the second light source illuminates a portion of the second mirrored surface that includes the substantially straight edge. When the substantially straight edge is placed proximal to the focal plane of the projection lens there is preferably a sharp angular transition between the light projected form the first light source and the second light source.
[0017] As noted above, the first and second mirrored surfaces of the present light assemblies preferably are substantially planar. In certain prior art PAPIs, hyperbolic mirrors are employed to reflect light from halogen and similar lamps. Hyperbolic mirrors are, by definition, not planar. In the present preferred light assemblies, it is substantially advantageous that the first and second mirror surfaces be substantially planar, for example, to aid in providing the desired orientation of the light passing through the projections lamps.
[0018] When the present invention comprises the use of light emitting diodes, at least one and preferably each of such LEDs in each of the arrays of LEDs preferably is equipped with a collimating optic. In a particularly preferred embodiment of the invention the LEDs are equipped with an encapsulated optic. By encapsulated optic is meant an assembly that collects as much light as is practical or necessary from the source and typically at least partially surrounds and covers the light source. In the present invention the preferred embodiment for an encapsulated optic is a catadioptric optic utilizing refractive and internal reflecting surfaces.
[0019] Light from the encapsulated optic reflects off the mirror and passes through the image plane of the projection lens. The encapsulated optic collects as much light as possible while maintaining Etendue efficiency and minimum encapsulated optic diameter. Etendue efficiency determines how much light fills the aperture of the projection lens (for a given lens diameter). The minimum optic diameter determines how closely the encapsulating optics are placed together. This is preferably considered particularly carefully in the high intensity zone, because enough light must pass through the image plane in the center to meet optimal PAPI intensity requirements. Like the collimating optics the encapsulated optic may be optimized. Such LEDs with collimating optics are well known and are commercially available. The use of LEDs with collimating optics is advantageous in that the light emitted by the LED is focused toward the mirror component so that a substantial portion, for example a major portion, that is at least about 50%, or even substantially all, of the light emitted by the LED is focused toward the mirror component.
[0020] The at least one first LED or the first array of LEDs advantageously emits light having a first color, for example, the first color may be white, and the at least one second LED or the second array of LEDs emits light having a second color different from the first color, for example, the second color may be red. The first and second colors being white and red, respectively, is very advantageous in that such colors facilitate employing the present PAPIs in place of prior art PAPIs without substantial re-education of the airport staff or pilots.
[0021] The number of LEDs that may be included in each first array of LEDs and second array of LEDs may be any suitable number effective to provide the desired light signals. As noted elsewhere herein, an array of LEDs includes at least one LED. In one embodiment, the first and second arrays of LEDs each include a number of LEDs in a range of about 2 to about 60 or more. The brightness obtainable from individual LEDs has continually increased in the past up to the present time. If this brightness trend continues the number of LEDs in each of the first and second arrays may be reduced. Light assemblies including a single first LED and/or a single second LED are within the scope of the present invention.
[0022] The present light assemblies preferably further comprise a spreader lens. A spreader can be placed on the other side of the lens or even comprise a part of the projection lens, however in a preferred embodiment the spreader is positioned so that light reflected by the first and second mirrored surfaces passes through the spreader lens prior to passing through the projection lens. The spreader redirects light in the horizontal direction to conform with intensity and distribution requirements. The spreader permits the pilot to see the PAPI when the airplane is “off axis” in the horizontal direction. The spreader lens may also be effective in diffusing the individual, relatively focused beams of light emitted from the first and second arrays of LEDs (or other similar light sources) (each array including a plurality of LEDs). Again, this feature facilitates the replacement of the prior art PAPIs with the present PAPIs with a minimum of disruption to the operation of the airport and the safety of the aircraft landing there.
[0023] The present light assemblies advantageously further comprise a housing sized and structured to at least partially contain the first and second light sources (preferably LEDs), the mirror component and the projection lens. It is important that the projection lens be located relative to the housing so that light passing from the mirror component through the projection lens can be seen by pilots and/or other aircraft crew members, as needed to receive the approach slope guidance offered by the present PAPIs.
[0024] In one embodiment, the present light assemblies further comprise an angle adjustment subassembly operatively coupled to the housing and structured to maintain, and preferably adjust, the housing at or to a desired angular orientation relative to* horizontal. Various angle adjustment assemblies are conventional and/or well known and/or currently employed in the prior art PAPIs and such prior art angle adjustment subassemblies may be employed in the present light assemblies.
[0025] The projection lens of the present light assemblies may be of any suitable configuration effective in providing the desired slope approach guidance. In one useful embodiment, the projection lens is a plano convex lens, preferably such a lens with the convex surface facing away from the mirror component.
[0026] The present PAPIs advantageously include a plurality of the present light assemblies as described herein. The plurality of assemblies is advantageously positioned to allow a single human observer to see the projection lens, or at least light passing through the projection lens, of each of the assemblies at the same time. In one embodiment, the plurality of assemblies is positioned so that the projection lens of each of the assemblies faces in substantially the same direction. The projection lenses of different light assemblies may be located at different angles from each other relative to horizontal. The plurality of light assemblies may include at least two assemblies positioned at different angles relative to horizontal. For example, in two-light PAPIs the two light assemblies are positioned at different angles relative to the horizontal to provide slope approach path guidance.
[0027] In other embodiments, the plurality of assemblies includes at least three of the assemblies or four assemblies positioned at different angles relative to horizontal. For example, in a four-light PAPI system, all four of the light assemblies are positioned at different angles relative to the horizontal. For example, each of the light assemblies may be positioned about 20 minutes or about one third of a degree (of an arc) from the next light assembly. This is in line with conventional or common practice used with currently used PAPIs and again is designed to allow the use of the present PAPIs in place of the currently used or prior art PAPIs with little or no disruption in operation or safety of the airport.
[0028] In certain instances, the plurality of assemblies include two or three or more assemblies positioned at substantially the same angle relative to horizontal. For example, in order to more clearly identify the signal or information desired to be given, two, three or more assemblies located in close proximity to each other at substantially the same angle relative to horizontal may be employed to provide that signal or information.
[0029] As with the current PAPIs the present PAPIs are advantageously positioned on or in proximity to an airport runway. Advantageously, the PAPIs are positioned in substantially identical positions as the currently used PAPIs. Such placement facilitates the present PAPIs being employed with little or no disruption to airport operation and safety.
[0030] Each and every feature described herein, and each and every combination of two or more of such features, is included within the scope of the present invention provided that the features included in such a combination are not mutually inconsistent.
[0031] These and other aspects and advantages of the present invention are apparent in the following detailed description, claims and drawings in which like parts bear like reference numerals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIGS. 1 ( a ), 1 ( b ), 1 ( c ) and 1 ( d ) are somewhat schematic views of various components of an embodiment of a light assembly embodiment in accordance with the present invention.
[0033] FIG. 2 is a perspective view of certain components of a light assembly in accordance with the present invention.
DETAILED DESCRIPTION
[0034] Referring now to FIGS. 1 ( a )- 1 ( d ), a light assembly, shown generally at 10 includes a housing 12 which contains a mirror component 14 , a first array 16 of white LEDs with encapsulated optics, a second array 18 of red LEDS with encapsulated optics, a horizontal spreader lens 20 and a projection lens 22 . The forward end of the housing 12 is structured, for example, is transparent (preferably clear) or cut away, to allow light passing through the projection lens 22 from inside the housing to be seen from an appropriate distance, for example, in a range of about 5 miles to about 20 miles or more, away from assembly 10 , for example, by a pilot in an aircraft approaching an airport for landing.
[0035] Each individual white LED 24 includes a collimating or encapsulating optic 26 . Similarly, each individual red LED 28 includes a collimating or encapsulating optic 30 . Such collimating or encapsulating optics 26 , 30 are effective to provide a substantially focused beam of light from each of the LEDs 24 , 28 . LEDs with collimating optics are custom, while encapsulated optics may be readily fabricated, and such LEDs may be used in the present light assemblies.
[0036] The present light assembly 10 advantageously is structured to meet the requirements of aviation red. Such light assembly is structured to make effective and efficient use of LEDs.
[0037] The first array 16 of white LEDs 24 and the second array 18 of red LEDs 28 project white light and red light, respectively, onto mirror component 14 . Mirror component 14 includes a first, substantially planar mirrored surface 32 and a second, substantially planar surface 34 which are disposed at an angle of 90° relative to each other and meet at a straight line edge 36 . The light assembly 10 preferably is configured and/or structured so that light from the first array 16 of LEDs does not project onto second mirrored surface 34 , and light from the second array 18 of LEDs does not project onto first mirrored surface 32 . Advantageously, the first and second array of LEDs 16 and 18 are positioned within housing 12 at an angle of about 45° relative to the first and second mirrored surfaces 32 and 34 .
[0038] The straight line edge 36 of the mirror component 14 lies in a plane which is also located at an angle of 45° relative to the first and second mirrored surfaces 32 and 34 . Such plane, shown as 38 in FIG. 1 ( d ), is the plane which is imaged by the projection lens 22 .
[0039] The mirrored component 14 is structured to allow or provide for a substantially sharp transition between the red and white light with the peak power at the cutoff line.
[0040] White and red light from first and second arrays 16 and 18 of LEDs, respectively, are projected onto first and second mirrored surfaces 32 and 34 , respectively, and are reflected off such mirrored surfaces and travel to spreader lens 20 which is located just behind (or posterior of) projection lens 22 . Spreader lens 20 is structured and effective in spreading light in the horizontal direction. In the absence of the spreader lens 20 , the intensity or light pattern eminating from the projection lens 22 has a series of hot and cold spots corresponding to the spaced apart configuration of the first and second arrays 16 and 18 of LEDs.
[0041] After passing through, and being horizontally spread by, the spreader lens 20 , the reflected light than passes through the projection lens 20 . Advantageously, the projection lens 20 is a plano-convex lens with the convex surface 40 facing away from the mirror component 14 .
[0042] The mirror component 14 can be made from readily available materials. Advantageously, the first and second mirrored surfaces 32 and 34 are highly polished and/or otherwise structured and/or treated to enhance the ability of such surfaces to reflect light. Such enhanced reflectability, for example, relative to substantially identical mirrored surfaces without being highly polished and/or otherwise structured and/or treated, facilitates enhanced performance benefits for the present light assemblies and PAPIs.
[0043] The spreader lens 20 is fabricated and, projection lens 22 is commercially available and/or well known in the art.
[0044] The present light assembly 10 is structured to meet the requirement for translation from red to white, such requirements being red to white transition within 3minutes of arc at beam center and 5 minutes of arc at beam edges and meet the requirement for light beam parallel to zero aiming angle of 35 5 minutes of arc.
[0045] FIG. 2 shows a prototype of certain components of light assembly 10 . In particular, light assembly 10 as shown in FIG. 2 does not include a portion of the housing, in order to more clearly show other components of the assembly. The spreader lens 20 and projection lens 22 are shown in the foreground of FIG. 2 , secured to frame member 46 of housing element 48 . Located in the background of FIG. 2 is mirror component 14 including mirrored surfaces 32 and 34 and straight line edge 36 . A reflection of the first array 16 of LEDs is seen in first mirrored surface 32 , and a reflection of second array 18 of LEDs is seen in second mirrored surface 34 .
[0046] The first array 16 of LEDs is located in top member 50 and the second array 18 of LEDs is located in bottom member 52 . Top member 50 and bottom member 52 are secured to the housing and hold the LEDs in fixed positions. A bottom platform member 56 is provided and is structured to be oriented at one of various angles relative to horizontal, for example, using any one of a number of conventional angular adjustment structures to properly align the angle of the assembly 10 relative to horizontal as desired to be effective in a PAPIs including a plurality of such assemblies.
[0047] Each of the light assemblies and the PAPIs of the present invention include additional components, for example, electrical components, such as power sources, wiring, regulators, switches, etc., which are conventionally employed to provide for proper functioning of equipment including the preferred LEDs.
[0048] Since such additional components are conventional and/or well known in the art to be useful to provide such proper functioning, no detailed description of such additional components is presented here, it being understood that such additional components and the description thereof are well within the ordinary skill of the art.
[0049] To maintain a consistent luminous output and insure high lumen maintenance from the light sources in the present light assemblies, a constant current source advantageously is employed to drive such light sources. This is particularly useful when using Pulse Width Modulation (PWM) to dim the light sources (e.g., LEDs). To achieve low parts count and high efficiency, two switched mode buck regulators are employed in each light assembly 10 to drive each array of red and white LEDs. The buck regulators allow an external control source to modify the duty-cycle of the PWM so that dimming is easily achieved. The high voltage DC required to drive the large number of series LEDs can be derived from incoming 240 Vac system power.
[0050] While this invention has been described with respect to various specific examples and embodiments, it is to be understood that the invention is not limited thereto and that it can be variously practiced within the scope of the following claims.
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Precision approach path indicator systems (PAPIs) effective in providing approach slope guidance for aircraft approaching an airport runway are provided. Such PAPIs include a plurality of light assemblies positioned on or in proximity to an airport runway and structured or configured to be effective in providing approach slope guidance light signals to a pilot of an aircraft approaching a runway. Each light assembly includes a light source comprising light emitting diodes (LEDs), preferably a first array of LEDs and a second array of LEDs.
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BACKGROUND AND SUMMARY OF THE INVENTION
[0001] Despite great strides in cell culture technology and in the medical profession's ability to isolate stem cells and manipulate them to differentiate into various cell types, accomplishments in the field of tissue engineering solid organs remain limited.
[0002] This is because in addition to being a collection of specialized cells, a functional tissue engineered organ is generally thought to necessarily be capable to fulfill the following requirements:
[0003] 1. Contain a scaffold within which the cells reside and organize themselves in the specific three dimensional architectural arrangement required for the organ to function. This scaffold is known in the art as the stromal component of the tissue.
[0004] 2. Ensure that each individual cell in the organ remains within very close proximity to a capillary blood vessel that can supply it with the necessary nutrients. For this to happen, the construct needs to have a dense three-dimensional vascular network of blood vessels and capillaries.
[0005] 3. Be able to connect this capillary network to the systemic circulation.
[0006] These three requirements constitute what is known in the art as the “Holy Grail” of tissue engineering. However, building in the laboratory a stromal scaffold with a functional capillary circulation connected to the arterial and venous circulation of the recipient remains an elusive goal.
[0007] Without a functional internal capillary network, current tissue engineered organs are generally limited to one or two cell layered constructs such as skin, cornea, blood vessels, and most recently urethras. The cells in these tissue engineered organs are generally not more than 1-2 millimeters away from the recipient circulation such that nutrients can reach them by diffusion from the nearby endogenous capillaries of the recipient.
[0008] One known technique used to obtain the expansion of breast tissue without prosthesis implant, is called lipofilling and envisages the graft of adipose tissue (properly treated) into the breast that is to be expanded. The adipose tissue, after a suitable period (some weeks), gives mature fat cells fully integrated into the pre-existing tissue and makes the expansion of the breast essentially complete to result in a breast augmentation or a breast reconstruction in the case of a mastectomy. Even if the basic mechanism is not completely clear, it is supposed that such fat cells come from the transformation of mesenchymal stem cells present in the treated adipose tissue, favoured by the particular environmental conditions in which they are. (see G. Rigotti, A. Marchi, M. Galie, G. Baroni, D. Benati, M. Krampera, A. Pasini and A. Sbarbati (2007) “ Clinical treatment of radiotherapy tissue damages by lipoaspiratres transplant: a healing process mediated by adipose derived adult stem cells ”. Plast Recon Surg. 119(5):1409-22; Rigotti G, Marchi A, Baroni G, Sbarbati A, Delay E, Rietjens M, Coleman SR (2010) “ Far grafting to the breast: aesthetic and reconstructive applications ” In ed. Jones GE. Bostwick's Plastic and Reconstructive Breast Surgery, Third Edition, Quality Medical Publishing, 2010, pp 251-293; e Rigotti G, Marchi A, Sbarbati A “Adipose-derived mesenchymal stem cells: past, present and future” Aesthetic Plast Surg. 2009 May; 33(3):271-3. Epub 2009 Apr. 21. PMID: 19381713 [PubMed—indexed for MEDLINE].
[0009] The treatment of the adipose tissue to be grafted in the involved body region is a known technique: the tissue fat is centrifuged and the fraction containing the vascular-stromal component is actually grafted. Alternatively, the fat harvested by liposuction can be allowed to sediment and the entire supernatant fat suspension used as the grafting material. This approach has several advantages, particularly when the graft is autologous, that is when the fat is taken from another body area of the patient. This technique makes it possible to obtain the elimination of any problem of rejection. In addition, other problems related to the use of prostheses are avoided, such as the risk of failure of the implant (breakage or other). Besides these advantages, the technique of lipofilling (that is the grafting of fat) has, however, some drawbacks, including the fact that the newly grafted fat tissue, before giving mature adipocytes well integrated into the surrounding tissue, may be at least partially absorbed into the body, reducing the effectiveness of the tissue expansion induced by the graft.
[0010] The inventors observed that this phenomenon is facilitated by the natural tendency of the expanded tissues to contract elastically to recover their original condition and therefore, have understood the need to support adequately the expanded body region in order to keep it in shape for the time necessary for the grafted adipose tissue to give rise to mature fat cells, that have stably taken root on the pre-existing tissue.
[0011] The invention as disclosed herein comprises a method of tissue engineering which is a radical departure from the prevailing wisdom in the art of trying to build an organ ex-vivo, in the laboratory (or in what is commonly referred to a tissue reactor), and then transplant it to the needy host. Also disclosed are several devices for achieving this method. The invention finds as one of its main applications in plastic and reconstructive surgery, in particular in the treatments necessary to achieve an increase in the volume of human breast, for example in mammary reconstruction and augmentation mastoplasty, although the invention has broader applications as well and should not be considered as limited thereto. For example, the method and devices disclosed herein also have application in the treatment of body contour defects, whether from scaring or congenital abnormality. Another application is in the expansion of solid organs as the expansion generates the scaffold or stromal component and the grafting provides the necessary cellular complement (whether obtained by liposuction or other harvesting and tissue culturing methods) required to regenerate the organ.
[0012] Previously disclosed in several of a co-inventor's earlier issued patents is a novel method and devices for performing the method of tissue engineering whereby the host organism is induced to generate in-situ this vascular stromal scaffold. As this vascular scaffold grows, it induces new blood vessel formation (neoangiogenesis) and derives its additional circulation from the host. MRI angiograms demonstrate that this method accomplished this tissue engineering crucial effect. This is disclosed and claimed in any one or more of one of the co-inventor's issued U.S. Pat. Nos. 5,536,233; 5,662,583; 5,676,634; 5,695,445; 6,083,912; 6,500,112; 6,514,200; 6,641,527; 6,699,176; 6,730,024; and 6,296,667, the disclosures of which are incorporated herein by reference.
[0013] External expansion as disclosed and claimed in these earlier patents achieved this effect by applying an external or “dynamic” orthogonal outward distractive pull against the surface of the tissues targeted to grow. The preferred methods and devices for achieving this external force application at the time was disclosed and claimed in the co-inventor's previous patents mentioned above, which are presently being successfully commercialized as the Brava Bra® device. At present, to the inventors' knowledge, this device is the only FDA reviewed external three dimensional tissue expander on the market. The Brava® device applies an external distractive pull on the outer surface of the targeted soft tissues by means of a controlled and continuous, relatively low, vacuum pressure. Although modifications of the vacuum pressure and intermittent cycling of the pressure to higher levels that cannot be tolerated for long periods was found to be a more effective method of expanding the organ.
[0014] Vacuum applies an isotropic force on the surface of the tissue, and its outward pull can be controlled through regulating the amount of negative pressure maintained in the dome shell. However, applying constant vacuum over complex and naturally moving surfaces is a challenge and the necessary device, while comfortable enough to achieve commercial success, is necessarily more cumbersome and difficult to wear and, while the inventors are unaware of any serious issues caused directly or indirectly by the use of this device, it must be acknowledged that it may, if not properly administered in accordance with the recommended regimen, exhibit a risk of problems for internal organs and for the surface upon which the device is applied.
[0015] Alternative means of applying a distractive force on an external organ such as the breast is to mechanically pull on the skin surface by pulling on an intermediate layer mechanically secured to the skin by means of an adhesive, or surface tension or sutures, or other mechanical fastening devices. Various examples of these devices may be found in the co-inventor's patents mentioned above.
[0016] In a presently pending U.S. patent application Ser. No. 12/298,011 filed Jul. 24, 2009 with a priority claim to Ser. No. 11/409,294 filed Apr. 21, 2006, the disclosures of both of which are incorporated herein by reference, there is a method disclosed for generating a tissue scaffold with external expansion by applying a vacuum followed by seeding the tissue scaffold with a suspension of fat cells obtained by liposuction and holding the enlarged expanded grafted space open to allow for successful engraftment. Also disclosed is the step of after injecting an expanded scaffold with more liposuctioned fluid volume, maintaining that further enlarged state for a certain period of time so that as the tension dissipates, the tissues stabilize and the graft revascularizes and survives.
[0017] Disclosed also is that to achieve this desired effect a Brava® bra-like external expander device could be used, or alternatively, a splint, bandage or other immobilizing device (hereinafter “splint” or “stent”) could be applied that conformed to the new enlarged shape, adhered to the skin and was rigid enough to prevent any significant recoil, collapse or loss of the surgically engrafted expansion for a period of time.
[0018] As the inventors have continued their inventive activity during the course of their surgical practice, they have discovered that a splint or stent was more comfortable to wear than the Brava® device. Furthermore, compared to the Brava® device where wearing of the larger than ordinary bra was required for hours at a time, which translated to less than desirable patient compliance, a splint which is less cumbersome and more comfortable to the skin resolves the very important patient compliance issue.
[0019] As the patient's expanded scaffold is engrafted with “dilute lipoaspirate”, the injected volume further enlarges the organ (the breast) and holds it in this enlarged state by means of an adhered, at least semi-rigid, splint that prevents recoil, this method not only helps the engraftment process, but can also cause further expansion.
[0020] As the procedure has been refined, more and more dilute lipoaspirate (more fluid, less fat cells) can be injected and more grafting sessions that were smaller in extent (less liposuction required) have been used. In between the grafting sessions, the semi-rigid conforming adherent splint is more comfortable, less discernible to others, and hence more likely to be worn than the Brava Bra® device. With this improved method, the need for using the Brava external expansion device between grafting sessions has been obviated, having been replaced by the less intrusive splint.
[0021] In further refining the procedure, to cause the organ to swell, instead of pulling on the outside for a long sustained period of time as originally performed with the external expander devices, physiologic fluid was injected inside the organ alone, without cells. The injection caused significant swelling and was limited by the internal tension inside the organ. In essence, injecting the breast with fluid produced the same effect as the external expander, i.e. tension in the breast. Left alone, the injected fluid would be expected to be rapidly reabsorbed by the body thereby simply reversing the expansion and reducing the swelling. Thus the tissue would not ordinarily be expected to sense any sustained tension that would induce the formation of a stromal matrix and recipient scaffold and the desired increase in volume obtained with the injection would be lost.
[0022] While working with the external expander and inflating breasts with physiologic solutions, the inventors came to the realization that the immediate application of the splint that retains the swelling maintains the sustained tension required for the tissue engineering matrix to form. Within a period of days to weeks, that sustained tension has been found to induce the formation of the stromal matrix in as effective manner to that of the sustained tension of the Brava external expander.
[0023] Internal tissue fibers under tension sense the same forces whether (under the effect of the Brava® device or other dynamic traction device) the skin surface is pulled from the outside or whether the skin is held up to prevent recoil once the internal tension has already been induced. From a mechanical standpoint the forces required for inflation of the tissue are thought to be approximately the same forces that will be forcing its recoil. The inventors therefore came to the conclusion that preventing the recoil of forced internal inflation by holding up the skin (forced inflation and passive splinting) achieves the same physiologic effect as pulling up on the skin to force its inflation (external dynamic expansion).
[0024] Interestingly, patients subjected to both modalities confirmed experiencing the same sensation.
[0025] While inflation is ideally diffuse if the inflating agent is placed throughout the tissue and within all tissue planes, it is also effective if the inflating agent is placed only in localized areas and we allow for natural diffusion of the injected material through osmotic forces and mechanical gradients of tissue compliance amongst the tissue types and the tissue planes. With respect to cellular agents injected into the tissue, such as fat, stem cells or the like, in order to achieve the best results with minimal necrosis, it has been found that diffuse injection of the inflating agent is preferred. For inflating agents that are acellular, such as saline, suspensions of particulate matters such as tissue matrix agents, or gels and other physiologically compatible fluids such as maybe even air (which has not yet been tried by the inventors but is conceived as eligible for use), it has been found that optimum results are not as dependent on a diffuse inflation.
[0026] The description above discusses inflating the soft tissue through injection of a physiologically compatible agent or fluid. While injection has been used by the inventors with success, the inventors conceive that the soft tissue can also be inflated through other means that can apply a distractive force to the tissues. One such example is to induce acute edema to the tissue and then while the tissue is expanded rapidly apply a passive stent. Using the breast as an example, a high pressure pump may be used to create a temporarily strong distractive force in cups applied to one or both of the breasts at pressures above what can be physiologically tolerated for more than a few minutes and then recycling after a few minutes rest giving time for the tissue to recover to achieve the desirable augmentation, remove the cups, and then apply passive stents to the breasts which are suitable for being comfortably and unobtrusively worn for some extended time period. Depending on the particular construction of the stent, and its ease of application (and expense), the inventors conceive that a patient could herself replace the stent to allow for personal hygiene, or return to the Doctor's office for another round of inflation and then another set of stents larger than the previous ones. In this way, the patient can take a stepwise expansion of her breasts until the desired size has been reached.
[0027] In yet another modality, the inventors are well aware of a low pressure bra-like device made and sold by Brava, LLC as one of the co-inventors is the inventor of that device. One of the issues which interferes with patient success in using the Brava Bra® is that of patient compliance. Although many patients are quite successful and are very happy with the results achieved with the Brava Bra®, some patients are not as diligent in their wearing of it as while it is remarkably slim and unobtrusive, it is yet more so than a thin bra cup. Furthermore, the recommended wear times are less than 24 hours a day, which gives the breast time to recoil and then when the Brava Bra® is reapplied, the starting size is less than when it was removed. The present invention of a passive stent may be coupled for use with the Brava Bra® in order to prevent breast recoil and thereby accelerate the augmentation process. Simply put, use of the passive stent for those times when the Brava Bra® is not worn transforms a sawtooth pattern into a stepwise expansion pattern of augmentation.
[0028] It is also contemplated by the inventors that the repeated inflation or distension of the soft tissue (breast as used for exemplary purposes only) may be achieved through a mixing of these various methods. In other words, the first inflation may be achieved through the creation of an edema or injection in the Doctor's office and subsequent inflations could be achieved through use of a low pressure or higher pressure cycling vacuum pump at home by the patient. It is also conceived by the inventors that a “kit” for home use could be put together comprising the presently commercially available Brava Bra® and vacuum pumps and a set of passive stents which the patient could self-apply during the intervals when not wearing the Brava Bra®.
[0029] In sum, the present invention is expected to be able to be used to maximize expected results through use of the Brava Bra® in soft tissue augmentation without surgical intervention or even injection.
[0030] When the patient returns back to the office, a few days to a few weeks after inflation, the splint is removed and the inventors have found that the organ (breast) has substantially maintained the operative enlargement due in large part to the adherent splint that prevented tissue recoil. However, while immediately after injection the breast was initially tight and firm from the large injection volume, it has been found after the passage of time to be soft and loose as the tissues had internally and externally stretched and expanded to accommodate the tension. In this regard, the physiologic process of tissue expansion has been found to be essentially similar to the dynamic external expanders.
[0031] With the enlarged (organ) breast now soft again, additional physiologic fluid may then be injected, enlarging it more until it becomes tight and firm again. A new splint may then be applied so that it conforms to the newly enlarged expanded state and the patient is then free to return to their normal activities, wearing this rigid splint as an adherent bra cup for the few days to weeks as required for the tension to equilibrate as the tissues expand further.
[0032] The process may then be repeated a few times until the desired recipient scaffold size is reached. At that point, the graft is diffusely dispersed inside the expanded scaffold and a new splint is applied to allow the grafts to revascularize and successfully engraft to regenerate the deficient organ.
[0033] Alternatively, this process of physiologic solution injection to expand the tissues followed by passive splinting to maintain the expanded state can be serially repeated until mechano-transduction, the process through which tissues grow in response to sustained mechanical expansion, generates enough tissue to obviate the need for tissue grafting. In essence, the inventors discovered a new method of tissue expansion which, in effect is an alternative to the devices described in previous patents and patent applications.
[0034] It is thus one aspect of the present invention to create a physical structure to be applied to a body area subject to tissue expansion, which is structurally and functionally designed to overcome the limitations described above with reference to the cited state of the art. In this regard, one function of the invention is to provide a device for maintaining morphology of a soft tissue site or organ, i.e. that is able to maintain the shape and volume of the body area subject to expansion, and to counteract any natural tendency to contract by the involved tissues.
[0035] Another desirable feature of a preferred embodiment of the invention is to provide such a device that is immediately usable in a post-operative phase and which also exhibits a high biocompatibility with the skin, in order to permit it to be safely and comfortably worn for a period of 2-3 weeks. Yet another desirable feature of a preferred embodiment of the invention is to provide such a device that is lightweight and easy to carry, in order to encourage its being worn by the patient during normal daily activities and thus improve patient compliance. Still another desirable feature of a preferred embodiment of the invention is to provide such a device that is readily customizable (malleable) so as to be able to more fully adapt to the shape of the body area of the individual patient. Yet another desirable feature of a preferred embodiment of the invention is to provide such a device that is easy to apply to the involved body area and, if necessary, just as easy to replace.
[0036] The invention also comprises a kit that can contain a device to distend the breast, such as a vacuum pump of the Brava modality or a high pressure pump, one or more breast cups to be applied to the breast to achieve the distention, and one or more passive splints which could potentially be applied over several weeks by the patient herself.
[0037] It will be apparent to any person of ordinary skill in the art of surgical reconstruction that one of the invention's preferred embodiments comprising the splint to be applied over the breast (organ) can be embodied in a multitude of designs using a large variety of materials.
[0038] The common requirement however to these are as follows:
[0039] Important Attributes:
a. adheres firmly to the skin or the surface of the organ to prevent recoil and detachment during the patient's regular activities. b. can be conformed to match and cover the exact shape and contour of the swollen breast or organ. c. while malleable when first applied, it should rapidly harden to espouse the desired shape. d. in the hardened state have mechanical properties that can counteract the tissue recoil. e. be bio-compatible and capable of being tolerated for long term application (1-3 weeks of uninterrupted wear). The splint is conveniently adapted to be made out of many bio-compatible “breathable materials” as known in the art.
[0045] Desirable Attributes:
a. easy to apply kit b. comfortable (semi-rigid, that is while preventing collapse, rubber like to allow for some bending, as compared to rock hard plastic) c. thin (one Inch or less) d. skin colored e. smooth contours that blend and taper with the chest wall skin f. have the appearance of a stick on, well camouflaged external breast prosthesis. g. items b-f should render the device easy to conceal and to wear 24/7. h. transparent or translucent so the underlying skin can be monitored, both to ensure that the splint is in good adhesive contact at the time of application and that any rash or irritation can be readily detected.
[0054] Another way of mechanically coupling the splint to the skin is surface tension. Surface tension is the naturally occurring means by which the body holds together tissues that need to remain mechanically coupled but yet glide and avoid shear forces. This is how the expanding rib cage transmits the mechanical force of inhalation to the soft sponge like lungs to expand and this is how bowel loops can glide past another while held together too.
[0055] The external splint can be akin to a swim cap or to a toilet plunger pump. Semi-rigid, conforming and with a film layer of surface tension that transmits the mechanical recoil of the plunger rubber to the skin surface and pull it outward.
[0056] The many embodiments of this splint embodiment (or adherent semi-rigid, conforming bra cup) that can be applied over an organ swelled up and tensed up by injection include but are not limited to:
[0057] A. Single Layer Embodiment:
[0058] Here a spray, paint, or putty form of a soft rubber or a rubber sheet is applied over the surface of the organ and that material cures to become rigid enough to prevent recoil. It could be adherent by itself or might require the addition of an adhesive glue such as a biologically tolerated adhesive or use surface tension. It might include imbedded or subsequently applied reinforcing fibers that contribute to the desired mechanical characteristics.
[0059] Specific embodiments would include:
[0060] 1. The hair spray like device: an aerosol delivered spray of a plastifying material that can coat the surface of the organ and rapidly dry or cure to become an exoskeleton-like shell structure that is hard enough to prevent the forces of recoil. This might be achieved by a modification of the current colloid dressing solutions or the liquid band aids or the cyanocarylate glues used for wound closure or other biocompatible polymers that can offer the desired characteristics.
[0061] 2. Materials similar to the above, instead of being sprayed could be painted or smeared over the surface of the organ where they would rapidly cure to become a hard shell that espouses its exact swollen contour and prevents it from recoiling. A solvent can then be used to remove it when needed.
[0062] 3. A putty-like soft rubber that can be spread over the surface and made to cure and become hard either with a catalyst or on air contact or by varying the temperature or by UV light exposure. The material can be delivered as sheets that are inherently tacky and stick to the surface when applied, or that need a priming sticky layer like a tissue glue to be applied first and then the confirming rubber putty adheres to that glue. Examples of these materials include the cyanoacrylates, epoxy, acrylic, urethane or other polymers such as silicone based medical adhesive glues.
[0063] 4. A sheet of adhesive tape like material. This can be either a textured or fibrous material or it can be a foamy or porous material that is taped over the surface of the organ. There are many well-tolerated pressure sensitive adhesive compounds that can provide a firm adhesion between that tape or sheet and the skin. The adhered sheet or tape can then become hard either because of its inherent ability to cure on exposure to air or water or with the help of a catalyst, temperature changes or UV exposure. The device would be supplied in an air tight pouch ready to be applied and would cure either by itself on exposure to air or water, or with the help of the necessary catalyst. Alternatively, the device can be made to harden by painting it, spraying it or adding to it a plastic, rubber, fiberglass, epoxy, urethane or other biocompatible polymer, even a plaster of Paris like material.
[0064] B. Two layered embodiment: First apply over the breast or the organ a layer of material that will adhere to the skin or to the surface of the organ to be enlarged. This must be a material known to be well tolerated for prolonged surface contact (this can range from adhesive tape to hydrogels and hydrocoloids, to cyanocarylates and other liquids or gels that stick to the tissue surface). Then add to this another layer of a material that can be made to adhere to the first layer, be malleable to precisely espouse the contour of the swollen organ, and that can be made to cure and become rigid in this new shape and form (this can range from thermoplastics to fiberglass like tape to plastics that can be cured on air or water contact or with the help of curing agents, catalysts, or temperature or UV light, to rubbers and other biocompatible polymers such as silicone and/or polyurethane and their related products and derivatives.
[0065] Specific embodiments would include:
[0066] 1. an adhesive hydrogel for the first layer and then glued and stuck to it.
a. a thermoplastic material added for rigidity and made to adhere to the hydrogel. b. fiberglass like material added for rigidity and made to adhere to the hydrogel. c. plaster of Paris-like material added for rigidity and made to adhere to the hydrogel. d. a natural or synthetic polymer or their derivatives capable of adhering to the hydrogel and be malleable enough in the first state to conform to the surface contour and become rigid in the second state to prevent recoil.
[0071] 2. An adhesive silicone gel for the first layer and a rigidifying silicone putty adhered to it for the second layer. That putty might contain a fibrous mesh as a rigidifying framework.
[0072] 3. An adhesive foam for the first layer and then glued or stuck to it:
a. a thermoplastic material added for rigidity and made to adhere to the foam b. fiberglass like material added for rigidity and made to adhere to the foam. c. plaster of Paris-like material added for rigidity and made to adhere to the foam. d. a natural or synthetic polymer or their derivatives capable of adhering to the foam and be malleable enough in the first state to conform to the surface contour and become rigid in the second state to prevent recoil.
[0077] 4. An adhesive biocompatible sheet lilke Tagaderm® or OpSite® or a woven or knitted material similar to the Second Skin.
a. a thermoplastic material added for rigidity and made to adhere to the breathable material adherent to the skin. b. fiberglass like material added for rigidity and made to adhere to the breathable material adherent to the skin. c. plaster of Paris-like material added for rigidity and made to adhere to the breathable material adherent to the skin. d. a natural or synthetic polymer or their derivatives capable of adhering to the breathable material adherent to the skin and be malleable enough in the first state to conform to the surface contour and become rigid in the second state to prevent recoil.
[0082] Anyone of ordinary skill in the art, given the teaching herein, can also understand that in 1-4 above, the first layer that is conforming, biocompatible and adhesive can be subsequently made rigid by adding to it chemical compounds that can provide it with the desired mechanical rigidity.
[0083] 5. Biocompatible Materials that can be used:
Natural polymers and their derivatives such as Nitrocellulose, Chitin, etc. Synthetic polymers such as polycarbon, polyvinyl, polyurethane, polyesther, silicone, and their derivatives.
[0086] C. Multiple layer sandwich: First an adherent layer (same range of materials as above) then a rigidifying layer (same range of materials as above), then a final layer that camouflages the entire construct.
[0087] The disclosed invention may also be used for a method of three dimensional tissue expansion.
[0088] In conventional tissue expansion, inflatable silicone shells are surgically inserted and after the surgical wound heals, the expander is serially filled with physiologic fluid to distend it. Multiple filling sessions a few days to a few weeks apart compress the intervening tissues between the skin surface and the expander shell and only expand the surface envelope. When removed these expanders then leave behind a cavity, a dead space that needs to be collapsed if the expansion is used for tissue coverage or in the case of breast reconstruction replaced with an inert foreign material implant.
[0089] With the present invention of tissue expansion, there is no surgical intervention required to insert any device. By simply injecting a physiologic fluid inside the organ to be augmented, by inducing an edema, or otherwise mechanically deforming it, not only is the envelope generated and stretched, but what does occur is that a stromal three dimensional recipient matrix for tissue engineering is also generated. As with conventional expansion, the quantity injected is limited by the level of tissue tension that can be tolerated and repeated injections are preferably needed a few days to weeks apart, or once the tissues expand and become lax again to become eligible for further injections. However, while with the internal expanders tension is maintained by the distended shell that compresses the underlying tissue and only stretches the outer envelope, with the present invention the tension on the tissues is generated by the application of an external shell that prevents collapse and uniformly distributes the tension to all the tissues contacting the splint to induce their uniform expansion. With the present invention using the splint, no surgery is required, no complication can result from foreign material being inserted, no tissue compression at all. Only diffuse generalized internal expansion forces (tension) are created, which have been found to be adequate to achieve the desired effect.
[0090] Other examples of suitable injectable materials range from simple physiologic electrolyte solutions to dilute suspension of specialized cells, to solutions containing growth promoting agents, or to suspensions and solutions of tissue matrix components that might altogether obviate the need for the cell seeding step as the improved injectate stimulates not only stromal matrix formation but also the proliferation of cells required to populate the organ.
[0091] As for the preferred embodiment, the inventors continue to search for new materials which satisfy both the important as well as the desirable attributes. However, at the time of filing, the inventors have successfully used the process of applying a layer of surgical tape, microfoam or hypofix type, and added on top a layer of fiberglass material customarily used to make fracture casts. While it is still malleable, the fiberglass plastic can be made to stick to the tape while it rapidly cures into a hard shell (like a cast) that espouses the contour of the expanded breast. This hard cup bra-like splint then remains adhered to the tape which is itself adhered to the skin. If well applied, the inventors have found that this construction will hold for a week, however the inventors would prefer other materials that would exhibit a longer life. This construction results in a somewhat cumbersome device but does have the advantage of being made out of off the shelf materials routinely available to any surgeon.
[0092] While not to be considered as limiting in any way, or as fully and completely defining the scope of the inventions disclosed herein, the inventors shall further exemplify the invention through the illustrative description and drawings depicting the preferred embodiments.
Definitions
[0093] It should be noted that in the present description and following claims, an element will be called “deformable” or “malleable” if its shape can be changed even under the effect of negligible forces, such as those expressed by a simple manipulation of an operator, particularly when it can be manually morphed to the shape of a human breast or other organ or other contour defect in need of correction. Malleable would include a moldable or shapeable sheet of material or sheets of material such as fiberglass or plaster of Paris impregnated cloth which is initially shapeless and adopts the morphology of the body tissue to which it may be closely applied. In addition, an element will be called “rigid” or “semi-rigid” when it will not deform significantly due to typical stresses caused by morphological forces such as the natural contraction of a distended breast, which is expanded by for example injecting a physiologically compatible fluid, inducing an edema such as by applying and cycling a high pressure vacuum to the breast, by applying a continuous low pressure vacuum over time (such as under pressures recommended for use with the Brava Bras), etc. Furthermore, in the description and subsequent claims, the deformation of an element will be called “not appreciable”, when, conformed to the shape of the tissue desired to be enlarged, such as by having the shape of a cup similar to a human breast, and undergoing a load of radial compression, produces a not meaningful volumetric shrinkage which materially detracts from achieving the desired tissue expansion.
[0094] As used herein, the term “physiologically compatible agent” or “physiologically compatible fluid” should be understood as including both “cellular agents” or “cellular fluids” such as stem cells and fat, as well as “acellular agents” or “acellular fluids” such as saline, gels, air, etc. Cellular agents or cellular fluids are understood as an agent or fluid that principally comprises cells, stem cells, harvested cells, genetically manipulated cells, cultured cells or the like. Acellular agents or fluids are understood as comprising gels, suspensions or solutions such as saline, chemicals that might promote growth or stabilization or tissue health, biologic tissue promoters or tissue substitutes, tissue inductive material, tissue matrices, etc.
[0095] As used herein, and elsewhere, the words “splint” and “stent” are used interchangeably but both can be defined as a deformable or moldable device intended to be shaped to be in intimate contact with the skin or other soft tissue surface and which maintains the morphology of the surrounding and underlying tissues. The word “splint” is generally considered as being relatively rigid in orthopedic uses while a “stent” is generally considered as being deformable or moldable to more closely follow the contours of the surface in question. The desirable properties of the stent or splint as described herein characterize the device being referred to so as to enable those of ordinary skill in the art to understand this reference.
[0096] The term “passive splint” or “passive stent” or “splint” or “stent” as used herein shall be understood as meaning a device which does not apply an external force to any underlying tissue to which it might be adhered, other than to resist the natural morphological forces which seek to return soft tissue to its previous relaxed or natural state. It is to be contrasted with what might be referred to as a “dynamic” force application device, such as a vacuum pump, which has the capability to apply an external force to body tissue.
BRIEF DESCRIPTION OF THE DRAWINGS
[0097] FIG. 1 is a cross-sectional view of a first embodiment of the invention comprising a stent or dome applied to a breast previously subjected to tissue expansion;
[0098] FIG. 2 is a perspective view of a sheet shaped adhesive element to be adhered to the breast and conform to its shape;
[0099] FIG. 3 : is a perspective view of a second sheet of material, adhered to the first and adjustable between deformable and rigid in character;
[0100] FIG. 4 is a cross-sectional view of a second embodiment of the invention, applied to a breast subject to tissue expansion;
[0101] FIG. 5 is a cross-sectional view of another embodiment of the invention comprising what can be a single or multiple layer splint, applied to a breast;
[0102] FIG. 6 is a perspective view of another embodiment of the invention comprising a malleable sheet;
[0103] FIG. 7 is a perspective view of yet another embodiment of the invention comprising a malleable sheet which may be woven or reinforced;
[0104] FIG. 8 is a perspective view of yet another embodiment of a splint that may be pre-formed in the approximate shape of a breast;
[0105] FIG. 9 is a perspective view of a vacuum pump connected to a bra cup for inducing an edema to thereby distend the breast;
[0106] FIG. 10 is a perspective view of yet another embodiment of the invention comprising a splint formed in an approximate circular pattern with a slit for being folded over onto itself and creating an approximate cone shape; and
[0107] FIG. 11 is a perspective view of the cone-shaped splint formed with the circular shaped splint shown in FIG. 10 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0108] With reference to FIGS. 1 to 3 , the first embodiment is generally referred to as 1 . The device ( 1 ) is intended to be applied to the soft tissue body area subject to tissue expansion. In this instance, and for illustrative purposes only, the body area consists of a breast ( 2 ) whose volume was increased, preferably by injecting a physiologically compatible fluid such as saline, or less preferably by grafting properly treated autologous adipose tissue, in each instance optionally preceded by a period of treatment of vacuum or mechanical stimulation. Nevertheless it is understood that the present invention can be applied in the same way in any surgery, aimed at changing the congenital or acquired body profile through fluid injection or adipose tissue graft, such as in the treatment of depressions caused by scars, surgical resections or malformations. The device is not only limited to external skin surfaces but can also be applied to internal defects and to solid organs.
[0109] The device ( 1 ) preferably includes a sheet-like layer of an adhesive element ( 3 ), which is preferably made from materials that are easily deformed even at room temperature (about 25° C.) and able to adapt to the widely varying shapes and sizes of the female breast ( 2 ). The adhesive element ( 3 ) is preferably sheet-shaped, and includes, in correspondence of its outer surface ( 3 a ), an adhesive layer ( 4 ) that may be applied directly on the skin surface of the breast ( 2 ), and a backing layer ( 5 ) superimposed to the adhesive layer ( 4 ). Both layers ( 4 ) and ( 5 ) may preferably have a thickness between about 0.5 and 3 mm. The adhesive layer ( 4 ) is preferably an hydrocolloid, with high biocompatibility with the skin, so to ensure that the device ( 1 ) can be safely and comfortably applied to, and worn on, the breast ( 2 ) for reasonably lengthy periods of time, if necessary, without needing replacement. In addition, the biocompatibility of the adhesive layer ( 4 ) allows its application on the skin immediately after the surgical breast expansion, even in the presence of post-operative edema which is typically present after these surgical interventions.
[0110] The backing layer ( 5 ) is preferably made of soft polymer material, e.g. thermoplastic polyurethane based foam or other polymeric material with similar characteristics of softness and deformability. In this way, the adhesive element ( 3 ) can adhere completely to the skin surface of the breast ( 2 ), adapting virtually perfectly to its shape. The adhesive elements described above may be provided for example by the company Convatec under the trade name of DuoDerm®.
[0111] The device ( 1 ) also preferably includes a structural element ( 10 ) coupled to the opposite side of the adhesive layer ( 4 ). Even the structural element ( 10 ), like the adhesive element ( 3 ), is preferably sheet-shaped, with a thickness preferably between 0.5 and 4 mm. The structural element ( 10 ) is preferably basically rigid at room temperature, so that it does not deform significantly when subjected to stresses caused by the natural contraction of the body area involved in the tissue expansion. In particular, the structural element ( 10 ), at room temperature, is preferably able to resist without deforming significantly when loaded by the natural contraction of the expanded soft tissue, such as the breast ( 2 ), following tissue expansion and, among other factors arising from the tissue elasticity and from the post-operative reabsorption of the edema. The material preferably used for the structural element ( 10 ) exhibits a high chemical compatibility with the material used for the backing layer ( 5 ) of the adhesive element ( 3 ), so that it can ensure an effective adhesion to it, even without additional layers of glue. However, it is optionally envisaged that an additional adhesive layer can be applied between the two elements 3 and 10 , for example a cyanoacrylate-based material indicated for medical use. Most preferably, the structural element ( 10 ) is made of thermoplastic polymer having properties such that when heated to a temperature between 50° and 80° C. (at first instance comparable to the melting point of the polymer), it softens in such a way to be easily deformed by a surgeon's manual manipulation. In this way, the structural element ( 10 ) can be stretched over the adhesive element ( 3 ), be adapted perfectly to the shape of the breast ( 2 ) and maintain this conformation.
[0112] Thermoplastic polymer materials softening at temperatures above 80° C. are not presently considered suitable for use in the present invention, because they would be too hot to be manipulated by a surgeon or to be used on a patient, even in overlap with the adhesive layer ( 3 ). On the other hand, thermoplastic polymer materials softening at temperatures below 50° C. are not presently considered suitable for use in the present invention, because they would not have adequate stiffness at room temperature or at temperatures between 35 and 40° C., easily accessible in many countries in summer. Preferably, the structural element ( 10 ) is made of a polymer based on polycaprolactone, covered with a layer of urethane acrylates. Several holes with a diameter ranging between 3 and 5 mm are made preferably on the structural element ( 10 ) and placed regularly on its surface. These holes ( 11 ) allow an easier deformation of the structural element ( 10 ) when brought to temperatures between 50 and 80° C., allowing at the same time a decrease of the mass of the structural element ( 10 ), in order to be lighter and to provide faster and more even temperature changes both in the heating and the cooling phases.
[0113] The use of this preferred embodiment takes place as described below, at the end of the treatment of tissue expansion of the soft tissue, preferably obtained through the injection of physiologically compatible fluid or grafting of properly treated autologous fat tissue. In the first phase, the adhesive element ( 3 ) is carefully laid on the expanded breast ( 2 ) to adhere perfectly to the skin surface. After that, the structural element ( 10 ) is heated at a temperature between 50 and 80° C. so that the surgeon can easily deform it and lay it on the adhesive element ( 3 ) previously applied to the breast ( 2 ), adapting to its morphological conformation. The preferable chemical compatibility between the adhesive element ( 3 ) and the structural element ( 10 ) permits their mutual adhesion. Both the adhesive element ( 3 ) and the structural element ( 10 ) are laid to cover the entire area involved in the tissue expansion, including preferably a considerable margin around it. The structural element ( 10 ) cools rapidly to room temperature, making it stiff enough to hinder effectively the natural tendency to contract of the expanded tissue.
[0114] The sizing and the material of the structural element ( 10 ) are such that the cooling takes place as quickly as possible, but long enough to provide the surgeon with the time necessary to lay the structural element on the adhesive element ( 3 ). After the application of the structural element ( 10 ) and its cooling, the device ( 1 ) can be left on the breast ( 2 ) for a long period, even weeks if considered desirable, to promote the development of mature fat cells and their integration into the pre-existing tissue. If necessary, the device ( 1 ) can be replaced, by detaching the adhesive layer ( 4 ) from the breast ( 2 ) and repeating the steps described above with a new adhesive element and a new structural element. The device of the present invention is very lightweight and easy to wear, without causing discomfort or pain in the body region around the expanded tissue (breast). In fact, the pressures caused by the tissue's natural contraction is very low, in particular if compared with those necessary to stimulate its expansion by vacuum application as in the known devices. In addition the device of the present invention is customizable, as it is adaptable to the morphology of the specific patient. A further advantage of this invention is that its application promotes a biological response, which is thought to lead to the transformation of the stem cells present in the treated and grafted adipose tissue into mature adipocytes. The structural element ( 10 ), before being used, can be provided in the form of a flat sheet or in a convenient alternative, already preformed cup according to different predefined sizes.
[0115] With reference to FIG. 4 , another embodiment of the invention is shown and referred to generally as 100 therein. The device 100 differs from device 1 described above by incorporating an additional element with variable thickness 101 , interposed between the adhesive element ( 3 ) and the structural element ( 10 ). The function of this element with variable thickness ( 101 ) is to improve the adaptability of the structural element ( 10 ) to the morphology of the expanded body region through a controlled reduction of its volume and thickness.
[0116] The element ( 101 ) designed with variable thickness is preferably made of polymer foam, e.g. polyurethane, whose radial thickness is adjusted by aspiration of the air contained in it.
[0117] Yet another embodiment 120 is depicted in FIG. 5 and includes within this single drawing figure a number of alternative constructions. For example, there is depicted a stent 122 which has been adhered to a breast with an adhesive layer 124 . Stent 122 could have the layer 124 of adhesive applied to its inner surface 126 , or the adhesive could be applied separately such as by being sprayed on or as being part of a double-sided, adhesive coated tape 124 . Layer 124 could be a layer of gel or silicone and if necessary an additional layer of adhesive could be applied. Layer 124 could also be a layer of second skin. The single layer stent 122 could be formed from a sheet of material (see FIGS. 6 & 7 ) such as a thermoplastic material, natural or synthetic polymer or from multiple sheets of overlapping material which cures into a rigid construction, like fiberglass or plaster of Paris as might be used for a cast, for example. Stent 122 could also be applied like a putty, such as silicone. There are many other materials, as known to those of skill in the art which could be substituted for these exemplary materials, using the teaching and guidance of the present disclosure.
[0118] As shown in FIG. 6 , the stent 122 may be a single sheet of material before application to the soft tissue site; flexible for being readily conformed to the soft tissue site and then being capable of becoming rigid to maintain the morphology of the site. For example, such a flexible single sheet of material 122 may be sized to adequately cover the breast and as explained above have one of its surfaces covered with adhesive or not. As shown in FIG. 7 , the stent 122 may be woven or reinforced which can make it both easier to pre-mold into shape and also better hold its molded shape after it is cured or otherwise transformed into a rigid structure adhering to the breast. FIG. 8 depicts yet another representative shape for the stent 122 . As shown therein, the stent 122 may be pre-molded into somewhat the shape of different breast cup sizes to minimize the possible introduction of wrinkles as the stent 122 is manipulated around the breast. Also, optionally, a flattened edge surface 126 to help form a seal at the edge of the stent 122 against the patient's chest.
[0119] As shown in FIG. 9 , a Brava Bra® system 128 may include a breast cup 130 adhered around a breast and held in place by a vacuum created between them by a pump 132 . The periphery may also have an adhesive applied to help hold it in place during wearing. Pump 132 could be either a low pressure pump for continuous use in accordance with the recommended protocol, or a higher pressure pump for recycling as explained above to distend the breast.
[0120] As shown in FIG. 10 , the splint or stent 122 may be pre-formed in an approximately circular shape with a slit 134 to facilitate its being folded or collapsed around itself and thereby form the cone shape shown in FIG. 11 .
[0121] The methods of use of the various inventions disclosed herein have been explained above as would be readily understood by those of skill in the art.
[0122] The invention has been illustrated through its preferred embodiments as shown in the drawing figures and as described in the description above. These preferred embodiments are not intended to be limiting in any way. Instead, the invention is intended to be limited solely by the scope of the claims appended hereto and their equivalents.
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A device for maintaining or achieving soft tissue expansion applicable to any body region already temporarily expanded including: an adhesive element deformable and capable of adapting to the shape of this body region, and which can then itself become mechanically rigid enough to resist tendency of the expanded tissue to recoil or to which a second material can be applied to form a stent adapted to the shape of the body area to provide the necessary structural rigidity to prevent recoil of the expansion and thereby induce its retention of its expanded shape after the stent is removed.
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BACKGROUND OF THE INVENTION
This invention relates to an aquarium that is designed to maintain a healthy environment for aquatic life by giving one the ability to balance and stabilize water in a separate enjoined tank before inducing the water into the main aquarium tank. Secondly, this aquarium water changing and water stabilization system prevents unnecessary work related to aquarium maintenance.
BRIEF SUMMARY OF THE PRESENT INVENTION
The inventor, who is an aquarium enthusiast, noted that it is difficult to change a substantial amount of water in a medium to large aquarium. For example, not having running water that runs directly into the aquarium system requires one to use pails and hoses that can cause a mess. Also, taking water directly from an exterior source and introducing it into the aquarium can be detrimental to the health of the living organisms in the aquarium. By attaching a second tank to the main aquarium tank through which water can be transferred, water can be conditioned and stabilized in the secondary tank before being introduced into the main aquarium tank. Also, by attaching an overflow and drainage system from both tanks to an existing sewer connection, allows for fast and safe removal of unwanted aquarium water. Redundant check valves and ball valves must be strategically placed to prevent backflow, valve failure backup and easy use.
As with most medium to large aquarium cabinetry, structural integrity and functionality are important so as to provide support and easy accessibility for the total aquarium system. In this present invention, the second water conditioning and stabilization tank is located above the main aquarium talk which is a gravity-flow water changing system. Plumbing runs behind and below both tanks.
As with most medium to large aquarium cabinetry, structural integrity and functionality is important so as to provide support and easy accessibility for the total aquarium system. In this present invention, the second water conditioning and stabilization tank is located above the main aquarium tank which is a gravity-flow water changing system. Plumbing runs behind and below both tanks.
The cabinet is designed to support the weight of both tanks when full and allow proper access to all working components of the aquarium.
This invention allows aquarium water to be easily stabilized and conditioned before being introduced into the main aquarium tank and allows for water to be easily and quickly drained from the aquarium while supporting all the components of the aquarium in a modular cabinet unit that provides easy access to all the important components of the aquarium.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and objects of the invention will be apparent from the following specification drawings, all of which disclose non-limiting embodiments of the invention. In the drawings:
FIG. 1 is a close up view of the valve for the top tank of the aquarium from a perspective slightly above and to the right of the aquarium.
FIG. 2 is a right side sectional view of the overflow drainage plumbing only for the aquarium.
FIG. 3 is a sectional right side view of the plumbing that leads from the bottom of the top tank into the back of the lower tank that introduces conditioned water into the lower main fish tank. The splash guard that buffers the water entering into the lower main fish tank is visible at the very bottom of this figure.
FIG. 4 is a sectional front view of the tanks, tank shelves and plumbing only.
FIG. 5 shows a view of the aquarium from a perspective of slightly above and to the left of the front of the aquarium and cabinet.
FIG. 6 is a sectional front view of all aquarium plumbing only from a perspective slightly above and to the right of the aquarium.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is a saltwater or freshwater mixing tank and aquarium environmental control system which is designed to exchange used water for pre-conditioned and stabilized water and can be used to quickly drain the main fish tank for easy cleaning and refilling. This invention is designed to connect to existing plumbing both drainage and water supply at the location that the aquarium is installed. Secondly, the current invention requires a cabinet that provides access to the components of the aquarium and proper support. The present invention is designed as a complete modular unit that does not allow for various embodiments within the design of the aquarium. Instead, all of the necessary aquarium components are designed and assembled to work together when connected to existing plumbing. The present invention is a manual aquarium water changing and water stabilization system. Future designs will allow for other tank position setups and aesthetics.
As depicted in FIG. 1 the present invention includes ½ inch copper supply lines 1 , for hot and cold water. A valve body 2 , that is bracketed to the left side of the cabinet mixes hot and cold water which exits thru the neck of the valve 3 .
As depicted in FIG. 4 the top water change tank 32 , can be filled with water that will empty into the main fish tank 38 , thru piping system (see FIG. 3 ) that empties from the bottom of the water change tank 32 and exits into the top of the main fish tank 38 . In the case of an overfilling of the tanks, an 1.5 inch overflow drain piping system (see FIG. 2 ) allows for proper overflow drainage for both tanks.
As depicted in FIG. 2 the present invention includes an overflow drainage flange 4 that secures a horizontal 2.3 inch length of 1.5 inch pipe 5 , to the back of the upper part of the top water change tank ( FIG. 4 , 32 ). In FIG. 2 , this pipe empties into a vertical 90° tee connector 6 , which connects to a vertical segment of pipe that serves both as a connector and vent opening for the overflow drain system. Two vertical segments of pipe 7 are connected with a vertical 90° tee connector 10 , the top vertical pipe segment is approximately 20 inches long and the bottom vertical pipe segment is approximately 26 inches long. The segments of pipe and the 90° tee connector total 47.5 inches. A 1.5″ diameter double threaded bulkhead fitting 8 , is put through the back of the upper part of the main fish tank ( FIG. 4 , 38 ) and is connected to a horizontal 2.3 inch length of 1.5″ diameter pipe 9 which connects to the vertical 90° tee 10 .
The bottom of the 47.5 inch vertical overflow pipe segment 7 connects to a horizontal 90° tee connector 17 . Main fish tank water empties from a drain at the bottom of the main fish tank ( FIG. 4 , 38 ). As depicted in FIG. 2 , a 1.5″ diameter double threaded bulkhead goes through the bottom of the main fish tank and connects to a vertical piece of pipe 12 that contains an inner check valve 13 , to prevent backflow. This vertical drain pipe segment 12 is connected to a vertical primary ball valve 14 with a total length of 4 inches for both items 12 and 14 , that is connected to a 1.5 inch elbow 15 , pointing to the back of the aquarium and connects to a horizontal secondary ball valve 16 , which connects to the front of the horizontal tee connector 17 , at the base of the vertical overflow main pipe 7 . A horizontal piece of pipe 18 , connects to the back of the tee connector 17 , which is to be connected to existing plumbing. Items 16 , 17 and 18 have an approximate total length of 7 inches.
To empty water into from the top water change tank ( FIG. 4 , 32 ) into the lower main fish tank ( FIG. 4 , 38 ) a ¾ inch pipe system (see FIG. 3 ) is used.
As depicted in FIG. 3 , a drain flange 19 , at the bottom of the top water change tank ( FIG. 4 , 32 ) connects and secures a 3.5 inch vertical pipe segment 20 , that contains a check valve 21 , to prevent backflow from the lower main fish tank ( FIG. 4 , 38 ). In FIG. 3 this vertical pipe segment 20 connects to an elbow 22 , and points towards the back of the aquarium. The elbow 22 connects to a horizontal pipe segment 23 , and a ball valve 24 , that have a combined length of 3 inches. This segment connects to an elbow 25 , and points downward and connects to a vertical nine inch length of pipe 26 . At the bottom of pipe 26 , an elbow 27 , is connected pointing towards the front of the aquarium. This elbow 27 , is connected to a 1.5 inch length of horizontal pipe 28 , that goes thru upper part of the back of the main fish tank ( FIG. 4 , 38 ). In FIG. 3 , pipe 28 connects to an elbow 29 that points downward and allows water to run over a splash guard 30 , to buffer the entry of water into the bottom main fish tank ( FIG. 4 , 38 ).
FIG. 4 is a sectional front view of the shelves, tanks, and plumbing in the aquarium. The outer cabinet walls, top, bottom and cabinet supports have been hidden in this view to reveal the interior parts of the aquarium. Only the upper shelf 43 , and the lower shelf 45 , are parts of the cabinet. The water change tank 32 , has a top tank wall restraint cap, with two equally spaced 18.5″ times 14″ water access cutouts. The tank wall retainer 31 , extends down and around the top of the water change tank 32 , by one inch and has a two inch cross piece to add strength to the top of the tank. On the back wall of tie water change tank 32 , two inches down and three inches in from the right side of the tank (from a front view perspective) is the center of a 1.5″ diameter hole 35 , that serves as access for the overflow plumbing into the back of the tank and allows excess water to drain out of the tank. The flat bottom of the water change tank 33 , and a bottom tank wall retainer 34 , goes around the rim of the bottom of the tank raising the tank up off the shelf 43 , by about ¾'s of an inch to prevent condensation on the bottom of the tank. The shelf that the water change tank rests on is 50″.times.1″.times.22″ and has an 8.7″.times.5.8″ cutout 44 , four inches from the right side of the shelf and ¾'s of an inch from the back of the shelf. This cutout allows space for the water change tank 32 , transfer line (see FIG. 3 ) that leads into the main fish tank 38 . Three inches from the back of the water change tank and five inches from the left side of the water change tank is the center of a ¾″ circular hole 36 , that allows the water change tank transfer line to be connected to the bottom of the water change tank via a threaded flange.
Also, in FIG. 4 , the main fish tank 38 , that has a dimension of 48″×24″×18″, rests on a 50″×1″×22″ lower shelf 45 , that has a 9″×6.5″ cutout 46 , that starts two inches from the right side of the lower shelf 45 , and ¾'s of an inch from the back of the shelf. This cutout allows the main fish tank 38 , overflow plumbing to go through the shelf 45 , and attach to the main fish tank waste line (see FIG. 2 ). The main fish tank 38 has a top tank wall restraint cap 37 , with two equally spaced 20″×16″ water access cutouts. The tank wall retainer 37 extends down and around the top of the main fish tank 38 , by one inch and has a four inch cross piece to add strength to the top of the tank. On the back wall of the main fish tank 38 , two inches down and seven inches in from the right side of the tank (from a front view perspective) is the center of a 1.5″ diameter hole 41 , that serves as access for the overflow plumbing into the back of the tank and allows excess water to drain out of the tank. The flat bottom of the main fish tank 39 , and a bottom tank wall retainer 40 , goes around the rim of the bottom of the tank raising the tank up off the shelf 45 , by about ¾'s of an inch to prevent condensation on the bottom of the tank. In the bottom of the main fish tank 39 , there is a 1.5″ circular hole 42 , seven inches to the left of the right side of the tank that allows the main fish tank 38 , waste line (see FIG. 2 ) to enter into the bottom of the main fish tank 38 . This allows for quick and easy draining of the main fish tank 38 .
FIG. 5 shows a complete wire-frame view of the aquarium water changing and stabilization system from a perspective to the left and slightly above the front of the aquarium. FIG. 5 's numbered items point out the components of the aquarium cabinet. The cabinet is made primarily of a wood product. All shelves and wall sections of the cabinet are doweled together for support. The top of the cabinet 47 , has a dimension of 50″×22″×1″ as do all the shelves of the cabinet. The bottom of the cabinet 57 , has a slightly larger dimension of 52″×1″×23″ for additional stability. The upper left and right cabinet side panels 48 , have a dimension of 22″×14″×1″, are doweled into the top of the cabinet 47 , and the upper shelf ( FIG. 4 , 43 ). Two 24″×15″×0.3″ left and right upper cabinet doors 49 , provide access to the water change tank cabinet area. Between and behind the upper front cabinet doors 49 , is a 3″×14.5″×1″ center upper front cabinet door support and stop 63 . All cabinet doors use appropriately placed hidden European hinges and have appropriately placed cabinet door handles.
On the front of the cabinet and doweled into the bottom of the upper cabinet shelf ( FIG. 4 , 43 ), is a 48.25″×2.6″×1″ wood product panel 51 . Also, below the upper cabinet shelf ( FIG. 4 , 43 ), are a left and right mid cabinet side panels 54 , that have a dimension of 22″×35.5″×1″ and are doweled into the upper cabinet shelf ( FIG. 4 , 43 ) and lower cabinet shelf ( FIG. 4 , 45 ). Each of these left and right mid cabinet side panels 54 , have two 7″×6″×1″ cutouts who's both upper right hand corners begin at 1.8″ down from the top of the mid cabinet side panel 54 , and three inches and 12 and a half inches respectfully from the right side of the mid cabinet side panel 54 . These cutouts provide access to each side of the main fish tank cabinet area. Each of these mid cabinet side panel cutouts are covered with relatively small 8″×7″×0.3″ cabinet doors 50 , that use appropriately placed hidden European hinges and cabinet door handles. Approximately ¼″ below the front cabinet panel 51 , is a swing up front access panel 53 , that has a dimension of 48.6″×10.8″×0.3″ and is connected to the mid cabinet side panels 54 , with metal pins 52 , that allow this front access panel 53 , to swing up and provide access to the front of the main fish tank. When this panel 53 , is in the down position, it provides a pleasing aesthetic look to the front of the aquarium cabinet by blocking the view into the interior plumbing and open back of the aquarium.
In FIG. 5 , at rear of the mid cabinet section is a left and right mid section “L” strut 62 . Each of these struts 62 consists of two pieces of wood product, 3″×35.59″×1″ and 5″×35.5″×1″ that are doweled and glued together at right angles for strength. The 3″×35.5″×1″ side of these struts are attached to the interior wall of the mid cabinet side panels 54 , with at least four appropriately placed #6 gauge wood screws.
The lower portion of the aquarium cabinet is designed to allow room 64 , for normal aquarium filtration system hardware. At rear of the lower cabinet section is another set of left and right lower section “L” struts 60 . Each of these struts 60 consists of two pieces of wood product, 3″×26″×1″ and 5″×26″×1″ that are doweled and glued together at right angles for strength. The 3″×26″×1″ side of these lower section “L” struts 60 , are attached to the interior wall of the lower left and right side cabinet side panels 55 , with at least four appropriately placed #6 gauge wood screws. These lower cabinet side panels 55 , have a dimension of 22″×26″×1″ and are doweled into the lower cabinet shelf ( FIG. 4 , 45 ) and the cabinet bottom 57 . On all of the back-facing five inch wide piece of “L” struts in the mid and lower cabinet sections 62 & 60 , that are flush with the backend of the aquarium cabinet side panels and shelves, there are 0.5″×0.5″×1″ bolt holes 61 , that allow for 7/16″ diameter bolts or #30 gauge self anchoring wood screws to be attached through the back of the aquarium cabinet to the building wall where the aquarium is located. The “L” strut bolt holes are located four inches from the top and bottom of the struts and are centered in the back-facing five inch wide piece of the “L” strut. These bolts ensure a secure and stable aquarium that will not tip over or sway when properly bolted to the building wall behind the aquarium cabinet. On the front side of the lower part of the aquarium cabinet are two slot vented 24″×26″×0.3″ left and right lower cabinet filtration system access doors 56 . There are eight equally spaced 23″×0.45″×0.3″ slots 65 , that start at about eighteen inches down and are centered on each lower cabinet door. These front lower cabinet doors are attached to the cabinet by appropriately placed hidden European hinges. Appropriately placed cabinet door handles must be on the all cabinet doors for easy opening. Between and behind the lower front cabinet doors 56 , is a 6″×2″×1″ center lower front cabinet door support and stop 58 .
FIG. 6 is a sectional right side view of the aquarium plumbing only that allows conditioned and stabilized water from the water change tank ( FIG. 4 , 32 ) to flow into the lower main fish tank ( FIG. 4 , 38 ). This section of plumbing starts with a ¾″ double threaded bulkhead fitting 19 , that is inserted down into the plumbing access hole located on the bottom of the water change tank (see FIG. 4 ). This bulkhead 19 , is connected to one of two ¾″ diameter segments of vertical pipe 20 which includes a ¾″ check valve 21 in the middle. The total length of segments 19 and 20 is 3.5 inches. At the bottom of the lower pipe segment 20 , is a ¾″ elbow 22 that points towards the back of the aquarium at a 90° angle and is attached to horizontal segments of ¾″ pipe 23 that has a ¾″ ball valve socket 24 , in the middle. Segments 23 and 24 have a total length of three inches. Attached to the end of the back portion of segments 23 and 24 is another ¾″ elbow that points 90° downward and is attached to a nine inch vertical segment of ¾″ pipe 26 . The bottom end of this nine inch vertical segment of pipe 26 , is attached to a ¾″ elbow 27 , that points towards the front of the aquarium at a 90° angle and is attached to a horizontal 1.5″ length of ¾″ diameter pipe 28 . At the front end of this horizontal segment of pipe 28 , is a ¾″ elbow 29 , that points downward at a 90° angle and directs the water flowing out of this plumbing system onto a splash guard 30 , to prevent splashing within the main fish tank when this plumbing is in use. The splash guard 30 , is attached to the back main fish tank wall centered ½″ below the elbow 29 .
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An aquarium water changing and stabilization system consists of an initial tank designed to stabilize and condition water before it is entered into a subsequent tank that contains live aquatic animals such as fish. This system has a cabinet that is designed to aesthetically enclose, protect and support the components of the aquarium while providing access to the system. Water is introduced into the system from existing hot and cold water plumbing which is connected to this system. Water exits from this system into existing sewerage plumbing which is also connected to this system. Conditioned water from the conditioning tank enters the main fish tank via plumbing from one tank to the other. In case too much water is introduced to either tank, overflow drains in both tanks prevent water from overflowing over the top of either tank. Plumbing check valves and ball valves create safe and easy plumbing.
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FIELD OF THE INVENTION
[0001] The present invention relates to a silicone composition and, more particularly, to a curable organopolysiloxane composition and a semiconductor device formed by curing the composition.
BACKGROUND OF THE INVENTION
[0002] A basic structural unit of a silicone polymer consists of silicon-oxygen chains, through silicon atoms, side chains are connected with other various organic groups. Compared with other polymer materials, the silicone polymer has the following outstanding properties: 1. Heat-resistance: a silicone product is constituted by a main chain of silicon oxygen (Si—O) bonds, therefore, silicone products have high temperature resistance, and the molecular bond will not break or decompose at a high temperature (or irradiation). 2. Weather resistance: the main chain of a silicone product consists of —Si—O—, which has better thermostability, radiation resistance, weather resistance and longer service life under natural environments. 3. Electrical insulation properties: a silicone product has good electrical insulation properties, its dielectric loss, withstand voltage, corona-resistance, volume resistivity and surface resistivity are all among the best in insulating materials, furthermore, its electrical performances are hardly effected by temperature and frequency. Thus, based on the aforementioned good properties, as a kind of silicone products, organopolysiloxane is widely used in LED photovoltaic industry.
[0003] CN103342816A describes a curable organopolysiloxane composition, which is used in LED lamp package and has the following advantages: excellent adhesion, high hardness, excellent thermal shock resistance, high transparency, etc.
[0004] Generally, a LED lamp package comprises a light-emitting component and a LED support, the light-emitting component is fixed on the LED support, the LED support is usually made of a metal substrate, the metal substrate is provided with a silver coating, and the silver coating is used for focusing or diffusing the light of the light-emitting component. By coating and curing the organopolysiloxane composition on the light-emitting component and the silver coating of the LED support, the packaging of LED lamp is basically completed. However, in the prior art, during the course of long-term use of the LED lamp package, sulfur in the ambient air will gradually erode to the silver coating, cause the silver coating to be vulcanized and tarnish, and further cause serious light attenuation; furthermore, in humid environments, the gradual penetration of moisture in the air can also cause problems of light-emitting components and seriously affect the lifetime of LED lamps.
SUMMARY OF THE INVENTION
[0005] A technical problem to be solved by the present invention is to provide a curable organopolysiloxane composition with prolonged vulcanization resistance time and excellent humidity resistance on the premise of maintaining high hardness and high index of refraction, so as to overcome the defects of poor vulcanization resistance and poor humidity resistance in the prior art.
[0006] To solve the above technical problems, the present invention also provides a semiconductor device comprising a light-emitting component and a support to fix the light-emitting component, wherein, the light-emitting component is coated with the cured substance of the curable organopolysiloxane composition of the present invention.
[0007] In a cured state and under conditions that the temperature is 25° C. and the humidity is 60% RH, the curable organopolysiloxane composition provided by the present invention has a tensile strength of 2 to 8 Mpa, an elongation at break of 35% to 100%, and an index of refraction being equal to or greater than 1.45. The composition comprises:
[0008] (A) organopolysiloxane comprising an R 1 3 SiO 1/2 unit, an R 2 2 SiO 2/2 unit and an R 3 SiO 3/2 unit, wherein R 1 is selected from similar or different alkenyl groups, univalent substituted or unsubstituted hydrocarbonyls which do not contain any aromatic hydrocarbon and aliphatic unsaturated bond, R 2 is selected from similar or different alkenyl groups, aromatic groups, univalent substituted or unsubstituted hydrocarbonyls which do not contain any aromatic hydrocarbon and aliphatic unsaturated bond, and R 3 is an aromatic group; wherein the content of the aromatic group is larger than 10 mol % and the content of alkenyl groups is larger than 0.1 mol/100 g;
[0009] (B) branched polyorganohydrogensiloxane having the viscosity of 300 to 4000 mPa·s, wherein each molecule has on average at least three silicon-bonded hydrogen atoms and at least one aromatic group, and the content of the aromatic group is larger than 10 mol %;
[0010] (C) a hydrosilylation catalyst having the content capable of facilitating curing of the composition.
[0011] Wherein, the molecular structure of the component (A) is a branch structure. The alkenyl groups of the component (A) may represent vinyl, propenyl, butenyl, pentenyl and hexenyl, most preferably vinyl. The univalent substituted or unsubstituted hydrocarbonyls which do not contain any aromatic hydrocarbon and aliphatic unsaturated bond of the component (A) can comprise the following groups: methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl or other similar alkyls, chloromethane, 3-chloropropyl or other similar haloalkyls, most preferably methyl. The aromatic group in the component (A) can be phenyl, tolyl, xylyl, and naphthyl, and phenylethyl, phenylpropyl and other similar alkyl benzenes, and most preferably phenyl. In order to further improve the index of refraction of the cured body obtained from the composition of the present invention, the content of the aromatic group is preferably greater than 20 mol %. In order to further improve the reactiveness of the component (A) and component (B), the content of the alkenyl groups is preferably 0.1-0.4 mol/100 g; the viscosity of the component (A) of the present invention at 25° C. is not particularly limited, which can be can be 10-1000000 mPa·s, and preferably be 100-100000 mPa·s.
[0012] More preferably, the component (A) consists of the aforementioned R 1 3 SiO 1/2 unit, the R 2 2 SiO 2/2 unit and the R 3 SiO 3/2 unit. As a preferred embodiment of the present invention, the component (A) has the following average unit formula:
[0000] (R 3 SiO 3/2 ) a1 (R 2 2 SiO 2/2 ) a2 (R 1 3 SiO 1/2 ) a3 ,
[0013] Wherein R 1 is selected from similar or different alkenyl groups, univalent substituted or unsubstituted alkyl, R 2 is selected from similar or different alkenyl groups, alkyl and aromatic groups that are univalent substituted or unsubstituted, R 3 is an aromatic group. Wherein 0.1<a1<0.8, 0.1<a2<0.6, 0.02<a3<0.5, and a1+a2+a3=1. The alkenyl groups in R 1 may represent vinyl, propenyl, butenyl, pentenyl and hexenyl, and most preferably vinyl. The univalent substituted or unsubstituted alkyl in R 1 can comprise the following groups: methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl or other similar alkyls, and most preferably methyl.
[0014] The aromatic group in R 1 may represent phenyl, tolyl, xylyl and naphthyl, and phenylethyl, phenylpropyl and other similar alkyl benzenes, and most preferably phenyl.
[0015] The component (A) further preferably has the following average unit formula:
[0000] (R 3 SiO 3/2 ) a1 (R 21 2 SiO 2/2 ) a21 (R 21 R 22 SiO 2/2 ) a22 (R 1 3 SiO 1/2 ) a3 ,
[0016] Wherein R 1 is selected from the aforementioned similar or different alkenyl groups, univalent substituted or unsubstituted alkyl, R 21 is a phenyl, and R 22 is a univalent substituted or unsubstituted alkyl, which comprises the following groups: methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl or other alkyl alike, and most preferably methyl. R 3 is the aforementioned aromatic group, which can be phenyl, tolyl, xylyl and naphthyl, phenylethyl, phenylpropyl and the like, and most preferably phenyl. 0.1<a1<0.8, 0.1<a21<0.4, 0<a22<0.2, 0.02<a3<0.5, a1+a21+a22+a3=1.
[0017] The component (B) is a branched polyorganohydrogensiloxane, of which the molecular structure is a branched structure. The component (B) works as a cross-linking agent, in the present invention, the SiH of the branched structure component (B) and the alkenyl group of the branching structure component (A) generate an addition reaction (hydrosilylation) and form a cross-linked network structure. The molar ratio of silicon-bonded hydrogen atoms in the component (B) to the alkenyl groups in the component (A) is 0.9-2.0. The component (B) has a viscosity of 300 to 4000 mPa·s, within the viscosity range, the composition of the component (B) and other components of the present invention has a prolonged vulcanization resistance time and excellent humidity resistance after curing, and more preferably, the component (B) has a viscosity of 1000 to 3000 mPa·s. The component (B) comprises an R 4 3 SiO 1/2 unit and an R 5 SiO 3/2 unit, wherein R 4 is selected from similar or different univalent substituted or unsubstituted hydrocarbyl and hydrogen atoms, which do not contain any aromatic hydrocarbon and aliphatic unsaturated bond, and R 5 is aromatic group. The univalent substituted or unsubstituted hydrocarbonyl which do not contain any aromatic hydrocarbon and aliphatic unsaturated bond of the component (B) can comprise the following groups: methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl or other alkyl alike, chloromethane, 3-chloropropyl and other similar haloalkyl, most preferably methyl. The aromatic group in the component (B) can be phenyl, tolyl, xylyl and naphthyl, and phenylethyl, phenylpropyl and other similar alkyl benzenes, and most preferably phenyl. The present invention has no special restrictions to the content ratio of the component (A) to the component (B), the weight ratio of the component (A) to the component (B) may range from 1:99 to 99:1, more preferably, from 20:80 to 80:20. As both the component (A) and the component (B) are similar branched structures, composition formed by any weight ratio may have similar properties, as long as the silicon-bonded hydrogen atoms in the component (B) and the alkenyl groups in the component (A) generate a sufficient reaction, for example, the molar ratio of silicon-bonded hydrogen atoms in the component (B) to the alkenyl groups in the component (A) is preferably 0.9-2.0.
[0018] More preferably, the component (B) consists of the aforementioned R 4 3 SiO 1/2 unit and R 5 SiO 3/2 unit. As a preferred embodiment of the present invention, the component (B) has the following average unit formula:
[0000] (R 5 SiO 3/2 ) b1 (R 4 3 SiO 1/2 ) b3 ,
[0019] Wherein R 4 is selected from the aforementioned similar or different alkyl groups, hydroxy and hydrogen atoms, which are univalent substituted or unsubstituted, R 5 is the aforementioned aromatic group, which can be phenyl, tolyl, xylyl and naphthyl, and phenylethyl, phenylpropyl and other similar alkyl benzenes, and most preferably phenyl; wherein 0.5<b1<0.9, 0.1<b3<0.5, b1+b3=1.
[0020] The component (B) further preferably has the following average unit formula,
[0000] (R 5 SiO 3/2 ) b1 (R 4 3 SiO 1/2 ) b31 (R 4 2 HSiO 1/2 ) b32 ,
[0021] Wherein R 4 is a univalent substituted or unsubstituted alkyl, which can comprise the following groups: methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl or other similar alkyls, chloromethane, 3-chloropropyl and other similar haloalkyls, most preferably methyl; R 5 is a phenyl; wherein 0.5<b1<0.9, 0.1<b31<0.4, 0.1<b32<0.5, and b1+b31+b32=1.
[0022] The composition of the present invention may further comprises component (A′), the component (A′) comprises R 1 3 SiO 1/2 units and the R 3 SiO 3/2 units, R 1 is selected from similar or different alkenyl groups, univalent substituted or unsubstituted hydrocarbonyls which do not contain any aromatic hydrocarbon and aliphatic unsaturated bond, and R 3 is an aromatic group; wherein the content of the aromatic group is larger than 10 mol % and the content of alkenyl groups is larger than 0.1 mol/100 g. Wherein the alkenyl groups, univalent substituted or unsubstituted hydrocarbonyl which do not contain any aromatic hydrocarbon and aliphatic unsaturated bond, and hydroxy and aromatic groups are as defined above. The component (A) has a viscosity that is less than 15000 mPa·s at 25° C., and component (A′) has a viscosity that is more than 15000 mPa·s at 25° C., the weight ratio of the component (A′) to the component (A) is 100:(20-500).
[0023] More preferably, the component (A′) consists of the R 1 3 SiO 1/2 units and the R 3 SiO 3/2 units. As a preferred embodiment of the present invention, the component (A′) has the following average unit formula:
[0000] (R 3 SiO 3/2 ) a′1 (R 1 3 SiO 1/2 ) a′3 ,
[0024] Wherein R 1 is selected from similar or different alkenyl groups, and univalent substituted or unsubstituted alkyls and hydroxyls, and R 3 is an aromatic group, wherein 0.1<a′1<0.9, 0.1<a′3<0.9, and a′1+a′3=1.
[0025] In the present invention, the component (C) acts as a catalyst to facilitate the hydrosilylation reaction between alkenyl groups of the component (A) and (A′) and silicon-bonded hydrogen atoms of the component (B). In other words, the component (C) is a catalyst that promotes curing of the composition. Wherein, the present invention has no special limit to the kind of catalysts, all catalysts that are commonly used in this field, such as platinum catalyst, rhodium catalyst or palladium catalyst may be used, and platinum catalyst is preferred in the present invention. Specific examples include platinum black, chloroplatinic acid, alcohol solutions of chloroplatinic acid, platinum-alkenylsiloxane complexes, platinum-olefin complexes, etc., preferably platinum-alkenylsiloxane complexes. The present invention employs a platinum catalyst having tetramethyl-vinyldisiloxane as a ligand. There is no special restriction to the content of the component (C), as long as the content is enough to facilitate the curing reaction of the composition.
[0026] The curable organopolysiloxane composition of the present invention further comprises a component (D) as an inhibitor of the addition reaction, which prolongs the shelf life of the curable organopolysiloxane composition of the present invention. The inhibitor of the addition reaction is a temperature-dependent substance, which loses its inhibitory effect rapidly when being heated to a certain extent, so that the composition generates a curing reaction. There is no special restriction to the kind, weight and content of the component (D), inhibitors commonly used in the art can be used, and can be added by an amount as required. For example, the component (D) of the present invention is ethynylcyclohexanol, and the addition amount thereof is 0.05% by weight of the total content of the components (A) and (B).
[0027] There is no special restriction to the preparation method of the components (A)-(C) in the present invention, the components can be obtained by preparation methods commonly used in the art or by commercial purchases.
[0028] In the present invention, the curable organopolysiloxane composition can be prepared by mixing the necessary components (A)-(C), and adding the component (A′), (D) and other addictives such as inorganic fillers, pigments, flame retardants, heat-resistant agents and the like as required. The present invention provides a semiconductor device comprising a light-emitting component and a support configured to fix the light-emitting component, the aforementioned mixed composition is coated on the surface of the support for the light-emitting component and cured. The curing time or temperature may vary, for example, the first cure is carried out at 100° C.-150° C. for 0.5-2 h, and then the second cure is carried out at 150° C.-200° C. for 2-4 h. A cured body that is formed at a temperature of 25° C. and a humidity of 60% RH has a tensile strength of 2-8 Mpa, an elongation at break of 35%-100%, and an index of refraction equal to or more than 1.45, preferably more than 1.5. In contrast, it is difficult for a conventional organopolysiloxane composition to form a cured body that has the aforesaid good properties in tensile strength, elongation at break and index of refraction, and further has the advantages of a prolonged vulcanization resistance time and excellent humidity resistance.
[0029] A measuring method for a tensile strength and an elongation at break is that: the obtained composition is defoamed and made into a sheet with a thickness of 2 mm; the sheet is held at 100° C. for 1 h, and then cured at 150° C. for 3 h; the sheet is the processed into a dumbbell-shape, and the tensile strength and elongation at break thereof are measured at 25° C. and 60% RH by a universal materials tester.
[0030] The present invention has the following beneficial effects: compared with the prior art, the curable organopolysiloxane composition and its cured semiconductor device of the present invention not only maintain good thermal shock resistance, high index of refraction and high hardness, but also have a prolonged vulcanization resistance time and excellent humidity resistance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 is a cross-sectional schematic view of a packaged semiconductor unit provided by an embodiment of the present invention;
[0032] The reference signs in the drawings are as follows:
[0033] 1-LED support; 2-light-emitting component; 3-electrode; 4-wire; 5-cured body of a curable organopolysiloxane composition.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] In order to make the purposes, technical solutions, and advantages of the present invention be clearer, the present invention will be further described in detail hereinafter with reference to accompany embodiments. It should be understood that the specific embodiments described here are only intended to illustrate the present invention, but not to limit the present invention.
Synthesis Example 1
[0035] Phenyltrimethoxysilane (68.3 g) is added into a flask, deionized water (15 g) and concentrated hydrochloric acid having a concentration of 37% by mass (15 g) are added successively, and a reaction is performed at 70° C. for 5 min; dimethoxymethylphenylsilane (12.0 g) and diphenyldimethoxysilane (9.3 g) are added quickly, and refluxing is performed at 70° C. for 60 min; divinyltetramethyldisiloxane (14.0 g) is added and refluxing is further performed for 60 min. The reactants are transferred into a separatory funnel, an acid layer is removed, the organic layer is washed with water to a neutral pH, and then transferred to a flask; deionized water (1 g) is added, refluxing is performed at 70° C. for 60 min, and a concentration by distillation under reduced pressure is performed by a vacuum pump. Solvent and substances with low boiling point are removed by reducing the pressure, such that the resin with the following structure is obtained:
[0000] (PhSiO 3/2 ) 0.58 (Ph 2 SiO) 0.09 (PhCH 3 SiO) 0.10 [(CH 3 ) 2 (CH 2 ═CH)SiO 1/2 ] 0.23 (A1)
[0036] The product is a silicone polysiloxane having a viscosity of 10000 mPa·s at 25° C., which is an organic silicon resin with a benzene content of 40% and a vinyl content of 0.25 mol/100 g.
Synthesis Example 2
[0037] Phenyltrimethoxysilane (70.4 g) is added into a flask, deionized water (15 g) and concentrated hydrochloric acid having a concentration of 37% by mass (15 g) are added successively, diphenyldimethoxysilane (15.6 g) is added quickly, and refluxing is performed at 70° C. for 60 min; divinyltetramethyldisiloxane (13.8 g) is added and refluxing is performed for 60 min. The reactants are transferred into a separatory funnel, an acid layer is removed, the organic layer is washed with water to a neutral pH, and then transferred to a flask; deionized water (1 g) is added, refluxing is performed at 70° C. for 60 min, and a concentration by distillation under reduced pressure is performed by a vacuum pump. Solvent and substances with low boiling point are removed by reducing the pressure, such that the resin with the following structure is obtained:
[0000] (PhSiO 3/2 ) 0.61 (Ph 2 SiO) 0.16 [(CH 3 ) 2 (CH 2 ═CH)SiO 1/2 ] 0.23 (A2)
[0038] The product is a silicone polysiloxane with a benzene content of 45% and a vinyl content of 0.25 mol/100 g, and has a viscosity of 11000 mPa·s at 25° C.
Synthesis Example 3
[0039] Phenyltrimethoxysilane (77.3 g) is added into a flask, deionized water (15 g) and concentrated hydrochloric acid having a concentration of 37% by mass (15 g) are added successively, and a reaction is performed at 70° C. for 5 min; divinyltetramethyldisiloxane (10 g) and hexamethyldisiloxane (10 g) are added and refluxing is performed for 60 min. The reactants are transferred into a separatory funnel, an acid layer is removed, the organic layer is washed with water to a neutral pH, and then transferred to a flask; deionized water (1 g) is added, refluxing is performed at 70° C. for 60 min, and a concentration by distillation under reduced pressure is performed by a vacuum pump. Solvent and substances with low boiling point are removed by reducing the pressure, such that the resin with the following structure is obtained:
[0000] (PhSiO 3/2 ) 0.76 [(CH 3 ) 3 SiO 1/2 ] 0.10 [(CH 3 ) 2 (CH 2 ═CH)SiO 1/2 ] 0.14 (A′)
[0040] The product is a silicone polysiloxane with a benzene content of 40% and a vinyl content of 0.15 mol/100 g, and has a viscosity of 20000 mPa·s at 25° C.
Synthesis Example 4
[0041] Phenyltrimethoxysilane (60.3 g) is added into a flask, deionized water (15 g) and concentrated hydrochloric acid having a concentration of 37% by mass (15 g) are added successively, and a reaction is performed at 70° C. for 5 min; tetramethyldisiloxane (15 g) and hexamethyldisiloxane (12 g) are added and refluxing is performed for 180 min. The reactants are transferred into a separatory funnel, an acid layer is removed, the organic layer is washed with water to a neutral pH, and then transferred to a flask; deionized water (1 g) is added, refluxing is performed at 70° C. for 60 min, and a concentration by distillation under reduced pressure is performed by a vacuum pump. Solvent and substances with low boiling point are removed by reducing the pressure, such that resin with the following structure is obtained:
[0000] (PhSiO 3/2 ) 0.53 [(CH 3 ) 3 SiO 1/2 ] 0.16 [(CH 3 ) 2 HSiO 1/2 ] 0.31 (B1)
[0042] The product is an organosilicon compound with a benzene content of 30% and a hydrogen content of 0.37 mol/100 g, and has a viscosity of 4000 mPa·s at 25° C.
Synthesis Example 5
[0043] Phenyltrimethoxysilane (55.3 g) is added into a flask, deionized water (15 g) and concentrated hydrochloric acid having a concentration of 37% by mass (15 g) are added successively, and a reaction is performed at 70° C. for 5 min; tetramethyldisiloxane (16.2 g) and hexamethyldisiloxane (14.4 g) are added and refluxing is performed for 60 min. The reactants are transferred into a separatory funnel, an acid layer is removed, the organic layer is washed with water to a neutral pH, and then transferred to a flask; deionized water (1 g) is added, refluxing is performed at 70° C. for 60 min, and a concentration by distillation under reduced pressure is performed by a vacuum pump. Solvent and substances with low boiling point are removed under reduced pressure, such that the resin with the following structure is obtained:
[0000] (PhSiO 3/2 ) 0.49 [(CH 3 ) 3 SiO 1/2 ] 0.22 [(CH 3 ) 2 HSiO 1/2 ] 0.29 (B2)
[0044] The product is an organosilicon compound with a benzene content of 30% and a hydrogen content of 0.35 mol/100 g, and has a viscosity of 300 mPa·s at 25° C.
Synthesis Example 6
[0045] Phenyltrimethoxysilane (57.1 g) is added into a flask, deionized water (15 g) and concentrated hydrochloric acid having a concentration of 37% by mass (15 g) are added successively, and a reaction is performed at 70° C. for 5 min; tetramethyldisiloxane (15.6 g) and hexamethyldisiloxane (13.6 g) are added and refluxing is performed for 120 min. The reactants are transferred into a separatory funnel, an acid layer is removed, the organic layer is washed with water to a neutral pH, and then transferred to a flask; deionized water (1 g) is added, refluxing is performed at 70° C. for 60 min, and a concentration by distillation under reduced pressure is performed by a vacuum pump. Solvent and substances with low boiling point are removed under reduced pressure, such that the resin with the following structure is obtained:
[0000] (PhSiO 3/2 ) 0.50 [(CH 3 ) 3 SiO 1/2 ] 0.23 [(CH 3 ) 2 HSiO 1/2 ] 0.29 (B3)
[0046] The product is an organosilicon compound with a benzene content of 30% and a hydrogen content of 0.35 mol/100 g, and has a viscosity of 2000 mPa·s at 25° C.
Synthesis Example 7
[0047] Phenyltrimethoxysilane (75.3 g) is added into a flask, deionized water (15 g) and concentrated hydrochloric acid having a concentration of 37% by mass (15 g) are added successively, and a reaction is performed at 70° C. for 5 min; tetramethyldisiloxane (14.2 g) and hexamethyldisiloxane (12.4 g) are added and refluxing is performed for 300 min. The reactants are transferred into a separatory funnel, an acid layer is removed, the organic layer is washed with water to a neutral pH, and then transferred to a flask; deionized water (1 g) is added, refluxing is performed at 70° C. for 60 min, and a concentration by distillation under reduced pressure is performed by a vacuum pump. Solvent and substances with low boiling point are removed under reduced pressure, such that the resin with the following structure is obtained:
[0000] (PhSiO 3/2 ) 0.56 [(CH 3 ) 3 SiO 1/2 ] 0.16 [(CH 3 ) 2 HSiO 1/2 ] 0.28 (B4)
[0048] The product is an organosilicon compound with a benzene content of 30% and a hydrogen content of 0.34 mol/100 g, and has a viscosity of 5000 mPa·s at 25′C.
Synthesis Example 8
[0049] Phenyltrimethoxysilane (49.5 g) is added into a flask, deionized water (I 5 g) and concentrated hydrochloric acid having a concentration of 37% by mass (15 g) are added successively, and a reaction is performed at 70° C. for 5 min; tetramethyldisiloxane (16.4 g) and hexamethyldisiloxane (14.1 g) are added and refluxing is performed for 60 min. The reactants are transferred into a separatory funnel, an acid layer is removed, the organic layer is washed with water to a neutral pH, and then transferred to a flask; deionized water (1 g) is added, refluxing is performed at 70° C. for 60 min, and a concentration by distillation under reduced pressure is performed by a vacuum pump. Solvent and substances with low boiling point are removed under reduced pressure, such that the resin with the following structure is obtained:
[0000] (PhSiO 3/2 ) 0.48 [(CH 3 ) 3 SiO 1/2 ] 0.21 [(CH 3 ) 2 HSiO 1/2 ] 0.31 (B5)
[0050] The product is an organosilicon compound with a benzene content of 30% and a hydrogen content of 0.39 mol/100 g, and has a viscosity of 100 mPa·s at 25° C.
Practical Examples 1-8
[0051] The resins (A) and (B) prepared by the synthesis example 1-8, a catalyst for the addition reaction (C): chloroplatinic acid in octanol solution (a platinum concentration of 5 wt. %), and (D) a inhibitor: 2-Phenyl-3-butyn-2-ol are mixed according to the combination as shown in Table 1 (all components are calculated by mass), and the compositions of the present invention are obtained.
[0052] The semiconductor device LED light shown in FIG. 1 is packaged in the following manner: a LED support 1 to which a light-emitting component 2 is fixed is provided, wherein the light-emitting component 2 is connected with a electrode 3 by a wire 4 (usually a gold wire), then the aforementioned curable organopolysiloxane composition 5 of the present invention is coated on the LED support 1 to which a light-emitting component 2 is fixed.
[0053] The physical and chemical properties of the obtained compositions are measured by the following means, and the results are recorded in Table 1.
Hardness
[0054] The obtained composition is defoamed and 10 g of the defoamed composition is kept at 100° C. for 1 h, and then cured at 150° C. for 3 h; at 25° C. and 60% RH, the hardness thereof is measured at three points using a Shore D hardness tester, and the average value is recorded.
Index of Refraction
[0055] The cured organopolysiloxane is measured at 25° C. by an Abbe refractometer, and the light source utilizes a visible light of 589 nm.
Tensile Strength and Elongation at Break
[0056] The obtained composition is defoamed and made into a sheet with a thickness of 2 mm, which is held at 100° C. for 1 h and then cured at 150° C. for 3 h; the sheet is then processed into a dumbbell-shape, and the tensile strength and elongation at break are measured at 25° C. and 60% RH by a universal materials tester.
Vulcanization Resistance
[0057] The obtained composition is defoamed and dispensed on Enrui type 5050 support (without chip gold wire) which has been dehumidified at 150° C. for 2 h, the dispensed composition is held at 100° C. for 1 h and then cured at 150° C. for 3 h. The support is hung in a 250 ml reagent bottle receiving 2 g powdered sulfur and baked at 90° C., whether a silver coating layer on the support tarnishes is observed, and the time when the silver coating of the support is tarnished is recorded.
Moisture Proof of 5050 White Light SMD (Monochromatic Light)
[0058] The obtained composition is defoamed and dispensed on Enrui type 5050 support (without chip gold wire) which has been dehumidified at 150° C. for 2 h, the dispensed composition is held at 100° C. for 1 h, and then cured at 150° C. for 3 h. A lamp bead is placed at 60° C. and 60% RH for 52 h, then removed and placed for 15-30 min, and reflowed with the highest temperature of 270° C. over five temperature zones for three times; whether there is a dead lamp status is observed.
[0000]
TABLE 1
Practical
Practical
Practical
Practical
Practical
Practical
Practical
Practical
Parts by mass
Example 1
Example 2
Example 3
Example 4
Example 5
Example 6
Example 7
Example 8
Synthesis
A1
48
43
40
57
42
43
48
Example 1
Synthesis
A2
48
Example 2
Synthesis
A′
12
12
17
20
0
12
17
12
Example 3
Synthesis
B1
39.85
39.85
42.85
Example 4
Synthesis
B2
39.85
Example 5
Synthesis
B3
39.85
45.85
Example 6
Synthesis
B4
39.85
Example 7
Synthesis
B5
39.85
Example 8
C
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
D
0.05
0.05
0.05
0.05
0.05
0.05
0.05
0.05
Si—H/Si-Vi
1.08
1.08
1.08
1.08
1.08
1.08
1.08
1.08
(molar ratio)
Evaluation Results
Hardness
D50
D52
D35
D45
D30
D38
D55
D25
(25° C.)
Index of
1.53
1.53
1.53
1.53
1.53
1.53
1.53
1.53
Refraction
Tensile
4
3.8
2.5
3.0
2.2
2.8
5
0.9
strength Mpa
Elongation at
40
42
55
50
60
52
15
60
break %
Vulcanization
5 h
5 h
5 h
5 h
5 h
5 h
4 h
2 h
resistance time
5050 white
✓
✓
✓
✓
✓
✓
✓
✓
light support
moisture
resistance test
[0059] As can be seen from the results in Table 1, by the present invention, by combining the component (A) comprising a branched structure, in particular, comprising R1 3 SiO 1/2 unit, R 2 2 SiO 2/2 unit and R3SiO 3/2 unit, with the component (B) comprising a branched structure and has a viscosity of 300-4000 mPa·s, a composition is obtained; the composition has high hardness after heating curing, further has a prolonged vulcanization resistance time and excellent humidity resistance, and can be applied in a 5050 white light support in LED package. It can be seen from Table 1 that, compared with the embodiments of which the component (B) has a viscosity outside the range of 300-4000 mPa·s, and a tensile strength and an elongation at break that are not greater than 2 Mpa and 40% respectively, the embodiments of which component (B) has a viscosity of 300-4000 mPa·s, a tensile strength higher than 2 Mpa, and an elongation at break higher than 40% possesses outstanding advantageous performances in both the vulcanization resistance time and the humidity resistance.
[0060] The above contents are only preferred embodiments of the present invention, and are not intended to limit the present invention. Any modification, equivalent replacement or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
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A curable organopolysiloxane composition and a semiconductor device are described. In a cured state and under conditions that the temperature is 25° C. and the humidity is 60% RH, the composition has the tensile strength of 2 to 8 Mpa, the elongation at break of 35% to 100% and the index of refraction being equal to or greater than 1.45. The composition includes: (A) organopolysiloxane comprising an R 1 3 SiO 1/2 unit, an R 2 2 SiO 2/2 unit and an R 3 SiO 3/2 unit; (B) branched polyorganohydrogensiloxane having the viscosity of 300 to 4000 mPa·s, wherein each molecule has on average at least three silicon-bonded hydrogen atoms and at least one aromatic group, and the content of the aromatic group is larger than 10 mol %; and (C) a hydrosilylation catalyst having the content capable of facilitating curing of the composition.
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STATEMENT OF RELATED APPLICATIONS
[0001] This patent application claims the benefit of German Patent Application No. 10 2013 006 200.4 having a filing date of 11 Apr. 2013.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The invention relates to a method for the wet-treatment, preferably the washing, of laundry, wherein the laundry is first washed and rinsed and, after rinsing, a neutralization of the laundry is carried out in that neutralizing agent is added as necessary to the liquid in which the laundry is located and/or which is bound in the laundry.
[0004] 2. Prior Art
[0005] The wet-treatment of laundry is usually carried out by means of washing, rinsing and, if appropriate, at least one aftertreatment. One such type of aftertreatment can involve neutralization.
[0006] The neutralization of the washed laundry items is necessary if, for example, the wash liquid takes on an acidic or alkaline pH value resulting from treatment additives, for example detergents, employed during washing. The acidic or alkaline treatment fluid cannot be completely removed during the rinsing operation which follows the washing process. This applies in particular to the treatment liquid bound in the laundry items, that is to say, the bound liquor. Prior to the invention, the method employed to neutralize the bound treatment liquid after rinsing was to employ a neutralizing agent in an estimated quantity or based on values gained from practical experience. In general this results in an overdose of the neutralizing agent. This causes the pH value to shift from an acidic range to an alkaline one, or vice versa, so that a sufficient neutralization is no longer possible. Furthermore, an overdosage of the neutralizing agent adds to environmental pollution and results in unnecessary high costs.
BRIEF SUMMARY OF THE INVENTION
[0007] The object of the invention is to provide a method for the wet-treatment of laundry items which results in a complete, or at least virtually complete, neutralization using the smallest possible quantity of neutralizing agents.
[0008] A method for achieving this object is a method for the wet-treatment, preferably the washing, of laundry, wherein the laundry is first washed and rinsed and, after rinsing, a neutralization of the laundry is carried out in that neutralizing agent is added as necessary to the liquid in which the laundry is located and/or which is bound in the laundry, characterized in that at least one sample is taken from the liquid, the sample is filtered and at least one pH value of the filtered sample is measured, with neutralizing agent being added as necessary to the liquid in a targeted manner based on the pH value of the liquid obtained from the measurement. Accordingly, it is provided that at least one sample is to be taken of the liquid added to the laundry after the rinsing cycle. The sample is filtered, with the pH value of the filtered sample then being measured. If the measurement indicates an acidic or alkaline pH value, neutralization agent is added to the liquid in a targeted manner. The pH value of the laundry liquid after rinsing can thus be specifically set to a neutral pH value. The method according to the invention can preferably be employed to regulate the pH value of the liquid in order to achieve a pH-neutral or an essentially pH neutral liquid.
[0009] The method preferably provides that samples are repeatedly taken from the liquid that is supplied to the laundry items after rinsing. Here, too, every sample is first filtered, with the pH value of each sample then being determined from the filtered sample. By comparing a plurality of samples, it is possible to determine the change in the pH value. In particular, it can thus be established how the pH value changes as a result of the added neutralization agent. The setting of the pH value or the neutralization of the liquid added to the laundry after rinsing can thus be changed or adjusted little by little, preferably iteratively. Preferably only small quantities of neutralization agent are ever added to the liquid, specifically until the subsequently measured samples reach a neutral pH value indicating complete or virtually complete neutralization. This effectively prevents an overdosage of the neutralization agent or even a shift in the pH value from an acidic pH value to an alkaline pH value, or vice versa.
[0010] An advantageous further development of the method provides that the targeted addition of at least one neutralization agent does not commence until there is no change or no significant change in the pH value of two successive samples. This ensures that neutralization does not begin until the rinse liquid carried over from the rinsing operation and still bound in the laundry has sufficiently mixed with the liquid added to the laundry after rinsing in order that the sample taken from the liquid corresponds to the actual pH value of the liquid containing the rinsing liquid still bound in the items of laundry. The measured pH value of the liquid containing the bound rinsing liquid from the laundry then provides a reliable value for the subsequent start of the neutralization procedure. While neutralization is taking place, the progress of neutralization is determined by taking further samples on a continuous basis and then ending any further addition of neutralization agent when a neutral pH value has been measured.
[0011] In the case of the advantageous method, a filtration of the samples is carried out, preferably of all samples of the liquid, prior to the measurements of the pH value. The filtration method is preferably fine filtration or even microfiltration. If necessary, even finest filtration can be performed. The fine or finest filtration of at least the samples removes from the sample any components which might influence the measurement of the pH value. The filtered sample thus allows for an exact pH value measurement. Above all, this prevents accompanying substances in the samples from negatively affecting the measuring technique or measuring sensors and thus any possible distortion of the measurement results.
[0012] According to a preferred design of the method, samples of the liquid added after the rinsing of the laundry are taken via a bypass. A small quantity of sample liquid, in particular a small measuring volume flow, is taken through the bypass, preferably continuously. The bypass allows for continuous sampling.
[0013] It is preferably provided that, after the metered addition of preferably small quantities of at least one neutralizing agent to the liquid added to the water after rinsing, samples of the liquid are repeatedly taken along with the neutralizing agent already added to it. These samples are also filtered, in particular fine filtered, before their pH value is measured. If the pH value measurement of the sample most recently taken still indicates an acidic or alkaline pH value, in other words that complete neutralization has not yet been reached, small quantities of neutralizing agent continue to be added to the liquid, with at least one further pH value measurement being taken afterwards. Only when the pH value measurement of the last sample indicates that neutralization has been achieved or that the liquid has been substantially set to a neutral pH value, is the neutralization process concluded and no further samples are taken. The neutralization process is thus incremental and controllable, preferably controlled automatically.
[0014] According to the method it is preferably provided that fresh water and/or recycled water is used as the liquid added after the rinsing of the laundry. In the case of recycled water, this for example is water that accumulates during the removal of water from the laundry after the neutralization process has been carried out, that is to say so-called press water or also dewatering fluid. This liquid already contains neutralized water or neutralized liquid that can also be used after the rinsing of the laundry to dilute any acidic or alkaline rinsing liquid remaining in the laundry and subsequently to neutralize it. It also conceivable that, following the rinsing step and prior to the start of the neutralization process, fresh water as well as recycled water or recirculated liquid is added. The amount of fresh water required for neutralization can hereby be at least reduced.
[0015] Another preferred development of the method provides for the taking of samples and/or the metered addition of at least one neutralization agent while the laundry is being agitated in the liquid. The rinse liquid bound in the laundry is thereby flushed out of the laundry by the liquid added after rinsing, in particular pH neutral liquid, and mixed with the liquid added after rinsing. Here the bound rinse liquid is diluted with the added pH neutral liquid that is present in a much greater volume. The pH neutral liquid added to and mixed with the still acidic or alkaline bound rinse liquid can then be effectively neutralized.
[0016] Furthermore, provision is preferably made for the laundry to be washed, rinsed and neutralized in a tunnel-type washing machine having a rotary driven drum with successive chambers. In the drum, which is also driven in rotation during neutralization, the pH neutral liquid is moved or mixed with the laundry and the bound rinse liquid contained therein.
[0017] According to a further advantageous design of the method, provision is made for taking the samples from the chamber of the tunnel-type washing machine in which the neutralization of the laundry is carried out, preferably from a stationary outer drum assigned to this chamber. This is preferably done by means of a bypass line. The bypass line allows for a continuous withdrawal of a measuring volume flow, namely a relatively small quantity of sample liquid. By having neutralization take place in at least one of the tunnel-type washing machine's own chambers, with the drum being driven in the same manner of rotation as during the washing and rinsing of the items of laundry, the laundry is agitated during neutralization and mixed in the liquid to be neutralized. Also preferred is neutralization of the laundry in the liquid when the drum of the tunnel-type washing machine is driven in rotation. In this case the at least one chamber used for carrying out the neutralization of the laundry rotates exactly as the other chambers for washing and rinsing the laundry. This also promotes effective neutralization, with the collected samples exhibiting a representative pH value as a result of the intensive mixing of the neutral pH liquid added after the rinsing of the laundry with the bound rinsing liquid remaining in the laundry from the rinsing process.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] A preferred exemplary embodiment of the invention is described in more detail below on the basis of the drawings, which show:
[0019] FIG. 1 is a schematic side view of a tunnel-type washing machine with a sample collecting and pH value measuring device, and
[0020] FIG. 2 is a cross-sectional view through the chamber of the tunnel-type washing machine in which a neutralization process is conducted with the device for collecting samples, filtration and measuring the pH value of the sample.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0021] In the following, the invention will be described in conjunction with the wet treatment of laundry in commercial laundries by means of a tunnel-type washing machine 10 . It is in the tunnel-type washing machine 10 where washing, rinsing and aftertreatment, in particular neutralization, of the laundry is carried out. The laundry can involve any kind of laundry item, specifically flat textiles, clothing, in particular working clothes, but also dirt mats and the like.
[0022] The tunnel-type washing machine schematically illustrated in FIG. 1 is equipped with a drum 11 which can be driven to rotate or swivel (in a reciprocating movement) about a preferably horizontal axis of rotation. The laundry to be washed is transported in batches in the passage direction 12 through the rotating or swiveling cylindrical drum 11 , specifically, in reference to the illustration in FIG. 1 , from left to right. A plurality of chambers 14 which follow one another in the passage direction 12 are formed in the drum 11 by transversely directed partition walls 13 . The chambers 14 can have the same size or vary in size. The tunnel-type washing machine 10 shown in FIG. 1 has thirteen successive chambers 14 . However, the invention is not limited to this number of chambers. The invention is also suited for tunnel-type washing machines 10 having a greater or lesser number of successive chambers 14 .
[0023] The shown tunnel-type washing machine 10 has three successive treatment ones which follow each other in the passage direction 12 , specifically a prewash zone 15 , a main-wash zone 16 and a rinse zone 17 . A neutralization zone is integrated into the rinse zone 17 . In the case of the tunnel-type washing machine 10 shown here, the neutralization zone is formed by a single chamber 14 of the tunnel-type washing machine 10 , namely by a neutralization chamber 18 . The neutralization chamber 18 is the last chamber 14 of the rinse zone 17 , as seen in the passage direction 12 , and is at the same time also the last chamber 14 of the tunnel-type washing machine 10 .
[0024] The rotary driven drum 11 of the tunnel-type washing machine 10 is assigned a plurality of stationary and liquid-tight outer drums 19 to 23 . A first outer drum 19 , as seen in the passage direction 12 , is situated at the end of the prewash zone 15 . A second outer drum 20 is arranged at the start of the main-wash zone 16 . In addition, there is a third outer drum 21 at the end of the main-wash zone 16 . A fourth outer drum 22 is arranged at the start of the rinse zone 17 and a fifth (and final) outer drum 23 is located at the end of the rinse zone 17 . This outer drum 23 is assigned to the neutralization chamber 18 at the end of the tunnel-type washing machine 10 .
[0025] Located in front of the drum 11 is a loading chute 24 by means of which the tunnel-type washing machine 10 is loaded with dirty laundry that is sent through the loading chute 24 into the first chamber 14 of the prewash zone 15 . Situated at the end of the tunnel-type washing machine 10 is a discharge chute 25 . The washed, rinsed and neutralized laundry exits the neutralization chamber 18 of the tunnel-type washing machine 10 via the discharge chute 25 . From the discharge chute 25 the washed, rinsed and neutralized items of laundry still containing the bound neutralized liquid, the bound liquor, can be fed to a dewatering device, such as a water-removal press or a centrifuge.
[0026] A bypass line 26 runs from the lowest point of the outer drum 23 assigned to the neutralization chamber 18 . This line is used to collect samples, it preferably being possible to take a small quantity or a small volume flow of liquid (sample liquid) from the neutralization chamber 18 . A pump 28 is situated in the bypass line 26 . As seen in the direction of flow 27 of the sample liquid pumped by the pump 28 through the bypass line 26 , the pump 28 is followed by a filter 29 . The filter 29 is preferably a fine filter for the fine filtration, or a micro filter for the micro filtration, of the sample liquid. But it can also be a finest filter. The filter 29 is assigned a discharge line 30 for substances or particles filtered out of the sample liquid. As seen in the flow direction 27 of the sample fluid, the filter 29 is followed by a pH-value measuring device 31 . The pH value measuring device 31 employed is one which determines the pH value in the filtered sample liquid as the latter passes through the pH value measuring device 31 . The bypass line 26 is led back from the pH value measuring device 31 to the outer drum 23 of the neutralization chamber 18 . Provided in the section of the bypass line 26 which follows the pH value measuring device 21 , as seen in the flow direction 27 of the sample liquid, is a junction 32 leading to a drain pipe 33 . The drain pipe 33 can lead to a drain, for example. By virtue of a valve assigned to the junction 32 , the sample liquid that has already passed the pH value measurement device 31 can be alternatively returned to the neutralization chamber 18 or directed into the drain pipe 33 .
[0027] The neutralization chamber 18 is assigned a feed line for at least one neutralization agent. In addition, a metering device (not shown) is provided for the at least one neutralizing agent. The metering device can be integrated into the pH value measuring device 31 and likewise a control system for metering the quantity of the neutralizing agent to be added. Preferred for such use is a liquid neutralizing agent or a neutralizing agent dissolved in a liquid. This can be fed through the bypass line 26 along with the at least one neutralizing agent and the measured sample liquid to the neutralization chamber 18 of the tunnel type-washing machine 10 . But it is also conceivable to supply a neutralizing agent at a different location (not shown) of the neutralization chamber 18 . For example, this can be the case if a solid neutralizing agent is employed. The metering device is then also positioned at the location where the neutralizing agent is fed to the neutralization chamber 18 . The control system can then be assigned to the metering device or integrated therein. However, the control system for the quantity of neutralizing agent to be added can also be located elsewhere, such as being assigned to the pH value measurement device 31 or integrated therein.
[0028] In the following, the method according to the invention will be described in more detail with reference to FIGS. 1 and 2 of the drawings:
[0029] A plurality of laundry batches are concurrently prewashed, washed and rinsed in the rotary-driven or swivel-driven drum 11 of the tunnel-type washing machine 10 and neutralized in the neutralization chamber 18 .
[0030] The respective batch of laundry, along with the free rinse liquid and rinse liquid bound in the laundry, is transferred from the second (middle) chamber 14 of the rinse zone 17 to the neutralization chamber 18 . The free rinse liquid is then discharged from the outer drum 23 of the neutralization chamber 18 , so that only the rinse liquid bound in the laundry (bound liquor) remains in the batch of laundry. The neutralization chamber 18 is then filled with preferably pH neutral liquid. This can be either fresh water or even recycled water or some other recycled pH neutral liquid, for example liquid from the water-removal process that has been separated from the laundry in the water-removal step which follows the neutralization process and stored temporarily in a reservoir (not shown).
[0031] While other batches of laundry are being prewashed, washed and rinsed in the other chambers 14 , the laundry in the neutralization chamber 18 is flushed by the pH neutral liquid as the drum 11 is driven in a rotary or swiveling movement, with the rinse liquid bound in the laundry mixing with the added pH neutral liquid, i.e. the neutralization liquid, as a result of the laundry being agitated in the latter.
[0032] Immediately after the liquid is fed to the neutralization chamber 18 , there commences the removal from the neutralization chamber 18 of a small partial flow of the liquid as a sample liquid via the bypass line 26 in the flow direction 27 . This is preferably conducted in a continuous manner, thus allowing for a constant removal of sample liquid from the neutralization chamber 18 through the bypass line 26 during the agitation of the laundry in the neutralization chamber 18 .
[0033] During the initial mixing of the bound rinse liquid in the laundry with the added pH neutral liquid, no neutralization is yet carried out by the addition of a neutralizing agent. However, the current pH value is measured, preferably at regular intervals, during the mixing of the added pH neutral liquid with the bound rinse liquid without the addition of a neutralizing agent. As the added and originally pH neutral liquid increasingly mixes with the rinse liquid bound in the laundry and the laundry continues to be agitated in the added liquid over a period of time, a constant pH value is reached in the samples taken from the sample liquid. As soon as this is the case, in other words, as soon as the ongoing measured pH value of the sample liquid no longer changes, or does not change significantly, the neutralization process commences.
[0034] Depending on the measured pH value of the bound rinse liquid mixed together with the added liquid, namely the sample liquid, an appropriate neutralizing agent is added successively, preferably in small quantities, to the liquid mixed with the bound rinse liquid in the neutralization chamber 18 . In the process, an ongoing measurement is made of the pH value in the sample liquid, which changes as small quantities of the neutralizing agent are added. The addition of small quantities of neutralizing agent continues until the measurements indicate that the sample fluid has reached a neutral or virtually neutral pH value, in other words, when the neutralization of the liquid in the neutralization chamber 18 is complete.
[0035] It is conceivable that, shortly before the end of the neutralization process, the intervals between the addition of the neutralizing agent are altered, preferably lengthened, and/or the quantity of the at least one added neutralizing agent is reduced. This allows a reliable determination to be made during the final phase of the neutralization process as to whether a neutral pH value has been established during the mixing of the laundry with the liquid and the added neutralization agent and whether the neutralization process is being precisely controlled or regulated.
[0036] The sample liquid is continuously pumped by the pump 28 through the bypass line 26 in the flow direction 27 . Downstream of the pump 28 , as seen in the flow direction 27 , the sample fluid flows through the filter 29 , preferably the fine or finest filter. The sample fluid is filtered in said filter. This preferably involves fine filtration, finest filtration or micro-filtration. Once filtered by the filter 29 , the sample fluid then flows in the flow direction 27 through the pH value measurement device 31 . In the latter, successive samples of the sample liquid are measured with respect to their pH value. This measurement is conducted at successive intervals, preferably brief successive intervals. The intervals between measurement can be equal in length but can also become longer as the neutralization process progresses. Taking measurements of the pH value of the samples at successive intervals results in a virtually continuous pH value measurement.
[0037] Upon leaving the pH value measurement device 31 in the flow direction 27 , the sample fluid can be optionally diverted to a drain via the drain pipe 33 or can also be fed back into the neutralization chamber 18 via the bypass line 26 .
[0038] The metered addition of at least one liquid or liquefied neutralizing agent can be conducted in the region of the pH value measurement device 31 . However, it is also conceivable to add at least one neutralizing agent directly to the neutralization chamber 18 at some other appropriate location.
[0039] The addition of at least one neutralizing agent to the sample liquid that has been fed back into the neutralization chamber 18 or the direct addition of at least one neutralizing agent to the liquid in the neutralization chamber 18 is performed by a metering device (not shown). The metering device is controlled or regulated by a corresponding actuating means, specifically as a function of the pH value that has been determined by the pH value measurement device 31 . To this end, the metering device, or also the pH value measurement device 31 , is assigned a control or regulation means, in particular in the form of a computer.
[0040] The method according to the invention can be utilized not only in conjunction with the tunnel-type washing machine 10 shown in the figures, but also with any tunnel-type washing machine of any design, in particular with an arbitrary number of chamber 14 . The method according to the invention can also be utilized with other washing machines used in commercial laundries, such as wash centrifuge machines.
LIST OF DESIGNATIONS
[0000]
10 tunnel-type washing machine
11 drum
12 passage direction
13 partition wall
14 chamber
15 prewash zone
16 main-wash zone
17 rinse zone
18 neutralization chamber
19 outer drum
20 outer drum
21 outer drum
22 outer drum
23 outer drum
24 loading chute
25 discharge chute
26 bypass line
27 flow direction
28 pump
29 filter
30 discharge line
31 pH value measurement device
32 junction
33 drain pipe
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Washed laundry that has been rinsed still contains bound acidic or basic rinsing liquid. In many cases this must be neutralized. This used to be conducted on the basis of values gained from experience, which generally resulted in only partial neutralization. Herein, sample liquid is taken continuously from the neutralization chamber ( 18 ) and, after the fine filtration of same, the pH value of the sample liquid is continuously measured by a pH value measurement device ( 31 ). In this manner a pH value control system is possible which ensures an automatic and complete neutralization of the rinse liquid still bound in the laundry after rinsing.
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RELATED APPLICATIONS
This application claims priority from U. S. Provisional Patent Application Serial No. 60/111,558, filed Dec. 9, 1998, the contents of which are hereby incorporated by reference. This application claims priority from U. S. Provisional Patent Application Serial No. 60/111,560, filed Dec. 9, 1998, the contents of which are hereby incorporated by reference. The subject matter disclosed herein is related to the subject matter disclosed in application Ser. No. 09/456,584, filed on even date herewith, entitled “System and Method for Limiting Histograms.”
FIELD OF THE INVENTION
The present invention relates in general to radio frequency (RF) energy analysis systems and methods. More particularly, the present invention analyzes wideband RF in realtime to extract potential signals of interest while removing noise. The present invention performs the extraction and analysis function in all bands, Hf to microwave, for radar and communications signals.
BACKGROUND OF THE INVENTION
Typical signal collection and processing systems detect the presence of signals of interest in an RF environment by determining whether signal power within a certain frequency range exceeds a predefined threshold level for a sufficient duration of time. “Channelized” systems, for example, tune a receiver having a known bandwidth to a certain frequency and collect all the RF energy present in the environment in that frequency range. These systems determine whether the signal power exceeds the predefined threshold and, if so, conclude that a pulse exists in that range. The channelizers then define a pulse start time as the time at which the signal energy first exceeded threshold, and a pulse end time as the time that signal energy falls below threshold. A known deficiency of such channelized systems is that they require significant resources to monitor a large number of frequency bands. Another deficiency of these systems is that each channelizer is tuned to a fixed bandwidth that may or may not be consistent with the bandwidths of the signals of interest. Consequently, these systems do not provide optimal sensitivity.
“Compressive receivers” continually sweep a broad bandwidth with a narrowband filter. These systems can detect narrowband pulses in a broadband environment, but suffer from an inability to detect the presence of signal energy that is present in the environment during periods in which the narrowband filter is not tuned to the frequency band in which that signal energy is present. Additionally, the bandwidth of the narrowband filter is tuned to a fixed bandwidth that may or may not be consistent with the bandwidths of the signals of interest. Consequently, these systems do not provide optimal sensitivity, do not necessarily capture the signal of interest, and are analog systems.
Instantaneous Frequency Measurement (IFM) receivers minimize the sweep time limitations of the compressive receiver by providing a broadband frequency discriminator that rapidly responds to a signal's presence. The IFM receiver, however, is unable to provide accurate frequency measurements in the presence of multiple simultaneous input pulses, as are typically encountered in crowded RF environments.
Broadband signal processing systems are often required to detect the presence of narrowband signal energy in a wideband RF environment that includes, for example, radar pulses and/or communications pulses. It is desirable that such systems are able to detect all that RF energy that is present in a wide frequency range for a certain period of time. It is also desirable to minimize the resources required to detect these signals. Designers of such signal processing systems, therefore, would benefit from methods and apparatus that analyze wideband radio frequency spectra that include both radar and communications signals to extract potential signals of interest while removing noise and other unwanted RF energy.
SUMMARY OF THE INVENTION
The present invention satisfies these needs in the art by providing apparatus and methods for processing RF signals. The inventive method comprises generating an energy map of collected radio frequency (RF) energy as a function of time and frequency for a predefined dwell period and dwell bandwidth. The collected RF energy can include energy from communications signals as well as radar signals, transient signals as well as continuous signals. From the energy map, it can be determined whether a pulse is present in the RF spectrum. If a pulse is present in the RF spectrum, then a pulse bandwidth and pulse duration can be determined from the energy map.
The energy map can be generated by dividing the dwell period into a set of k time windows and dividing the dwell bandwidth into a set of n frequency bins. An energy grid comprising n×k frequency-time cells can then be generated. Each frequency-time cell corresponds to one of the frequency bins and to one of the time windows and has a value based on the collected RF energy present in the corresponding frequency bin during the corresponding time window. A binary value can be assigned to each of the frequency-time cells based on whether the collected RF energy present in the corresponding frequency bin during the corresponding time window exceeds a predefined energy presence threshold. If noise is present in the RF spectrum, the noise can be filtered from the energy map.
If a pulse is present in the RF spectrum, a tag can be generated for the pulse that includes a pulse characterization parameter that characterizes the pulse. The pulse characterization parameter can be based, for example, on pulse width, center frequency, angle of arrival, or time of arrival.
A method according to the present invention can also include “pulse healing.” That is, for a first pulse and a second pulse, a combined pulse duration can be defined that extends from a start time of the first pulse to an end time of the second pulse. It is then determined whether the start time of the second pulse exceeds the end time of the first pulse by less than a predefined threshold, which can be based, for example, on the combined pulse duration. If the start time of the second pulse exceeds the end time of the first pulse by less than the predefined threshold, then the first pulse and the second pulse are combined into a single pulse (i.e., the single pulse is “healed”).
Similarly, pulses can be “healed” in frequency. That is, for a first pulse and a second pulse, a combined pulse bandwidth can be defined that extends from a lower frequency of the first pulse to an upper frequency of the second pulse. It is then determined whether the lower frequency of the second pulse exceeds the upper frequency of the first pulse by less than a predefined threshold, which can be based, for example, on the combined pulse bandwidth. If the lower frequency of the second pulse exceeds the upper frequency of the first pulse by less than the predefined threshold, then the first pulse and the second pulse are combined into a single pulse.
Another method for processing RF signals according to the invention comprises receiving a set of time domain energy samples representing signal energy present in an RF spectrum. The set of time domain energy samples can be transformed into a set of frequency domain power samples. Transforming the set of time domain samples into a set of frequency domain samples can include dividing the set of time domain energy samples into a plurality of N windows, each of which is associated with a predefined window period. For each of the N windows, an FFT is performed to generate a set of K frequency bins. Each of the frequency bins has a value based on energy present in a predefined frequency band during the corresponding window period.
From the set of frequency domain power samples, it can be determined whether a signal of interest is present in the RF spectrum. A subset of the set of frequency domain power samples can be forwarded to a follow on system, where the subset corresponds to the signal of interest. To determine whether a signal of interest is present can include generating an energy map that represents energy present in the RF spectrum as a function of frequency and time. The energy map can be a bitmap comprising N×K frequency cells, wherein each frequency cell has a binary value based on the value of a corresponding frequency bin. The binary value can be based, for example, on whether the value of the corresponding frequency bin exceeds a predefined threshold.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing summary, as well as the following detailed description of the preferred embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings an embodiment that is presently preferred, it being understood, however, that the invention is not limited to the specific apparatus and methods disclosed.
FIG. 1 is a plot of RF energy as a function of frequency and time.
FIG. 2 is a block diagram of an RF energy collection and analysis system.
FIG. 3 is a block diagram of an RF energy mapper according to the present invention.
FIG. 4 is a block diagram of a tag generator according to the present invention.
FIG. 5 is an RF energy bitmap according to the present invention.
FIG. 6 is a block diagram of a tag screening process according to the present invention.
FIG. 7 is a block diagram of a histogramming limiter according to the present invention.
FIG. 8 provides a frequency histogram with a pulse duration histogram for one frequency bin.
FIG. 9 provides a flowchart for a frequency histogramming limiter according to the present invention.
FIG. 10 provides a flowchart for a duration histogramming limiter according to the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Definitions
FIG. 1 provides a general reference for definitions of certain terms that will be used throughout this disclosure. A “dwell” is a collection of radio frequency (RF) spectra within a lower frequency limit, f l , and an upper frequency limit, f u , with a center frequency f 0 halfway between f l and f u , during period t s to t e . An “emitter” is an RF source that contributes to the spectra. A “dwell data set” is a formatted data set representative of all the spectra contained in a dwell.
A dwell results from a receiver being tuned to f 0 and the RF energy being collected over a period between a dwell start time, t s , and a dwell end time, t e . For events within a dwell, time is relative, where the beginning of a spectrum observation period, i.e., the dwell, is zero time and t 1 and t 2 are some number of ticks on a counter that is initialized at the beginning of the spectrum observation period.
A “pulse” is an energy burst occurring within a dwell. Typically, many pulses occur within one dwell. A pulse is characterized by an upper and lower frequency bound, f 2 and f 1 , respectively, and occurring between the start of the energy burst, t 1 , and the end of the energy burst, t 2 . A pulse has a center frequency of f c halfway between f 1 and f 2 , and a “pulse duration” of t 2 −t 1 . A “tag” is a characterization of a pulse and contains the value t 1 , t 2 , f 1 , and f 2 , which mark the pulse boundaries. A “tag generator” is a device that converts a pulse into a tag. A “frequency segment” consists of the frequencies spanned by a frequency bin (i.e., an FFT bin).
RF Energy Mapper
FIG. 2 is a block diagram of an RF energy collection and analysis system according to the present invention. A wideband receiver 10 receives analog RF signals via an antenna 12 . Receiver 10 passes the analog signals through an analog-to-digital (A/D) converter 14 , wherein the analog signals are converted to digital signal samples via well-known analog-to-digital conversion techniques. A/D converter 14 outputs a digitized spectrum in the time domain, that is, a stream of digital signal samples that represents the received signal energy as a function of time.
According to the present invention, the stream of time domain samples is input into an RF energy mapper 100 . RF energy mapper 100 , which is described in detail below, performs a spectral analysis on the input signal samples to detect the presence of signals of interest in the digitized spectrum. Energy tags are generated for the signals of interest and can be passed on to one or more follow-on systems for further analysis. Preferably, RF energy mapper 100 stores the signal samples and can forward the stored signal samples to a follow-on system on request.
Generally, RF energy mapper 100 provides apparatus and methods for detecting and capturing broadcast radar and communications signals that are present in a frequency spectrum having a spectrum bandwidth that is wide relative to the bandwidth of the signals. RF energy mapper 100 detects and captures both short and transient signals (e.g., frequency hoppers), as well as conventional continuous (i.e., CW) signals (e.g., air guidance signals) and continuous modulated signals (e.g., commercial broadcast).
The input into RF energy mapper 100 is a stream of digitally encoded signal samples sourced by a wideband receiver. The bandwidth of the wideband receiver typically encompasses many hundreds or thousands of simultaneously transmitted signals. The system outputs tags for those collected signals. The tags describe the start and stop time and the lower and upper frequency bound of all of the signals meeting preset criteria for tagging. Where a signal is continuous rather than transient, such signal will be noted in the output tag as having a time period longer than the criteria for transient signals. A second product of the system is a randomly accessible delay line that stores all FFT representations of the incoming spectrum so that the signal associated with the tags is also outputted. The follow-on system uses the tags to request the signal samples associated with the tag.
An advantage of the system is that any and all signals within the spectrum being intercepted by the wideband receiver can be captured and described for downstream (i.e., follow on) systems that will further process the signals. Thus, RF energy mapper 100 provides a very efficient method for providing the comparatively narrowband signals along with their descriptors (i.e., the so-called tags). Preferably, RF energy mapper 100 tags and stores both communications signals and radar signals.
As shown in FIG. 3, RF energy mapper 100 receives digital receiver samples in the time domain from one or more digital receivers, and generates selected energy tags for a follow-on subsystem. Preferably, RF energy mapper 100 performs this function in a twostep process. First, a tag generation process 102 identifies those spectral energy segments in the RF search band that are above a minimum amplitude and are not noise related. Tag generation process 102 is illustrated in FIG. 4 . Next, a tag screening process 104 is employed to limit the number of tags that are output to the follow-on system. Tag screening process 104 is illustrated in FIG. 6 .
As shown in FIG. 4, a tag generator 102 according to the present can include an FFT and windowing function 106 , a thresholding function 108 , a pattern recognition and noise filter function 110 , a line of bearing (LOB) filter 112 , a signal of interest (SOI) energy definition function 114 , and a signal storage function 116 .
FFT and windowing function 106 serves to convert the time domain representation of the spectrum into its equivalent in the frequency domain. FFTs are performed on the signal samples at rates that accommodate the signal set intended to be captured. Thus, FFT/windowing function 106 is typically constructed to provide for variable frequency binning and variable FFT rates. For communication systems intercept, for example, narrow frequency bins can be used as part of the FFT, while for radar intercept, wide frequency bins with FFTs executed at a much more rapid rate is required. FFT bin size selection will determine the detectability of the signal, as well as the system's ability to measure the arrival and departure time of the signals to be intercepted.
The output of the FFTs, which is a set of frequency domain power samples, is stored in signal storage 116 . Each of the frequency domain power samples has a value based on the RF energy that is present in the dwell bandwidth (f u −f l ) during the corresponding FFT window. The frequency domain samples are stored until a decision is made as to whether a pulse of interest is present in the RF spectrum. As will be described in detail below, if a pulse is detected in the RF spectrum, the tags that correspond to that pulse are forwarded to a follow-on system for further processing. Since the frequency domain samples are stored in signal storage 116 , the frequency domain samples can be forwarded to the follow on system on request. The follow on system can then perform an inverse FFT on the requested frequency domain samples, which will be, in general, a subset of the set of frequency domain samples stored in signal storage 116 , to reconstitute the signal of interest in the time domain.
It is important to note that this approach (i.e., storing and forwarding frequency domain samples) is much more efficient than storing and forwarding the corresponding time domain samples. According to the invention, only those bins that are required to reconstitute a relatively narrow band signal detected in a relatively wide band spectrum need to be forwarded to the follow on system. At the same time, no information is lost because the set of frequency domain samples includes all the signal information that the time domain samples include.
Thus, as a practical consideration, storing the frequency domain samples in signal storage 116 (which is basically a delay line) provides for an efficiency of processing of the selected signals. A broadband receiver that captures all the signals within its bandwidth makes it more difficult to process the multiplicity of individual narrowband signals. Preferably, the receiver is matched to the bandwidth of the signal desired to be processed. In such an implementation, with the signals being stored as their frequency domain representation, the follow on systems need only process a very small part of the entire intercepted spectrum related to the (comparatively) narrow band. This can result in an order of magnitude decrease in the follow-on processing of the signal, the order of magnitude being determined by the ratio of the full spectrum to the signal bandwidth.
The output of the FFTs is also inputted to threshold detector 108 , which basically converts the 3-dimensional output of the FFT function into a 2-dimensional representation. More specifically, the signal as presented at the output of the FFT function is a series of FFT bins. Thus, there is a first dimension, i.e., a representation of the spectrum in frequency. Second, the FFTs are performed periodically (i.e., once each FFT window period), thus there is a time dimension. Third, the value the FFT assigns to each frequency bin is a power level that represents the signal energy in that frequency bin during that window period. Thus, the third dimension is signal power.
For each frequency cell for each FFT window period, a binary decision is made to indicate the presence or absence of energy relative to a noise floor computation that, preferably, is continually adjusted for the RF intercept environment. The frequency-time-power vectors that are inputted to thresholding function 108 is reduced to a frequency-time grid, whose entries have a binary value (i.e., either a 1 or a 0) that depends on the power within each cell. The thresholding is a decision that can be made using varying degrees of complexity. The simplest form is a fixed level entered into the thresholder and any bin having a power level that exceeds the threshold results in the power level being converted to a one; wherever it is below the threshold, the power level is replaced by a zero. Thus, the output of threshold detector 108 is a grid in frequency and time that depicts significant power exceedances in each of the bins.
An exemplary frequency-time grid is shown in FIG. 5 (where Xs are used to represent bins having a value of one, and blanks are used to represent bins having a value of zero). As shown in FIG. 5, a preferred frequency-time grid includes 1024 frequency cells for each 2.56 microsecond window period. It should be understood that the number of frequency cells (i.e., FFT bins) can be selected based on the requirements of the specific application. For example, some radar signals are known to have pulse widths as low as 50 nanoseconds with a duty cycle on the order of 1%, while other radar signals can have pulse widths up to 1.5 microseconds at nearly 50% duty cycle. The proliferation of radar signals is typically in the 2-18 GHz band, but can occur in the range of 500 MHz to 40 GHz. Communications signals, on the other hand, can be much more narrow band than radar signals, and typically have nearly 100% duty cycle. It is known, however, that for signal systems such as frequency hoppers, the 100% duty cycle is relative to a hop frequency. Most communications signals are under 2 GHz, but can extend above 2 GHz in microwave and millimeter wave communications.
One advantage of the present invention is that the RF energy mapper provides apparatus and methods for detecting the presence of radar signals as well as communications signals in the same dwell data set. A system according to the present invention can utilize the RF energy mapper for both radar and communications intercept, although, in a preferred embodiment, it does not perform them simultaneously, but rather sequentially.
Threshold detector 108 can also be built to include more complex criteria for inclusion of a 1 or a 0 in each cell. That criteria analyzes the degree to which the power exceeds the threshold and for the duration that the power is there. Thus, short signals that barely make thresholds are more likely to be noise than signal, while strong signals of short duration are more likely to be signals than noise. Signals of low power with extended duration are also more likely to be signals than noise. Thus, a set of rules are formulated and implemented in a combination of hardware, firmware and software to execute this more elaborate threshold making function.
At this point, there is an N-to-1 data reduction in the amount of data passing through the system, where N is determined by the dynamic range of the digital samples representing the spectrum. For example, an 8-bit code would result in an 8-bit bin size, while a 16-bit code would result in a 16-bit bin size. In the first example, there would be an 8-to-1 data reduction, while in the second example there would be a 16-to-1 data reduction. The data reduction is a function of the requirements of the system that includes the RF Energy Mapper as a subsystem.
The frequency-time grid output from threshold detector 108 is then submitted to a noise filter 110 , wherein the grid is processed to eliminate noise. Noise, as that term is used herein, means anything other than a pattern indicative of a signal of interest (SOI), and that will be most of the energy in the frequency-time grid. Thus, a system according to the present invention is very much a noise processor. The noise filter is used principally to separate pulsed from continuous signals and to eliminate obvious noise patterns. “Continuous” includes modulated continuous waveform (CW) which, on a map, will appear as a continuous ragged signal relative to the frequency cells occupied. Lightning strokes, ignition noise, and other spiking, broadband noise produces clear patterns that can be deleted.
Once the noise is eliminated from the signals in the frequency-time bit map, the bit map is passed to a line of bearing (LOB) filter 112 . Line of bearing is also commonly referred to as “angle of arrival” or “azimuth.” The next level of processing uses angle of arrival to pass only those signals that are radiating from a sector or sectors that could contain signals of interest. The angle of arrival data reduction in a uniformly distributed environment will be the ratio of the sector size to 360 degrees.
Those spectral energy segments that have not been eliminated as noise are then subjected to pattern recognition and SOI energy definition process 114 to formally define the energy time and frequency extent. Process 114 follows a set of rules (which can be implemented in hardware, firmware, or software) for drawing rectangles in time and frequency around the patterns in the frequency-time grid. The length and width of those rectangles are measured in frequency and time, with specific starting and stopping positions, such as a lower frequency extent, f L , an upper frequency extent, f U , a start time of the rectangle, t 1 , and an end time of the rectangle, t 2 . The rules are set to encompass the whole frequency-time pattern of a given transient pulse when characterizing transient pulses. Thus, maximum variations in frequency determine the frequency extents and maximum extents in time determine the time extents. Any signal having a duration (t 2 −t 1 ) that exceeds a preset time duration, T max , is considered to be a continuous signal.
Process 114 also includes rejecting corrupted pulses and collecting fractured pulses in order to define a rectangular area to completely encompass each valid pulse. Energy may appear disassociated in a frequency-time grid when, in fact, the energy should be treated as a unified transmission. For example, in communications, voice signals have numerous breaks. Discrete frequency shifts and data communications will result in disconnections within the bit map when, in fact, it is a single, unified transmission.
Breaks in a pulse, if less than a preset percentage, can be ignored. In a preferred embodiment, this so-called “signal drop time percentage” is set at ⅓ of t 2 minus t 1 . It should be noted that this percentage is not critical to the pattern recognition function. It is merely a judgmental factor that can be considered a design variable. This sub-function within pattern recognition function 110 , which is sometimes referred to as “pulse healing,” can be implemented in hardware, firmware or software.
Then, as a function of the SOI, rules are applied for examination of not only each region where there is energy evident, but also in the surrounding region and an estimate is made of the frequency and time extents and a rectangle in frequency and time is drawn around energy containing regions. A tag is generated for each rectangle defining its bandwidth, center frequency, duration, and time of arrival. These tags are then subjected to a tag screening process as shown in FIG. 6 . This screening begins by subjecting the tags to a bandwidth filter 120 and a duration filter 122 . Signals that are too short or too long to fit the SOI characteristic will be filtered out. Signals with bandwidths not matching the SOI will also be filtered out. At this point, a refined examination of the RF energy map has been made.
For high rate signals, histogramming limiters 130 , which are described in greater detail below, can be used to limit pulses entering the narrowband processing section, which can be as high as 300,000/pps for a pulse doppler emitter. The azimuth and frequency histogrammers 124 , 126 serve to limit the maximum number of pulses accepted from a single emitter. In the case of a pulse doppler where a 100 ms dwell is employed during the intercept, as many as 30,000 pulses could be submitted to the system, it is unnecessary and undesirable to collect and process all of these pulses. The azimuth and frequency histogrammers will limit pulses to a programmable maximum, usually 128 pulses in any azimuth frequency range (nominally 1.25 MHz by 3 degrees). Typically, 128 pulses will be more than sufficient to characterize an emitter and track it accurately. In the example provided, a 300:1 reduction with no loss of performance is realized. For pulse rates under 1 kilopulse/sec with system setup described, no pulses would be lost due to thresholding.
Histogramming Limiters
A histogramming limiter according to the present invention is a system that uses histograms to limit data flow through a signal processing system so that the system is not overloaded. In a preferred embodiment, the histogramming limiter selectively limits data flow based on density of signal frequency and signal duration.
As described above in connection with FIG. 2, data flows through the system in dwell data sets. Typically, the dwell data set has redundant information in the case of high rate emitters when the purpose of the system is to detect and locate an emitter. To reduce data flow, a histogramming limiter allows only essential data to pass through the system while blocking redundant data.
FIG. 7 provides a flowchart of a histogramming limiter according to the present invention. A set of tags is produced, for example, by a tag generator such as described above. Each tag represents a pulse defined by a start time, end time, upper frequency, and lower frequency. From these values, pulse center frequency and pulse duration can be determined. The set of tags is provided as input to the histogramming limiter.
At step 202 , a frequency histogrammer generates a frequency histogram that represents the number of pulses that fall into each of a plurality of frequency bins. The frequency histogram is generated based on the center frequencies that are included in the tags. At step 204 , a frequency limiter determines, for each frequency bin, whether the number of pulses that fall into that bin exceed a predefined threshold. If so, only the threshold number of tags is passed on further into the signal processing system. Thus, the frequency histogrammer limits the number of tags that are allowed through the system based on frequency.
At step 206 , a pulse duration histogrammer generates a pulse duration histogram that represents the number of pulses that fall into each of a plurality of pulse duration bins. The pulse duration histogram is generated based on the pulse durations that are included in the tags. At step 208 , a pulse duration limiter determines, for each pulse duration bin, whether the number of pulses that fall into that bin exceed a predefined threshold. If so, only the threshold number of tags is passed on further into the signal processing system. Thus, the pulse duration histogrammer limits the number of tags that are allowed through the system based on pulse duration.
FIG. 8 provides a frequency histogram example with a pulse duration histogram for one frequency bin.
FIG. 9 provides a detailed description of a frequency histogrammer according to the present invention. As described above, the frequency histogrammer receives as input all the tags for a given dwell. In a preferred embodiment, the histogram is empty at the start of each dwell because the histogram counts pulses within each dwell period. At step 212 , the center frequency, f c , of each tag is computed by taking an average of the sum of f 1 and f 2 , the lower and upper frequencies of the tags. At step 214 , a histogram bin address is determined for each pulse. The frequency bin within which the pulse falls is determined by f c and its relation to f 1 , the lower frequency limit of the dwell. Thus, each frequency bin covers a range of frequencies.
Preferably, the pulse center frequency, f c , is rounded to the numeric precision of bin size at step 216 . For rapid computation and ease of construction, binary integer bin sizes can be used. At step 218 , the resulting binary integer is used as a relative address into the histogram, which, in a preferred embodiment, is a set of counters in memory. The content of a counter is advanced by one each time a pulse falls within its range. When a counter is advanced, the count is compared to a threshold value, at step 220 , and if the count exceeds the threshold, the limiter stops the tag from proceeding further through the system. Otherwise, the tag is passed through the system. The threshold is a value typically established when the system is initialized.
A similar process occurs for the pulse duration histogramming limiter, as shown in FIG. 10 . The input to this part of the histogrammer limiter is the subset of tags output from the frequency histogrammer limiter, and comprises the tag and the frequency bin number associated with each tag. The first operation is the computation of the pulse duration, t 2 −t 1 , at step 232 . The bin associated with the duration is determined, at step 234 , by rounding to a binary integer of length log 2 (M), where M is the total number of duration bins. Preferably, the pulse duration histogrammer limiter uses a set of histograms, one histogram for each frequency bin. At step 234 , the frequency bin number in the input then is used to select the corresponding duration histogram and, at step 236 , the pulse duration counter corresponding to the pulse duration bin is advanced within the selected histogram. The bin count in the selected bin is then output at step 238 . The output bin count is compared to a threshold at step 240 and, if the count does not exceed threshold, the tag is outputted for additional system processing. Otherwise, the tag is suppressed. Again, this threshold is normally set at system initialization.
Thus there have been described systems and methods for detecting signals across radar and communications bands. Those skilled in the art will appreciate that numerous changes and modifications can be made to the preferred embodiments of the invention and that such changes and modifications can be made without departing from the spirit of the invention. It is therefore intended that the appended claims cover all such equivalent variations as fall within the true spirit and scope of the invention.
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Apparatus and methods for processing RF signals are disclosed. A method according to the invention includes receiving a set of time domain energy samples representing signal energy present in an RF spectrum, transforming the set of time domain energy samples into a set of frequency domain power samples, determining from the set of frequency domain power samples whether a signal of interest is present in the RF spectrum, and forwarding to a follow on system a subset of the set of frequency domain power samples, wherein the subset corresponds to the signal of interest. Transforming the time domain samples can include dividing the set of time domain energy samples into a plurality of N windows, each of which is associated with a predefined window period, and performing an FFT on each said window to generate a set of K frequency bins, wherein each frequency bin has a value based on energy present in a predefined frequency band during the corresponding window period. Determining whether the signal is present can include generating an energy map that represents energy present in the RF spectrum as a function of frequency and time. The energy map can be a bitmap having N×K frequency cells, wherein each frequency cell has a binary value based on the value of a corresponding frequency bin. The binary value can be based on whether the value of the corresponding frequency bin exceeds a predefined threshold.
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BACKGROUND
[0001] Optical devices such as scanners and imagers are relied on for business and personal use in a wide variety of applications. Many of these devices are used in a variety of environments where rapid changes in temperature and humidity are common.
[0002] As would be understood by those skilled in the art, a rapid change in the temperature of the air within the housing of such a device can cause condensation to build up on an optical window of the device, interfering with operation. Although, condensation on an outer surface of the window can be wiped away, condensation within the housing is a more difficult problem to address.
SUMMARY OF THE INVENTION
[0003] The present invention is directed to an anti-condensation arrangement for an optical apparatus including a window mounted in a housing, the anti-condensation arrangement comprising an isolating member sealed around an end of an image collecting device of the optical apparatus and around a perimeter of the window, the isolating member substantially preventing airflow between a portion of the housing surrounding the isolating member and a space enclosed by the isolating member.
[0004] The present invention is further directed to an apparatus for controlling airflow within a housing including an image capturing device and a window through which light is transmitted between the image capturing device and an outside of the housing. The apparatus comprises a first sealing surface sealingly engaging a perimeter of the image capturing device, a second sealing surface sealingly engaging a perimeter of the window and a wall separating a space between the first and second sealing surfaces from a remainder of a space within the housing, the wall substantially preventing air flow between an outside thereof and the space enclosed thereby.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 shows a perspective view of a mobile device including an anti-condensation arrangement according to a first embodiment of the present invention;
[0006] FIG. 2 shows a perspective view of the device of FIG. 1 with a top of a housing thereof removed to show the anti-condensation arrangement according to the first embodiment of the invention;
[0007] FIG. 3 shows a perspective view of a front of an anti-condensation baffle of the anti-condensation arrangement of FIG. 2 ;
[0008] FIG. 4 shows a perspective view of a back of the anti-condensation baffle of FIG. 3 ;
[0009] FIG. 5 shows a perspective view of a mobile device including an anti-condensation arrangement with a top of a housing thereof removed to show the anti-condensation arrangement according to a second embodiment of the invention;
[0010] FIG. 6 shows a perspective view of a front of an anti-condensation baffle of the anti-condensation arrangement of FIG. 5 ; and
[0011] FIG. 7 shows a perspective view of a back of the anti-condensation baffle of FIG. 6 .
DETAILED DESCRIPTION
[0012] The present invention may be further understood with reference to the following description and the appended drawings, wherein like elements are referred to with the same reference numerals. The present invention will be described in regard to an anti-condensation arrangement for a laser scanning device and a digital imaging device. However, those skilled in the art will understand that these devices are exemplary only and that the anti-condensation arrangement according to the present invention may be applied to any device with a window.
[0013] As shown in FIGS. 1-4 , an optical device 10 which in this embodiment is a bar code scanner, includes a window 12 mounted in a housing 14 which includes, for example, a pistol grip 16 and a scanning actuator 18 . As shown in FIG. 2 , a known scanning engine 20 is mounted within the housing 14 along with supporting electronics, a battery, etc. As would be understood by those skilled in the art, the position of the scanning engine 20 relative to the window 12 is determined based on properties of the scanning engine 20 , the window 12 and the desired functionality of the device 10 . Specifically, the device 10 is constructed in a manner similar to known optical devices (with the exception of the anti-condensation arrangement described below) with optical properties of the window 12 and the scanning engine 20 dictating an optimal distance between a forward end 22 of the scanning engine 20 and an inner face of the window 12 and, consequently, determining the size of a space 24 within the housing forward of the forward end 22 of the scanning engine 20 .
[0014] An anti-condensation arrangement of the optical device 10 according to the present invention includes a baffle 26 which extends around the forward end 22 of the scanning engine 20 and encloses a portion of the space 24 including a line of sight for a laser or other light source of the scanning engine 20 and for light returning to the scanning engine 20 after reflection from a target. The baffle 26 seals around the forward end 22 of the scanning engine 20 to isolate the enclosed portion of the space 24 from the balance of the space 24 and from the interior space within the housing 14 . This reduces air flow between the enclosed portion of the space 24 and all other areas within the housing 14 except for such air flow as passes through the scanning engine 20 to the enclosed portion of the space 24 .
[0015] Specifically, as shown in FIG. 4 , a rearward facing portion of the baffle 26 includes a recess 28 which receives the forward end 22 of the scanning engine 20 with a sealing lip 30 sealingly engaging a perimeter of the forward end 22 of the scanning engine 20 . A forward end of the baffle 26 , as shown in FIGS. 3 and 4 , includes a window receiving recess 32 with an optical opening 34 formed therein. A sealing lip 36 extends around a perimeter of the opening 34 to sealingly engage an inner perimeter of the window 12 , pressing an outer perimeter of the window 12 against the perimeter of an optical opening in the housing 14 .
[0016] A wall 38 of the baffle 26 is preferably substantially continuous so that air flow to and from the enclosed portion of the space 24 through the wall 38 is substantially prevented. Of course, those skilled in the art will understand that the term continuous, in regard to this surface, is meant only with regard to the ability of air to pass therethrough and is not intended to limit the shape of the baffle 26 or any part thereof. Rather, the baffle 26 may be formed in any shape dictated by the shape and size of the housing 14 and the components to be included therein. In a preferred embodiment, the sealing lip 30 is joined to the forward end 22 of the scanning engine 20 to form an air-tight seal therewith while the sealing lip 36 forms an air-tight seal with the inner perimeter of the window 12 . As described above, this limits air flow between the enclosed portion of the space 24 and the rest of the interior of the housing 14 to air-flow passing to and from the enclosed portion of space 24 through the forward end 22 of the scanning engine 20 . However, those skilled in the art will understand that the baffle 26 need not completely seal the enclosed portion of the space 24 . Rather, to reduce condensation, the baffle need only restrict air flow to and from this enclosed portion of the space 24 to attenuate temperature fluctuations within the enclosed portion of the space 24 .
[0017] The baffle 26 is preferably formed of a compressible material which will, for example, absorb the force of any impact to the front of the device 10 and attenuate this force before it reaches the scanning engine 20 . In a preferred embodiment of the invention, the baffle 26 is formed of GLS Versollan OM 1262NX available from GLS Corporation. As would be understood by those skilled in the art, the baffle 26 may be formed of any suitable rubber or foam material which exhibits the desired shock absorbing properties and which provides a desired level of impenetrability to air.
[0018] As would be understood by those skilled in the art, the baffle 26 includes mounting features 40 which engage corresponding shapes of the engine mounting features to maintain the baffle 26 and the scanning engine 20 in desired positions relative to one another and to the housing 14 . Alternatively, the baffle 26 may be maintained in the desired position by a friction fit within the housing 14 and/or through engagement with the forward end 22 of the scanning engine 20 .
[0019] As described above, rapid changes in the temperature of the air within the housing of an optical device can cause condensation to build up on a window of the device. However, with the device 10 , the air in the enclosed portion of the space 24 between the forward end 22 of the scanning engine 20 and the window 12 is substantially isolated from the air in the rest of the interior of the housing 14 . Thus, the temperature of the air in the enclosed portion of the space 24 varies more slowly than that in the rest of the housing 14 and, as air is interchanged with this enclosed portion of the space 24 only by passing through the scanning engine 20 , the temperature change of the air within the enclosed portion of the space is further attenuated by exposure to the warmth emanating from the scanning engine 20 . By slowing the rate of temperature change of the air within the enclosed portion of the space 24 and reducing the overall volume of air in contact with the window 12 and, thereby reducing the volume of water in that air, the anti-condensation arrangement of the present invention reduces the build up of condensation on the inner surface of the window 12 , enhancing the operation of the device 10 .
[0020] An optical device 50 according to a second embodiment of the invention is shown in FIGS. 5-7 . The device 50 is, for example, an imager (e.g., a digital camera), with an imaging unit 52 mounted within a housing 54 in a manner similar to that described above for the scanning engine 20 . However, those skilled in the art will understand that the size of a space 56 between a forward end 58 of the imaging unit 52 and a window 60 of the device 50 may be smaller than the space 24 of the device 10 (i.e., the distance required between the window 60 and the forward end 58 is often less than that required for scanners). Those skilled in the art will understand that these distances may vary significantly depending on the components and desired characteristics of these devices.
[0021] The device 50 includes an anti-condensation arrangement including a baffle 62 which encloses a portion of the space 56 between the forward end 58 of the imaging unit 52 and the window 60 . Similarly to the anti-condensation arrangement of the device 10 described above, the anti-condensation arrangement of the device 50 substantially prevents air flow between the enclosed portion of the space 56 and the rest of the housing 54 except for air which flows through the imaging unit 52 .
[0022] As shown in FIG. 7 , a rearward facing portion of the baffle 62 includes a recess 66 in which the forward end 58 of the imaging unit 52 is received with a sealing lip 64 sealingly engaging a perimeter of the forward end 58 . In addition, as shown in FIG. 6 , a forward end of the baffle 62 includes a plurality of openings 63 to accommodate illumination LED's as would be understood by those skilled in the art. In addition, a window receiving recess 65 is formed in the baffle 62 with an optical opening 67 formed therein. A sealing lip 68 extends around a perimeter of the opening 67 to sealingly engage an inner perimeter of the window 60 , pressing an outer perimeter of the window 60 against the perimeter of a window receiving opening in the housing 54 .
[0023] As with the baffle 26 , a wall 70 of the baffle 62 is preferably substantially continuous so that air flow to and from the enclosed portion of the space 56 is substantially prevented. As described above, the term continuous, in regard to this surface, is meant only with regard to the ability of air to pass therethrough and is not intended to limit the shape of the baffle 62 or any part thereof. The baffle 62 may also be formed in any shape dictated by the shape and size of the housing 54 and the components to be included therein. In a preferred embodiment, the sealing lip 64 is joined to the forward end 58 of the imaging unit 52 to form a substantially air-tight seal therewith while the sealing lip 68 forms an air-tight seal with the inner perimeter of the window 60 . As described above, this limits air flow between the enclosed portion of the space 56 and the rest of the interior of the housing 54 to air-flow passing to and from the enclosed portion of space 56 through the forward end 58 of the imaging unit 52 . For example, the baffle 26 preferably restricts air flow into the enclosed portion of the space 24 by at least 80% as compared to a device without such a baffle while the baffle 62 restricts air flow to the enclosed portion of the space 56 by at least 90% as compared to a device without such a baffle. As would be understood by those skilled in the art, the difference in the restriction of air flow seen with the baffles 26 and 62 is substantially entirely due to difference in air flow through a scanning engine and a digital imager.
[0024] Similarly to the baffle 26 , the baffle 62 is preferably formed of a compressible material such as, for example, GLS Versaflex, which will, for example, absorb the force of any impact to the front of the device 50 and attenuate this force before it reaches the imaging unit 52 .
[0025] The baffle 62 includes mounting features 72 which engage corresponding shapes of the engine mounting features to maintain the baffle 62 and the imaging unit 52 in desired positions relative to one another and to the housing 54 .
[0026] It will be apparent to those skilled in the art that various modifications and variations can be made in the structure and the methodology of the present invention, without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
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An anti-condensation arrangement for an optical apparatus including a window mounted in a housing comprises an isolating member sealed around an end of an image collecting device of the optical apparatus and around a perimeter of the window, the isolating member substantially preventing airflow between a portion of the housing surrounding the isolating member and a space enclosed by the isolating member.
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OBJECT OF THE INVENTION
[0001] As stated in the title of this descriptive specification, the present invention relates to a machine for cleaning tunnels, walls and similar, which has been conceived for being able to carry out the cleaning in all kinds of tunnels, whether the roadway is wide or narrow, whether the height is high or low, as well as in tunnels with square cross-section or even those in the form of an arch in which the roof has a very pronounced curvature.
[0002] The object of the invention is to provide a machine capable of carrying out cleaning operations in tunnels, for both the walls and the roof and floor, on the basis of some special means which permit the positions of the cleaning tools to be adapted in the most appropriate and convenient way, according to is the type of tunnel or surface to be cleaned in each case.
BACKGROUND OF THE INVENTION
[0003] When cleaning tunnels, machines are normally used which are mounted on the trailer of a towing vehicle, whether this be a truck or other vehicle for hauling and/or appropriate transportation, and in this regard a machine described in WO 9749868 can be cited, as well as that described in Spanish Utility Model U 9301786, in which a machine is described that is preferably hauled with a towing vehicle and that comprises a tank with water for cleaning, along with an array of arms with nozzles for the outlet of water which is projected in the form of a curtain on the surfaces to clean. The cleaning elements themselves which consist of brushes, are fitted in a chassis made up of several articulated sections which can be activated by hydraulic cylinders, said chassis with the brushes forming a unit which is mounted in articulated fashion on the telescopic arm provided on the platform of the machine or carrier vehicle under consideration.
[0004] The said machine is valid for cleaning concrete tunnels in the form of an arch and those that are wide, carrying out the cleaning in the direction perpendicular to that in which the machine itself advances.
[0005] Nevertheless, when the tunnel has a square cross-section or its roof has a large curvature, or it is low and also very narrow, then the machine described in U 93017686 is not valid, or at least it encounters serious difficulties when it comes to carrying out the cleaning of the roof and walls, and it is currently impossible to clean the floor or the left-hand wall for all kinds of tunnel.
DESCRIPTION OF THE INVENTION
[0006] The machine forming the object of the present invention presents a series of features which permit an efficient cleaning to be carried out on any kind of tunnel, whether of the kind which has its roof in a pronounced arch and/or very high, or the kind which has a rectangular or quadrangular cross-section etc., which is achieved on the basis of certain means that allow for rotation and/or swiveling both upwards and downwards, as well as to the right and to the left, and it can be said that it performs three movements of rotation which make it possible to position the brushes on any part and surface.
[0007] Specifically, the inventive machine consists of a rotating cane column fitted on the appropriate transport or hauling vehicle, to which column is fitted an upper telescopic arm, with the ability to swivel upwards and downwards in order is to position its end at a higher or lower height, and fitted to this arm is an arm for holding the cleaning tools, the latter arm being able to rotate to the right or to the left in the horizontal plane, as well as to swivel upwards or downwards, and to have an end part holding the cleaning brushes, with the ability to rotate in order to achieve the folded position during transportation or the extended position in the work position, all this in such a way that, based on said rotations and/or swivelings, three movements are established which correspond to those that are considered as being the folding movement, the twisting movement and the tilting movement, according to three different points of rotation.
[0008] In terms of the means which the machine incorporates so that the arm holding the cleaning tools can perform the movement of folding towards the left and towards the right in the horizontal plane, these are constituted on the basis of a rotation shaft, by means of which the union is established between the telescopic arm of the crane, said rotation shaft belonging to that telescopic arm, and with respect to which is mounted a first piece which corresponds to the initial part of the arm holding the cleaning tools, in order to permit the rotation of the latter with respect to the said telescopic arm of the crane. That part of the arm holding the cleaning tools incorporates a hydraulic cylinder attached, via an articulation, to the first piece belonging to the said arm holding the cleaning tools, while the piston of that cylinder is articulated via its end to the actual arm of the crane, in such a way that the extension and/or retraction of the piston entails the lateral pushing or pulling of the arm holding the cleaning tools and with it the rotation of the same in one direction or the other, forming in each case an angle with the said telescopic arm of the crane.
[0009] In terms of the means which the machine incorporates so that the arm holding the cleaning tools can perform the swiveling movement of twisting upwards or downwards in the vertical plane, these are constituted on the basis of the first piece belonging to the initial part of the arm holding the cleaning tools, on which first piece is articulated, via a rotation shaft, a second piece belonging to that arm. Articulated to the rear end of the first piece is a hydraulic cylinder whose piston is simultaneously articulated to two plates, one articulated via its other end to said first piece and the other articulated via its free end to the second piece of the said arm holding the cleaning tools, in such a way that the extension or retraction of the piston of the hydraulic cylinder entails the swiveling upwards or downwards of the said second piece and with it that of the is rest of the arm holding the cleaning tools.
[0010] In terms of the means which the machine incorporates so that the arm can hold the cleaning tools, and more specifically the chassis forming part of that arm and in which the actual cleaning tools are fitted, they are constituted on the basis of a third piece articulated to the second piece of the said arm, and joined via its other end to the actual chassis of the cleaning tools. Between both second and third pieces is fitted a hydraulic cylinder whose piston is articulated to the second piece of the arm, while the cylinder itself is attached to the third piece, in such a way that the extension or retraction of the piston of the cylinder entails the rotation in the vertical plane in one direction or the other of the third piece and therefore of the chassis in which the cleaning tools are fitted.
[0011] In accordance with the three movements described for the arm holding the cleaning tools, the cleaning can be carried out of any kind of tunnel, be it of the kind with an arched roof, or of quadrangular or rectangular cross-section, permitting to carry out the cleaning of walls and floors with complete efficiency, by virtue of the fact that the chassis on which the cleaning brushes or tools are fitted is determined by a succession of articulated sections on one side and the other, in which sections the actual brushes constituting the cleaning tools are fitted, said sections being able to occupy different angular positions between each other, commanded by the respective hydraulic cylinders associated with the same, and thereby being able to adopt a trajectory that is twisted, appreciably bent or straight and thus being able to adapt itself to the surfaces to clean.
[0012] Finally, it can be said that the machine will be complemented with the appropriate water/detergent ducts along with control and handling devices for its correct functioning.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] In order to complement the description that is going to be made forthwith, and with the aim of facilitating a better understanding of the characteristics of this invention, this specification is accompanied by a set of drawings on the basis of which the innovations and advantages of the inventive machine will be more easily understood.
[0014] FIG. 1 . Shows a general schematic view of the machine on a carrier vehicle.
[0015] FIG. 2 . Shows a perspective view of part of the machine where the means of rotation in the horizontal plane, to the left and the right, of the arm holding the cleaning tools are established.
[0016] FIG. 3 . Shows a perspective view of part of the machine where the means of swiveling upwards and downwards of the arm holding the cleaning tools are established.
[0017] FIG. 4 . Shows a perspective view of part of the machine where the means of rotation in the vertical plane of the chassis, forming part of the arm holding the cleaning tools are established, in which chassis the actual cleaning tools are fitted.
[0018] FIG. 5 . Shows a schematic plan view of the telescopic arm belonging to the crane of the machine, connected to the arm holding the cleaning tools and the chassis of this arm with the articulated sections on which the actual cleaning tools will be fitted. This figure allows one to see by means of dashed lines the different angular positions which can be occupied by the sections of the chassis corresponding to the arm of the cleaning tools.
DESCRIPTION OF THE PREFERRED FORM OF EMBODIMENT
[0019] With the said figures in view, it can be seen how the machine forming the object of the invention is constituted on the basis of a crane column 1 mounted in rotating fashion on the platform of a carrier vehicle 2 , which can be a truck, a tractor with trailer, etc. Articulated on the upper end of said column 1 is a telescopic arm 3 able to swivel upwards or downwards by means of a hydraulic cylinder 4 , said telescopic arm 3 having another hydraulic cylinder 5 which is in charge of carrying out the extension or retraction of said arm 3 , the free end of which is in turn articulated to an arm 6 holding the cleaning tools 7 , such as brushes, scrapers or similar.
[0020] The said arm 6 can carry out various rotation movements in order to appropriately direct and adapt the cleaning tools 7 on the surface to clean, whether these be the side walls or even the floor, independently of the width, height and general configuration of the tunnel in question.
[0021] One of the movements which the arm 6 can make is the horizontal rotation to the left and to the right with respect to a rotation shaft 8 provided in the end of the telescopic arm 3 and secured to it. This rotation shaft 8 forms a means of articulation of a first piece 9 belonging to the arm 6 on the actual telescopic arm 3 , to which piece 9 is laterally articulated the body of a hydraulic cylinder 10 whose piston 10 ′ is articulated to the actual telescopic arm 3 . The articulation of the body of the cylinder 10 to the first piece 9 of the arm is referenced with 11 , while the articulation of the piston 10 ′ to the telescopic arm 3 is referenced with 12 . On the basis of the aforementioned means, when the piston 10 ′ of the cylinder 10 extends or retracts, the rotation of the piece 9 will take place and therefore of the entire arm 6 to the left or to the right, forming an angle with respect to the telescopic arm 3 .
[0022] Another movement which the arm 6 can make is that of swiveling in the vertical plane, upwards or downwards, for which provision has been made for a second piece 13 of the arm 6 to be articulated by means of the rotation or swiveling shaft 14 to the first piece 9 of said arm 6 .
[0023] The activation is effected starting from a hydraulic cylinder 15 with its end 16 articulated to the first piece 9 , in correspondence with the lower and rear part of the latter, while the piston 15 ′ of said cylinder 15 is articulated, according to the point 16 , simultaneously to two plates 18 and 19 , the first of them articulated via its other end 20 to the first piece 9 while the second plate 19 is articulated via its other end 21 to the second piece 13 of the arm 6 . In this way, when the piston 15 ′ of the cylinder 15 is extended or retracted, the swiveling will be produced upwards or downwards of the second piece 13 with respect to the first piece and therefore of the arm 6 , starting from said first piece 9 .
[0024] Moreover, the arm 6 can carry out a third rotation movement, specifically of the end chassis 22 which forms part of the actual arm 6 , and on which the cleaning tools 7 are fitted.
[0025] Said chassis 22 is integral with a third piece 23 of the actual arm 6 , this third piece 23 being fitted in an articulated and rotary manner with respect to the second piece 13 , with the particular feature that articulated to a lug 24 of that piece 13 is the end of the piston 25 ′ corresponding to a hydraulic cylinder 25 , the body of which is articulated to the said third piece 23 , this articulation being referenced with 26 , while the articulation of the piston 25 ′ to the lug 24 is referenced with 27 .
[0026] In accordance with the aforementioned means, when the piston 25 ′ of the cylinder 25 is extended or retracted the swiveling or rotation is produced towards the right or left, in the vertical plane, of the third piece 23 , and with it that of the chassis 22 on which the cleaning tools 7 are fitted.
[0027] The said chassis 22 is prolonged to both sides in an array of sections 22 ′ successively articulated together, permitting the assembly to adapt itself to the is different zones or surfaces on which the cleaning is intended to take place, since it is on those sections where the actual cleaning tools 7 are fitted. The articulations between sections 22 ′ are referenced with 28 , between each pair 22 ′ of which is a hydraulic cylinder 29 by means of which one or the other orientation of a section is carried out with respect to the contiguous one and so an appreciably bent, straight, twisted, etc., trajectory is thus obtained.
[0028] Logically, the machine being described will be complemented with the appropriate ducts and means suitable for pumping water and detergents towards the cleaning tools 7 , these elements not having been represented since they are conventional and in order to permit a greater clarity in the representation of the means involved in executing the movements which the arm 6 can, as a whole, carry out, in accordance with what has been described above.
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The machine comprises a rotating crane column ( 1 ) with a telescopic arm ( 3 ) activatable by a hydraulic cylinder ( 5 ). The arm ( 3 ) supports a second arm ( 6 ) to which the cleaning tools ( 7 ) are fitted. The arm ( 6 ) can make different movements with a view to directing and adapting the cleaning tools ( 7 ) over any surface (walls, ceiling and floor). Said cleaning tools ( 7 ) are fitted to a chassis ( 22 ) attached to the arm ( 6 ), a chassis ( 22 ) which has a series of mutually articulated sections ( 22′ ), in such a way that the various articulated arms, sections and elements enable all types of movements driven by appropriate hydraulic cylinders ( 10, 15, 25, 29 ).
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[0001] This patent application claims priority from and is a continuation-in-part of and incorporates by reference the specification of U.S. patent application Ser. No. 10/801,410 filed Mar. 16, 2004, the specification which is incorporated herein by reference, which in turn claims priority from and is a continuation-in-part of U.S. patent application Ser. No. 10/062,119 filed Jan. 31, 2002, which in turn claims priority from and claims the benefit of 60/299,225 filed Jun. 19, 2001.
FIELD OF THE INVENTION
[0002] Applicant's invention relates to a method for making road base using primarily waste material from oil and gas waste solids and non-hazardous industrial waste or natural occurring porous or semi-porous material to create a asphalt stabilized road base that is environmentally safe and meets industry standards for quality materials. More particularly, it relates to combining, in a cold batch mixing process, treated oil and gas waste material with aggregate to provide the major components for the roadbed base material.
BACKGROUND OF THE INVENTION
[0003] Because of their importance in all aspects of both business and private life, the construction of roads has historically been of prime importance to a society. That importance remains today. However, it has also become more apparent in recent years that most resources are not infinite but rather, are depletable. Additionally, disposing of waste materials is becoming harder and harder due both to space limitations and liability resulting from waste materials entering the environment.
[0004] Thus, there is a need for developing methods to recycle waste products into new, usable products. If the components of roadbeds can be obtained from the waste products of other products and processes, then both waste product production is decreased and new product consumption is decreased. Further, it is advantageous to recycle waste products due to the economic advantage of using recycling materials and thus compounding return on the original costs of the products.
SUMMARY OF THE INVENTION
[0005] The primary focus of the invention is the treatment of oil and gas waste for use with other materials to make a suitable road base material. Treatment of oil and gas waste is done to remove at least a portion of a liquid component, typically primarily oil and water to yield a treated oil and gas waste portion which is then combined with an aggregate and a binder and stabilizer to produce a suitable road base material. The treatment of the oil and gas waste, while yielding a liquid portion may also yield other recyclable or useable products such as clean mud. Clean mud is a product often desired by oil and gas well drillers. Thus, it is the desired result of the present invention of using oil and gas waste material treated such that it is converted into a material that is useable and, excepting perhaps “waste water” which may be reinjected, yields environmentally friendly, economically valuable components.
[0006] Turning to the separation of the liquid component from the oil and gas waste material it is anticipated by the present invention that there are a number of methods of liquid portion removal. One such method is a novel means of stacking of oil and gas waste, to yield gravity induced separation of some of the liquid portion from the solid portion. Another method is mechanical separation, such as by a centrifuge. A third method is mixing with a dry material, such, for example, as soil, overburden, or caliche limestone.
[0007] The present invention provides a novel method to produce road base material using waste products from one or both of two industries: oil and gas well drilling and from construction and/or demolition and manufacturing projects. The present invention also provides for a novel road base composition. The oilfield waste is typically comprised of hazardous and/or non-hazardous oilfield solid or liquid waste such as water based drilling fluid, drill cuttings, and waste material from produced water collecting pits, produced formation sand, oil based drilling mud and associated drill cuttings, soil impacted by crude oil, dehydrated drilling mud, waste oil, spill sites and other like waste materials tank bottoms, pipeline sediment and spillsite waste. Oilfield waste may include waste or recycled motor oil, petroleum based hazardous or non-hazardous materials, such oilfield waste materials are collectively referred to as “oil and gas waste material.” They typically have a solid component and a liquid component, the liquid component including quantities of oil and water. The solid components may be, in part, particulate.
[0008] An aggregate component of the road based material may include a non-hazardous industrial waste as defined in more detail below or any natural occurring stone aggregate such as limestone, rip rap, caliche, sand, overburden, or any other naturally occurring porous material. There may or may not be preparation of the aggregate material prior to combining with the treated oil and gas material to form the primary component of the road based material of Applicant's present invention.
[0009] The construction and/or demolition or manufacturing waste component of the aggregate material is typically comprised of non-hazardous industrial waste such as waste concrete, waste cement, waste brick material, gravel, sand, and other like materials obtained as waste from industrial construction, demolition sites, and/or manufacturing sites. Such materials are collectively referred to as “non-hazardous industrial waste.”
[0010] One application of the method of the present invention provides for recycling the oil and gas waste material and the non-hazardous industrial waste to combine to produce road base. Another application of the present invention provides for recycling the oil and gas waste material and an aggregate including limestone, rip rap, caliche, or any naturally occurring porous or semi-porous material to combine to produce road base. Hydration and mixing of the treated oil and gas waste material and aggregate along with a binder such as cement, fly ash, lime, kiln dust or the like, will achieve an irreversible pozzolanic chemical reaction necessary for a road base. An asphalt emulsifier may be included in the binder to manufacture asphalt stabilized road base. The ingredients are typically mixed in a cold batch process.
[0011] Solid waste from the oil and gas waste material typically contains naturally occurring aluminas and silicas found in soils and clays. The added pozzolan will typically contain either silica or calcium ions necessary to create calcium-silica-hydrates and calcium-aluminatehydrates. A pozzolan is defined as a finally divided siliceous or aluminous material which, in the presence of water and calcium hydroxide will form a cemented product. The cemented products are calcium-silicate-hydrates and calcium-aluminate-hydrates. These are essentially the same hydrates that form during the hydration of Portland Cement. Clay is a pozzolan as it is a source of silica and alumina for the pozzolanic reaction. The aggregate including natural stone aggregate or non-hazardous industrial waste adds structure strength and bulk to the final mix.
[0012] The process of creating a stabilized road base using an aggregate including non-hazardous industrial waste and oil and gas waste material may incorporate a water based chemical agent such as waste cement, varying amounts of aggregate and waste to produce a cold mix, stabilized road base product. An aggregate crusher may process the inert material (typically aggregate including the non-hazardous industrial waste or natural stone aggregate), into the size and texture required (from, for example ½″ to 4″). The aggregate is added to the treated oil and gas waste material at a desired ratio. It has been found that an approximate ratio of one-to-one treated oil and gas waste material to aggregate provides a good mix. This could vary depending upon the degree of contamination or the quality of the oil and gas waste. A chemical reagent is added to congeal the mixture. An asphalt emulsifier is added to create an asphalt stabilized road base. The resulting product is a stabilized road base that not only is of a superior grade, but will not leach hydrocarbons, chlorides or RCRA metals in excess of constituent standards set forth in the Clean Water Act.
[0013] In order to further the environmental objectives of the present invention, it is desirable to isolate the oil and gas waste material from the environment prior to mixing. Thus, while the aggregate may be stored on the ground, oil and gas waste material should be stored surrounded by a berm and/or placed on a cement pad, or otherwise isolated by a physical barrier that will prevent leaching of liquid contaminates into the soil. This also prevents storm water runoff. The manufactured road base typically is mixed, processed, and likewise stored surrounded by an earthen berm and on a cement pad and/or other physical barrier that will prevent leaching of liquid contaminates into the soil. Thus, the present invention provides a novel method that will produce grade road base material.
[0014] Among the objectives of the present invention are to:
[0015] a. combine treated oil and gas waste material with aggregate to produce a stabilized road bed composition;
[0016] b. reduce waste from oil drilling, and construction/demolition and manufacturing;
[0017] c. reduce the use of new materials for roadbeds;
[0018] d. provide a method for producing roadbed material at a lower cost than conventional methods;
[0019] e. provide methods of treating oil and gas waste material to yield a material that can be used for preparing a stabilized roadbed and also yield clean mud and water;
[0020] f. combine treated oil and gas waste material with non-hazardous industrial waste or naturally occurring material to yield an environmentally safe, usable, stabilized road bed composition;
[0021] g. provide simple methods of removing a liquid component from oil and gas waste material;
[0022] h. recycle aggregate waste from construction, demolition and manufacturing sites;
[0023] i. provide for a single site or location to which oil and gas waste is transported and at which it is treated and mixed to a road base composition; and
[0024] j. extract products of economic value from oil and gas waste material; including, without limitation, crude oil, diesel oil, water, oil-based drilling mud and water-based drilling mud.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is an overview of a process of storage and treatment by dry mixing the oil and gas waste material.
[0026] FIG. 1A is a generalized view of a process of Applicant's present invention.
[0027] FIG. 2 is a flow chart illustrating an overview of a process of combining treated oil and gas waste material and aggregate to produce, typically in a pug mill, waste mix 14 , which cures to form a novel road base.
[0028] FIGS. 2A-2D illustrate Applicant's novel method and device for stacking oil and gas waste material.
[0029] FIGS. 3 and 3 A represent preferred alternate embodiments of a process of treating the oil and gas waste material to prepare it for combination with the aggregate waste material.
[0030] FIG. 4 shows an alternate preferred embodiment of Applicant's present invention that may be incorporated in whole or in part into previous embodiments of Applicant's present invention.
[0031] FIG. 5 illustrates an alternate preferred embodiment of Applicant's present invention that may be incorporated in whole or in part into the embodiments set forth here and above.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] FIG. 1A illustrates an overview of the steps of Applicant's present invention, Applicant provides for, in obtaining step 1 A, obtaining oil and gas waste from an oil and gas waste site as set forth in more detail below and transferring the waste to a treatment and mixing site. The second step, the obtaining step 1 B, is that of obtaining an aggregate, typically inert, from a natural source such as limestone rock, caliche, rip rap, sand, dirt or the like or, as waste material from a construction, manufacturing, or demolition site. Step 2 is the treatment of oil and gas waste to remove fluids and obtain water and recyclable material, which may be further processed. The third step is some form of mixing (as described in more detail below) wherein treated oil and gas waste is combined with aggregate and other material to provide an environmentally safe roadbed.
[0033] Turning back to the oil and gas waste, it is typically transported to the treatment site where Applicant's novel treatment provides several methods of removing at least some of the fluids, from the oil and gas waste material to provide a treated oil and gas waste material road base component which then is mixed with the aggregate to form a road base. As is apparent from FIG. 1A , the treatment step, step 2 removes water and also provides for recyclable or reusable material, such as clean mud and oil in step 2 A. Further, it is seen that step 3 , a step of mixing, may include not only the mixing of the aggregate with the treated oil and gas waste, but also mixing in other material such as binder, emulsion, etc., as set forth in more detail below. The result of the novel process is to provide a novel road base composition which is made up of treated oil and gas waste material and an aggregate and to apply such composition to a road base location.
[0034] Turning to FIG. 1 , it is seen that, what is received from the oilfield site ( 32 ) at mixing site ( 16 ) is either tank liquids ( 30 A) or truck solids ( 30 B) sometimes called “cuttings”. We will call these materials collectively oil and gas waste material ( 10 A). Upon arrival at mixing site ( 16 ), tank liquids ( 30 A) may be deposited into a leak proof liquid storage tank ( 11 ). Truck solids ( 30 B), which have a more solid like consistency than the tank liquids ( 30 A), may be deposited on an impervious layer ( 19 ) and contained, typically, in a earthen storage berm ( 13 ). FIG. 1 shows that tank liquids ( 30 A) and truck solids ( 30 B), collectively referred to as oil and gas waste material ( 10 A) is obtained from an oilfield site ( 32 ) including but not limited to drilling sites, pit clean-up sites, spill clean-up sites, blow-out sites and oil and gas exploration, pipelines and refining industry or production sites. Typically the oil and gas waste material ( 10 A) will be either “liquids” transported away from the oilfield site ( 32 ) in vacuum trucks or waste of a more “solid” or “slurry” consistency and transported in dump trucks. The oil and gas waste material ( 10 A) is transported from the oilfield site ( 32 ) to a mixing site ( 16 ) by a first transport such as by a vacuum truck for liquids (“tank liquids”) ( 30 A) or a second transport such as a dump truck for the “slurries” (“truck solids”) 30 B. FIG. 1 illustrates the dry mixing method of treatment; truck solids ( 30 B) may be combined with soil ( 15 ) or other dry, absorptive indigenous material to help dry them and then stored on an impervious layer ( 19 ) as dried truck solids ( 17 ) in a storage pile ( 19 A) on an impervious layer ( 19 ). The impervious layers disclosed herein are man-made, as from concrete, plastic, steel, the road base material described herein or the like. Indeed, all of the storage and treatment of the oil and gas waste material ( 10 A) may take place in an enlarged enclosure the bottom of which has an impervious layer ( 19 ) and optionally, sides of which include a storage beam ( 13 ) made of either concrete or some other suitable material.
[0035] The next step in handling the oil and gas waste material ( 10 A) is to treat it to at least remove some of the liquids therefrom (typically oil and water) so as to prepare a treated oil and gas waste/road base component material ( 29 ) for mixing in the pug mill ( 18 ) to produce road base ( 20 ). Applicant provides a number of processes to treat the oil and gas waste material ( 10 A). These processes include “dry mixing” as illustrated in FIG. 1 , “stacking” as illustrated in FIG. 2B and “mechanical separation” as illustrated in FIGS. 3 and 3 A. FIG. 1 illustrates a treatment of oil and gas waste material 10 A.
[0036] Turning to FIGS. 2A-2D , Applicant's treatment by stacking is illustrated. In this preferred embodiment of treatment of oil and gas waste by way of a draining/evaporation process, the draining induced by gravity and the weight of the waste material itself is used along with a unique apparatus including a drainage assembly ( 60 ) to help remove oil and other liquids from either the truck solids ( 30 B) or a mixture of truck solids ( 30 B) and tank liquids ( 30 A). It is pointed out here that it is preferable that the oil and gas waste material ( 10 A) be treated to remove some of the liquids as it then makes the mixing of the road bed composition more effective. Typically, when the treated oil and gas waste material ( 10 A) is paint filter dry or thereabout, it is sufficiently dry or damp to be processed in the pug mill. Moreover, it is not necessary for all the fluids to be removed from the oil and gas waste material ( 10 A) which may in fact, be somewhat damp after treatment.
[0037] Turning back to FIG. 2A it is seen that the stacking step ( 28 A) includes a step of providing a drainage assembly ( 60 ) which includes a screened enclosure ( 62 ) typically three-sided and contained within the an impervious enclosure ( 64 ). More specifically, drainage assembly ( 60 ) is designed to contain within impervious enclosure ( 64 ) the screen enclosure ( 62 ) which is usually constructed from rigid frame member ( 62 A) consisting of angle iron welded or bolted together, which frame members secure screened walls ( 62 B), which screened walls may be made from a suitable screening material or expanded metal, with holes, typically in the range of sixty mesh to ¼ inch. The screened enclosure ( 62 ) is located in an impervious enclosure ( 64 ), which impervious enclosure includes a bottom wall ( 64 A) and a side wall portion ( 64 B). It is seen that the dimensions of the screen enclosure ( 62 ) are such that there is a gap created between screened wall ( 62 B) and side wall ( 64 B) of the impervious enclosure ( 64 ). It is in the gap ( 65 ) created by the dimensions of the screened enclosure ( 62 ) and impervious enclosure ( 64 ) respectively, that drainings ( 71 ), that is liquids comprising typically oil or some water, collect. Within screened enclosure ( 62 ) and typically piled such that its vertical height exceeds the length or width of the screened enclosure ( 62 ) is stacked oil and gas waste ( 59 ) which is comprised of either truck solids ( 30 B) or a combination of truck solids ( 30 B) and tank liquids ( 30 A). Stacking the stacked oil and gas waste ( 59 ) in a manner so that is has a substantial vertical dimension (height) helps to ensure that there is sufficient weight to squeeze out drainings ( 71 ), which may be then evacuated either continuously or periodically from gap ( 65 ) through the use of a pumping or vacuum system ( 66 ). The pumping system includes pump ( 66 A) and an engaging tube or hose ( 66 B) or a vacuum hose attached to a vacuum truck (not shown). Tube or hose ( 66 B) has a first end for immersion in the drainings ( 71 ) and a removed end outside impervious enclosure for transporting drainings to a desired site. Pump ( 66 A) may be electric or hydraulic or any other suitable means and may be float controlled for it to be activated when draining ( 71 ) reaches sufficient depth within impervious enclosure ( 64 ).
[0038] An alternate preferred embodiment of Applicant's drainage assembly ( 60 ) there may be troughs or grooves ( 65 ) provided in the bottom wall ( 64 A) of impervious enclosure ( 64 ) to assist in the draining of the stacked oil and gas waste ( 59 ) (See FIG. 2B ).
[0039] The drainage assembly ( 60 ) may be any size, but is preferably designed to contain from 1 yard to 300,000 yards of stacked oil and gas waste ( 59 ) which may be dumped into the screened enclosure ( 62 ) using a front end loader or by dump truck or vacuum truck. They may be left to allow for the draining anywhere from a day to ten days or longer depending upon how saturated they are at the beginning of the treatment process. They are then removed from the screened enclosure ( 62 ) by any suitable method and are then typically ready for transport to the pug mill for mixing.
[0040] FIGS. 2C and 2D represent comp elevation of use and a cutaway side view of an ultimate preferred embodiment of Applicant's drainage assembly ( 80 ). This embodiment differs from the embodiment illustrated in FIGS. 2A and 2B in several respects. First, the stacked oil and gas waste ( 59 ) is enclosed in a three-sided or walled mesh enclosure ( 82 ). That is, drainage assembly ( 80 ) includes a three-walled mesh enclosure ( 82 ) that consists of a side wall ( 82 A), a back wall ( 82 B) and a second side wall ( 82 C), opposite side wall ( 82 A). The three-walled mesh enclosure has an open front ( 82 D). The mesh enclosure ( 82 ) lies within concrete retainer shell ( 86 ) or impervious layer and slightly spaced apart therefor to create a gap ( 65 ). Retainer shell ( 86 ), typically made from concrete and about three feet high, has typically three walls: side wall ( 86 A), back wall ( 86 B), second side wall ( 86 C), the second side wall being opposite the first side wall. The retainer shell has an open front ( 86 D) to allow dump trucks to back in and dump their load of oil and gas waste. A floor ( 86 E), typically concrete, is provided.
[0041] The retainer shell is typically about 100 feet by 100 feet with the back and two side walls about three feet high. Further, the floor is typically slanted a few degrees from horizontal dipping towards the back wall to allow liquids to drain to the back rather than out the open front.
[0042] Mesh or screen sections ( 84 ) typically come in 4-foot by 8-foot sections and can be laid lengthwise inside the side and back walls of the impervious enclosure spaced apart therefrom by the use of steel braces ( 88 ) set vertically on the floor and typically having a length of about four feet (representing the height of the 4′×8′ sections) which lay on the concrete floor. The braces will prevent the mesh or screen ( 84 ) from collapsing from the weight of the oil and gas waste material stacked against it and the braces provide for a gap ( 65 ), usually about six inches or so, from which a pump or vacuum system and related plumbing may be provided to remove liquids accumulating therein. It is seen that across the top of the beams enjoining a top perimeter of the wire or mesh section is a closed top ( 90 ) typically with an access door ( 90 A). The function of the closed top is to prevent any oil and gas waste material stacked too high from falling over the top perimeter of the mesh section into the gap between the mesh section and the concrete wall. The access door may be opened to periodically insert a hose or pipe to evacuate accumulated liquids from gap ( 65 ). It is noted with reference to FIG. 2D that mesh typically stands a bit higher than the top of the three walls of the retainer shell. The space between the top of the impervious layer and the closed top ( 90 ) may be left open or closed with a suitable member. Closing that area would of course prevent accidental spillage of material into gap ( 65 ).
[0043] The material that accumulates in the gap is oil with some water and may be sent to the mud tank or used to add to clean mud. It further may be separated, having an oil component and a water component with the water component disposed of, and the oil component used to add to the clean mud.
[0044] As is illustrated in FIG. 2 , the oil and gas waste treatment ( 28 ) may also treat the oil and gas waste ( 10 A) to remove a crude oil or diesel oil component ( 21 ), a clean mud component ( 23 ), both water-based and oil-based, and a water component ( 25 ), yielding treated oil and gas waste/road base component material ( 29 ). These components in many instances have economic value and are either resold or reprocessed. Oil and gas waste material produced from a working oil well typically comprises at least some production and/or completion fluids, cuttings, drilling mud, and some residual crude oil. As discussed in further detail below, the liquid components are extracted during the treatment ( 28 ) process. Crude oil and diesel oil ( 21 ) are skimmed from the extracted liquids. The crude oil is then typically resold and the diesel oil is typically reapplied into finished drilling mud that is then resold or reused.
[0045] The treated oil and gas waste/road base component material ( 29 ) may then be combined with stone ( 42 ), “sized” stone ( 44 ), non-hazardous industrial waste ( 12 ), or “sized” non-hazardous industrial waste ( 37 ) or a combination of the preceding. These may be combined directly with the treated oil and gas waste/road base component material ( 29 ) in a pug mill ( 18 ) or other suitable mixer or may be combined to form a pre-mix ( 31 ), which is then deposited into a pug mill ( 18 ) for further combining the two components together and for adding such as portland cement ( 22 ) and a binder such as asphalt emulsion ( 24 ) to yield, upon curing, the stabilized road base ( 20 ) (water may be added as necessary).
[0046] The second of the two primary components of the stabilized road base ( 20 ) is an aggregate component ( 61 ) which is collectively either stone ( 42 ) (naturally occurring) and/or non-hazardous industrial waste ( 12 ). This non-hazardous industrial waste ( 12 ) typically consists of inert aggregate material, like broken up brick or cinderblock, broken stone, concrete, cement, building blocks, road way, and the non-metallic and non-organic waste from construction and demolitions site.
[0047] Non-hazardous waste ( 12 ) can be obtained from many sources and have many compositions. It includes waste brick materials from manufacturers, waste cement or other aggregate solid debris of other aggregate from construction sites, and used cement and, cement and brick from building or highway demolition sites.
[0048] Aggregate sites ( 34 ) include construction sites, building and highway demolition sites and brick and cement block manufacturing plants quarries, sand, dirt, or overburden or caliche pits. The aggregate is transported by dump trucks or the like to mixing site ( 16 ) where it may be separated down to a smaller size, that is, into aggregate particles typically less than 1½″ in diameter by running them through a screen ( 33 ). Any material that is left on top of the screen may go to a crusher ( 35 ). That material may go back to the screen ( 33 ) until, falling through the bottom of the screen and measuring less than about 1½″ in size. This will result in what is referred to as “sized” aggregate ( 30 ). This sized aggregate ( 30 ) is the aggregate component of the stabilized road base ( 20 ). It may then be combined with the treated oil and gas waste/road base component material ( 29 ) in a pre-mix ( 31 ) as by using backhoes or loaders to scoop treated oil and gas waste/road base component material ( 29 ) to physically mix with sized aggregate ( 30 ) (or unsized aggregate) to create a pile or batch of pre-mix ( 31 ), which then can be added to the pug mill ( 18 ). Optionally, this premix ( 31 ), if it has sufficient dampness from residual oil and moisture, may be combined with sufficient portland cement ( 22 ) to coat the particles, before putting it into the pug mill ( 18 ). As set forth above, treated oil and gas waste/road base component material ( 29 ) may be deposited directly into the pug mill ( 18 ) and sized aggregate ( 30 ) can be separately dumped into the pug mill ( 18 ) and the material mixed directly without a pre-mix ( 31 ). Note that portland cement ( 22 ) and asphalt emulsion ( 24 ) may also be added to the pug mill ( 18 ) while the two primary components, treated oil and gas waste/road base component material ( 29 ) and aggregate are being mixed. Typically, the treated oil and gas waste/road base component material ( 29 ) and aggregate ( 30 ) are mixed in a ratio of about 50/50, but may be between 20/80 and 80/20. After the material is thoroughly mixed in the pug mill ( 18 ), it is deposited on the ground and may be contained by a berm ( 13 ) on a impervious layer ( 19 ) for curing (typically for about 48 hours). At this point, leach testing ( 40 ) can also be performed to determine whether or not the ratios of any of the materials need to be adjusted. Leach testing is usually done at a lab to ensure that materials from the road base do not leach into the ground.
[0049] The oil and gas waste material ( 10 A) is comprised of hazardous and non-hazardous hydrocarbon based discarded material by oil and gas exploration production, transportation, and refining industries. Oil and gas waste material may include water base drilling fluid, drill cuttings, waste material from produced water collecting pits, produced formation sand, oil based drilling mud and associated drill cuttings, soil impacted by crude oil, dehydrated drilling mud, oil, pipelines and refining industries and like waste materials. It may be “dried” by one or more of the novel drying processes disclosed herein. The term oil and gas waste material as used herein is not intended to be limited by definitions found in various codes or statutes.
[0050] Typically the oil and gas waste material ( 10 A) contains enough liquids such that the aggregate ( 61 ) will likely become saturated if a mix is prepared without removal of some liquids, Therefore, the oil and gas waste treatment ( 28 ) of the tank liquids ( 30 A) or truck solids ( 30 B) is usually required. Oil and gas waste treatment ( 28 ) may also be used when clean mud is desired, since clean mud is often readily saleable. The oil and gas waste treatment ( 28 ) results in the production of clean oil and gas waste/road base component material ( 29 ) from the oil and gas waste material ( 10 A).
[0051] The term “dry” is relative and means less liquid than before oil and gas waste treatment ( 28 ), typically, resulting in the loss of sufficient liquid such that mixing with the aggregate ( 61 ) will not result in saturation of the combination. If an oil and gas waste treatment ( 28 ) is used, then the treated oil and gas waste/road base component material ( 29 ) are mixed with the aggregate ( 61 ) and portland cement ( 22 ) and emulsion ( 24 ) in a ratio that results in a stabilized product. That ratio is determined by testing leachability of the roadbase for Benzene and RCRA metals; also for strength by testing for compressive strength and vheem stability, pH and chlorides. The ratio may be between 20/80 and 80/20, typically about 50/50. Whether oil and gas waste material ( 10 A) is mixed with aggregate ( 61 ) directly in a dry mix ( 17 ), or if oil and gas waste ( 10 A) is subjected to oil and gas waste mechanical or stacking treatment and treated oil and gas waste/road base component material ( 29 ) are mixed with aggregate ( 61 ), an oil/aggregate mix ( 14 ) results from by the combination.
[0052] Typically, aggregate ( 61 ) is optimally sized to ¾ inch to 1½ inch diameter pieces but may include a substantial portion smaller than ¾″. Therefore, a determination of desired size is made and, if the aggregate waste is in pieces that are determined to be too large, they may be crushed in a crushing process ( 35 ) such as by a jaw crusher, to obtain the desired size prior to being added to the treated oil and gas waste/road base component material ( 29 ).
[0053] It has been found that a pug mill ( 18 ) provides adequate characteristics for proper mixing. The characteristics of a good mixer are consistency, coatability and durability. An emulsion ( 24 ) is added to the oil/aggregate waste mix ( 14 ) in the pug mill ( 18 ). The emulsion ( 24 ) serves to hold or bind the treated oil and gas waste/road base component material ( 29 ) to the aggregate waste ( 12 ) when the components are mixed and cured. The stabilizer ( 22 ) is, typically, comprised of portland cement. A binder ( 24 ) is also provided, typically asphalt emulsion. While the portland cement and asphalt emulsion can be added in desired quantities, it has been found that portland cement added in range of ½-10% of the final product weight and asphalt emulsion added in range of ½-10% of the final product weight provides good characteristics for the finished product. The oil/aggregate waste mix ( 14 ), binder ( 24 ), and stabilizer ( 22 ) are mixed and cured and the final product, stabilized road base ( 20 ) as determined by compressive strength testing and leachate testing results. Portland cement and asphalt emulsion are added to the waste mix ( 14 ) and mixed into the pug mill ( 18 ) or may be added separately to the pug mill ( 18 ). Optionally, treated oil and gas waste/road base component material ( 29 ) which is sometimes damp, may be coated with portland cement before it goes into the pug mill ( 18 ). The pug mill mixing ( 18 ) is a cold batch process.
[0054] More details of Applicant's oil and gas waste material treatment ( 28 ) are provided for in FIGS. 3 and 3 A. It will first be noted that one of the purposes of treating oil and gas waste material ( 10 A) may be to derive from it clean mud ( 23 ) which can be sold to oil and gas operators. Secondly, water is taken out of the oil and gas waste materials to be reinjected or otherwise disposed of. Finally, the majority of the oil and gas waste material ( 10 A), upon treatment, will result in treated oil and gas waste/road base component material ( 29 ), that is, oil and gas waste material ( 10 A) from which at least some liquids have been removed.
[0055] Turning now to FIGS. 3 and 3 A, it is seen that tank liquids ( 30 A) and tank solids ( 30 B) may be treated differently to achieve the removal of a liquid component and for the purposes of obtaining clean mud. Turning to FIG. 3A , it is seen that tank liquids ( 30 A) are typically stored in tank liquid storage ( 11 ) from which they may be piped to and deposited on the top of a fine shaker ( 41 ) which will typically remove off the top thereof a damp solids component ( 63 ). However, a substantial portion of the tank liquids ( 30 A) will work through the fine shaker ( 41 ) into a mud tank ( 43 ) typically located just below the fine shaker ( 41 ). From the mud tank, the fluid will enter a centrifuge ( 46 ) which will separate out another damp solids component ( 65 ) and send a fluid component to a 3 phase centrifuge ( 51 ). From the 3 phase centrifuge will come an additional damp solids component ( 67 ), clean mud ( 23 ) and water ( 25 ).
[0056] Turning now to the truck solids ( 30 B), they may be stored “unmixed” ( 16 ) or in a storage pile of dried truck solids ( 17 ) (see FIG. 1 ). Either way, truck solids ( 30 B) may be deposited, typically using a backhoe (or front loader) and a hopper and a conveyor belt onto a coarse shaker ( 45 ) off the top of which come particles which will be a course component ( 69 ). Much of the truck solids ( 30 B) will, however, fall through the coarse shaker ( 45 ) and these are transported or dropped into a centrifugal drier ( 47 ). The centrifugal drier ( 47 ) will yield a treated oil and gas waste/road base component material ( 29 C) and a liquid portion ( 49 ) which will be transported to mud tank ( 43 ) (see FIG. 3A for processing).
[0057] Thus it is seen that both tank liquids ( 30 A) and truck solids ( 30 B) coming from oil and gas waste material sites ( 32 ) will undergo some physical separation of some solids from liquids, the liquid portion of which will typically end up in mud tank ( 43 ). The liquids in mud tank ( 43 ) will undergo a process that yields a treated oil and gas waste material/road base component material ( 29 ) and also clean mud ( 23 ) and water ( 25 ).
[0058] Novelty is achieved in taking oil and gas waste material including tank liquids and truck solids and making a road base that meets industry standards and is environmentally safe. From the solids a liquid is extracted by stacking, dry mixing or mechanical separation. From the tank liquids a solid portion and a clean mud portion and water is produced (see FIGS. 3 and 3 A). Depending on weather, type of or source of waste material, extent of drying desired, economic consideration, environmental consideration may dictate which of the three types, or combination of the three types will be used.
[0059] The oil and gas waste material that is treated according to Applicant's present invention usually contains a solid phase and a liquid phase. It is Applicant's novel methods of treatment that help remove a part of the liquid phase. The following areas list of some of the oil and gas waste material that may be subject to Applicant's novel treatment and use and Applicant's novel roadbase:
Basic sediment and water (BS&W) and tank bottoms; Condensate; Deposits removed from piping and equipment prior to transportation (i.e., pipe scale hydrocarbon solids, hydrates and other deposits); Drilling fluids and cuttings from offshore operations disposed of onshore; Hydrogen sulfide scrubber liquid and sludge; Liquid and solid wastes generated by crude oil and tank bottom reclaimers; Weathered oil; Pigging wastes from producer operated gathering lines; Pit sledges and contaminated bottoms from storage or disposal of exempt wastes; Produced sand; Produced water constituents removed before disposal (injection or other disposal); Slop oil (waste crude oil from primary field operations and production); Crude oil contaminated soil; Tank bottoms and basic sediments and water (BS&W) from: storage facilities that hold product, exempt and non-exempt waste (included accumulated material such as hydrocarbons, solids, sands and emulsion from production separators, fluid treating vessels, production and refining impoundments); Work over wastes (i.e., blowdown, swabbing and balling wastes); Unused methanol; Used equipment lubricating oil; Paint and paint wastes; Pipe dope (unused), Refinery wastes (e.g. tank bottoms); Compressor oil and blowdown wastes; Unused drilling fluids; Chemical contaminated soil; Lube oil contaminated soil; Spent solvents, including wastes solvents; Hydraulic fluids (contaminated); Waste in transportation pipeline related pits, Cement slurry returns from the well and cement cuttings; Produced water—contaminated soils; and PCB (polychlorinated biphynols) contaminated soils.
[0090] The attached FIGS. 4 and 5 illustrate at least part of an alternate preferred method for treatment of oil and gas, and more specifically for the treatment of drilling waste. Drilling waste is intended to identify waste more specifically than oil and gas waste. That is, drilling waste is waste material directly associated with the drilling of a well. Drilling waste is typically in the nature of: drill cuttings, drilling mud, and clean up material from a drilling location. Applicant has found that the method set forth herein and hereinabove may be advantageously and more specifically directed to drilling waste, accumulated from offsite and shipped to Applicant's site for processing and combined with aggregate, the aggregate also typically trucked in from offsite. In this manner, drilling waste may be effectively combined with an aggregate to form an environmentally safe road base capable of passing most governmental agency standards and engineered to pass tests to determine its structural soundness.
[0091] The roadbase compositions prepared by the methods set forth in FIGS. 4 and 5 may be mixed in accordance with the recipes set forth hereinabove, with asphalt emulsion as an optional additive. Further, while the methods, devices and compositions set forth in these specifications are satisfactory with most oil and gas waste as set forth herein, drilling wastes are favorably disposed of and converted herein to an environmentally compatible and soundly engineered road base.
[0092] In FIGS. 4 and 5 , methods and devices are provided that will assist in efficiently handling oil and gas waste, but more specifically drilling waste. It will be noticed with reference to the figures that Applicant may utilize a conveyor system which may be screw or auger conveyors (or belt conveyors, pneumatic pressure feed, or direct feed with heavy equipment) for the transport of materials, from any one location to any other location, in applying the method of Applicant's present invention.
[0093] Turning now to FIG. 4 , Applicant discloses a pile of, typically, stacked aggregate ( 61 ), brought to Applicant's site from, typically, an offsite location. Applicant also discloses a pile, typically stacked, of drilling waste ( 101 ). This drilling waste originated offsite, being transported to Applicant's facility typically by trucks and/or barges and the like. The material (61/101) is typically underlain by an impervious layer and may or may not include a berm. Excavators ( 105 ), or backhoes or the like with front-end loaders attached thereto may scoop and transport material (61/101) to a screen shaker ( 108 ) for separation of large chunks of material, typically greater than about 3 to 4 inches in their narrowest dimension from the mix that will then directly enter pugmill or other mixer ( 112 ). Optionally, excavators ( 105 ) may load aggregate ( 61 ) and/or drilling waste ( 103 ) onto a screen and/or shaker ( 108 ) with the droppings going into a screw auger ( 104 , 106 ), which typically contains a hopper ( 104 A, 105 A) thereon for transportation to the mixer.
[0094] In the alternative, pugmill ( 112 ) may be placed directly beneath shaker ( 108 ) with the shaker loaded by heavy equipment or a conveyor. Screw conveyor ( 114 ) having a hopper ( 114 A) thereon may be placed beneath or adjacent pugmill ( 112 ) for transporting the mixed material, now road base material, to a stacking location typically underlain by an impervious layer, here seen as road base material ( 20 ). In the alternative, the pugmill can dump its contents directly on the ground.
[0095] Thus, it is seen that Applicant has provided for the transportation of materials through the use of a conveyor system and has, further, provided for the introduction of drilling waste on the one hand and aggregate ( 61 ) on the other, either contemporaneously or sequentially into a screen shaker for initial separation followed by conveyance to a pugmill. It is noted that, optionally, liquids may be removed from drilling waste material ( 101 ) before movement to the shaker screen and pugmill according to FIG. 4 . It is to be understood that the same screw conveyor (or belt conveyor, pneumatic conveyor, or direct feed) may be used to first take one of the aggregate or drilling waste to the pugmill then the other. Wherever either of these materials need to be conveyed from its storage point to the pugmill and/or shaker, any one of: a screw conveyor, a belt conveyor, a pneumatic pipe/air pressurized delivery system, or direct feed (heavy equipment) may be used.
[0096] FIG. 5 illustrates the use of yet another screw conveyor ( 116 ). Here, Applicant has found it effective to combine liquids received as drilling waste, typically held in a container or tank ( 103 ), with drilling waste material that is received in trucks and is typically drier, here drilling waste material ( 101 ) (typically stored on an impermeable pad). An excavator ( 105 ) may be used to load a hopper of screw conveyer ( 116 ), creating a stackable mass ( 111 ) of waste material, comprising liquid components of drilling waste and solid stackable components of drilling waste material ( 101 ) thereof. An excavator or loader and a screw conveyor may be used to form a stackable mass ( 111 ) of drilling waste. This drilling waste may be further processed according to methods and with equipment set forth herein to produce an environmentally compatible effective road base material according to the method set forth herein.
[0097] It is noted that the use of the screw conveyors, conveyor belts, pneumatic delivery systems and/or direct feed by heavy equipment, may allow effective transportation of material from one point to another at Applicant's facility regardless of the liquid hydrocarbon component thereof and even in inclement weather. The use of a screw auger allows some mixing during the transportation process, therefore further effectuating, such as set forth in FIG. 5 , the creation of a stackable waste material that still has a liquid component typically not, however, to the point of saturation.
[0098] With respect to FIG. 5 , it is seen that liquids from drilling waste materials are brought from offsite locations by vacuum trucks and/or barges. Typically, however, waste material ( 101 ) as identified in FIG. 5 from drilling sites is typically brought in via dump truck and simply dumped on the impervious pad.
[0099] Further, Applicant has found through testing that a particular type of centrifuge works best for the drilling mud production process set forth herein (see FIG. 2 ). These specifications of the centrifuge are as follows: Three phase, with an external adjustable skimmer. One such three phase centrifuge is available from Flotwig.
[0100] Applicant provides a conveyor system for movement of drilling waste and/or aggregate about Applicant's treatment site. The conveyor system may be one or more: belt conveyors; screw conveyors; pneumatic pressure feed conveyors, or direct feed (that is by heavy equipment such as front-end loaders). Optionally, a screen or shaker may be used at any point in the conveying system where it desired to remove larger chunks from entry into either belt conveyor or screw conveyor or the pugmill. Further, while aggregate is typically transported from offsite, the treatment facility may be built on a site where aggregate is readily available, such as a caliche pit.
[0101] Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limited sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the inventions will become apparent to persons skilled in the art upon the reference to the description of the invention. It is, therefore, contemplated that the appended claims will cover such modifications that fall within the scope of the invention.
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The present invention provides a novel method to produce grade road base material using recycled oilfield waste, called “oil and gas waste,” more specifically, drilling waste and aggregate and a novel road base material. Hydration and mixing of the waste materials along with an aggregate will form an environmentally safe, structurally sound road base material. An asphalt emulsifier may be included in the binder to manufacture asphalt stabilized road base. The entire method is a cold batch process.
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FIELD OF THE INVENTION
This invention relates to the separation of fibers from larger fibrous agglomerates.
BACKGROUND OF THE INVENTION
Aramid fibers, including fibers of the "Kevlar" aramid polymer manufactured and sold by DuPont, are finding wide usage as a reinforcing material in gaskets, moldings, bulletproof vests, and other applications wherein they provide qualities of excellent tensile strength, light weight, and/or heat resistance. Although these fibers can be manufactured in continuous filament fiber form, for example by extrusion through spinerettes, for some purposes it is more convenient and less expensive for the supplier to ship such materials in the form of multiple fiber agglomerates or clumps, rather than as discrete fibers. The fiber agglomerates may for example be in the form known as "pulp," wherein many short fibers are closely matted as a spongy mass, somewhat like a cotton ball. In another common form, the product may be in the form of "fiber staple," which comprises clumps of longer, roughly parallel fibers. Other common examples of resilient fibrous materials sometimes supplied in fibrous agglomerate form include carbon fibers, Mylar fibers, nylon fibers, asbestos, and so on.
Where the user receives a fibrous material in the form of pulp, staple, or other multi-fiber agglomerate, it is often necessary that the material be separated into discrete fibers. The process of fiber separation is sometimes referred to as fiber "development," "expansion," or "exfoliation". This is required where individual fibers are to be coated or mixed with various bonding agents, for example, as where fibers are to be mixed with a matrix material for molding, or where the fibers are to be incorporated in friction linings or gaskets. It is to such fiber separation that this invention is directed.
PRIOR ART
Apparatus for separating asbestos into discrete fibers is known in the art. Such apparatus is shown in Herbst Pat. No. 3,974,969, issued Aug. 17, 1976, which teaches separation by rotary blades mounted on a shaft which projects through the sidewall of a mixing drum, radially toward the drum axis. The blades have step-like radial edges and rotate in planes parallel to the axis of the chamber; the fibers are swept across the blades by separate rotating arms. Such apparatus is expensive, bulky and relatively slow acting. Moreover, it is often desirable to obtain the highest possible fiber volume per unit weight, in order to maximize fiber surface area and strengthening effect when mixed with binder; but the prior art apparatus has not provided a high a degree of fiber fluffing or expansion. Thus there has been a clear need for a faster acting, less expensive apparatus and process, suitable for the small user as well as by the large manufacturer, for developing asbestos, Kevlar and other fiber agglomerates to high volume/weight form.
BRIEF DESCRIPTION OF INVENTION
I have discovered that fibrous agglomerates can be separated into discrete fibers by a technique wherein the clumps are confined and are resiliently contacted with a series of blades which have pick-like or pointed tips. The agglomerates are held resiliently in contact with the blades; the blades do not shear or grind the fibers against a fixed rigid surface. A surrounding mass of fibers resiliently urges fibers radially toward the blades. An airstream removes the separated fibers, but not the agglomerates, from the confined space.
In a preferred form of apparatus in accordance with the invention the blades are spaced along a shaft which is rotated to provide a blade tip velocity preferably of at least about 5000 feet per minute, and more preferably at least 7000. The shaft is journaled in a cylindrical chamber which provides a spacing between the blade tips and the cylinder inside wall substantially larger than the diameter of the fibers and greater than the fiber length. The resilient fibers are thrown outwardly by the rapidly rotating blades, but the housing resiliently confines the fibers so that they remain near the tips, where they are lightly engaged by the blade tips. The action of the blades on the fibers appears to be a tangential rubbing and dissecting action; the blades exfoliate or rub the clusters into smaller clusters, and ultimately dissect individual fibers from the clusters. The minimum spacing between the blade tips and the wall is much greater than the diameter of the fibers and the blades do not crush or trap the fibers against the chamber wall.
Without intending to limit the invention, it is theorized that this rubbing/dissecting action is enhanced because the resiliency of fibers between the blades and the chamber wall tends to "bias" inner fibers toward the blades so that they can yield resiliently outwardly when the blades impact them. It is to be noted that this apparatus does not cut the fibers, i.e., does not substantially reduce average fiber length, but rather separates fibers from the fiber bundles without substantial length reduction.
It is important that fibers be conveyed past the blades and to and out of an outlet by an airstream, the rate of flow of which is sufficient to carry separated fibers to the outlet but insufficient to remove the fiber agglomerates. It is further desirable that the space between the blades and the chamber wall be in the form of a cylindrical annulus with the shaft at its center. The air stream carries the fibers in a spiral path through this annular space.
The invention can best be described and explained by reference to the accompanying drawing, in which:
FIG. 1 is an axial section, somewhat diagrammatic in nature, of apparatus in accordance with a preferred embodiment of the invention; and
FIG. 2 is an enlarged perspective view of a preferred form of a single blade having four pick-like points, for use in the apparatus of FIG. 1.
DETAILED DESCRIPTION
Referring to FIG. 1, an apparatus 10 is illustrated having a hollow generally cylindrical housing 11 which presents a processing chamber 12 on its interior. Housing 11 is preferably oriented to that its axis 13 is horizontal. The housing may be a length of steel or plastic pipe, closed at its ends by end plates 14, 15. An inlet 18 enters chamber 12 through the sidewall, adjacent one end plate 14, and an outlet 19 is provided through the side wall adjacent the other end 15. It is preferred, although not absolutely necessary, that inlet 18 direct incoming material downwardly radially toward the axis 13 of chamber 12. It is also preferred, but not absolutely necessary, that the outlet 19 be spaced in the axial direction from inlet 18, and that it projects upwardly from chamber 12 as shown in FIG. 1.
A shaft 23 is journaled in the end plates 14, 15 of housing 11 and extends through chamber 12 along axis 13. This shaft mounts a series of blades 24 (in the embodiment shown there are 15 such blades, although number is not critical). The blades are spaced along the length of the shaft. Each blade 24 has one or more pick-like tips, as at 25. In the embodiment shown the blades 24 are of what may be described as a "butterfly" shape with four tip points 25; the four tips define a rectangle with a deep V notch between the two tips on the same side of shaft 23. The blades can suitably be punched or cut from 1/8" steel; the pointed tips 25 are formed where the sides of the "V" meet the long sides of the blade. Each tip 25 can thus be formed by the intersection of two essentially planar surfaces; the tips need not form a conical point. Other blade shapes can be used, but the blades should have tips which are defined by an acute angle. The edges of the blade inward of the tip need not be sharpened, since it is not desired to cut the material. On the contrary, it is desired not to cut the fibers. Shaft 23 is rotated by a high speed drive motor 30, preferably capable of developing a blade tip speed of 5000 feet per minute or more.
The radial distance between the tips 25 of the blades and the inside surface 31 of housing 11, which distance is designated at R in FIG. 1, should generally be greater than the diameter of any solid particles which are fed into the machine, and should be many times greater than the diameter of the single fibers separated from the bundles. This insures that the individual fibers are not caught and sheared between the blades and the wall. By way of example, a blade tip clearance of about 1/4" works well for use of Kevlar pulp. This is many times larger than the fiber diameter, which is of the order of 10-30 microns.
The device requires a high tip speed for most efficient exfoliation. I have found that blade tip speeds in excess of about 5000 ft. per minute, and preferably of 7000 to 9000 feet per minute, are very effective for exfoliating Kevlar pulp and staple. At low speeds the incoming agglomerates increasingly tend to become "impaled" on the tips, which in turn tends to clog or jam the machine. The rotor speed should be such that the agglomerates and fibers are slung outwardly by centrifugal force as they are swept through the annular space 33 outwardly of the blade tips 25 and inwardly of the cylinder wall 31. Virtually none of the particles pass through the series of blades inwardly of the tips.
The separated fibers are carried from the inlet to the outlet by an air current. This current is preferably of such velocity as to carry the separated fibers out of the outlet, but not to remove the feed or unexpanded fiber agglomerates. This air current can be established by a blower or source of compressed air which creates a positive pressure at the inlet, and/or by a blower which creates a reduced pressure at the outlet. In the embodiment shown, a high-speed centrifugal blower 40 (e.g., 10,000 rpm) is mounted in outlet line 41. Line 41 feeds the blower inlet 43; the blower has a rotary impeller 44 which receives fibers centrally and slings them outwardly to deliver the fibers to a discharge line 45. This blower preferably establishes a pressure differential between inlet and outlet of about 50" water. More generally, the differential should be at least about 40" for processing Kevlar pulp.
It is found that the provision of a centrifugal blower having an inlet which is fed through the processing chamber outlet line 41 does more than merely provide an inlet-to-outlet draft to carry the fibers past the blades. The blower impeller itself acts on the fibers in a way that further "de-clumps" or expands them, and increases fiber volume above what it was prior to entering the blower. This can be observed from the fact that the volume of a given weight of feed material is increased when the draft is established by a centrifugal impeller at the outlet so that the fibers pass through it, as compared to fiber volume if the draft is established by the same blower positioned at the inlet, upstream of the point where the particles are introduced, so that the fibers do not pass the impeller.
It is important that incoming fiber particles not be fed into the machine at such rate as to choke it. For that reason it is usually desirable to feed the material gradually, as by using a gate or shutter valve through which material can be introduced intermittently or at a restricted rate. These valves are known in the art and do not comprise the invention.
Although it is preferred that the processing chamber present a cylindrical space as illustrated, and that the particles be introduced in the radial direction into the plane of rotation of the one or more blades, it should be understood that the feed material can alternatively be introduced in the axial direction, and that the chamber need not be cylindrical. In general, the use of a cylindrical chamber having a smooth internal surface and oriented horizontally, wherein the particles are conveyed entirely by the action of air rather than by gravity or by impeller type blades, provides much better results. This can be seen by the following example.
SPECIFIC EXAMPLE
As previously indicated, this machine can be quite small and yet have extremely high throughput as compared to devices of the type shown in the Herbst patent previously identified. A test was made using a machine in accordance with that shown in FIG. 1 of the drawing, wherein the cylinder was 30" long, had an inside diameter of 6", the diameter of the blades (as measured diametrically from tip to tip) was 5.5", and the blades rotated at a speed of about 7000 rpm or 10,000 feet per minute. Blade tip clearance was 0.25", which was greater than average fiber length of 0.2". This machine would handle a throughput of 10 pounds per minute of Kevlar pulp, and expanded it to fibers having approximately 40 times the volume of the input material. A centrifugal blower, rotating at 10,000 rpm, was connected to the outlet. The blower established an airstream through the chamber from the inlet and through the outlet at a pressure differential of about 50" water. The agglomerates were poured into the airstream at the inlet.
The machine described did not work when the blower was not operating, that is, when there was no airstream through the chamber. This is so even if the chamber is set vertically, so that gravity draws fibers toward the outlet. If the blower was mounted at the inlet, rather than the outlet, so as to blow air through the chamber but without the separated fibers passing through the impeller, the fiber agglomerates were separated, but the volume expansion was only 20×, rather than the 40× expansion obtained when the fibers passed through the blower at the outlet. The device worked best if oriented horizontally, but worked acceptably (at a slower rate) if oriented vertically. At lower blower speeds, below approximately 5000 rpm, there is rapid loss of fluffing capacity, and chunks of unfluffed material appear at the outlet.
The same machine was also used to separate clusters of asbestos, nylon and carbon fibers. Generally comparable volumetric expansion (approximately 30-40×) was achieved in each case.
A molding resin for example phenolic resin, or a molding filler such as dolomite, carbon black, barium carbonate, or cashew particles, in particle form, could be introduced directly into the apparatus along with the fiber agglomerates. The blades intimately mixed the additive with the fibers, and/or coated it on the fibers. The fiber/additive mix was conveyed to and through the outlet by the airstream. The composite mixture could be molded to a uniform product in the usual manner without further mixing.
From the foregoing it will be seen that I have provided a compact, efficient, means for exfoliating aramid and other flexible fibrous agglomerates at a high rate, which provides much better results than prior art devices.
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Disclosed is an apparatus and method for separating clumps of resilient fibers such as aramid polymer fiber agglomerates. Rotating blades throw the fiber clumps outwardly against a surrounding resilient "cushion" of fibers of the material. Rather than physically cutting or chopping the fibers, the blade tips exert a rubbing or dissecting action on the clumps. The separated fibers are swept to an outlet by an airstream, while unseparated fibers in the cushion are urged toward the blades for further separation. It is an important advantage of the invention that the average length of the fibers is not substantially reduced as the clumps are being separated by the blades.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The subject application is the §371 national stage filing of PCT/EP2006/008924 filed Sep. 13, 2006, which also claims priority to DE 10 2005 043 609.9, filed Sep. 13, 2005.
FIELD OF THE INVENTION
The present invention relates to a method for preparing a thread from silk proteins as well as an apparatus which is appropriate for performing the method. Moreover, the invention is directed to the threads obtained therewith as well as to the use thereof.
BACKGROUND OF THE INVENTION
Natural silk, e.g. spider silk, is an extraordinary material having a very high tensile strength in combination with a high extensibility. Due to these properties it has been tried for many years to prepare this material in larger amounts. Since it is not possible to use animals as e.g. spiders for this purpose, research is focussing on the investigation of methods in which the starting material for silk (e.g. spider silk) proteins is obtained recombinantly and then spun to a thread.
As raw materials there are used authentic silk proteins (recombinant proteins which are obtained by means of authentic sequences of the silk gene) and synthetic silk proteins (proteins based on synthetic genes, wherein their primary sequence widely corresponds to the natural sequences). The quality of an artificially produced thread is assumed to be defined by both the raw material used and the spinning method applied.
As in the natural spinning process, in the artificial spinning process, the silk proteins have to be transferred from a soluble form into an insoluble form, the structure of which shall be as identical to the authentic thread as possible. For this, the working group of Jelinski has developed a micro spinning apparatus which allowed spinning a few milligrams of silk proteins to silk threads with a length of several meters (Liivak et al., 1998). Silk of the spider Nephila clavipes dissolved in hexafluoroisopropanol was used as a starting material. The so dissolved protein was injected in a precipitation bath of acetone through a spinning nozzle. However, the threads obtained therewith were very refractory and did hardly show any structural similarity to natural silk threads (Seidel et al., 1998; Seidel et al, 2000). Primarily, by treating it with water and supplementary drawing the thread (post spin draw), both mechanical and structural parameters could be improved. However, the properties of natural silk have not been achieved (Seidel et al., 2000).
Another group developed a spinning technique, in which a methanol/water mixture was used as a precipitation bath. With this, a synthetic silk protein and a recombinant MaSp1 of the spider Nephila clavipes could be spun from an urea-containing solution. However, these were also refractory (Arcidiacono et al., 2002).
By using the same technique, recombinant ADF-3 being solved without chaotropic reagents could be spun to threads. Also in this case, the properties of the thread could be improved by post spin draw (Lazaris et al., 2002), though the tensile strength of natural threads has not been achieved. The companies Oxford Biomaterials (Oxford, Great Britain), Spin 'Tech GmbH (Ludwigsburg, Germany) and the Institut für Mikrotechnik Mainz GmbH (Mainz, Germany) have developed a method according to the state of knowledge of the inventors, with which silk proteins can be spun to threads by a microdialysis method or a similar method.
Additionally, there are successful trials to obtain threads from silk proteins by means of the so called electro-spinning (Prof. Frank Ko, Drexel University, Philadelphia, Pa., U.S.A.). However, there has not been disclosed anything about the mechanical properties of the so produced threads yet.
US 2003/0201560 relates to an apparatus for spinning threads from protein solutions. It is stated that the apparatus has a funnel-formed section through which the protein solution or “dope”, respectively, is passed, wherein this passage is at least partially consisting of a semipermeable and/or porous material.
WO 2005/017237 inter alia relates to an apparatus for assembling proteins. The apparatus has a tubular passage, the walls of which are partially permeable or porous. This has the advantage of monitoring the pH, the water content and the ion composition.
WO 2004/057069 relates to a method and an apparatus for preparing objects, especially also for spinning threads from spider silk proteins. This method essentially relates to the sol-gel transition of the protein solution which is for example achieved by adding potassium, preferably potassium fluoride. Furthermore, it is stated here that the apparatus used for performing the method has a semipermeably or porously formed “transition compartment”.
WO 2003/060099 refers to the preparation of spider silk fibres or bio-filaments, respectively. In the apparatus given, there is described an “extrusion unit” through which the spider silk protein solution is passed. WO 2003/060099 is especially directed to inserting the filaments in a coagulation bath after air contact.
Consequently, the previously used and publicated methods for spinning spider silk proteins mostly base on the injection of a protein solution in a precipitation bath. For stabilizing the soluble state of the proteins in the spinning solution, the precipitation bath usually contains chaotropic substances or organic solvents. For compensating the effect of these additives and inducing the protein assembly, lyotropic agents are accordingly added to the precipitation bath.
BRIEF SUMMARY OF THE INVENTION
In contrast, it is an object of the present invention to provide a method and an apparatus for preparing silk proteins which make the use of the precipitation bath and the addition of natural, chaotropic or lyotropic agents unnecessary. It is another object of the present invention to prepare stable silk proteins having mechanical properties which approximate or correspond to natural silk proteins by means of a method and an apparatus. An additional object of the invention is the preparation of silk threads with a high yield, i.e. in such an amount which is appropriate for large scale preparation.
These objects are solved by the subject-matter of the independent claims. Preferred embodiments are given in the dependent claims.
As stated above, the previously used methods for spinning spider silk proteins mostly base on the injection of a protein solution in a precipitation bath, wherein the precipitation bath usually contains chaotropic, lyotropic substances or organic solvents for stabilizing the soluble state of the proteins in the spinning solution.
It has been found that by contrast, the natural silk assembly, e.g. in the spider, is mediated by other factors. A key process is a phase separation of the spinning solution induced by adding potassium and phosphate ions into an aqueous, protein-poor and a protein-rich phase. The elongation of the protein-rich phase by subsequently drawing the finished thread leads to the assembly of the silk proteins.
The mechanical properties of the artificially spun threads according to prior art which are comparatively poor when compared to natural spider silk indicate that phase separation and elongation are important factors for the formation of mechanically stable structures. However, this finding has not been used for producing silk threads yet.
The approach of the present invention contains several differences when compared to the spinning methods of the prior art described above.
The method according to the invention is exclusively based on aqueous solution without addition of non-natural chaotropic or lyotropic agents. Without wishing to be bound by any theory, the proteins are presumably present in a conformational state corresponding to the natural state due to that.
Changes of the composition of the spinning solution will be effected via diffusion. Thus, the solution can be transferred to an assembly-competent state without having to immediately take a solid state, as this is the case in a precipitation bath.
The thread assembly is completed by drawing the partially assembled protein-rich phase. Form studies on chemical polymers there is known that an elongation of concentrated polymer solutions results in an alignment of the single polymer chains and thus to an increased stability of the fibre formed therefrom. Thus, it has to be supposed that the spinning method used herein, which is based on drawing, outclasses the methods based on pressure.
The spinning apparatus of the present invention allows for the production of high-performance fibres from synthetic spider silk to be used in many fields of technology and industry. Beside ballistic applications such as the development of bulletproof equipment, synthetic spider silks could be used for parachutes, special ropes and nets, sporting goods, textiles, but for light construction components as well.
The present invention relates to the following aspects and embodiments:
According to a first aspect, the present invention relates to a method for the preparation of a thread from silk proteins, comprising the following steps:
a) providing a solution of silk proteins;
b) transferring the solution into a diffusion unit containing a composition comprising potassium and phosphate ions;
c) passing the solution through the diffusion unit, wherein the solution comes into contact with the potassium and phosphate ions diffusing out of the diffusion unit;
d) separating the solution into a silk protein-rich and poor phase;
e) obtaining the silk thread from the protein-rich phase.
Obtaining the silk thread is preferably carried out by drawing.
It should be noted that the term “silk protein”, as it is used in this application, is principally not subjected to any limitations. The only requirement is the ability of the protein to assemble to a thread under appropriate conditions. In the closer sense, the silk proteins are characterised by proteins from natural or recombinant origin, respectively, e.g. proteins which are, for example, derived from arachnids (Arachnida) or insects (Insecta). Examples of the origin of the protein are the silkworm ( Bombyx mori ), the green lacewings ( Chrysoperla carnea ), the araneus ( Araneus diadematus ) and the golden orb-web spider ( Nephila clavipes ).
The silk proteins used herein can be authentic, i.e. constitute the natural sequences, or can be synthetic, i.e. proteins based on synthetic genes, wherein their primary sequences widely correspond to the natural sequence.
The single silk protein sequences are accessible for a person skilled in the art via databases, wherein it is only exemplarily referred to the sequences ADF-3 and ADF-4 of Araneus diadematus which are accessible under the Nos. U47855 and U47856.
The term “diffusion unit”, as it is used herein, describes a storage medium enabling the diffusion of components out of this and into this. The diffusion unit of the present invention is not the porous or semipermeable membrane conventionally used in the prior art through which an unilateral passage of components without storage properties shall be enabled. The diffusion unit of the present invention can rather be termed as a matrix, in which, on the one hand, there are provided the potassium and phosphate ions necessary for the formation of protein-rich and poor phases, and in which the protein-poor phase (not to be used for the thread assembly) is taken up on the other hand.
In one embodiment, the spinning solution provided in a) contains at least 1%-50%, preferably 10-40%, most preferably 10-20% (w/v) silk protein. From experience, the pH of the solution ranges from 4.0-12.0, preferably from 6.5-8.5 and is most preferably 8.0. The solution is also called “dope”. “Dope” means a fluid or solution which, besides protein monomers, can additionally include protein aggregates, for example dimers, trimers and/or tetramers. Additionally to the solvents listed below, this protein solution can also include additives as e.g. preservatives as well as agents for enhancing the stability or the processability of the solution.
In the method according to the invention, the solution preferably comprises a polar solvent selected from water, alcohols and mixtures thereof. Examples of alcohols comprise methanol, ethanol, propanol, isopropanol or polyvalent alcohols such as glycerol or propylene glycol. Besides their solvent properties, the last-mentioned solvents can also be used as agents for setting the viscosity and/or as preservatives.
According to a preferred embodiment, the step of obtaining the silk thread includes the contacting of the protein-rich phase with a gas or a fluid. Usually, the gas will be an oxygen-containing gas, i.e. in a case, wherein an oxidizing action inter alia is desired. On the other hand, the gas can also be an inert gas such as e.g. nitrogen, argon, helium etc. Mixtures of these gases are also contemplated.
In addition to the contact with the gaseous substances, a contact with fluids, examples of which are methanol, ethanol, propanol, isopropanol, acetone, acetonitrile and preferably methanol, may be contemplated.
In an especially preferred embodiment, the diffusion unit of the present invention is formed from a gel material. A preferably used gel material is a hydrogel, especially a hydrogel comprising polyacrylamide, cellulose derivative, polyvinylmethylether (PVME), polystyrene-polybutadiene (PS-PB), stearylacrylate, polyethylene (PE), polystyrene (PS), polyvinylalcohol (PVA), polyacrylic acid, poly(N-vinylpyrrolidone) (PVP), polyethyleneterephthalate (PET), polyisopropyleneacrylamide, polyethersulfonic acid and/or silicone hydrogels.
Alternatively, the diffusion unit can be formed from ceramics.
According to a second aspect, the present invention relates to an apparatus for performing the method defined above, with:
a first device transferring a solution of silk proteins into the diffusion unit; a diffusion unit having a channel for passing the solution which channel is surrounded by the potassium and phosphate ions containing composition, wherein the solution comes into contact with the potassium and phosphate ions diffusing out of the diffusion unit, so that the diffusion unit provides a solution separated into a silk protein-rich and poor phase at the outlet of its channel; and a second device generating the silk thread from the protein-rich phase of the solution.
According to one preferred embodiment of the apparatus according to the invention, the first device is formed as a syringe coupled to a controllable pump. For example, a control device, as for example a micro-controller, controls the controllable pump. The control device preferably has a memory, in which a sequential program for actuating the controllable pump can be stored.
According to one preferred embodiment, the first device is formed as a controllable pump system transferring the solution in a continuous process into the diffusion unit. Especially, the control program described above is formed in such a way that it controls and thus ensures the continuous process for transferring the solution into the diffusion unit.
According to another embodiment, the diffusion unit has a diminution or a nozzle at the outlet of its channel by which the discharge of the solution out of the diffusion unit is controllable. The nozzle or diminution is constructed in such a way, that its cross sectional areas diminish outwardly.
According to another preferred embodiment, the second device is formed as a roll or a reel actuated by an actuating device, which draws the silk thread out of a drop formed at the outlet of the diffusion unit from the protein-rich phase of the solution. Especially, the actuating device is also coupled to the control device such that the sequential program stored in the memory of the control device also controls the actuating device, thereby especially ensuring the continuous process of drawing the thread.
According to another preferred embodiment, the roll or reel draws the spider silk thread by means of a tensile force necessary for the protein assembly.
According to another preferred embodiment, the diffusion unit is formed as an exchangeable cartridge.
According to another preferred embodiment, the actuating device has a motor and/or a gear box.
According to another preferred embodiment, the channel of the diffusion unit has a substantially constant inside diameter for passing the solution.
Herewith, the approach of the present invention especially differs from the state of the art, e.g. the US 2003/0201560, wherein the tubular section is illustrated in all embodiments as a funnel. It is specifically pointed out that the orientation of the molecules in a fibre can be improved when a nozzle having a convergent geometry can be used. Preferably, the present invention does not follow this approach.
According to another preferred embodiment, the diffusion unit has a third device with which the protein-rich phase can be removed from the diffusion unit.
According to another preferred embodiment, the third device is formed as a vacuum pump.
In a third aspect, the present invention relates to a thread obtainable by the method according to one or more of claims 1 - 10 . This thread is preferably used in technology and industry for ballistic applications such as the development of bulletproof equipment for the manufacture of parachutes, special ropes and nets, sporting goods textiles, medicine technology, but also for light construction components of aircrafts.
BRIEF SUMMARY OF THE FIGURES
The present invention will now be illustrated with the use of figures and examples. The figures show the following:
FIG. 1 is a schematic block diagram of an exemplary embodiment of the apparatus according to the invention for the manufacture of a thread from silk proteins;
FIG. 2 is a schematic block diagram of an exemplary embodiment of the diffusion unit according to the present invention;
FIG. 3 is a photographic picture of an apparatus of the present invention;
FIG. 4 is a photographic picture of a diffusion unit of the present invention;
FIG. 5 represents an analysis of the assembled thread, wherein FIG. 5A shows thread 7 wound up by means of the teflon roll 6 , and FIG. 5B shows a scanning electron microscopic picture of the generated thread. FIG. 5C shows mechanical properties of the natural silk of the European garden spider ( Araneus diadematus ) compared to the fibres of the synthetic silk (AQ) 24 NR3 after spinning in the spinning apparatus; and
FIG. 6 shows natural silk from A. diadematus wherein FIG. 6(A) shows the silk before the tensile test, FIG. 6(B) shows the silk after disrupting the sample; FIG. 6(C) shows a cross section; and FIGS. 6(D-F) show synthetic silk (AQ)24NR3 sample 1 wherein FIG. 6(D) shows the sample before the tensile test, FIG. 6(E) shows silk sample 1 after disrupting the sample; and FIG. 6(F) shows a cross section.
In all figures, identical or functionally identical elements and devices, respectively, are assigned with the same reference numerals—unless it is stated otherwise.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 , there is shown a schematic block diagram of a preferred exemplary embodiment of the apparatus according to the invention.
The apparatus 1 according to the invention for performing the method for the preparation of a silk thread 7 from silk proteins has a first device 2 , a diffusion unit 4 and a second device 6 .
The first device 2 transfers the solution 3 of silk proteins into the diffusion unit 4 . The first device 2 is preferably formed as a syringe 22 coupled to a controllable pump 21 . A reservoir 23 for the solution 3 is preferably disposed between the pump 21 and the syringe 22 . According to FIG. 1 , the reference number F refers to the flow direction of the solution 3 in the reservoir 3 . The first device 2 can further be formed as a controllable pump system that transfers the solution 3 in a continuous process into the diffusion unit 4 . The pump system preferably has at least one hose pump.
For example, the first device 2 is connected to the diffusion unit 4 via a cannula 8 .
The diffusion unit 4 has a channel 41 for passing the solution 3 . The channel 41 is surrounded by a potassium and phosphate ion containing composition 42 . The solution 3 comes into contact with the potassium and phosphate ions diffusing out of the diffusion unit 4 , so that the diffusion unit 4 provides a solution 3 separated into a silk protein-rich phase 5 and a silk protein-poor phase at the outlet 43 of its channel 41 . Preferably, the diffusion unit 4 has a diminution or nozzle 44 at the outlet 43 of its channel 41 by which the leaving of the solution 3 out of the diffusion unit 4 is controllable, especially due to its geometrical construction.
Further, the apparatus 1 according to the invention has a second device 6 generating the silk thread 7 from the protein-rich phase 5 of the solution 3 . Especially, the second device 6 is formed as a roll or a reel actuated by an actuating device, which draws the silk thread 7 from a drop which is formed from the protein-rich phase 5 of the solution 3 at the outlet 43 of the diffusion unit 4 . The roll 6 especially draws the silk thread by means of a tensile force necessary for the protein assembly. The actuating device actuating the roll 6 especially has a motor and/or a gear box.
FIG. 2 shows a more preferred exemplary embodiment of the diffusion unit 4 shown in FIG. 1 . The inside diameter d of the channel 41 serving for passing the solution 3 is preferably substantially constant.
The diffusion unit 4 is preferably formed as an exchangeable cartridge so that the diffusion unit 4 can especially be exchanged when it is saturated with the protein-poor phase of the solution 3 . The diffusion unit 4 especially has a third device by which the protein-poor phase of the diffusion unit 4 can be removed. For example, this third device is formed as a vacuum pump. Additionally, the unit shown in FIG. 2 refers to a buffer reservoir having the reference number 45 .
EXAMPLES
The invention described herein integrates these processes into a spinning method allowing the automatic production of mechanically resilient protein threads.
FIG. 1 shows a schematic diagram of the spinning method of the invention in form of an embodiment. This method substantially includes four components. A controllable motor/gear box unit provides for continuous supply of the spinning solution in a diffusion unit via a syringe. In this unit, which consists of a gel, potassium and phosphate ions diffuse into the spinning solution resulting in a phase separation. The protein-rich and poor phases will be further transported to the outlet of the diffusion unit and there, they will come into contact with air. This contact is essential for the spinning process and presumably leads to the reduction of the aqueous phase by drying processes.
A thread can be drawn from the formed drop of the protein-rich phase ( FIG. 2 ). By winding up the thread onto a roll being actuated via a controllable motor, the tension necessary for the protein assembly can be maintained and a continuous thread formation can be achieved. FIG. 2 shows elements of the diffusion unit according to one embodiment of the invention.
The functional capability of the presented technique could be shown by the construction of a prototype ( FIG. 3 ). The motor and gear box unit as well as the scaffold of the prototype were assembled from elements of a metal construction kit (Compakt Technik GmbH, Schriesheim, Germany). A 25 μl glass syringe having a metal needle (gauge 22, Point Style 3; Hamilton, Bonadutz, Switzerland) was used for supplying the spinning solution. FIG. 3 shows a preferred embodiment of the invention.
The diffusion unit consists of a 20% polyacrylamid gel being equilibrated in 0.5 M potassium phosphate pH 8.0. A channel having a diameter of 0.7 mm was passed through the gel and ended in a plastic tip with an inside diameter of about 0.2 mm ( FIG. 4 ). The protein thread is wound up by a teflon roll having a diameter of 4 cm and rotating with 60 rpm. FIG. 4 shows a summary about the diffusion unit.
With this prototype, a 25% solution of the synthetic silk protein (AQ) 24 NR3 (see Huemmerich et al., 2004) could be spun to a 4 μm thick thread. FIG. 5 presents an analysis of the assembled thread. (A) The thread is wound up by means of the teflon roll. (B) Scanning electron microscopic picture of the generated thread.
Mechanical properties of the natural silk of the European garden spider ( Araneus diadematus ) compared to the fibres of the synthetic silk (AQ) 24 NR3 after spinning in the spinning apparatus described (see FIG. 5C ):
tensile
average
Young's
tensile
elongation
energy
area
Module
strength
at rupture
robustness
absorption
material
[μm 2 ]
[GPa]
[MPa]
[%]
[J/m 2 ]
[MJ/m 3 ]
naturals
2.5 ± 0.1
11.9 ± 0.9
474 ± 20
8.96 ± 0.06
1232 ± 50
28.7
silk from:
Araneus
diadematus
(AQ) 24 NR3
1.7 ± 0.4
6.9 ± 1.4
238 ± 58
14.1 ± 0.1
1029 ± 242
25.4
sample 1
(AQ) 24 NR3
1.8 ± 0.2
8.2 ± 2.0
254 ± 45
10.8 ± 0.1
1169 ± 154
24.5
sample 2
REFERENCES
Arcidiacono, S., Mello, C. M., Butler, M., Welsh, E., Soares, J. W., Allen, A., Ziegler, D., Laue, T. & Chase, S. (2002) Aqueous processing and fiber spinning of recombinant spider silks. Macromolecules 35: 1262-6.
Huemmerich, D., Helsen, C. W., Quedzuweit, S., Oschmann, J., Rudolph, R. & Scheibel, T. (2004) Primary structure elements of spider dragline silks and their contribution to protein solubility. Biochemistry 43: 13604-12
Lazaris, A., Arcidiacono, S., Huang, Y., Zhou, J. F., Duguay, F., Chretien, N., Welsh, E. A., Soares, J. W. & Karatzas, C. N. (2002) Spider silk fibers spun from soluble recombinant silk produced in mammalian cells. Science 295: 472-6
Liivak, O., Blye, A., Shah, S. & Jelinski, L. W. (1998) A Microfabricated Wet-Spinning Apparatus To Spin Fibers of Silk Proteins. Structure-Property Correlations. Macromolecules 31: 2947-51
Seidel, A., Liivak, O. & Jelinski, L. W. (1998) Artificial Spinning of Spider Silk. Macromolecules 31: 6733-6
Seidel, Al., Liivak, O., Calve, S., Adaska, J., Ji, G. D., Yang, Z. T., Grubb, D., Zax, D. B. & Jelinski, L. W. (2000) Regenerated spider silk: Processing, properties, and structure. Macromolecules 33: 775-80
Vollrath, F. & Knight, D. P. (2001) Liquid crystalline spinning of spider silk. Nature 410: 541-8
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The present invention relates to a thread preparation process from silk proteins including an apparatus which is appropriate for performing the method. Furthermore, the invention is directed to the threads obtained therewith as well as the use thereof. The invention uses a diffusion unit leading to the production of high-quality silk threads with high yield.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is based on and claims priority under 35 USC 119 from Japanese Patent Application No. 2010-108161 filed on May 10, 2010.
BACKGROUND
1. Technical Field
The present invention relates to a video signal transmission apparatus, an identification information acquisition method for a video signal transmission system, and a computer readable medium storing an identification information acquisition program for a video signal transmission system.
2. Related Art
A serial data signal for a digital video so called a DVI (Digital Visual Interface) or HDMI (High Definition Multimedia Interface) requires high-speed signal which is equal to or higher than 1 Gbps. Therefore, such signal can be transmitted only up to about 10 m, when transmitted by an electric cable. Accordingly, when transmission of such signal for more than 10 m is required, the serial data signal needs to be converted into an optical signal and an optical fiber may be used to transfer such optical signal. In the case of using the optical fiber, an optical transmitter and an optical receiver, connected to both ends of the optical fiber, may be provided between a video source device such as a PC (including a video card) and a sink device such as a display.
The serial data signal includes a high-speed video signal, information of the display (hereinafter referred to as “EDID”), and a DDC (Display Data Channel) control system signal used to exchange an encryption key called an HDCP (High-bandwidth Digital Content Protection). Since this DDC control system signal is a DC signal or a low-speed signal of lower than 100 KHz, and is a bidirectional signal. The DDC control system signal may be transmitted through a metal cable such as a LAN (Local Area Network) cable.
Namely, when transmitting the serial data signal of digital video, different kinds of cables may be used to transmit the video signal and the DDC control system signal, respectively.
The HDCP is a type of digital copyright management technology that functions to prevent illegal copying by encrypting a digital type image or an output signal of video content.
Also, the DDC is a standard for exchanging various kinds of information between the display and the PC for realizing PnP (Plug and Play). According to the DDC, information representing permissible resolution of a display, color depth, a scanning frequency, and a model number of a product is exchanged between the PC (video source device) and the display (sink device). Through the exchange of the information, setting information of the display is transferred, and thus the setting is automatically performed to match the performance of the respective displays.
SUMMARY
According to a first aspect of the present invention, there is provided a video signal transmission apparatus including: an optical transmitter, connected to a video source device, that uni-directionally transmits video data input from the video source device; an optical receiver, connected to a sink device, that receives the video data transmitted from the optical transmitter and outputs the received video data to the sink device; a first transmission medium, connected to the optical transmitter and the optical receiver, that transmits the video data at a speed higher than a predetermined reference transmission speed; a second transmission medium, connected to the optical transmitter and the optical receiver independently from the first transmission medium, that transmits identification information for identifying the sink device at a speed lower than the predetermined reference transmission speed; an identification information acquisition control section, provided in the optical transmitter, that acquires the identification information from the sink device through a bidirectional communication using the second transmission medium in accordance with a request from the video source device; a storage section, provided in the optical receiver, that stores general-purpose identification information generally used for a plurality of types of sink devices that are connectable to the optical receiver; an acquisition possibility determination section that determines whether the identification information can be acquired from the sink device; and a general-purpose identification information reply control section that replies the general-purpose identification information stored in the storage section to the video source device if the acquisition possibility determination section determine that the identification information cannot be acquired.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the present invention will be described in detail based on the following figures, wherein:
FIG. 1 is a structural diagram illustrating the configuration of a video signal transmission system according to an exemplary embodiment of the present invention;
FIG. 2 is a functional block diagram illustrating an electrical connection in a video signal transmission system according to an exemplary embodiment of the present invention;
FIG. 3 is a flowchart illustrating a flow of LAN cable connection state monitoring control executed by an optical transmitter cable connection circuit, an address setting circuit, and a delay circuit, according to an exemplary embodiment of the present invention; and
FIG. 4 is a functional block diagram illustrating an electrical connection in a video signal transmission system according to an alternative exemplary embodiment of the present invention.
DETAILED DESCRIPTION
Herebelow, an example of an exemplary embodiment of the present invention will be described in detail with reference to the drawings.
FIG. 1 is a structural diagram illustrating the configuration of a video signal transmission system according to an exemplary embodiment of the present invention.
In a video signal transmission system, a host computer 10 and a display 12 are connected through a video signal transmission apparatus 14 for optical communication of a video signal. The host computer 10 is applicable as a video source device. The display 12 is applicable as a sink device.
The video signal transmission apparatus 14 includes an optical transmitter 16 , an optical receiver 18 , and an optical fiber cable 20 . The optical fiber cable 20 is provided between the optical transmitter 16 and the optical receiver 18 .
The optical fiber cable 20 includes an optical fiber harness 22 for respective colors (R, G, and B) and a clock (CLK) which corresponds to a DVI video signal. Both end portions of the optical fiber harness 22 are bundled and are connected to optical fiber connectors 24 , respectively. Each optical fiber connector 24 is connected to an optical transmission interface 26 of the optical transmitter 16 , and an optical reception interface 28 of the optical receiver 18 , respectively.
The optical transmitter 16 includes an interface 30 for receiving a serial data signal of a digital video, such as DVI or HDMI, from the host computer 10 . The host computer 10 includes an interface 32 for outputting a serial data signal of the digital video. Accordingly, the host computer 10 and the optical transmitter 16 are electrically connected when the connectors 36 installed at both ends of the DVI or HDMI dedicated connection cable 34 are connected to the interface 32 of the host computer 10 and the interface 30 of the optical transmitter 16 .
Further, the optical receiver 18 includes an interface 38 for outputting the serial data signal of the digital video, such as DVI or HDMI, to the display 12 . The display 12 includes an interface 40 for receiving the serial data signal of the digital video. Accordingly, the optical receiver 18 and the display 12 are electrically connected when the connectors 44 installed at both ends of the DVI or HDMI dedicated connection cable 42 are connected to the interface 38 of the optical receiver 18 and the interface 40 of the display 12 .
Here, the serial data signal of the digital video, such as DVI or HDMI, includes a DDC control system signal in addition to the video signal.
The DDC control system signal is a standard for transmitting/receiving information between the host computer 10 and the display 12 for realizing PnP (Plug and Play). In the communication of the DDC control system signal (hereinafter referred to as “DDC communication”), information representing a permissible resolution of the display 12 , color depths, a scanning frequency, and a model number of a product is exchanged between the host computer 10 and the display 12 . According to this information, the setting is automatically performed to match the performance and specification of the display 12 connected to the optical receiver 18 .
The optical transmitter 16 transmits only the video signal to the optical receiver 18 through the optical fiber cable 20 in uni-directional communication. Optical communication using the optical fiber is advantageous in transmitting a high-speed signal of equal to or higher than 1 Gbps over a transmission distance of equal to or longer than 10 m. In other words, the high-speed signal of equal to or higher than 1 Gbps has the limit of transmission distance of 10 m, when transmitted via a metal cable. In the present exemplary embodiment, the optical communication by the optical fiber is performed particularly in transmitting the video signal.
On the other hand, the DDC control signal is a low-speed signal (in comparison to the transmission speed of the video signal) of about 100 kHz, and also requires bidirectional communication. Accordingly, in the present exemplary embodiment, the DDC control signal is bidirectionally communicated by using a LAN cable 46 which is cheaper than the optical fiber cable 20 and can be applied as a metal cable.
Namely, as illustrated in FIG. 1 , in the optical transmitter 16 and the optical receiver 18 , LAN interfaces 50 and 52 are provided, to which the connectors 48 connected to the end portions of the LAN cable 46 are connectable.
FIG. 2 is a functional block diagram illustrating an electrical connection in a video signal transmission system shown in FIG. 1 .
[Video Signal Transmission System]
Four laser drivers 100 are connected to the interface 30 of the optical transmitter 16 respectively. The DVI video signals R, G, B, and CLK from the host computer 10 is input to the four laser drivers 100 .
Laser diodes 102 are connected to the four laser drivers 100 . The laser diodes 102 emit light or are turned OFF based on light-emitting control signals from the laser drivers 100 . Namely, the light emitting of the laser diodes is controlled based on the video signal input to the laser drivers 100 .
The laser diode 102 is connected to one end of each optical fiber 104 . The other end of the optical fiber 104 is connected to the optical transmission interface 26 . At one side of the optical fiber connector 24 of the optical fiber cable 20 , the optical transmission interface 26 is connected. The optical transmission interface 26 configures the optical fiber 104 connected to the laser diode 102 and the optical fiber constituting the optical fiber cable 20 , substantially coaxial with each other. Note that the term “substantially” means that the light emitted from the laser diode 102 is optically coaxial to the optical fiber cable 20 , and may not be physically coaxial.
The other-side of the optical fiber connector 24 of the optical fiber cable 20 is connected to the optical reception interface 28 of the optical receiver 18 . The optical reception interface 28 has a function that is equal to the optical transmission interface 26 . Namely, four photodiodes 106 are installed in the optical receiver 18 , and one end of each optical fiber 108 is connected to the optical receiver 18 , respectively. In the optical fiber cable 20 , the surface of one end portion of the four optical fibers are configured to be substantially coaxial with the surface of the other end portion of the optical fibers 108 connected to the photodiodes 106 . The surfaces of the end portions of the four optical fibers exchange optical communication information (namely, the optical converted video signal). Note that the term “substantially” means that the light emitted from the optical fiber on the side of the optical fiber cable 20 is optically coaxial to the optical fiber 108 on the side of the optical receiver 18 , and may not be physically coaxial.
The four photodiodes 106 are connected to amplifiers 110 , respectively. The amplifiers 110 amplify the converted electric signals received by the photodiodes 106 , convert the electric signals into a DVI video signal R, G, B, and CLK, and output the DVI video signal to the display 12 through the interface 38 .
[DDC Communication Control Process]
The DDC communication control process is executed by the host computer 10 when it is recognized that the display 12 is connected in an HPD determination control process, which will be described later.
A DDC-CLK/DATA buffer circuit (hereinafter simply referred to as “buffer circuit”) 112 is connected to the interface 30 of the optical receiver 14 .
The buffer circuit 112 is connected to a buffer circuit 114 of the optical receiver 18 through the LAN interfaces 50 and 52 and the LAN cable 46 .
When DDC communication control process, the host computer 10 outputs an address that specifies a storage area of the display 12 in order to acquire a display identification code (hereinafter referred to as “EDID”) stored in a storage area (not illustrated) within the display 12 .
The buffer circuit 112 at the optical transmitter 16 acquires the EDID by accessing the storage area of the display 12 through the buffer circuit 114 at the optical receiver 18 , based on the address. The EDID acquired by the buffer circuit 112 at the optical transmitter 16 is output to the host computer 10 . The host computer 10 executes processes such as correction of the video signal based on the acquired EDID.
In the present exemplary embodiment, a configuration that transmits the video signal is configured even when the LAN cable 46 is not connected.
When the LAN cable 46 is not connected, the DDC communication control process can not be executed. Therefore, in the present exemplary embodiment, a storage section 116 that stores a virtual EDID is installed at the optical transmitter 16 . When the LAN cable 46 is connected, a form that acquires the EDID from the display 12 actually connected (hereinafter referred to as “first form”) is selectively executed, while when the LAN cable 46 is not connected, a form that acquires the virtual EDID from the EDID storage section 116 (hereinafter referred to as “second form”) is selectively executed.
In order to select the first form or the second form, a cable connection detection circuit 118 is provided in the optical transmitter 16 .
The cable connection detection circuit 118 is connected to a cable connection signal output circuit 120 of the optical receiver 18 through the LAN interfaces 50 and 52 and the LAN cable 46 .
The cable connection signal output circuit 120 , for example, has a simple loop circuit formed therein, and the cable connection detection circuit 118 determines the connection state of the LAN cable 46 by detecting whether a voltage applied from the corresponding cable connection detection circuit 118 is maintained and returns thereto.
The cable connection signal detection circuit 118 is connected to an address setting circuit 122 . This address setting circuit 122 is connected to the EDID storage section 116 . The address setting circuit 122 serves to set an address that is equal the storage area of the display 12 with respect to the corresponding EDID in the storage section 116 .
Namely, the cable connection detection circuit 118 outputs H (high level) signal to the address setting circuit 122 when the LAN cable 46 is connected, and outputs L (low level) signal to the address setting circuit 122 when the LAN cable 46 is not connected.
The address setting circuit 122 does not set the address with respect to the EDID storage section 116 when H signal is received from the cable connection detection circuit 118 (execution of the first form). On the other hand, the address setting circuit 122 sets the address with respect to the EDID storage section 116 when L signal is received from the cable connection detection circuit 118 (execution of the second form).
When an address is set in the EDID storage section 116 , the LAN cable 46 is not connected. Accordingly, the host computer 10 acquires the virtual EDID from the EDID storage section 116 based on the address reported in the DDC communication control process.
[HPD Determination Control Process]
An HPD setting circuit 124 is connected to the interface 30 of the optical transmitter 16 . The HPD setting circuit 124 reports whether the display 12 is connected to the host computer 10 . More specifically, the HPD setting circuit 124 outputs a different two-value signal when the display 12 is connected or is not connected (for example, H signal when the display is connected, and L signal when the display is not connected).
When it is recognized that the display 12 is connected through the HPD signal, the host computer 10 executes the above-described DDC communication control process.
In the present exemplary embodiment, even in the case where the LAN cable 46 is not connected, the HPD setting circuit 124 operates control to falsely report that the display 12 is connected to the host computer 10 . Namely, in the present exemplary embodiment, the first form and the second form are used together.
Accordingly, the HPD setting circuit 124 is connected to the cable connection detection circuit 118 through the HPD detection circuit 126 and the delay circuit 128 . The details of the delay circuit 128 will be described later.
[First Form]
The HPD detection circuit 126 is connected to an HPD detection transmission circuit 130 of the optical receiver 18 via the LAN interfaces 50 and 52 and the LAN cable 46 . For example, in the case where the display 12 is connected, the HPD detection transmission circuit 130 outputs a detection signal of 5 V (H signal) to the HPD detection circuit 126 . On the other hand, in the case where the display 12 is not connected, the HPD detection transmission circuit 130 output a detection signal of 0 V (L signal) to the HPD detection circuit 126 . This signal is output to the HPD setting circuit 124 , and when the signal from the cable connection detection circuit 118 is a signal (“H signal” to be described later) that indicates the LAN cable in a connected state, the HPD setting circuit 124 outputs the signal which indicates that the display 12 is connected, to the host computer 10 .
As a result, the host computer 10 recognizes whether the display 12 is connected or not by the signal from the HPD setting circuit 124 , and executes the DDC communication control process accordingly.
[Second Form]
On the other hand, when the signal from the cable connection detection circuit 118 is the signal (“L signal”) that indicates the LAN cable in a disconnected state, the HPD setting circuit 124 converts the HPD signal into the H signal (false signal), and outputs the H signal to the host computer 10 . The host computer 10 recognizes whether the display 12 is connected or not by the signal from the HPD setting circuit 124 , and executes the DDC communication control process accordingly. Namely, according to the second form, even in the case where the LAN cable 46 is not connected, the false HPD signal is output as if the display 12 was connected, and thus the host computer 10 executes the DDC communication control process accordingly.
[Function of Delay Circuit]
Here, as described above, a delay circuit 128 is provided between the HPD setting circuit 124 and the cable connection detection circuit 118 . The delay circuit 128 delays the transmission of the signal from the cable connection detection circuit 118 for 150 msec.
As a result, the HPD setting circuit 124 converts the H signal into the L signal after 150 msec, starting from a time when the connected LAN cable 46 is disconnected (or starting from a time when the disconnected LAN cable is connected).
Namely, at an initial setting such as starting (power ON) of the host computer 10 , the host computer 10 executes the DDC communication control process regardless of the connection/disconnection of the LAN cable 46 . However, in the case where the LAN cable 46 is disconnected during the operation of the host computer 10 (for example, outputting of the video signal or the like), the host computer 10 instantaneously (for example, in 100 msec or shorter) performs conversion from a true HPD signal (H signal) into a false HPD signal (H signal) using the signal from the cable connection detection circuit 118 .
On the other hand, during the execution of the DDC communication control process, a detection period of the L signal of the HPD signal equal to or longer than 100 msec is required. Therefore, the host computer 10 is unable to execute (re-execute) the DDC communication control process when the LAN cable 46 is disconnected.
Accordingly, by intentionally generating a disconnected state of the LAN cable 46 for equal to or longer than 150 msec by the delay circuit 128 , the execution of the DDC communication control process can be secured.
In the above, a case in which the LAN cable 46 in a connection state is disconnected during the operation (outputting of the video signal) has been described, however, the reverse is also the same. Namely, when disconnected LAN cable 46 is connected during the operation (outputting of the video signal), the signal sent from the HPD setting circuit 124 to the host computer 10 is temporarily (150 msec) in an L signal state, in the same manner.
Table 1 shows the output of the cable connection detection circuit 128 (LAN cable detection), the output of the HPD detection circuit 126 (HPD detection), and the output of the HPD setting circuit 124 (HPD output) based on the connection state of the LAN cable 46 and the connection state of the display 12 .
In Table 1, “non-detection (L)” indicates that the communication system from the HPD transmission circuit 130 to the HPD detection circuit 126 is disconnected due to disconnection of the LAN cable 46 , and as a result, a non-detection signal (L signal) is produced.
Further, in Table 1, “false H” indicates that the original signal is the L signal, but in order to realize the second form, the H signal is falsely output from the HPD setting circuit 124 to the host computer 10 .
TABLE 1
A signal
B signal
LAN cable
HPD
C signal
detection
detection
HPD output
State
H
H
H
(a) LAN cable
shifted from state (d) to H
connected,
after 150 msec (L) (*1)
display
connected
H
L
L
(b) LAN cable
connected,
display
disconnected
L
Non-
False H
(c) LAN cable
detection (L)
disconnected,
display
disconnected
L
Non-
False H
(d) LAN cable
detection (L)
shifted from state (a) to
disconnected,
false H after 150 msec (L)
display
connected
* For each output signal, H denotes detection, and L denotes non-detection
(*1) When A signal is L and B signal is H, C signal becomes L (in the case where A signal is delayed)
In Table 1, when shifting from state (a) to state (d), namely, in the case where the connected LAN cable 46 is disconnected, the HPD setting circuit 124 outputs a false H signal to the host computer 10 after temporarily (for a period of 150 msec) outputting a L signal. Accordingly, the DDC communication control process can be executed.
On the other hand, in Table 1, when shifting from state (d) to state (a), namely, in the case where the disconnected LAN cable 46 is connected, the HPD setting circuit 124 outputs a H signal to the host computer 10 after temporarily (for a period of 150 msec) outputting a L signal. Accordingly, the DDC communication control process can be executed.
Hereinafter, the operation in the present exemplary embodiment will be described.
Firstly, a flow of video signal transmission process when the optical fiber cable 20 and the LAN cable 46 are connected during power ON, will be described.
When the power is input to the host computer 10 , the optical transmitter 16 , the optical receiver 18 , and the display 12 , the host computer 10 receives an HPD detection signal from the HPD setting circuit 124 of the optical receiver 16 , and confirms the connection state of the display 12 .
When it is confirmed that the display 12 is connected, the host computer 10 executes the DDC communication control process for acquiring the EDID of the display 12 through a buffer circuit 112 of the optical transmitter 16 .
When a control signal form acquiring EDID information is received, the display 12 outputs a signal that indicates the EDID information, and the host computer 10 acquires the EDID information through a buffer circuit 114 , the LAN cable 46 , and the buffer circuit 112 .
Next, when the EDID is acquired, the host computer 12 recognizes a type of the display 12 and set values based on the corresponding EDID, generates and outputs a video signal that is in the specification of the display 12 based on the image information. This video signal is transmitted from the optical transmitter 16 to the optical receiver 18 through the optical fiber cable 20 .
Next, the optical receiver 18 converts the light signal received through the photodiodes 106 into electric signals, and outputs the electric signals to the display 12 to display an image.
Here, in the present exemplary embodiment, the video signal is transmitted via the optical fiber 20 , and the DDC control signal is transmitted via the LAN cable 46 . However, when the LAN cable 46 is not connected, the video signal can also be transmitted by the optical fiber 20 .
FIG. 3 is a flowchart illustrating a flow of LAN cable connection monitoring control in the cable connection circuit 118 , the address setting circuit 122 , and the delay circuit 128 of the optical transmitter 16 , that starts when the power of the optical transmitter is turned ON.
In step 150 , an initial resetting is performed, and in step 152 , the cable connection detection circuit 118 acquires the signal from the cable connection signal output circuit 120 .
In step 154 , it is determined whether the signal detected by the cable connection detection circuit 118 is H signal that indicates a connection state or L signal that indicates a disconnection state. The result of determination is reported to the address setting section 122 .
In step 156 , if the reported signal is L signal, the address setting section 122 sets an address of the EDID storage area of the display 12 in the EDID storage section 116 of the optical transmitter 16 , and proceeds to step 158 . Also, in step 154 , if the reported signal is H signal, the address setting unit 122 proceeds to step 158 .
Accordingly, the host computer 10 can acquire the EDID as described above, regardless of connection state of the LAN cable 46 .
In step 158 , by the monitoring performed by the cable connection detection circuit 118 , it is determined whether the connection state has changed or not.
Here, if the connection state has changed, the process proceeds from step 158 to step 160 , and is determined whether the change of the connection state is from H to L (the connected LAN cable 46 has been disconnected) or from L to H (the disconnected LAN cable 46 has been connected).
In step 160 , if it is determined that the change is from H to L, the process proceeds to step 162 , and the address of the EDID storage area of the display 12 is set in the EDID storage section 116 . Then, the process proceeds to step 166 . On the other hand, if it is determined that the change is from L to H in step 160 , the process proceeds to step 164 , and the address of the EDID storage area of the display 12 that is set in the EDID storage section 116 is canceled. Then the process proceeds to step 166 .
Next, in step 166 , the delay circuit 128 waits for the state that has been set in step 162 or 164 for 150 msec, and then proceeds to step 168 to report that the connection state of the HPD setting circuit 124 has been changed.
The host computer 10 executes the DDC communication control process again if the signal from the HPD setting circuit 124 becomes L signal for equal to or longer than 100 msec.
When the connected LAN cable 46 has been disconnected, the HPD setting circuit 124 is shifted from the state (a) to the state (d) in Table 1. In this case, since the output of a false H signal is delayed for 150 msec in which the L signal is maintained, the host computer 10 obtains the timing for executing the DDC communication control process.
Also, when the disconnected LAN cable 46 has been connected, the HPD setting circuit 124 is shifted from the state (d) to the state (a). In this case, since the connection is reported to the HPD setting circuit after a delay time of 150 msec, the HPD setting circuit 124 is in an actually non-existing combination state (which does not exist in Table 1) in which the LAN cable 46 is not connected (L signal) and the HPD detection circuit 126 detects the display (H signal). Accordingly, the output of the HPD setting circuit 124 becomes in a non-signal state (equal to the L signal), and after a delay time of 150 msec, the HPD setting circuit 124 is shifted to the state (a) in Table 1 to output a H signal, resulting in that the host computer 10 obtains the timing for executing the DDC communication control process. In this case, in order to cope with the case where the disconnected LAN cable 46 has been connected, a delay circuit may be separately installed between the HPD setting circuit 124 and the HPD detection circuit 126 .
In the present exemplary embodiment, a case in which the connection state of the LAN cable 46 is monitored and controlled by circuits has been described. However, the cable connection circuit 118 , the address setting circuit 122 , and the delay circuit 128 are electrical circuits, and thus are not operated by a software program. Note that the connection state monitoring control explained in the flowchart is to clarify the flow of process.
By contrast, instead of the circuit operation as described above, the connection state monitoring control of the LAN cable 46 may be executed by a software program under a hardware configuration of a computer including a CPU, a RAM, a ROM, and a bus.
In the above present exemplary embodiment, a case in which the delay circuit 128 is installed to cope with the case where the connection state of the LAN cable 46 is changed after power on (after the DDC communication control process is executed) has been described. However, if the configuration has been made such that the connection state of the LAN cable 46 does not change after power ON, the delay circuit 128 may be unnecessary.
FIG. 4 is a functional block diagram illustrating an electrical connection in a video signal transmission system without the delay circuit 128 according to an alternative exemplary embodiment of the present invention. Since the difference between the circuits in FIG. 2 and FIG. 4 is only the existence of the delay circuit 128 , the same reference numerals are used, and the explanation of the configuration will be omitted.
The foregoing description of the exemplary embodiments of the present invention has been provided for the purposes of illustration and description. It is not intended to be exhaustive or to limit the present invention to the precise forms disclosed. Obviously, many modifications and variations will be apparent to practitioners skilled in the art. The exemplary embodiments were chosen and described in order to best explain the principles of the present invention and its practical applications, thereby enabling others skilled in the art to understand the present invention for various embodiments and with the various modifications as are suited to the particular use contemplated. It is intended that the scope of the present invention be defined by the following claims and their equivalents.
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The present invention provides a video signal transmission apparatus including: an optical transmitter that uni-directionally transmits video data from a video source; an optical receiver that receives the video data and outputs the received video data to a sink device; a first transmission medium that transmits the video data at a high speed; a second transmission medium that transmits identification information for identifying the sink device at a low speed; an identification information acquisition control section that acquires the identification information from the sink device; a storage section that stores general-purpose identification information used for plural types of sink devices; a acquisition possibility determination section that determines whether the identification information can be acquired from the sink device; and a general-purpose identification information reply control section that replies the stored general-purpose identification information to the video source device if determined that the identification information cannot be acquired.
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RELATED APPLICATIONS
None
FEDERAL SPONSORSHIP
None
Background
1. Field of the Invention
The present invention pertains to the art of carrying and distributing goods—it is a type of basket that fits on a special conveyer for sorting similar baskets and bins.
2. Statement of the Problem
Designers of conveyer belts and automated distribution systems have long struggled to accommodate the infinite variety of paper boxes used to package goods. Dangerous material handling equipment such as pallet jacks and fork lifts must be used to handle fragile paper containers. Excessive manual labor is required to open, unload, then recycle corrugated boxes. Expensive store furniture such as shelving units are required to display goods once the goods are removed from their boxes. The object of this invention is to replace paper boxes and conveyer belts with a more efficient method of containing and sorting goods that can also be used to display the goods once they reach their destination.
SUMMARY OF THE INVENTION
Solution to the Problem
Shelving units made of Stackable Open Front Grocery and Goods Bins with Air Cushion Mobility standing one upon another (FIG. 7) are designed to ride on cushions of compressed air to slide easily across floors so that dangerous material handling equipment such as fork lifts are not required to load and unload trucks. By making the bins a uniform size, the conveyer and sorting mechanism is greatly simplified. Stacks of bins can be used to display goods for sale so that the goods will not need to be handled with excessive labor (FIG. 9 ).
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 shows the preferred dimensions of the Stackable Open Front Grocery and Goods Bin
FIG. 2 shows the bin as seen from the top front corner.
FIG. 3 shows a detailed view of the bottom front corner
FIG. 4 shows a cross section of two stacked bins cut vertically from front to rear with sprocket, idler wheel, and mold release angles.
FIG. 5 shows the top rear corners of two bins and the “D” ring grooves
FIG. 6 shows the bottom rear corner, curled top edges, and sprocket pits
FIG. 7 illustrates the stacking conveyer with bins full of groceries
FIG. 8 shows a cross sectional view of a bin in the loading conveyer cut vertically front to rear
FIG. 9 illustrates stacks of bins displaying goods inside a store
FIG. 10 illustrates bins stacked inside a shipping container awaiting delivery
FIG. 11 shows the cascading mechanism for lowering bins onto conveyers going in the opposite direction.
FIG. 12 shows the switching mechanism for diverting bins onto more than one conveyer
FIG. 13 illustrates nested bins
FIG. 14 shows a cross section cut vertically from front to rear of the conveyer for dumping bins
DESCRIPTION OF THE PREFERRED EMBODIMENT
1. Overview (FIG. 1, FIG. 2)
The Stackable Open Front Grocery and Goods Bin with Air Cushion Mobility is distinguished from other open front bins and baskets by load bearing wings bent back from the bottom front corners which shield and protect compressed air fittings concealed behind them (FIG. 3 ). There are grooves in the top front corners into which the wings of the bins stacked on top fit so a stack of bins will be firmly restrained when rocking from side to side inside a moving vehicle (FIG. 2, FIG. 10 ). The wings do not prevent bins from being nested to save space (FIG. 13 ).
2. Air Cushion Lip (FIG. 3, FIG. 4)
There is a molded lip around the bottom circumference of the bin to contain a cushion of compressed air when the bin is sitting on the floor that will allow it to fly like a hovercraft when a compressed air hose is attached (FIG. 3, FIG. 7 ). The front edge of this lip is turned upward to prevent goods inside the bin from sliding out and it is also turned downward to contain the cushion of air (FIG. 4 ). There is a hollow formed in the front bottom edge where the lip turns up and down which can be used to insert a rigid product identification card (FIG. 4) that will prevent goods in the bin stacked below it from falling out during transport. The product identification card is inserted by first shoving the card upward into the hollow of the bin above the card and then dropping the card behind the turned up portion of the bin below the card to secure the goods inside the bin. There is a small vertical ridge molded into the inside of the bottom of the bin to secure the card (FIG. 2, FIG. 4 ). Compressed air fittings with one way valves to prevent the escape of air pressure are inserted into the sides of the hollow bottom front edge and they are angled so that a hose with a right angle compressed air fitting on the end (FIG. 7) can be pressed onto the bin's compressed air fitting (FIG. 3) and pulled on like a rope to move the stack of bins over the floor without breaking the fittings (FIG. 7 ). The hose's right angle fitting (FIG. 7) is restrained by a notch in the protective wing which will absorb the force of pulling on the hose (FIG. 2, FIG. 3 ). Each top rear corner of the bin has two notches forming a quarter circle (FIG. 5) so that a 10 cm (4 inch) semicircular “D” ring attached to the inner wall of a truck trailer or cargo container can flop down into these notches when the corners of two bins are side by side underneath the “D” ring. The “D” rings will allow a partially loaded truck to carry tall stacks of bins against the walls (FIG. 9 ).
3. Materials
The preferred embodiment of the Stackable Open Front Grocery and Goods Bin with Air Cushion Mobility is injection molded plastic. The mold release angle is inclined approximately 20 degrees up and to the front (FIG. 4 ). The bottom mold release angle is inclined approximately 20 degrees down and to the rear. The sides of the bin are molded with an 8 to 10 degree release angle and the top edge of each side is turned outward and curled downward so form an approximately 2 cm wide curled ledge than can be used for picking up and carrying the bin by hand (FIG. 6 ). The top back edge of the bin is also turned outward to form about a 2 cm wide ledge than can be used for picking up and carrying the bin by hand, but the void under the rear curl is cast solid except for pits about 1 cm wide and 2 cm apart on the underside of this ledge to engage the sprockets of the bin's associated conveyer machinery (FIG. 6, FIG. 7 ). The top half of the back of the bin is vertical, but the bottom half of the back of the bin is tilted inward with approximately a 10 degree angle so that a plumb line hung over the top edge will exactly touch the radius of curvature where the back of the bin joins the bottom of the bin (FIG. 4, FIG. 6 ). It is because of this that the mold release angle must be approximately 20 degrees tilted toward the front and the bottom front of the bin be turned up no more than about 62 degrees to achieve efficient mold release (FIG. 4 ). The distance between a plumb line hung over the top rear edge and the lip containing the air cushion on the bottom rear edge of the bin will be about 2 cm so that the back of the lip will touch the front of the back ledge of the bin stacked below it to prevent stacked bins from shifting during transit (FIG. 4 ).
4. Preferred Dimensions (FIG. 1)
OD=Outer Dimension ID=Inner Dimension
The preferred dimensions of the Stackable Open Front Grocery and Goods Bin with Air Cushion Mobility are exactly 1 meter wide OD, 1 yard wide ID, 1 foot+1 cm high OD, 1 foot (minus the thickness of the material) high ID, with 1 foot stacking height (the exact distance between any two similar points on two stacked bins being exactly one vertical foot), and 22½ inches deep OD (minus tolerances) so that four bins can fit front to rear across a 90 inch wide ID truck cargo body or cargo container (FIG. 10 ). The top ledges should be 2 cm wide and the number of pits under the top back ledge should be exactly 32 and they should be 1 cm wide with 2 cm between them with the “D” ring grooves in the top rear corners spaced neatly between the pits so as not to create a weakness in the material. The inner radius of the joint between the back and sides of the bin should be greater than the outer radius so that material is bulked up in the corners to compensate for the reduction in corner strength resulting from the rear “D” ring grooves being in close proximity to the pits on either side. The corners should be strong enough to support the weight of the bin when it is loaded with 100 kg (220 pounds.) of goods when handled on the sorting and stacking conveyer described below (FIG. 7 ). The release angle of the back of the pits should be 30 degrees. The release angle in the front of the pits should be vertical. The depth of the pits should be 1 cm and the area of the pits at their highest point should be no less than 5 mm×5 mm. The depth of the grooves in all of the top corners must exactly equal the height of the air cushion lip and this dimension should be 1 cm. The air cushion lip should be positioned 2 cm forward of the back of the bin and 2 cm inward from the bottom edges of the bin. The product identification card should be 1 foot by 3 feet in size.
The “D” rings for the bins inside truck bodies and intermodal cargo containers should be mounted in 1 foot increments from the floor of the vehicle with “D” rings exactly 3 feet and 6 feet above the floor with centers one meter apart. The “D” rings should have the capability of standing vertically so that they will automatically fall into the grooves when a stack of bins is slammed against them. A thin metal yardstick inserted between the bins can be used to release the “D” rings to avoid unstacking them.
5. Conveyer (FIG. 7)
The conveyer for loading and sorting bins consists of a row of power driven sprockets above a row of weight bearing idler wheels mounted to a wall or other vertical structure so that sprocket teeth engage the pits under the top rear edges of bins and the idler wheels support the bottom rear edges of bins. The wheels may protrude from the wall or vertical support more than the sprockets so that the bins will be carried on the conveyer tilted at an angle to prevent goods from falling out of the bins during loading. The idler wheels may be vertically mounted or horizontally mounted (FIG. 4) and may touch the bottom edge radius of the bin at any angle between 0 and 90 degrees. Sprockets may drive the bins up or down hill and even around turns by first tilting the bins onto their backs. Note that only the bottom half of the back of the bin is angled, so product may spill out of the bin if the bin is tilted onto its back when more than half full. It is best for bins to go up or down hill while on turns like a roller coaster so that the bin will not need to be tilted all the way onto its back. The sprockets may be vertically mounted or they may engage the pits in the back of the bin at any angle up to 30 degrees from vertical (FIG. 7, FIG. 4 ). On long straight conveyers, only every other sprocket needs to be powered and they should be spaced in intervals of ½ meter. Idler wheels should be spaced every ¼ meter.
6. Bin Self-loader (FIG. 8)
Goods may be automatically loaded into bins off the end of an assembly line by tilting the bins on the conveyer 30 to 45 degrees (so that the back of the bin is lower than the front) while passing the bins under a shelf equipped with a device to propel the product into the bin (such as an air ram or a corkscrew device similar to vending machines that dispense cigarettes and potato chips). Bins can be loaded from shelves on both sides of the conveyer provided that the rear of the bin is loaded first. Products loaded from behind the bin will be stacked vertically inside the bin and products loaded from the front of the bin will be loaded side by side inside the bin. Canned goods and smaller products can be double stacked by laying a 3 foot by 21 inch card over the product in the bottom of the bin and then raising the shelf from upon which the next product is loaded. If a variety of very small products is to loaded, the conveyer should go up hill or down hill at a 20 to 30 degree angle during the loading process so goods pushed into the bins will stack by gravity into the bottom corners.
7. Cascading Mechanism (FIG. 11)
Conveyers may be connected in cascading fashion so that bins that reach the end of one conveyer will automatically be tipped onto the conveyer below. The cascading mechanism consists of a powered sprocket with a hydraulic coupling turning in the opposite direction one half meter beyond and six inches below the end of the conveyer (FIG. 11 ). One foot below and beyond that is a polished horizontal plate tilted to catch and stop the bin. When the bin reaches the end of the conveyer, it falls onto the cascading mechanism and overwhelms the hydraulic coupling until it reaches the plate. The hydraulic mechanism then gently accelerates the bin in the opposite direction until it falls onto the conveyer below.
8. Timing Switch (FIG. 8)
Bar codes will be printed on the front of each wing (FIG. 2) that can be scanned by the loading machine as the bins go by. A computer can be programmed to automatically assign an empty bin to a destination and automatically load it with proper amount of goods bound for that destination. The conveyer should move at a constant speed. The timing mechanism for the product loader should be equipped with a lever directly under the bar code reader that will touch the angled front wing of the bin and depress a switch as the front edge of the bin rubs against the lever. The computer should be programmed to remember how much product has been loaded into each bin so that additional product will be pushed into the bin at the proper elapsed time after the timing switch is activated to avoid overloading one end of the bin. Human loaders should only need to hand load the bins when they are nearly full. Product identification cards can be inserted into the fronts of bins to prevent goods from falling out when bins are stacked upon other bins. The computer should print a label to be attached to the front of the product identification card to indicate the contents and destination of each bin.
9. Switching Mechanism (FIG. 12)
The mechanism for switching bins onto conveyers above and below (or to the left and right if the bins are laying on their backs) consists of an unpowered idler sprocket attached to an arm held up by a catch pin. To send the bin to the lower conveyer, the catch is left in place. To send the bin to the upper conveyer, the catch pin is pulled to release the arm when the bin is supported by the sprockets to the right and to the left of it a certain time after it passes the timing switch. To reduce wear on the catch pin, the idler sprocket can be mounted slightly lower than the other sprockets. The idler sprocket falls under the weight of the bin and the bin tips up to the upper conveyer (FIG. 12 ). A spring returns the arm to normal position. A bevel on the end of the catch pin (like a door latch) allows the arm to click into place to be ready to support the weight of the next bin.
To merge bins from two conveyers on to one, the above mechanism is operated in reverse. The idler sprocket can be replaced by a normal fixed sprocket if the merging mechanism is not to be used for switching.
For the sake of production flexibility, segments of conveyers can be mounted as portable free standing units with sprockets up to ½ meter apart using alternating current to synchronize the speed of the drive motors. The layout of the production floor can then be easily changed by moving loading and switching mechanisms around as needed. It is also possible for personnel to pass through free standing segments of moving conveyers provided they watch out for bins. If conveyers are mounted this way, special guards must be mounted to prevent hair or clothing from being caught in the sprockets.
10. Lifting and Sorting Machine (FIG. 7)
Stacks of bins of varying height may be lifted onto a conveyer to be sorted by pushing the stacks on cushions of compressed air against a conveyer with powered sprockets tilted between 10 and 30 degrees from vertical with its idler wheels horizontal (FIG. 4) arranged on a slope of six inches in one meter (FIG. 7 ). An angled sprocket will engage the corner of the top bin of the stack and lift it up onto other conveyer sprockets. Once a bin has climbed up the slope to the top of the conveyer, it can be unloaded, sorted, dumped (FIG. 14) or rolled down the slope an unpowered conveyer with similarly angled sprockets onto another stack of bins waiting to be shipped to the same destination (FIG. 7 ). The stack to receive the bin must be positioned by hand under the conveyer so the front wing of the bin rolling down the conveyer falls into the groove in the top front corner of the top bin in the stack. It is important for the operator to match the motion of the stack with the bin coming down the conveyer for the machine to work smoothly. The top corner of the product identification card should also be tucked into the hollow in the upper bin at this time. Pulling the stack away from the conveyer at a slight angle will drop the rolling bin onto the stack with a minimum of effort. The stack can then be pushed to a position under a higher part of the conveyer slope to receive yet another bin. It is possible to secure the product identification card on the top bin in the stack with a one meter long rod laid in the top front grooves of the bin. Product identification cards may be manufactured with built in rods or with crushable 1 meter wide wings in the top corners that extend into the grooves.
11. Conveyer Materials
The preferred embodiment of the sorting machine (FIG. 7) is a steel beam structure behind a smooth polished wall with plastic or hard rubber wheels and metal sprockets that project through the wall as little as necessary. Danger signs to protect hands and fingers should be positioned around the sprockets.
The loading conveyer (FIG. 8) should be constructed so that the sprockets are concealed under a shelf so employees will not get their clothing, hands, or fingers caught in them. If possible the sprockets should be housed within a protective cover so that only the top of the sprocket is visible. There is excellent maintenance access to all sides of the machine when there is no bin in the conveyer, but as with all toothed sprockets and gears, precautions must be taken to ensure the safety of those who operate the machine. If bins are turned upside down for unloading (FIG. 14 ), a nylon bumper or idler wheel should be used to prevent the bin from sliding off the sprocket. A second wheel can roll along the front of the bin if necessary.
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The Stackable Open Front Grocery and Goods Bin with Air Cushion Mobility and its related conveyer together comprise a goods distribution system designed to deliver products ordered over the internet into special stores called Safety Malls which will lower the cost of everything you buy through the elimination of paper boxes and supermarket and department store janitors and stockmen. Goods ordered over the internet can be automatically be custom loaded into bins at the factory, sorted in a distribution center, and delivered to a store near your home without ever being touched by human hands. Empty bins can be nested, removed from the store, and put through a washing machine to keep the store hygienically clean.
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BACKGROUND OF THE INVENTION
This application relates to a method of sterilizing water supply systems to eliminate bacteria, and then maintaining additives in the system to ensure bacteria growth does not reoccur.
Water supply systems are often exposed to dangerous bacterial growth. Several types of bacteria are naturally present in water and breed in low temperature hot water systems such as those commonly found in hospitals, schools, offices, or other publicly used buildings. One such bacteria type is the Legionella organism, which can cause Legionnaires disease. Legionnaires disease strikes up to 25,000 people each year in the United Stats. Evidence has indicated that Legionnaires disease is often spread through hot water supply systems in large public buildings.
Processes have been developed to effectively clean water supply systems in an inexpensive and effective manner. One such process adds chlorine to the water supply system, killing the bacteria. Such a process has proven effective in controlling the growth of Legionella, however, there are drawbacks to such a process. One main drawback is that the use of chlorine potentially corrodes and damages pipes. As such, some prior art processes have utilized chlorine in combination with corrosion inhibitors. One such process is disclosed in U.S. Pat. No. 4,468,332.
Further, the process of treating water with chlorine and an corrosion inhibitor additive such as a silicate, is known. Such a process is disclosed in U.S. Pat. No. 4,874,526.
The known prior art processes have not disclosed a system which is incorporated into a water supply system in a large public building. Further, such known methods do not disclose a treatment process for initially setting up, disinfecting and maintaining the disinfectant within the water supply system. Chlorine is not stabile in hot water, and thus the amount of chlorine in the hot water will decrease with time. It is therefore an object of the present invention to disclose a complete system and method for disinfecting the hot water supply systems of large buildings and maintaining desired levels of chlorine in the system.
SUMMARY OF THE INVENTION
In a disclosed method, a water supply system in a large building is disinfected by adding liquid sodium hypochlorite, or chlorine, and a corrosion inhibitor, preferably a silicate, to the hot water supply system.
In a first stage, the water supply system is studied. Data is accumulated indicating the level of several materials in water samples taken from outlets of the water supply system. This data is utilized to determine preferred chlorine levels for the water treatment.
Samples taken from all monitored sites are tested for the level of Legionella, total bacteria, water temperature and corrosion indicators such as iron, zinc and copper. The outlet samples are utilized to determine desired levels for the additives to be contained in subsequent treatment processes.
Once preferred levels have been identified, an injection system is incorporated into the hot water supply system, and chlorine and a corrosion inhibitor are added to the water supply. All system outlets are flushed such that all lines and points within the system are exposed to chlorine.
Next, a high dosage disinfectant stage may be performed which lasts approximately one week. High dosages of chlorine and a corrosion inhibitor are added to the water. All outlets and fixtures are flushed to ensure that the chlorine extends to all areas of the water supply system. Chlorine levels in the water are tested at various outlets to ensure that adequate flow of the additives is provided to all areas within the water supply system.
All problem areas are closely monitored. Such problem areas could include patient care areas in hospitals, and in particular critical care areas such as a bone marrow transplant area. Any areas under reconstruction are also closely monitored. Fixtures at the far end of the system, which are potential stagnant areas, are closely monitored. The hot water storage tanks and return lines are closely monitored. The monitored areas are tested for the levels of the above-listed materials. All monitored areas that do not have a desired chlorine and corrosion inhibitor level are recorded for later investigation and corrective action.
After the high dosage stage achieves a desired chlorine level, a moderate dosage disinfectant stage is performed which lasts approximately five weeks. The level of chlorine and corrosion inhibitors may be somewhat reduced. The addition of the additives is continued, and continued sampling of various outlets is performed. As an example, if this period lasts for five weeks, one fifth of the outlets may be tested each week. The sampling would be as described above. After the end of the maintenance period, all outlets are tested to ensure that bacteria levels and corrosion indicators are as desired.
Finally, an ongoing maintenance stage is initiated. Chlorine and corrosion inhibitor injection is continued at relatively low levels. Problem areas are periodically flushed to ensure that those areas are exposed to chlorine. The fixtures are tested periodically to determine that the chlorine levels are as desired, and that bacteria growth does not reoccur.
These and other objects and features of the present invention can be best understood from the following specification and drawings in which the following is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a highly schematic view of a water supply system incorporating the additive system of the present invention.
FIG. 2 is a largely schematic view of a circuit for injecting additives to the water supply system.
FIG. 3 is a largely schematic view of a second embodiment circuit for injecting additives to the water supply system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Hot water supply system 20 is illustrated in FIG. 1 including hot water supply 22 leading to outlet line 24 which communicates with a plurality of outlets 26. Supply system 20 could be the hot water supply system for a large public building and there could be thousands of outlets 26. Return line 28 leads back to an inlet for hot water supply 22. In the method according to the present invention additives are added through line 30. The additives could include chlorine and a corrosion inhibitor, with the chlorine eliminating bacteria growth within the hot water supply system.
In a preferred method the additive levels for injection through line 30 are determined by intially making a preliminary investigation of the water supply system 20. An operator studies the water supply system, the plumbing design and blueprints and becomes familiar with the design and utilization of the building's water supply system. Water samples are taken to establish a reference base giving an indication of the level of bacteria problem within water supply system 20.
This initial water supply only need be on a relatively small percentage of the total outlets. As an example, in a public building having 400 hot water outlets, only 100 to 150 samples need be taken. Preferably, the samples would include any locations which could be defined as problem areas. These problems areas would include patient care and in particular, critical care areas in a hospital, areas under reconstruction, fixtures at the far end of the system which are potential stagnant areas, hot water storage tanks and return lines. The critical care and patient care areas are particularly important since it is necessary to ensure that no bacteria is in the water supply at those areas. Patients in those areas have reduced resistance to bacteria. Also areas under construction tend to have high bacteria levels.
Samples are initially analyzed for the level of Legionella bacteria in particular, and total bacteria in general. Further, corrosion indicators such as iron, zinc and copper are tested, to determine the level of corrosion within system 20. Water temperature is also tested.
Once the initial levels of bacteria are known, an initial chlorine level is determined. The higher the initial level of bacteria, the higher the chlorine level will be. Normally, chlorine levels of 7 to 10 parts per million will be adequate.
Then, a disinfection process begins. Chlorine is injected into system 20 at levels between 7 to 10 parts per million, depending on the degree of bacteria problem in system 20. A corrosion inhibiting material, which is preferably a sodium silicate blend, is set to 20 to 50 parts per million. Preferably, the sodium silicate is injected at a level not less than 3 times the level of chlorine being injected. The internal condition of the pipe prior to treatment determines the level of corrosion inhibitor required. If the distribution pipe is new or free from scale, the interior surfaces must be coated with the silicate inhibitor before the chlorine treatment is started, silicate levels of 50 parts per million should be used.
The disinfectant phase may require 5 to 7 weeks. Initially, the chlorine residual within the water must be maintained at 7 to 10 parts per million across the piping system. The chlorine level may be reduced after approximately a week from a high dosage level of 7 to 10 ppm to a more moderate level of 5 ppm. This disinfectant stage may include a first high dosage stage of approximately 10 parts per million for one week, then a more moderate dosage stage of 5 parts per million for approximately 5 weeks. Closely monitoring the test for Legionella bacteria and total bacteria will provide evidence of the chlorine level effectiveness. Alternatively, the levels will be adjusted based on the test data developed throughout the disinfectant phase. To protect the piping system against corrosion, the sodium silicate additive should be maintained at a minimum of 3 to 5 times the chlorine levels. Preferably, the sodium silicate is maintained at 4 times the level of chlorine. In a galvanized system, if the water becomes brown, one increases the silicate levels. The chlorine is preferably injected into line 30 at a time delay of approximately 4 seconds after the sodium silicate injection. This ensures that the corrosion inhibitor additive is in the water supply prior to chlorine injection.
Once injection begins, the combined chlorine and sodium silicate is drawn into storage tanks, through supply mains and into every water riser and outlet within the system. This continues until the chlorine level is tested between 7 and 10 parts per million within the water at every one of the building water outlet. If the water tested at any particular outlet does not have the desired level, the particular location is recorded for investigation and corrective action. Such corrective action would include attempts to increase water flow through that location, check the operation of the fixture, look for a cross-connector between the hot water and the cold water.
All hot water outlets are flushed during this period to ensure that they are all exposed to chlorine, and that bacteria will be eliminated. After the high dosage first week, the water will reach the desired chlorine level. Once this level has been stabilized throughout the system, the moderate dosage stage may be entered.
Samples continue to be taken from various outlets, although the percentage of samples may be reduced from the initial stage. As an example, should this moderate dosage stage continue for five weeks, 20 percent of the outlets could be tested each week. The samples are tested for the materials previously mentioned. It is desirable that the samples are rotated so that all outlets will be checked at least once during this period. It is desired to have final levels of zero Legionella and zero total bacteria at all outlets at the end of this stage.
During this stage, it is preferred that all outlets be flushed at least once a week to remove stagnate water and to flush out any organic debris. That would mean simply opening the outlets such that water flows out of them, and they are exposed to fresh chlorine. The problem areas described above should be flushed as much as twice a week during this phase. If the samples taken at the end of the moderate dosage stage are not as desired, the stage could be continued for additional weeks.
At the end of this stage, all outlets are tested. If the outlet water quality is as desired, then a maintenance phase may be entered. During the maintenance phase, a lower level of chlorine and corrosion inhibitor is maintained in the water supply system. The chlorine level may be reduced to 3.0 to 3.5 parts per million. The silicate level should be maintained at 25 parts per million, at least 4 times the chlorine level. Steps are taken to eliminate dead, stagnant and low flow areas. As an example, outlets which are seldom used are flushed occasionally to ensure that chlorine does flow through those outlet structures. Further, samples are periodically taken to ensure that the bacteria does not return.
FIG. 2 illustrates one system for adding additives to the water supply system. Additive system 34 includes hot water boiler 36 communicating with hot water tank 38 through line 40. Hot water tank 38 returns water to boiler 36 through line 44 and pump 46. Cold water makeup line 42 communicates with a source of cold water to ensure that the amount of water sent to hot water tank 38 from boiler 40 is sufficient. Return line 48 leads from the hot water supply system through pump 50, line 52, and line 44 to boiler 36.
A chlorine monitor 53 on line 52 monitors the amount of chlorine within return line 48. If the amount of chlorine is not as desired, a signal is sent through line 54 to chlorine injector 56 and line 57 to an corrosion inhibitor injector 58 to increase the supply of both additives to the water in makeup line 42. A main chlorine injector 61 and a main corrosion inhibitor injector 60 also supply additives to the water in makeup line 42.
A cold water supply 62 for the cold water makeup line 42 includes a direct line leading to cold water supply 42 and spur 64 leading through meter 66. Meter 66 controls chlorine injector 61, and injects an amount of chlorine proportional to the water passing into cold water makeup line 42. Meter 66 communicates through line 70 to the main corrosion inhibitor injector 60, which injects corrosion inhibitor additive into line 72. Line 72 communicates with outlet line 74 from hot water tank 38 leading to the hot water supply.
Since chlorine meter 53 monitors the amount of water in return line 48, and adds additional corrosion inhibitor material and chlorine to the line should that be necessary, it is ensured that the levels in the water are as desired. In a sense, chlorine monitor 53 acts as feedback to ensure that the desired amounts are maintained.
A second embodiment system 80 illustrated in FIG. 3 includes boiler 82 communicating with hot water tank 84 through supply line 86, and return line 88 leading through pump 90. Cold water makeup line 92 adds water to supply line 86. Return line 94 leads through pump 96 to line 98 which leads to line 88. Chlorine injector 100 leads through line 102 to cold water makeup line 92. Cold water supply line 104 leads to spur 106, which leads through meter 108. Line 110 controls the amount of chlorine sent into line 102. Line 112 leads to corrosion inhibitor injector 114, which controls the amount of corrosion inhibitor material sent to line 116 and to outlet 118 of hot water tank 84.
In a preferred embodiment of the present invention, the corrosion inhibitor material is a sodium silicate combination. A combination including 90.90% silicate of soda is combined with 4.953% water, and 2.73% caustic soda (78% NA 2 O) and 0.757% sodium ash 58% N 2 O and 0.66% tri-sodium phosphate. In one example, 600 pounds of silicate soda available from PQ Corporation are added to 33 pounds of water, 18 pounds caustic soda available from Allied Chemical Company, 5 pounds of soda ash available from Allied Chemical Company, and 4 pounds of the tri-sodium phosphate available from Monsanto Company are used. This mixture is created by heating a vat and gradually dissolving the soda ash, the tri-sodium phosphate and the caustic soda into the hot water. Then, the silicate of soda is slowly added and the mixture simmers for 15 to 30 minutes. The mixture is then used as an corrosion inhibitor additive in the above described systems.
The injectors are all preferably electronic controlled injection pumps. One such pump is a diaphragm type pump incorporating an anti-syphen valve available from Dihydro Services, Inc. of Sterling Heights, Mich. The water meter is preferably an electronic pulse generating meter, which communicates with the injection pumps and give signals indicative of a desired amount of chlorine and corrosion inhibitor to be added to the water supply. Further, the chlorine monitor is of a known sort, and also sends electric signals to the injection pumps.
Preferred embodiments of the present invention have been disclosed, however, a worker of ordinary skill in the art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied in order to determine the true scope and content of this invention.
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A method and system is disclosed for adding chlorine to a water supply system to kill bacteria, and in particular, Legionella bacteria. A corrosion inhibitor additive is added with the chlorine, to ensure that corrosion or other damage to the pipes does not occur. A method is disclosed for initially setting up proper levels of chlorine and corrosion inhibitor, and maintaining those levels. Systems for adding the materials to the hot water supply system are disclosed to ensure that they are adequately and thoroughly mixed into the water.
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BACKGROUND OF THE INVENTION 1. Field of the Invention
The present invention relates to a monoazo dye for thermal transfer printing, and especially to an imido-substituted monoazo dye for a sublimable magenta dye used in thermal transfer printing, which has good hue, gray and dye stability.
2. Description of the Related Art
In recent years, thermal transfer printing systems have been widely used in facsimile and copying machines, and have been further developed such that prints can be obtained from pictures generated electronically from a color video camera or computer. As one way of obtaining such prints, a thermal transfer printing system using a sublimable dye has been developed.
According to such a thermal transfer printing system, an electronically generated picture is first subjected to color separation by color filters. The respective color-separated images are then converted into electrical signals which are operated on to produce Y (yellow), M (magenta) and C (cyan) electrical signals. These signals are then transmitted to a thermal printer. Sublimable yellow, magenta and cyan dyes which are heat-transferable, are applied to a sheet-like substrate in the form of an ink, to form a transfer sheet. This is then placed in contact with the material to be printed, that is, a receiving sheet. The two sheets are then inserted between a thermal printing head and a platen roller. The thermal printing head hammer heating elements and is heated sequentially in response to the yellow, magenta and cyan signals. The transfer sheet is selectively heated in accordance with a pattern information signal corresponding to one color, so that dye from the selectively heated regions of the transfer sheet is sublimated and transferred to the receiving sheet and thereby forms a pattern thereon, the form and density of which is in accordance with the pattern and intensity of the heat applied to the transfer sheet. The process is then repeated for the other two colors, and by combining the three colors, a full-color hard copy is obtained which corresponds to the original picture viewed on a screen.
A sublimable dye for thermal transfer printing must satisfy several conditions. That is, such a dye should exhibit: (a) sufficient mobility so as to sublime while not thermally disintegrating during thermal printing head operation; (b) a high molar absorptivity coefficient; (c) stability with respect to light, humidity, heat and various chemicals; (d) good hue and gray characteristics; and (e) facility in manufacture.
As dyes for thermal transfer printing, U.S. Pat. No. 4,698,651 discloses a magenta dye-donor element comprising a substituted 5-arylazoisothiazole, U.S. Pat. No. 4,701,439 discloses a yellow dye-donor element having a cyanovinyltetrahydro-quinoline structure, and U.S. Pat. No. 4,695,287 discloses a cyan dye-donor element comprising a 2-carbamoyl-4- N-(p-substituted aminoaryl)imino!-1,4-naphthoquinone. Further, U.S. Pat. No. 4,764,178 discloses an azo dye having a diazotizable heteroaromatic amine and an aromatic coupling component. Also, Japanese Patent Laid-open Publication sho 59-78894 discloses a cyan dye having a naphthalene dione structure, and Japanese Patent Laid-open publication sho 59-227948 discloses a cyan dye having an anthraquinone structure. Many of these dyes, however, do not meet the requirements (a through e) for thermal transfer printing.
Furthermore, it would be desirable to improve stability with respect to light and heat as well as various color characteristics such as hue, and color development. To provide a magenta dye which has achieves such improvements, Japanese Patent Laid-open Publication sho 61-227092 discloses an azo dye having the following structure: ##STR2## wherein Y is hydrogen, alkoxy, methyl or halogen, and X is methyl, methoxy, formylamyl, alkylcarbonylamyl, alkylsulfonylamyl or alkoxycarbonylamyl. Similarly, Japanese Patent Laid-open Publication sho 62-99195 discloses an azo dye having the following structure: ##STR3## wherein Y is hydrogen, methyl or acylamyl, and X is cyano or halogen. However, neither of these azo compounds for magenta dye completely solves the above problems.
SUMMARY OF THE INVENTION
The object of the present invention is, therefore, to provide a new sublimable magenta monoazo dye for a thermal transfer printing, which exhibits substantial improvement in terms of stability, hue, gray and color development.
According to the present invention, there is provided a magenta monoazo dye for thermal transfer printing having the following Formula (I) ##STR4## wherein: R 1 and R 2 are each independently selected from the group consisting of hydrogen, substituted or unsubstituted C 1-8 -alkyl, cycloalkyl, aryl, 2-cyanoalkyl, 2-hydroxyalkyl, 2-alkoxyalkyl and 2-acetoxyalkyl;
A, B and C are each independently selected from the group consisting of hydrogen, halogen, cyano, nitro, carboxyamino, trifluoromethyl, acetoxy, benzoxy, C 1-4 -alkoxy, C 1-6 -alkyl, alkyl- or aryl-sulfonamino, alkyl- or aryl-sulfonyl, alkyl- or aryl-carbonyl, C 1-6 -hydroxy-alkyl and C 1-6 -alkoxyalkyl;
X is hydrogen, C 1-4 -alkyl, C 1-4 -alkoxy or halogen; and
Y is selected from the following substituents, ##STR5## wherein R 3 and R 4 are each independently selected from the group consisting of hydrogen substituted or unsubstituted C 1-4 -alkyl halogen, alkylcarboxylate, and carbonyl ##STR6## represents a cyclized structure where R 3 and R 4 are combined to form saturated or unsaturated cycloalkyl of C 3-6 , or represents a non-cyclized structure where R 3 and R 4 are each independently selected from the group consisting of hydrogen, substituted or unsubstituted C 1-4 -alkyl, halogen, alkylcarboxylate, and carbonyl; and
Z is nitro, halogen, C 1-4 -alkyl, C 1-4 -alkoxy, sulfonyl, carbonyl, carboxyamide, sulfonamino, cyano, hydroxy or hydrogen.
DETAILED DESCRIPTION OF THE INVENTION
In the present invention, by introducing a closed ring imido group into an aromatic azo compound, a substantial improvement is achieved in dye stability, hue, gray and color development.
The compounds used in the present invention may be prepared by an established synthetic procedure such as that described in Example 1 below.
In a preferred embodiment of the present invention, R 1 and R 2 in the structural Formula (I) are each independently selected from the group consisting of substituted or unsubstituted C 2-3 -alkyl, 2-cyanoethyl and 2-ethoxyethyl.
In another preferred embodiment of the present invention, X is hydrogen, methoxy or methyl group.
In still another preferred embodiment of the present invention, A and B are each independently selected from the group consisting of cyano, bromo, chloro and nitro, and C is chloro, cyano, nitro, fluoro, trifluoromethyl, C 1-2 -alkoxy or bromo.
In yet another preferred embodiment of the present invention, Y is a substituted or unsubstituted succinimide, maleimide, or phthalimide.
In yet another preferred embodiment of the present invention, R 3 and R 4 are each independently C 1-2 -alkyl group, or are combined together to form C 4-5 -saturated or unsaturated cycloalkyl.
In yet another preferred embodiment of the present invention, B is hydrogen or cyano, and A and C are each independently selected from the group consisting of cyano, nitro, chloro and fluoro.
In yet another preferred embodiment of the present invention, Z is acetamido, nitro, halogen or hydrogen.
The compounds of Formula (I) wherein R 1 and R 2 are each independently C 2-4 -alkyl, X is a hydrogen, Y is succinimide, and A and B are cyano, or C is nitro, preferably show good color development.
Compounds included within the scope of the present invention comprises the following:
__________________________________________________________________________ ##STR7##COMPOUND NO. R.sub.1 R.sub.2 X Y A B C__________________________________________________________________________1 C.sub.2 H.sub.5 C.sub.2 H.sub.5 H ##STR8## CN H NO.sub.22 C.sub.2 H.sub.5 C.sub.2 H.sub.5 H ##STR9## CN H NO.sub.23 C.sub.2 H.sub.5 C.sub.2 H.sub.5 H ##STR10## CN H NO.sub.24 C.sub.2 H.sub.5 C.sub.2 H.sub.5 H ##STR11## CN CN CN5 C.sub.2 H.sub.5 C.sub.2 H.sub.5 H ##STR12## CN CN CN6 C.sub.2 H.sub.5 C.sub.2 H.sub.5 H ##STR13## Br CN CN7 C.sub.2 H.sub.5 C.sub.2 H.sub.5 H ##STR14## Br CN CN8 C.sub.2 H.sub.5 C.sub.2 H.sub.5 OCH.sub.3 ##STR15## CN CN CH.sub.39 C.sub.2 H.sub.5 C.sub.2 H.sub.5 CH.sub.3 ##STR16## CN CN Cl10 C.sub.2 H.sub.5 C.sub.2 H.sub.5 OCH.sub.3 ##STR17## CN CN F11 C.sub.2 H.sub.5 C.sub.2 H.sub.5 H ##STR18## CN CN Cl12 C.sub.2 H.sub.5 C.sub.2 H.sub.5 OCH.sub.3 ##STR19## CN CN F13 C.sub.2 H.sub.5 C.sub.2 H.sub.5 H ##STR20## CN CN F14 C.sub.2 H.sub.5 C.sub.2 H.sub.5 CH.sub.3 ##STR21## CN CN CN15 C.sub.2 H.sub.5 C.sub.2 H.sub.5 OCH.sub.3 ##STR22## CN CN NO.sub.216 C.sub.2 H.sub.5 C.sub.2 H.sub.5 H ##STR23## CN CN ##STR24##17 C.sub.2 H.sub.5 C.sub.2 H.sub.5 OCH.sub.3 ##STR25## NO.sub.2 NO.sub.2 CN18 NCCH.sub.2 CH.sub.2 C.sub.2 H.sub.5 OCH.sub.3 ##STR26## CN CN Cl19 HOCH.sub.2 CH.sub.2 C.sub.2 H.sub.5 H ##STR27## NO.sub.2 Cl NO.sub.220 ##STR28## C.sub.3 H.sub.7 H ##STR29## NO.sub.2 H CN21 NCCH.sub.2 CH.sub.2 NCCH.sub.2 CH.sub.2 H ##STR30## CN CN ##STR31##22 ##STR32## C.sub.2 H.sub.5 OCH.sub.3 ##STR33## CN CN CF.sub.323 C.sub.2 H.sub.5 C.sub.2 H.sub.5 H ##STR34## CN CN ##STR35##24 C.sub.2 H.sub.5 C.sub.2 H.sub.5 CH.sub.3 ##STR36## Br CN CN25 C.sub.2 H.sub.5 C.sub.2 H.sub.5 CH.sub.3 ##STR37## CN CN NO.sub.226 C.sub.2 H.sub.5 C.sub.2 H.sub.5 H ##STR38## CN CN OCH.sub.327 C.sub.2 H.sub.5 C.sub.2 H.sub.5 H ##STR39## CN CN Cl28 C.sub.2 H.sub.5 C.sub.2 H.sub.5 H ##STR40## CN CN F29 C.sub.2 H.sub.5 C.sub.2 H.sub.5 CH.sub.3 ##STR41## CN CN F30 C.sub.2 H.sub.5 NCCH.sub.2 CH.sub.2 H ##STR42## CN CN CN31 C.sub.2 H.sub.5 C.sub.2 H.sub.5 H ##STR43## CN CN NO.sub.232 C.sub.2 H.sub.5 C.sub.2 H.sub.5 OCH.sub.3 ##STR44## CN CN CH.sub.333 ##STR45## C.sub.2 H.sub.5 H ##STR46## CN CN Br__________________________________________________________________________
Preferably, the compound of the Formula (I) is selected from following compounds: ##STR47##
The dye of the present invention may be dispersed and dissolved in an organic solvent with a binder to make an ink composition for thermal transfer. The ink composition may be coated on a substrate to make a transfer sheet. The transfer sheet coated with a dye may be in contact with a receiving sheet, so that the dye is adjacent to the receiving sheet. Then, selective heating and pressing of the back side of the transfer sheet with a thermal printing head results in a selective transferring of the dye to print a desired picture on the receiving sheet.
The ink composition containing a dye compound of the present invention preferably comprises: 2-8% by weight of a dye of Formula (I); 2-8% by weight of a binder; and 84-96% by weight of an organic solvent.
In the ink composition, the amount of the dye is preferably in the range of 2% to 8% by weight. If the amount of the dye is less than 2% by weight, the concentration of the dye transferred is low and the sensitivity of the color development decreases, while an amount of more than 8% by weight leads to problems of solubility and waste. The amount of the binder is preferably in the range of 2-8% by weight of the ink composition. If the amount of the binder is less than 2% by weight, the viscosity of the composition is low and the adhesiveness decreases, so that the dye may easily come off upon coating or after coating. On the other hand, for amounts of binder more than 8% by weight, the viscosity of the composition is so high that the coating process is difficult, the coating layer is uneven, and it is difficult to transfer the dye.
The binder may be any resinous or polymeric material suitable for binding the dye to the substrate. Examples of suitable binders are cellulose derivatives such as ethylcellulose, hydroxyethylcellulose, methylcellulose, cellulose acetate butyrate; vinyl resins and derivatives thereof such as polyvinyl alcohol, polyvinyl acetate, polyvinyl butyrate, polyacrylamide; polyacrylic acid, polymethylmethacrylate, polycarbonate, polysulfone and polyphenylene oxide.
The organic solvent used in the ink composition may be methanol, ethanol, toluene, methylethylketone, cyclohexanone, or N,N-dimethylformamide.
The ink composition may also contain other additives, such as curing agents or preservatives.
The ink composition may be coated on the substrate to form a dye layer with a preferred thickness of 0.4-2.0 μm.
The substrate for the transfer sheet may be any convenient sheet material capable of withstanding temperature of about 400° C. for periods of approximately 20 milliseconds, yet thin enough to transmit heat applied on one side through to the dye on the other side, to effect transfer to a receiving sheet within 10 milliseconds. Examples of suitable materials are polyester such as polyethylene terephthalate, polyamide, polyacrylate, polycarbonate, cellulose ester, fluorine polymer, polyacetal and polyamide. The thickness of the substrate is preferably in the range of 2-15 μm. If the thickness is less than 2 μm, the substrate film may be distorted upon contact with a thermal printing head of a high temperature, while thicknesses of more than 15 μm result in poor heat transfer and decreased thermal transfer sensitivity.
The backside of the substrate for a transfer sheet may be coated with a slipping layer to prevent the substrate film from being distorted and to prevent the thermal printing head from sticking to the film. The materials for such a slipping layer may be carboxylate, sulfonate, phosphate, aliphatic amine, polyoxyethylene alkylester, polyethyleneglycol fatty acid ester, silicone oil or synthetic oils.
A dye barrier layer may be employed between a substrate film and a dye layer to prevent the dye from thermally transferring to the substrate. The materials for the dye barrier layer may be a hydrophilic polymer such as polyacrylamide, butylmethacrylate, polyvinylalcohol and polyvinylacetate.
The receiving sheet usually comprises a substrate having thereon a dye receiving layer. The substrate for the receiving sheet may be polyethylene terephthalate, polyester sulfone, polyamide, cellulose ester, polyester with a white pigment incorporated therein, or a synthetic paper.
The dye receiving layer is coated on the substrate to absorb and diffuse the transferred dye more easily. The dye receiving layer may be, for example, polycarbonate, polyurethane, polyester, polyamide, polyvinylchloride, styrene-acrylonitrile copolymer, or polycaprolactam. The dye receiving layer may contain a slipping material, such as wax or silicone oil, to facilitate the separation of the layer after dye transferring.
The present invention will be described in detail by way of the following examples which are merely representative and illustrative of the present invention and in no way are to be considered as limiting the invention to specific examples.
Example 1
Synthesis of Compound 1
N,N-diethyl-3-succinimido aniline (1 mmol) was dissolved in a mixture of 5 g of water and 0.3 g of concentrated HCl, and then the solution was cooled to 0° C. A solution of 5-anthranilonitrile (1 mmol) in a mixture of 1 ml of concentrated H 2 SO 4 and 0.5ml of glacial acetic acid was dropped gradually in to a solution of sodium nitrite (1 mmol) in 0.5 ml of concentrated H 2 SO 4 below 5° C. Then, the mixed solution was stirred for 30 minutes. The stirred solution was dropped into the cooled solution of N,N-diethyl-3-succinimido aniline, neutralized for two hours at room temperature, and then filtered. The solid was washed several times with water and dried in a vacuum to give purified Compound 1 (0.9 mmol, i.e., a 90% yield).
Preparation of Ink Composition
4% by weight of Compound 1 and 4% by weight of BX-5 polybutyral resin were dispersed and dissolved in 96% by weight of methylethylketone at 50° C., and then the solution was cooled to room temperature, to give the ink composition.
Preparation of Transfer Sheet
A transfer sheet was prepared by applying the ink composition to a sheet of 7 μm thick polyethylene terephthalate film using a bar coater to give 1 g/m 2 of dry coat, and then drying the coating.
Examples 2 to 18
Transfer sheets were prepared by the method of Example 1 using compounds as indicated in TABLE 1, in place of Compound 1.
Comparative Example 1
A transfer sheet was prepared by the method of Example 1 using Compound A having the following formula, in place of Compound 1. ##STR48##
Comparative Example 2
A transfer sheet was prepared by the method of Example 1 using Compound B having the following formula, in place of Compound 1. ##STR49##
The color development and dye stability of each transfer sheets prepared in Examples 1 to 18 and Comparative Examples 1 and 2 were assessed by the following methods. The results of the assessments are set out in TABLE 1.
1) Assessment of color development
A color development was assessed using a transfer sheet prepared in each of the above examples and comparative examples and a receiving sheet (Sony, UPC 3010), at the thermal head (TH-FMR) conditions of 22 V and 1.5 W/dot. A color density was determined by densitometer (TR 1224).
2) Assessment of dye stability
A receiving sheet which has a dye transfer image formed from the transfer sheet prepared in each of the above examples and comparative Examples was placed at the condition of 35±2° C. and 60±2% RH for 48 hours using a xenon weather-o-meter (Atlas, ES-25). The density loss during the period was determined by the densitometer.
As shown in TABLE 1, when used as inks for the thermal transfer, the dyes of Formula (I) of the present invention all have good or acceptable hue and gray, and show superior dye stability compared to the control dyes of a similar structure.
TABLE I__________________________________________________________________________ DYE λmax COLOR DENSITYEXAMPLES COMPOUNDS (nm) DENSITY LOSS (%)__________________________________________________________________________EXAMPLE 1 COMPOUND 1 536.0 2.05 10.02 2 536.9 1.95 11.03 4 577.8 2.15 8.04 6 549.3 1.99 12.35 8 521.8 1.98 12.06 9 539.0 2.05 10.07 10 527.3 2.04 9.08 11 537.2 2.11 8.09 12 527.7 2.02 10.010 14 579.1 2.11 9.011 18 535.2 2.13 7.012 25 591.0 1.98 8.013 27 527.7 2.03 10.014 28 525.2 2.09 9.015 29 527.1 2.13 9.016 31 585.1 1.98 13.517 32 545.2 1.92 11.018 33 531.0 2.05 8.0COMPARATIVEEXAMPLE 1 COMPOUND A 554.8 1.75 18.02 B 534.8 1.82 17.0__________________________________________________________________________
The invention has been described in detail with particular reference to preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
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A new sublimable magenta monoazo dye for thermal transfer printing has a closed ring imido group in an aromatic azo compound, as the following formula: ##STR1## The magenta monoazo dye achieves substantial improvements in stability, hue, gray and color development.
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This is a continuation of U.S. patent application Ser. No. 08/340,109, filed Nov. 15, 1994, issuing as U.S. Pat. No. 5,497,840 on Mar. 12, 1996.
BACKGROUND OF THE INVENTION
The field of the present invention is well drilling equipment and processes.
In drilling operations in water environments such as undersea oil drilling, well leakage can be a critical problem. This also may be true regarding leakage between zones even in more conventional drilling operations. To avoid any problem of this sort, well cement is frequently employed to insure against such events.
When drilling to a productive zone, a casing is employed to line the wall of the well. The casing typically does not extend through the productive zone. Rather, when needed, a liner is positioned to extend downwardly in the well from the casing. A mechanism for sealing the upper end of the liner to the bottom portion of the casing is illustrated in U.S. Pat. No. 5,052,483 for a sand control adapter, the disclosure of which is incorporated herein by reference. Even with the seal, the well may be cemented around the periphery of the liner.
The process of placing and cementing a liner for the completion of a well has typically required multiple trips down the well to drill the bore, place, cement, seal and clear the liner. The liner may be drilled in or separately positioned. When the liner is drilled in, a drilling bit is positioned on the lower end of the liner. Some means for applying torque through the liner to the drilling bit is then necessary.
Cementing a well involves the introduction of cement into the well and down through the positioned liner. Through use of a wiper plug backed by fluid, the volume of cement previously introduced to the well is forced down and out of the bottom of the liner where it flows upwardly around the annular space outwardly of the liner. In cementing a liner, crews have found it advantageous to either oscillate the liner axially or rotationally to enhance cement flow. Thus, during cementing, some means for again providing forced driving of the liner is considered advantageous. Sealing and hanging the liner within the casing is typically also performed.
The steps necessary for such well completion have typically required multiple trips into the well. A desire to limit the number of trips into the well has existed. Schemes for gravel packing wells and the like with a single placement of drilling tools have been used. Reference is made to U.S. Pat. No. 5,253,708 for PROCESS AND APPARATUS FOR PERFORMING GRAVEL-PACKED LINER COMPLETIONS IN UNCONSOLIDATED FORMATIONS and U.S. Pat. No. 5,255,741 for PROCESS AND APPARATUS FOR COMPLETING A WELL IN AN UNCONSOLIDATED FORMATION, the disclosures of which are incorporated herein by reference.
SUMMARY OF THE INVENTION
The present invention is directed to processes for completing a well with a well liner which can be accomplished with a single placement of the equipment in the well.
In a first, separate aspect of the present invention, a process for placing a liner in a well with rotation of a drill bit, the liner and a drill string into position, locking the liner to the casing and removing the drill string is accomplished with a single trip into the well.
In a second, separate aspect of the present invention, the foregoing process is augmented by a sealing of the liner to the casing.
Accordingly, it is an object of the present invention to provide improved completion processes. Other and further objects and advantages will appear hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a string assembly employing the present invention.
FIG. 2 is a portion of the string assembly of FIG. 1 partially illustrated in cross section.
FIG. 3 is a portion of the string assembly of FIG. 2 with the piston setting tool advanced.
FIG. 4 is the completed liner assembly as illustrated in FIG. 3 with the piston setting tool removed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning in detail to the drawings, FIG. 1 illustrates a full tool string assembly to generally illustrate the layout of the preferred embodiment. A conventional cementing head 10 is positioned atop a head-pin crossover 12, drill pipe 14 and a sealed bumper 16. A dart 18 is shown in position for entry into the tool string assembly. The drill pipe 14 is shown broken and would extend for thousands of feet when the assembly is positioned in the well. Drill pipe 14 and sealed bumper 16 are capable of transmitting both torque and axial load from the top of the well to the lower assembly.
Coupled to the sealed bumper 16 is a hydraulic setting tool 20. The hydraulic setting tool 20 is better illustrated in FIGS. 2 and 3. The hydraulic setting tool 20 illustrated in the preferred embodiment is a dual piston setting tool. A central tube 22 is threadably engaged at its upper end with the sealed bumper 16. A passageway 24 extends therethrough. Two annular pistons 26 and 28 operate in parallel around the central tube 22. An outer piston sleeve 30 is coupled with the annular pistons 26 and 28 such that the outer piston sleeve 30 may be driven downwardly when the cavities behind each of the pistons 26 and 28 are exposed to differential hydraulic pressure. Knockout plugs 32 and 34 are arranged such that when removed, communication is established between the central tube 22 and each of the pressure areas behind the annular pistons 26 and 28. A first annular pressure cylinder 36 is defined radially between the central tube 22 and the outer piston sleeve 30 and axially between a shoulder 38 on the central tube 22 and the upper surface of the annular piston 26. A second annular pressure cylinder 40 is radially defined in the same way and axially defined between the upper surface of the annular piston 28 and an annular seal 42. Relief ports 44 and 46 provide pressure relief ahead of each piston. Ports 48 extend radially through the wall of the central tube 22. The outer piston sleeve 30 covers over these ports 48 until the pistons are hydraulically actuated. Because of the upper skirt on the outer piston sleeve 30, the ports 48 are not opened to outwardly of the hydraulically setting tool 20 until the outer piston sleeve 30 has moved almost completely through its stroke.
The lower end of the central tube 22 is threadably engaged with a stinger 50. The stinger 50 is hollow, extending to a slick joint 52. A latch in liner wiper plug 54 is retained at the end of the slick joint 52 by a shear screw adapter 56. The latch in liner wiper plug 54 initially has a passageway therethrough for circulation of materials downwardly through the drill pipe 14, the sealed bumper 16, the central tube 22 and the stinger 50 with the slick joint 52.
A liner assembly, generally designated 58, is associated with the hydraulic setting tool 20, extending downwardly therefrom. The principal length of the liner assembly 58 is made up of liner sections 60 with collars 62. At the bottom of the liner assembly 58 is a drill bit 64. The drill bit 64 is threadably engaged with a drill-in shoe 66. The shoe 66 includes double flapper valves (not shown) for preventing circulation upwardly through the liner. Above the shoe 66 is a float collar 68 having a reduced ID for receiving and retaining the latch in liner wiper plug 54 when released by the shear screw adapter 56. Upwardly of the main body of liner sections 60 is a drillable seal bore 70. The stinger 50 with the slick joint 52 extends through the drillable seal bore 70 with the latch in liner wiper plug 54 located below that drillable seal bore 70. An OD fluted gage ring 72 is arranged to assist in centering of the liner assembly 58.
Between the hydraulic setting tool 20 and the drillable seal bore 70, the liner assembly 58 includes a coupling, a hanger system and a seal. The coupling includes external splines 74 fixed to the lower portion of the central tube 22. The external splines 74 extend fully about the central tube 22 and have circulation passages 76 therethrough. The splines 74 are shown in the preferred embodiment to be a separate element fixed in place by welding or the like. External threads 78 are also located about the central tube 22 below the splines 74. Again, circulation passages 80 extend through the external threads 78. The threads are part of a ring fixed by welding or similar technique to the outer periphery of the central tube 22. The threads are lefthand threads.
An uppermost liner section 82 is conventionally threaded at its lower end to the drillable seal bore 70. At its upper end, internal reverse threads 84 are provided for mating with the external threads 78 located on the central tube 22 of the hydraulic setting tool 20. Also at the upper end of the liner section 82, external splines 86 are arranged about the periphery. The splines 86 are preferably the same as the external splines 74 associated with the central tube 22. Conveniently, the external splines 86 and the internal reverse threads 84 extend to the upper end of the uppermost liner section 82.
The liner assembly further includes an adapter sleeve 88. The adapter sleeve 88 forms a part of the coupling and has internal splines 90. These splines 90 are located near the bottom of the adapter sleeve 88. With the hydraulic setting tool 20 and the uppermost liner section 82 joined by the reverse threads 78 and 84 with the external splines 74 and 86 aligned, the internal splines 90 can be positioned over the external splines to retain the central tube 22 and liner assembly 58 coupled without possibility of separation. The adapter sleeve 88 extends upwardly from the uppermost liner section 82 to be axially aligned with the outer piston sleeve 30. Sheer pins 92 retain the adapter sleeve 88 in position relative to the uppermost liner section 82. However, when the hydraulic setting tool 20 is actuated so as to drive the outer piston sleeve 30 downwardly, the sheer pins 92 are broken and the splines 90 disengage the external splines 74. After this occurrence, the drill string can be detached from the liner assembly by rotating in the righthand direction.
The adapter sleeve 88, once the pins 92 have been sheered, is slidable on the uppermost liner section 82. It is originally arranged in a first position prior to the actuation of the hydraulic setting tool 20. It moves downwardly toward a second and final position. In that movement, the splines of the coupling are first released.
With continued downward movement of the adapter sleeve 88 under the influence of the hydraulic setting tool 20 toward the second position, the adapter sleeve 88 encounters a sleeve seal 94. The sleeve seal includes a cylinder 96 having a deformable cylindrical portion 98. A sleeve piston 100 is aligned with the cylinder 96 with the deformable cylindrical portion. 98 extending to slightly overlap the top of the sleeve piston 100. A pressure fluidizing solid 102 is positioned within a cavity defined within the cylinder 96 beneath the deformable portion 98 and extending to the leading edge of the sleeve piston 100. The sleeve piston 100 also has a sheer pin 104 to retain the sleeve seal 94 in place until it is to be activated. An outer cylindrical seal 106 is positioned over the deformable cylindrical portion 98. In the preferred embodiment, this seal 106 is rubber and bonded to the deformable cylindrical portion 98. It may also be a plastic material, malleable metal or the like as may be appropriate to make a seal with an outer casing.
Beneath the sleeve seal 94 is a hanger system using a slips set. A full circle slips 108 is arranged about the uppermost liner section 82. A wedge sleeve 110 having wedge shaped fingers 112 is arranged about the uppermost liner section 82. Sheer pins 114 retain the wedge sleeve 110 in position until actuated. The wedge sleeve 110 also abuts against the sleeve seal 94 such that actuation of the hydraulic setting tool 20 will set the slips set in achieving the second position of the adapter sleeve 88.
The preferred embodiment has particular applicability to offshore drilling where it is very important to prevent any leakage which is typically not the case for other wells. A well is typically drilled to a predetermined depth. A casing 116 is located in the well extending down to a casing shoe 118. The well is typically drilled further and logged. Once this is completed, a soft bentonite cement fills the lower portion of the casing shoe 118 to define a plug. The cement can be easily drilled out when setting the liner.
When the well is to be completed, the assembly described above is lowered into the well until reaching the bentonite cement. At this point, drilling is commenced to drill the plug out and run the liner to the bottom. The liner may extend any desired distance below the casing 116. The drill bit may be 2000 feet or more below the end of the casing at this point. The equipment was set up with the liner wiper plug 54 just below the drillable seal bore 70. Circulation for the drilling operation was through the drill pipe 14, the central tube 22, the stinger 50 and the wiper plug 54. Return circulation was upwardly outside of the liner and into the annular space around the casing 116. Flow may also circulate through the circulation ports 120 and through circulation passages 76 and 80 to then pass outwardly through circulation ports 122 and 46.
Next, cement is introduced into the well. The cement passes down through the drill pipe 14 in the same manner as the drilling circulation. When the predetermined amount of cement has been introduced, the liner interior is voided of cement. This is accomplished by introducing the dart 18 into the top of the well and driving it downward with fluids. The dart passes without obstruction through to the latch in liner wiper plug 54 where it seats. As fluid pressure builds behind the latch in liner wiper plug 54, it parts from the shear screw adapter 56 and travels downwardly to the float collar 68 where it too seats. The float collar may be some 40 to 60 feet above the drill bit. The cement is pushed ahead of the wiper plug 54 and out of the liner. Thus, the liner is wiped clean of cement. In introducing the cement, a common practice is to either move the liner up and down to assist in the flow of the cement or to rotate or oscillate the liner, again to help cement flow. As the coupling is still engaged, these actions are permitted. In sending the dart 18 through the bore, the knockout plugs 32 and 34 are removed. Once the wiper plug 54 has reached the float collar 68, hydraulic pressure in the drill pipe and liner continues to build. This includes pressure in the annular pressure cylinders 36 and 40 to operate on the pistons 26 and 28. When a predetermined level of pressure is reached, the pins 92 are sheered and the adapter sleeve 88 can move downwardly from its first position. The splines 74 are disengaged to release the coupling. The pins 104 and 114 are then sheered to drive the wedge sleeve 110 into engagement with the full circle slips 108 to hang the liner assembly 58 in position. The sleeve seal 94 is also deformed to form a full seal with the casing. At this point, the adapter sleeve 88 has reached its second position under the influence of the hydraulic setting tool 20. This condition is illustrated in FIG. 3. The drill pipe is then rotated in a lefthand direction to release the central tube 22 from the uppermost liner section 82. The equipment is removed, leaving a cemented liner sealed to the casing and hung from the casing as illustrated in FIG. 4.
Thus, a mechanism for drilling in, placing, hanging, sealing and cementing a liner all in one process is provided. While embodiments and applications of this invention have been shown and described, it would be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein. The invention, therefore is not to be restricted except in the spirit of the appended claims.
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Process for completing a well with a well liner which can be accomplished with a single placement of the equipment in the well
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BACKGROUND
1. Field of the Invention
My invention relates to the field of ladder work trays and more particularly relates to a ladder work tray designed for use with hollow rung ladders. The principle of the invention is a support shaft attached to the tray which passes through a hollow rung of the ladder. The shaft is kept from rotating by a block on the end of the shaft which engages one of the ladder side rails. Provision is made to hold the tray nearly level regardless of the angle of the ladder. The tray is designed to hold tools and painting equipment for workers on ladders.
2. The Prior Art
The prior art includes U.S. Pat. No. 3,822,846, to Jesionowski. This invention places a stud inside of the hollow ladder rung and uses a cam to lock the device in position. A similar invention is U.S. Pat. No. 4,318,523 to Weatherly. This invention uses two rungs for mounting the tray. Another invention, U.S. Pat. No. 4,445,659 to LaChance also requires the use of two hollow ladder rungs. Still another invention, U.S. Pat. No. 4,489,911 to Riley also uses two rungs of the ladder to hold the tray in place. These inventions have drawbacks that include overly complex manufacture, high cost and difficulty of erecting.
SUMMARY OF THE INVENTION
My invention is a solution to the problem of how to provide a ladder tray that is simple and inexpensive in construction. My invention also provides a ladder tray that may be mounted using one rung of the ladder and that may be adjusted and held to a nearly level position regardless of the angle of the ladder. I provide a tray on one end of a longitudinally fluted shaft. The shaft is small enough in diameter to produce a sliding fit when passed through the hole in one of the rungs of a conventional metal ladder. On the other end of the shaft I place a stabilizer block which engages the rail of the ladder on that side. Locking means are provided to keep the block engaged with the ladder rail and the shaft from rotating and thus to hold the tray rigid. In addition, provision is made to lock the tray in the desired angle relative to the ladder rails so as to be in a nearly horizontal position to keep tools and paints from sliding off the tray.
DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view of the invention on a ladder.
FIG. 2 is a side view of safety chain attachments.
FIG. 3 is a front view of the cinch nut of FIG. 1.
FIG. 4 is a side view of the cinch nut of FIG. 1.
FIG. 5 is a top view of the stabilizer block of FIG. 1.
FIG. 6 is a front view of the stabilizer block of FIG. 1.
FIG. 7 is a side view of the shaft of FIG. 1.
FIG. 8 is an end view of the threads of FIG. 7 taken along the plane 8--8.
FIG. 9 is a section of the flutes of FIG. 7 taken along the plane 9--9.
FIG. 10 is a section of the shaft of FIG. 7 taken along the plane 10--10.
FIG. 11 is a front view of the spacer of FIG. 1.
FIG. 12 is a side view of the spacer of FIG. 1.
FIG. 13 is a top plan view of the tray of FIG. 1.
FIG. 14 is a sectional view of the tray of FIG. 1 taken along the plane 14--14.
FIG. 15 is a sectional view of the tray of FIG. 1 taken along the plane 15--15.
DESCRIPTION OF PREFERRED EMBODIMENT
As shown in in the drawings, where like numerals refer to like parts throughout, I provide a tray 10 having a low raised edge 12 around the top surface. The tray 10 is attached to a shaft 14 that has a male longitudinally fluted portion 44 and a threaded end portion 42 as best seen in FIG. 7. On the other end of the shaft from the tray 10, I provide a stabilizer block 24 which has a centrally located female fluted hole 38. The block 24 is provided with shoulders 25. The block 24 is shaped to engaged the side rail 36 of a conventional commercially available aluminum, wood or fiber glass ladder 32 of the variety having a plurality of hollow rungs such as hollow rung 34. The stabilizer block 24 prevents rotation of the shaft 14 and the attached tray 10. The nut 26 is a non-essential safety feature which prevents separation of the block 24 and the tray 10. As shown in FIGS. 2, and 5, chains 16 may be fastened to the block 24 by means of a rivet eye bolt 18 and a female rivet 20. A hole 21 is provided in one of the shoulders 25 of block 24 for this purpose. Chain rings 22 may be used to attach the chains 16 to the rivet eye bolt 18. In the center of the block 24, as best seen in FIG. 6, is provided a female fluted hole 38. The fluting 38 is sized to slidably engage the male fluting 44 of the shaft 14 as seen in FIG. 7. The cinch nut 26, as seen in FIGS. 3 and 4, is provided to engage the threaded end 42 of the shaft 14. A spacer 28, as best seen in FIGS. 11 and 12, is provided to fit between the cinch nut 26 and the block 24. The spacer 28 is provided with a central hole 29. The function of the spacer 28 will be detailed hereinafter in reference to the operation of the invention. The construction of the tray 10 may be best understood with reference FIGS. 13 thru 15. The tray 10 may be made of metal, plastic, nylon, wood or other materials and may be provided with stiffening members 46 on the under side. A central hole 48 is provided in the tray 10 to receive the shaft 14. The invention is made so that the shaft 14 is rigidly attached to the tray 10. The shaft 14 is not allowed to use to rotate in the hole 48 of the tray 10. However, the shaft 14 and the tray 10 may be demountable, thus allowing for easy transport and storage.
OPERATION
In operation, the shaft 14 with its attached tray 10 is pushed through the center of the desired rung 34 of the ladder 32, as best illustrated in FIG. 1. The stabilizer block 24 is then placed over the shaft 14 so that the shoulders 25 of the block 24 engage the left side rail 36 of the ladder 32. The block 24 is followed by spacer 28 and finally the cinch nut 26 which is placed over the threaded end 42 of the shaft 14. The female flutes 38 of the block 24 engage the male flutes 44 of the shaft 14. The cinch nut 26 is then tightened to hold the desired angular position of the tray 10. The tray 10 is thus prevented from rotating and stays in the level position in which it was first inserted through the rung 34. The safety chains 16 may be then attached to the side of the building or other object to which the ladder 32 is applied. The flute arrangement illustrated in FIGS. 6, 7 and 9 allows the tray 10 to be adjusted to a nearly level position no matter what the angle of the ladder rail 36. Once the cinch nut 26 is tightened flutes 38 and 44 prevent any rotation of the tray 10 from the selected flute alignment. The present invention can be installed at any height by one person and is easily and safely moved. The tray 10 can support sufficient weight of the usual tools of a handyman. The raised portion 12 around the edge of the tray 10 keeps any materials from rolling off the tray 10 due to the normal minor motions of the ladder. The block 24 is sized to fit most available ladders and the spacer block 28 allows adjustment when the invention is applied to the upper half of an extension ladder in which the width of the side rail of the extension portion of the ladder is of slightly less than the side rail of the base portion of the extension ladder. Although illustrated with the tray on the right of the ladder, the invention can be reversed to put the tray on the left of the ladder for a left-handed user.
The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes such as the number of flutes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly all suitable modifications and equivalents may be resorted to falling within the scope of the invention as claimed.
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A work tray for mounting on hollow rung ladders. The tray has a single shaft which goes through one rung of the ladder. Lock means are provided to keep the tray from rotating or from pulling out of the rung. Angular adjustment means are provided so that the tray may be kept level when the ladder is used at different angles.
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BACKGROUND
1. Technical Field
The present disclosure generally relates to devices for separating workpieces (e.g., foam) from support materials.
2. Description of Related Art
Foam is widely used in the manufacturing of electronic devices. Before being assembled, foam is adhered on support materials, such as paper boards. During assembly, the foam having a relatively large size, can be effectively separated from the support materials using vacuum grip devices. However, it is difficult to separate the foam with small sizes, 4.8 mm×4.8 mm for example, from support materials using vacuum grip devices alone.
Therefore, there is room for improvement within the art.
BRIEF DESCRIPTION OF THE DRAWINGS
Many aspects of the disclosure can be better understood with reference to the drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the views.
FIG. 1 is an exploded, isometric view of a workpiece separating device in accordance with an exemplary embodiment.
FIG. 2 is an exploded, isometric view of the workpiece separating device of FIG. 1 viewed from another angle.
FIG. 3 is an assembled, isometric view of the workpiece separating device of FIG. 2 .
FIG. 4 is an enlarged view of circled portion IV of FIG. 3 .
DETAILED DESCRIPTION
FIGS. 1-3 show an exemplary embodiment of a workpiece separating device 100 . The workpiece separating device 100 may be used for separating workpieces 63 from support sheets 60 where the workpieces 63 are adhered. Each of the support sheets 60 defines two through holes 612 (best shown in FIG. 4 ) corresponding to each workpiece 63 . The workpieces 63 can be foam pieces or other elements of electronic devices. The workpiece separating device 100 includes an assembling board 10 , a first driving unit 20 , a second driving unit 30 , a lifting unit 40 , and a positioning assembly 50 . The first and second driving units 20 , 30 are assembled on the assembling board 10 . The lifting unit 40 is slidably assembled to the second driving unit 30 . The positioning assembly 50 is slidably assembled to the first driving unit 20 . The support sheet 60 is positioned on the positioning assembly 50 .
The first driving unit 20 includes two first sliding rails 21 , a first sliding block 23 , a first ball screw 25 , and a first driving element 27 . The two first sliding rails 21 are attached on the assembling board 10 and are substantially parallel to each other. The first sliding block 23 defines two sliding grooves 231 engaged with the two first sliding rails 21 . The first ball screw 25 is positioned between the two first sliding rails 21 and includes a first threaded shaft 251 and a first nut 253 slidably coiled around the first threaded shaft 251 . The sliding block 23 is attached to the first nut 253 and is capable of sliding relative to the first threaded shaft 251 and the two sliding rails 21 . The first driving element 27 can be a motor and drives the first threaded shaft 251 of the first ball screw 25 . When the first driving element 27 rotates the first threaded shaft 251 , the first nut 253 slides along the first threaded shaft 251 , thereby driving the sliding block 23 to slide along the two first sliding rails 21 . A direction parallel to the two first sliding rails 21 is defined as a first direction.
The second driving unit 30 is positioned adjacent the first driving unit 20 . The second driving unit 30 includes two second sliding rails 31 , a second sliding block 33 , a second ball screw 35 , and a second driving element 37 . The two second sliding rails 31 are attached on the assembling board 10 and are substantially parallel to each other. The two second sliding rails 31 are substantially perpendicular to the two first sliding rails 21 . An end of the two second sliding rails 31 is adjacent to and aligned with a substantially middle portion of one of the two first sliding rails 21 . The second sliding block 33 defines two sliding recesses 331 engaged with the two second sliding rails 31 . The second ball screw 35 is positioned between the two second sliding rails 31 and includes a second threaded shaft 351 and a second nut 353 slidably coiled around the second threaded shaft 351 . The second sliding block 33 is attached to the second nut 353 to be capable of sliding relative to the second threaded shaft 351 and the two first sliding rails 31 . The second driving element 37 can be a motor and drives the second threaded shaft 351 of the second ball screw 35 . When the second driving element 37 rotates the second threaded shaft 351 , the second nut 353 slides along the second threaded shaft 351 , thereby driving the second sliding block 33 to slide along the two second sliding rails 31 . A direction parallel to the two second sliding rails 31 is defined as a second direction.
The lifting unit 40 includes a lifting cylinder 45 , a support board 47 , and two pins 49 . The lifting cylinder 45 is attached on the second sliding block 33 . The support board 47 is connected to the lifting cylinder 45 to be raised and lowered by the lifting cylinder 45 . The two pins 49 are attached upright to the support board 47 . When the support board 47 is driven by the lifting cylinder 45 to move up and down, the two pins 49 are raised and lowered by the support board 47 . A moving direction of the pins 49 is substantially perpendicular to the first and second directions and is defined as a third direction.
The positioning assembly 50 includes a rotating cylinder 53 , a rotating board 55 , and two fixing plates 57 . The rotating cylinder 53 is attached to the first sliding block 23 . A center portion of a lower surface of the rotating board 55 is connected to the rotating cylinder 53 for rotation by the rotating cylinder 53 . The rotating board 55 defines two positioning recesses 553 in an upper surface. The two positioning recesses 553 are located at opposite ends of the rotating board 55 . Each positioning recess 553 is configured for receiving one support sheet 60 and one fixing plate 57 . Each positioning recess 553 has a plurality of limiting posts 5531 protruding from a bottom 5533 . The limiting posts 5531 are configured for limiting a position of the support sheets 60 . Each positioning recess 553 further defines a plurality of slots 555 to allow the pins 49 to be inserted through to separate the workpieces 63 from the support sheets 60 , by pushing the workpieces 63 via the through holes 612 of the support sheets 60 . Each fixing plate 57 defines a plurality of latching holes 573 corresponding to the limiting posts 5531 and defines a plurality of openings 571 corresponding to the slots 555 . The plurality of openings 571 are configured for a vacuum grip device attached on a robot (not shown) to take out the workpieces. When the support sheets 60 and the fixing plates 57 are received in the positioning recesses 553 , each support sheet 60 is located between the rotating board 55 and the corresponding fixing plate 57 with the through holes 612 aligned with the slots 555 . The limiting posts 5531 are inserted into the latching holes 573 , thereby securing the support sheets 60 in the positioning recesses 553 .
In use, referring to FIGS. 3 and 4 , the first driving element 27 drives the first ball screw 25 to rotate. The first ball screw 25 drives the first sliding block 23 bringing with the positioning assembly 50 to move along the first direction. The second driving element 37 drives the second ball screw 35 to rotate. The second ball screw 35 drives the second sliding block 33 , moving the lifting unit 40 along the second direction perpendicular to the first direction, and enabling the pins 49 to be aligned with two through holes 612 corresponding to a workpiece 63 , as shown in FIG. 4 . At this time, the vacuum grip device can be driven to be aligned with and in touch with the workpiece 63 . Then, the two pins 49 are moved towards the workpiece 63 by the lifting cylinder 45 to be inserted through the corresponding slot 555 to separate the workpiece 63 from the support sheet 60 , by pushing the workpiece 63 via the through holes 612 of the support sheet 60 . The separated workpiece 63 can be taken by the vacuum grip device. Then, the first driving unit 20 and the second driving unit 30 adjust the positioning assembly 50 and the pins 49 again, enabling the pins 49 to be aligned with another two through holes 612 corresponding to another workpiece 63 . The above steps are repeated until the workpieces 63 on the support sheet 60 positioned at one end of the rotating board 55 . The rotating cylinder 53 then drives the rotating board 55 to rotate, positioning another support sheet 60 at another end of the rotating board 55 correctly to allow the workpieces 63 thereon to be separated.
In other embodiments, the lifting unit 40 can have more than two pins 49 , multiples of two secured on the support board 47 , for example. The lifting unit 40 can also have only one pin 49 .
It is to be understood, however, that even through numerous characteristics and advantages of the present disclosure have been set forth in the foregoing description, together with details of assembly and function, the disclosure is illustrative only, and changes may be made in detail, especially in the matters of shape, size, and arrangement of parts within the principles of the disclosure to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
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A workpiece separating device for separating workpieces from support sheets includes a lifting unit and a positioning assembly supporting the support sheets with the workpieces adhered. The lifting unit includes a lifting cylinder and two pins raised and lowered by the lifting cylinder. The two pins are raised by the lifting cylinder to push the workpieces, thereby separating the workpieces from the support sheets in turn. A method for separating workpieces from support sheets using the present device is also provided.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application claiming priority to pending U.S. patent application Ser. No. 11/786,818, filed on Apr. 13, 2007, which is a divisional application claiming priority to U.S. patent application Ser. No. 09/962,303, filed on Sep. 26, 2001, now U.S. Pat. No. 7,220,571, which claimed priority to U.S. Provisional Patent App. No. 60/235,844, filed on Sep. 28, 2000, and now abandoned.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to the fields of microbiology and microbial genetics. More specifically, the invention relates to novel bacterial strains and processes employing these strains for fermentative production of amino acids such as L-threonine.
[0004] 2. Related Art
[0005] In Escherichia coli , the amino acids L-threonine, L-isoleucine, L-lysine and L-methionine derive all or part of their carbon atoms from aspartate (aspartic acid) via the following common biosynthetic pathway (G. N. Cohen, “The Common Pathway to Lysine, Methionine and Threonine,” pp. 147-171 in Amino Acids: Biosynthesis and Genetic Regulation , K. M. Herrmann and R. L. Somerville, eds., Addison-Welesley Publishing Co., Inc., Reading, Mass. (1983)):
[0000]
[0006] The first reaction of this common pathway is catalyzed by one of three distinct aspartate kinases (AK. I, II, or III), each of which is encoded by a separate gene and differs from the others in the way its activity and synthesis are regulated. Aspartate kinase I, for example, is encoded by thrA, its activity is inhibited by threonine, and its synthesis is repressed by threonine and isoleucine in combination. AK II, however, is encoded by metL and its synthesis repressed by methionine (although its activity is not inhibited by methionine or by paired combinations of methionine, lysine, threonine and isoleucine (F. Falcoz-Kelly et al., Eur. J. Biochem. 8:146-152 (1969); J. C. Patte et al., Biochim. Biophys. Acta 136:245-257 (1967)). AK III is encoded by lysC and its activity and synthesis are inhibited and repressed, respectively, by lysine.
[0007] Two of the AKs, I and II, are not distinct proteins, but rather a domain of a complex enzyme that includes homoserine dehydrogenase I or II, respectively, each of which catalyzes the reduction of aspartate semialdehyde to homoserine (P. Truffa-Bachi et al., Eur. J. Biochem. 5:73-80 (12968)). Homoserine dehydrogenase I (HD I) is therefore also encoded by thrA, its synthesis is repressed by threonine plus isoleucine and its activity is inhibited by threonine. Homoserine dehydrogenase II (HD II) is similarly encoded by metL and its synthesis is repressed by methionine.
[0008] Threonine biosynthesis includes the following additional reactions: Homoserine→Homoserine Phosphate→Threonine. The phosphorylation of homoserine is catalyzed by homoserine kinase, a protein which is composed of two identical 29 kDa subunits encoded for by thrB and whose activity is inhibited by threonine (B. Burr et al., J. Biochem. 62:519-526 (1976)). The final step, the complex conversion of homoserine phosphate to L-threonine is catalyzed by threonine synthase, a 47 kDa protein encoded for by thrC. (C. Parsot et al., Nucleic Acids Res. 11:7331-7345 (1983)).
[0009] Isoleucine can be produced in E. coli using threonine as a precursor (see Hashiguchi et al., Biosci. Biotechnol. Biochem 63:672-679 (1999) More specifically, isoleucine is produced via the following reactions:
[0000] Threonine→α-Ketobutyrate→α-Aceto-α-Hydroxybutyrate→α,β-Dihydroxy-β-Methylvalerate→α-Keto-β-Methylvalerate→Isoleucine. These reactions are catalyzed in E. coli , respectively, by the following enzymes: threonine deaminase (ilvA); aceto-hydroxyacid synthetase I, II, or III (ilvBN, ilvGM, and ilvIH, respectively); dihydroxyacid reductoisomerase (ilvC); dihydroxyacid dehydratase (ilvD); and transaminase-B (ilvE).
[0010] The E. coli isoleucine operon is composed of ilvA, ilvGM, ilvD, and ilvE. The ilvA gene product (i.e., threonine deaminase) is inhibited by L-isoleucine, and the ilvGM gene product (i.e., aceto-hydroxyacid synthetase II) is inhibited by L-valine. Further, the reactions catalyzed by threonine deaminase and the aceto-hydroxyacid synthetases are believed to be the main rate limiting steps in the production of isoleucine.
[0011] The thrA, thrB and thrC genes all belong to the thr operon, a single operon located at 0 minutes on the genetic map of E. coli (J. Thèze and I. Saint-Girons, J. Bacteriol. 118:990-998 (1974); J. Thèze et al., J. Bacteriol. 117:133-143 (1974)). These genes encode, respectively, for aspartate kinase I-homoserine dehydrogenase I, homoserine kinase and threonine synthase. Biosynthesis of these enzymes is subject to multivalent repression by threonine and isoleucine (M. Freundlich, Biochem. Biophys. Res. Commun. 10:277-282 (1963)).
[0012] A regulatory region is found upstream of the first structural gene in the thr operon and its sequence has been determined (J. F. Gardner, Proc. Natl. Acad. Sci. USA 76:1706-1710 (1979)). The thr attenuator, downstream of the transcription initiation site, contains a sequence encoding a leader peptide; this sequence includes eight threonine codons and four isoleucine codons. The thr attenuator also contains the classical mutually exclusive secondary structures which permit or prevent RNA polymerase transcription of the structural genes in the thr operon, depending on the levels of the charged threonyl- and isoleucyl-tRNAs.
[0013] Because of the problems associated with obtaining high levels of amino acid production via natural biosynthesis (erg, repression of the thr operon by the desired product), bacterial strains have been produced having plasmids containing a thr operon with a thrA gene that encodes a feedback-resistant enzyme. With such plasmids, L-threonine has been produced on an industrial scale by fermentation processes employing a wide variety of microorganisms, such as Brevibacterium flavum, Serratia marcescens , and E. coli.
[0014] For example, the E. coli strain BKIIM B-3996 (Debabov et al., U.S. Pat. No. 5,175,107), which contains the plasmid pVIC40, makes about 85 g/L in 36 hr. The host is a threonine-requiring strain because of a defective threonine synthase. In BKIIM B-3996, it is the recombinant plasmid, pVIC40, that provides the crucial enzymatic activities, i.e., a feedback-resistant AK I-HD I, homoserine kinase and threonine synthase, needed for threonine biosynthesis. This plasmid also complements the host's threonine auxotrophy.
[0015] E. coli strain 29-4 (E Shimizu et al, Biosci. Biotech. Biochem. 59:1095-1098 (1995)) is another example of a recombinant E. coli threonine producer. Strain 29-4 was constructed by cloning the thr operon of a threonine-over-producing mutant strain, E. coli K-12 (βIM-4) (derived from E. coli strain ATCC Deposit No. 21277), into plasmid pBR322, which was then introduced into the parent stain (K. Wiwa et al., Agric. Biol. Chem. 47:2329-2334 (1983)). Strain 29-4 produces about 65 g/L of L-threonine in 72 hr.
[0016] Similarly constructed recombinant strains have been made using other organisms. For example, the Serratia marcescens strain T2000 contains a plasmid having a thr operon which encodes a feedback-resistant thrA gene product and produces about 100 g/L of threonine in 96 hrs (M. Masuda et al., Applied Biochem. Biotechn. 37:255-262 (1992)). All of these strains contain plasmids having multiple copies of the genes encoding the threonine biosynthetic enzymes, which allows over-expression of these enzymes. This over-expression of the plasmid-borne genes encoding threonine biosynthetic enzymes, particularly a thrA gene encoding a feedback-resistant AK I-HD I, enables these strains to produce large amounts of threonine. Other examples of plasmid-containing microorganisms are described, for example, in U.S. Pat. Nos. 4,321,325; 4,347,318; 4,371,615; 4,601,983; 4,757,009; 4,945,058; 4,946,781; 4,980,285; 5,153,123; and 5,236,831
[0017] Plasmid-containing strains such as those described above, however, have problems that limit their usefulness for commercial fermentative production of amino acids. For example, a significant problem with these strains is ensuring that the integrity of the plasmid-containing strain is maintained throughout the fermentation process because of potential loss of the plasmid during cell growth and division. To avoid this problem, it is necessary to selectively eliminate plasmid-free cells during culturing, such as by employing antibiotic resistance genes on the plasmid. This solution, however, necessitates the addition of one or more antibiotics to the fermentation medium, which is not commercially practical for large scale fermentations
[0018] Another significant problem with plasmid-containing strains is plasmid stability High expression of enzymes whose genes are coded on the plasmid, which is necessary for commercially practical fermentative processes, often brings about plasmid instability (E. Shimizu et al., Biosci. Biotech. Biochem. 59:1095-1098 (1995)). Plasmid stability is also dependent upon factors such as cultivation temperature and the level of dissolved oxygen in the culture medium. For example, plasmid-containing strain 29-4 was more stable at lower cultivation temperatures (30° C. vs. 37° C.) and higher levels of dissolved oxygen (E. Shimizu et al., Biosci. Biotech. Biochem. 59:1095-1098 (1995)).
[0019] Non-plasmid containing microorganisms, while less efficacious than those described above, have also been used as threonine producers. Strains of E. coli such as H-8460, which is obtained by a series of conventional mutagenesis and selection for resistance to several metabolic analogs makes about 75 g/L of L-threonine in 70 hours (Kino et al., U.S. Pat. No. 5,474,918). Strain H-8460 does not carry a recombinant plasmid and has one copy of the threonine biosynthetic genes on the chromosome. The lower productivity of this strain compared to the plasmid-bearing strains, such as BKIIM B-3996, is believed to be due to lower enzymatic activities (particularly those encoded by the thr a operon) as these non-plasmid containing strains carry only a single copy of threonine biosynthetic genes.
[0020] An L-threonine producing strain of E. coli , KY10935, produced by multiple rounds of mutation is described in K. Okamoto et al., Biosci. Biotechnol. Biochem. 61:1877-1882 (1997). When cultured under optimal conditions with DL-methionine, strain KY10935 is reported to produce as much as 100 Biter L-threonine after 77 hours of cultivation. The high level of L-threonine produced is believed to result from the inability of this strain to take up L-threonine that accumulates extracellularly, resulting in a decrease in the steady-state level of intracellular L-threonine and the release the remaining regulatory steps in the L-threonine production pathway from feedback inhibition.
[0021] Other examples of suitable non-plasmid containing microorganisms are described, for example, in U.S. Pat. Nos. 5,939,307; 5,474,918; 5,264,353; 5,164,307; 5,098,835; 5,087,566; 5,077,207; 5,017,483; 4,463,094; 3,580,810; and 3,375,173.
[0022] In both the non-plasmid and plasmid containing strains of E. coli , the thr operon is controlled by the particular strains respective native threonine promoter. As described above, the expression of the native promoter is regulated by an attenuation mechanism controlled by a region of DNA which encodes a leader peptide and contains a number of threonine and isoleucine codons. This region is translated by a ribosome which senses the levels of threoninyl-RNA and isoleucinyl-tRNA. When these levels are sufficient for the leader peptide to be translated, transcription is prematurely terminated, but when the levels are insufficient for the leader peptide to be translated, transcription is not terminated and the entire operon is transcribe which, following translation, results in increased production of the threonine biosynthetic enzymes. Thus, when threonyl-tRNA and/or isoleucinyl-tRNA levels are low, the thr operon is maximally transcribed and the threonine biosynthetic enzymes are maximally made.
[0023] In the E. coli threonine-producing strain BKIIM B-3996, the threonine operon in the plasmid is controlled by its native promoter. As a result, the thr operon is only maximally expressed when the strain is starved for threonine and/or isoleucine. Since starvation for threonine is not possible in a threonine-producing strain, these strains have been rendered auxotrophic for isoleucine in order to obtain a higher level of enzymatic activity.
[0024] Another way of overcoming attenuation control is to lower the level(s) of threonyl-tRNA and/or isoleucinyl-tRNA in the cell. A thrS mutant, for example, having a threonyl-tRNA synthase which exhibits a 200-fold decreased apparent affinity for threonine, results in over-expression of the thr operon, presumably due to the low level of threonyl-tRNA (E. J. Johnson et al., J. Bacteriol. 129:66-70 (1977)).
[0025] In fermentation processes using these strains, however, the cells must be supplemented with isoleucine in the growth stage because of their deficient isoleucine biosynthesis. Subsequently, in the production stage, the cells are deprived of isoleucine to induce expression of the threonine biosynthetic enzymes. A major drawback, therefore, of using native threonine promoters to control expression of the threonine biosynthetic enzymes is that the cells must be supplemented with isoleucine.
[0026] The antibiotic borrelidin, a natural product of Streptomyces rochei , is also known to reduce the enzymatic activity of threonyl tRNA-synthetase, and thereby inhibit the growth of E. coli (G. Nass et al., Biochem. Biophys. Res. Commun. 34:84 (1969)). In view of this reduced activity, certain borrelidin-sensitive strains of E. coli have been employed to produce high levels of threonine (Japanese Published Patent Application No. 6752/76; U.S. Pat. No. 5,264,353). Addition of borrelidin to the culture was found to increase the yield of L-threonine Borrelidin-sensitive strains of Brevibacterium and Corynebacterium have also been used to produce high levels of threonine (Japanese Patent No. 53-101591).
[0027] Borrelidin-resistant mutants of E. Coli similarly exhibit changes in threonyl tRNA-synthetase activity. More specifically, borrelidin-resistant E. coli have been shown to exhibit one of the following features: (i) constitutively increased levels of wild-type threonyl tRNA-synthetase; (ii) structurally altered threonyl tRNA-synthetase; or (iii) some unknown cellular alteration, probably due to a membrane change (G. Nass and J. Thomale, FEBS Lett. 39:182-186 (1974)). None of these mutant strains, however, has been used for the fermentative production of L-threonine.
[0028] E. coli strains have recently been described which contain chromosomally integrated thr operons under the regulatory control of a non-native promoter (Wang et al., U.S. Pat. No. 5,939,307, the entire disclosure of which is incorporated herein by reference). One of these strains, ADM Kat 13, was shown to produce as much as 102 g/L of L-threonine after 48 hours in culture.
[0029] There remains a need in the art for microorganism strains which are readily culturable and efficiently produce large amounts of amino acids such as threonine and isoleucine.
SUMMARY OF THE INVENTION
[0030] One object of the present invention is to provide microorganisms which efficiently produce amino acids (e.g., L-threonine) in large amounts and high yields. In general, microorganisms of the invention do not require any recombinant plasmids containing genes that encode enzymes in the biosynthesis of the amino acid product and, in most instances, have no amino acid nutritional requirements.
[0031] When bacterial strains of the invention over-produce L-threonine, in many instances, these strains will be resistant to either L-threonine itself or threonine raffinate (TRF).
[0032] In one embodiment, the invention is directed to processes for producing Escherichia coli strains capable of producing between about 95 and about 150 g/L of L-threonine by about 48 hours of growth in culture comprising:
[0033] (a) inserting, into the chromosome of an E. coli at least one threonine operon operably linked to a non-native promoter to produce a parent strain; and
[0034] (b) performing at least one cycle of mutagenesis on the parent strain, followed by screening the mutagenized cells to identity E. coli which produce between about 95 and about 150 g/L of L-threonine by about 48 hours of growth in cultures. The invention also includes E. coli strains produced by the above processes.
[0035] In related embodiments, the invention is directed to processes for producing E. coli strains capable of producing between about 110 and about 120 g/L of L-threonine, between about 110 and about 130 g/L of L-threonine, or between about 100 and about 140 g/L of L-threonine by about 48 hours of growth in culture.
[0036] In additional related embodiments, the invention is directed to processes for producing N coli strains employing agents such as alkylating agents, intercalating agents, and ultraviolet light to induce mutations.
[0037] In other related embodiments, the invention is directed to processes for producing E. coli strains having two or three threonine operons inserted into the chromosome of the E. coli . Further, these individual threonine operons may be operably linked to at least two different non-native promoters. Non-native promoters suitable for use in the invention include the tac promoter, the lac promoter, the trp promoter, the lpp promoter, the P L promoter, and the P R promoter.
[0038] Related embodiments also include processes for producing E. coli strains having threonine operons containing genes that encode feedback-resistant aspartate kinase-homoserine dehydrogenases. Further, E. coli strains used to generate strains of the invention may contain a defective threonine dehydrogenase gene on their chromosomes.
[0039] Strains which may be used in the processes discussed above include those which contain a threonine operon obtained from the E. coli strain deposited as ATCC Deposit No. 21277.
[0040] The processes described above may also be used to generate strains which are resistant to threonine raffinate, resistant to borrelidin or cyclopentanecarboxylic acid (CPCA), or resistant to any combination of threonine raffinate, borrelidin and CPCA. Thus, the invention also includes strains of E. coli produced by the above process which are resistant to threonine raffinate, resistant to borrelidin or CPCA, or resistant to any combination of threonine raffinate, borrelidin and CPCA.
[0041] In other embodiments the invention is directed to E. coli strains comprising at least one chromosomally integrated threonine operon operably biked to a non-native promoter. These strains are capable of producing between about 110 and about 120 g/L of L-threonine, between about 110 and about 130 g/L of L-threonine, between about 100 and about 140 g/L of L-threonine, or between about 95 and about 150 g/L of L-threonine by about 48 hours of growth in culture. Strains of the invention will generally not include E. coli strains KY10935, ADM TH1.2, and ADM Kat13.
[0042] In related embodiments, the invention includes E. coli strains which have the above characteristics and comprise a threonine operon obtained from the ES coli strain deposited as ATCC Deposit No. 21277.
[0043] The invention also includes E. coli strains which are resistant to threonine raffinate and are capable of producing between about 110 and about 120 g/L of L-threonine, between about 110 and about 130 g/L of L-threonine, between about 100 and about 140 g/L of L-threonine, or between about 95 and about 150 g/L of L-threonine by about 48 hours of growth in culture.
[0044] In other embodiments, the threonine operon of E. coli strains of the invention encodes a feedback-resistant aspartate kinase I-homoserine dehydrogenase I gene (thrA), a homoserine kinase (thrB) gene, and a threonine synthase gene (thrC).
[0045] In further embodiments, E. coli strains of the invention contain a defective threonine dehydrogenase gene on their chromosomes.
[0046] The invention also includes E. coli strains which have the characteristics of the strain deposited as NRRL B-30319 (Agriculture Research Culture Collection (NRRL), 1815 N, University Street, Peoria, Ill., 61604, USA).
[0047] The invention further includes the E. coli strains deposited as NRRL B-30316, NRRL B-30317, NRRL B-30318, and NRRL B-30319 (Agriculture Research Culture Collection (N), 1815 N. University Street, Peoria, Ill., 61604, USA).
[0048] Additionally, the invention is directed to processes for producing l-threonine comprising the steps of culturing the strains mentioned above and recovering L-threonine produced.
BRIEF DESCRIPTION OF THE FIGURES
[0049] FIG. 1 depicts the construction of plasmid pAD103 from Kohara's lambda 676 and plasmid pUC19.
[0050] FIG. 2 depicts the construction of plasmid pAD106 from plasmid pAD103 and plasmid pUC4k.
[0051] FIG. 3 depicts the construction of plasmid pAD115 from plasmid pAD103 and plasmid pkk223-3.
[0052] FIG. 4 depicts the construction of plasmid pAD123 from plasmid pAD115 and plasmid pAD106.
[0053] FIG. 5 depicts the integration of the promoter region from plasmid pAD123 into the chromosome of E. coli.
[0054] FIG. 6 depicts the construction of plasmid pAD132 by the insertion of the tdh::cat deletion from E. coli strain SP942 into plasmid pUC18.
[0055] FIG. 7 depicts the construction of plasmid pAD133 by the insertion of nucleic acid containing a kanamycin resistance gene and a 1 hr operon operably linked to a tac promoter into plasmid pAD132.
[0056] FIG. 8 depicts one specific embodiment of the stepwise mutagenic process described in Example 6 to generate strains of the invention which demonstrate improved production of L-threonine.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0057] The present invention provides strains of novel microorganisms which, when grown in culture, produce relatively large amounts of amino acids (e.g., L-threonine and L-isoleucine). Further provided are methods for producing the aforementioned strains and methods for producing amino acids (e.g. L-threonine and L-isoleucine) using these strains. Thus, the invention is directed, in part, to novel bacterial strains which may be used in fermentation processes for the production of amino acid such as L-threonine or L-isoleucine.
[0058] In one aspect, the invention provides bacterial strains (e.g., strains of E. coli ) which demonstrate both resistance to raffinate and improved growth properties. These bacterial strains allow for the production of amino acids in high amounts and yields.
[0059] A number of alterations can be made to bacterial cells which alter their metabolism and confer upon them the ability to produce increased quantities of amino acids and other metabolic products. Examples of such alterations include the following:
[0060] 1. Eliminating or reducing feedback control mechanisms of one or more biosynthetic pathways which lead to the production of amino acids or amino acid precursors.
[0061] 2. The enhancement of metabolic flow by either amplifying or increasing the expression of genes which encode rate-limiting enzymes of biosynthetic pathways that lead to the production of amino acids or amino acid precursors.
[0062] 3. Inhibiting degradation of a desired amino acid end product or one or more intermediates and/or precursors of the desired amino acid end product.
[0063] 4. Increasing the production of amino acid intermediates and/or and precursors.
[0064] 5. When the pathway which leads to production of a desired amino acid end product is branched) inhibiting branches which do not lead to the amino acid to increase intermediate and/or precursor availability.
[0065] 6. Altering membrane permeability to optimize uptake of energy molecules (e.g., glucose), intermediates and/or precursors.
[0066] 7. Altering membrane permeability to optimize amino acid end product excretion.
[0067] 8. The enhancement of growth tolerance to relatively high concentrations of end products (e.g., amino acids), metabolic waste products (e.g., acetic acid), or metabolic side products (e.g., amino acid derivatives either formed by the bacterial themselves or formed in the culture medium) which are inhibitory to bacterial cell growth.
[0068] 9. The enhancement of resistance to high osmotic pressure during culturing resulting from high concentrations of carbon sources (e.g., glucose) or end products (e.g., amino acids).
[0069] 10. The enhancement of growth tolerance to changes in environmental conditions (e.g., pressure, temperature, pH, etc.).
[0070] 11. Increasing activities of enzymes involved in the uptake and use of carbon sources in the culture medium (e.g., raffinose, stachyose or proteins, as well as other components of corn steep liquor).
[0071] Bacteria optimized for production of a particular end product (e.g., L-threonine) will generally differ from wild-type bacteria by having multiple characteristics (e.g., two of more characteristics set out in the list above) which lead to increased production of the desired end product. The invention thus includes methods for producing bacterial strains which exhibit properties set out above and produce increased amounts of amino acids as compared to wild-type strains. The invention also includes bacterial strains produced by the methods disclosed herein.
I. DEFINITIONS
[0072] The following definitions are provided to clarify the subject matter which the inventors consider to be the present invention.
[0073] As used herein, the term “Yield” 1 refers to the amount of a product produced in relation to the amount of a starting material. With respect to amino acids produced by a microorganism, yield refers to the amount of amino acid produced with respect to the amount of intermediate, precursor or nutrient provided. For example, when 100 grams of dextrose is supplied to a microorganism which produces 25 grams of L-isoleucine, the yield of L-isoleucine, with respect to the dextrose, is 25%.
[0074] As used herein, the term t “raffinate” refers to wastestream products generated from ion-exchange operations for amino acid recovery from fermentation broth in which bacteria have been cultured.
[0075] As used herein, the phrase “threonine raffinate (TRF)” refers to wastestream products generated from ion-exchange operations for threonine recovery from fermentation broth in which bacteria that produce threonine have been cultured.
[0076] As one skilled in the art would recognize, TRF is a heterogenous composition, the content of which will vary with a number of factors (e.g., the composition of the initial culture medium, the nutritional requirements of the cultivated organism(s), metabolic products produced by the cultivated organism(s), and chromatographic preparation process used). For purposes of selecting and identifying bacteria which are resistant to TRF, TRF will generally have the characteristics set out herein in Section II.
[0077] As used herein, the term “strain” refers to bacteria of a particular species which have common characteristics. Unless indicated to the contrary, the terms “strain” and “cell” are used interchangeably herein. As one skilled in the art would recognize, bacterial strains are composed of individual bacterial cells. Further, individual bacterial cells have specific characteristics (e.g., a particular level of resistance to TRF) which identifies them as being members of their particular strain.
[0078] As used herein, the term “mutation” refers to an insertion, deletion or substitution in a nucleic acid molecule. When present in the coding region of a nucleic acid, a mutation may be “silent” (i.e., results in no phenotypic effect) or may alter the function of the expression product of the coding region when a mutation occurs to the regulatory region of a gene or operon, the mutation may either have no effect or alter the expression characteristics of the regulated nucleic acid.
[0079] As used herein, the term “mutagenesis” refers to a process whereby one or more mutations are generated in an organism's genetic material (e.g., DNA). With “random” mutagenesis, the exact site of mutation is not predictable, occurring anywhere in the chromosome of the microorganism. Further, with random mutagenesis, the mutations are generally brought about as a result of physical damage to the organism's nucleic acid caused by agents such as radiation or chemical treatment. As discussed in more detail below, numerous agents may be used to perform mutagenesis.
[0080] As used herein, the phrase “cycle of mutagenesis” in general refers to the treatment of cells with a mutagen, or combination of mutagens, followed by culture of those cells to allow surviving cells to reproduce. In many instances, the mutagenized cells will be screened to identify those with particular characteristics after each cycle of mutagenesis. Further, as part of a cycle of mutagenesis, cells treated with a mutagen may be exposed to a selective agent (e.g., TRF) immediately after mutagenesis or while still exposed to the mutagen.
[0081] As used herein, the term “phenotype” refers to observable physical characteristics dependent upon the genetic constitution of a microorganism. Examples of phenotypes include the ability to express particular gene products and the ability to produce certain amounts of a particular amino acid in a specified amount of time.
[0082] As used herein, the term “over-produce” refers to the production of a compound by a cell in an amount greater than the amount produced by a reference strain (e.g., a parent strain). One example of an over-producing strain would be a strain generated from a parent strain (i.e., the reference strain) using mutagenesis which produces more L-threonine than the parent. Thus, the strain generated by mutagenesis would “over-produce” L-threonine in comparison to the parent, reference strain.
[0083] As used herein, the term “operon” refers to a unit of bacterial gene expression and regulation. Operons are generally composed of regulatory elements and at least one open reading frame (ORF). An example of an operon is the threonine operon of E. coli which is composed of a regulatory region and three open reading frames. Another example of an operon is the isoleucine operon of E. coli which is composed of a regulatory region and four open reading frames.
[0084] As used herein, the term “parent strain” refers to a strain of a microorganism subjected to mutagenesis to generate a microorganism of the invention. Thus, use of the phrase “parent strain” does not necessarily equate with the phrase “wild-type” or provide information about the history of the referred to strain.
II. STRAINS OF THE INVENTION AND THEIR PREPARATION
[0085] Novel bacterial strains of the present invention have the following characteristics:
[0086] (1) they contain at least one operon which (a) is integrated into the bacterial chromosome, (b) is under the control of a non-native promoter, and (c) encodes enzymes involved in amino acid synthesis; and
[0087] (2) they are capable of producing one or more amino acids upon growth in culture.
[0088] In particular embodiments, novel bacterial strains of the present invention include strains which have the following characteristics:
[0089] (1) they contain at least one thr operon (i.e., contain at least one set of the genes encoding threonine biosynthetic enzymes) which (a) is integrated into the bacterial chromosome and (b) is under the control of a non-native promoter; and
[0090] (2) they are capable of producing either L-threonine or L-isoleucine upon growth in culture.
[0091] A. Operons Suitable for Use with the Invention
[0092] While, as explained below, the invention can be used to produce cells which over-produce a considerable number of amino acids, the invention is discussed below mainly with respect to cells which over-produce L-threonine and L-isoleucine, as well as processes for producing these amino acids.
[0093] The threonine (thr) operon on the chromosome of cells of bacterial strains included within the scope of the invention encodes enzymes necessary for threonine biosynthesis. Due to the fact that several enzymes are capable of catalyzing reactions to produce various intermediates in the threonine pathway, the genes present in the threonine operon employed can vary. For example, the threonine operon can be composed of an AK-HD gene (thrA or metL), a homoserine kinase gene (thrB), and a threonine synthase gene (thrC). Further, the thr operon can be composed of thrA (the AK I-HD I gene), thrB and thrC. Suitable thr operons may be obtained, for example, from E. coli strains deposited with the American Type Culture Collection (ATCC), 10801 University Blvd., Manassas, Va. 20110-2209, USA and assigned ATCC Deposit Nos. 21277 and 21530.
[0094] Further, multiple copies of the thr operon may be present on the chromosomes of bacterial cells of the invention. Increased copy number of the thr operon will generally result in increased expression of the genes of this operon upon induction.
[0095] In many instances, the thr operon contains at least one non-attenuated gene (i.e., expression of the gene is not suppressed by the levels (extra- and/or intra-cellular) of one or more of the threonine biosynthetic enzymes and/or the products thereof (e.g., L-threonine and L-isoleucine)). The inventive strains may also contain a thr operon having a defective thr attenuator (the regulatory region downstream of the transcription initiation site and upstream of the first structural gene) or a thr operon that lacks the thr attenuator altogether.
[0096] In one specific embodiment, the thr operon encodes one or more feedback-resistant threonine biosynthetic enzymes (e.g., the activity of the enzyme is not inhibited by the extra- and/or intra-cellular levels of the intermediates and/or products of threonine biosynthesis). In a more specific embodiment, the thr operon contains a gene that encodes a feedback-resistant AK-HD, such as a feedback-resistant AK I-HD I. Use of a feedback-resistant AK-HD provides a higher level of enzymatic activity for threonine biosynthesis, even in the presence of the L-threonine being produced.
[0097] Expression of the threonine operon(s) in strains of the invention will generally be controlled by a non-native promoter (i.e., a promoter that does not control expression of the thr operon in bacterial strains normally found in nature). Replacing the native promoter of the threonine biosynthetic enzymes with a strong non-native promoter to control expression of the thr operon results in higher threonine production even with only a single, genomic copy of the thr operon. In addition, when a non-native promoter is used to control expression of threonine operon, it is not necessary to render the bacterial strains auxotrophic for isoleucine to achieve this higher threonine production. Illustrative examples of promoters suitable for use in E. coli include, but are not limited to: the lac promoter, the trp promoter, the P L promoter of λ bacteriophage, the P R promoter, the lpp promoter, and the tac promoter. In one specific embodiment, the tac promoter is used.
[0098] In addition to the threonine operon, cells of the inventive bacterial strains may also contains at least one gene encoding aspartate semialdehyde dehydrogenase (asd) either integrated into their chromosomes or present on an extrachromosomal element (e.g., a plasmid). For example, the chromosome in cells of the present invention may contain at least one asd gene, at least one thrA gene, at least one thrB gene and/or at least one thrC gene. Of course, one, two, three, or more copies of each of these genes may be present.
[0099] Threonine dehydrogenase (tdh) catalyzes the oxidation of L-threonine to α-amino-β-ketobutyrate. Accordingly, in one specific embodiment, the chromosome of the inventive cells further contains at least one defective threonine dehydrogenase (tdh) gene. The defective tdh gene may be a gene having a reduced level of expression of threonine dehydrogenase or a gene that encodes a threonine dehydrogenase mutant having reduced enzymatic activity relative to that of native threonine dehydrogenase. For example, the defective tdh gene employed in inventive strains does not express threonine dehydrogenase. Illustrative examples of suitable tdh genes that do not express threonine dehydrogenase include a tdh gene having a chloramphenicol acetyltransferase (cat) gene inserted into it or a tdh gene having transposon Tn5 inserted into it, as described in U.S. Pat. No. 5,175,107.
[0100] The invention further provides microorganisms which express increased amounts of enzymes which catalyze the production of L-isoleucine, as well as microorganisms which over-produce L-isoleucine. As one skilled in the art, bacterial strains of the invention which produce increased quantities of L-threonine, in effect, allow for the production of substantial quantities of L-isoleucine. This is so because as already discussed, L-threonine is a precursor of L-isoleucine. Thus, operons suitable for use with the present invention include the isoleucine operon of E. coli , which is composed of the ilvA, ilvGM, ilvD, and ilvE genes.
[0101] In one embodiment of the invention, an isoleucine operon under the control of a non-native promoter is introduced into microorganisms. Further, nucleic acid encoding dihydroxyacid reductoisomerase (ilvC) may also be introduced into cells. These genes may be either inserted into chromosomal DNA or carried on plasmids.
[0102] In addition, because the reactions catalyzed by threonine deaminase and aceto-hydroxyacid synthetase are believed to be the rate limiting steps in the production of isoleucine, it will be advantages, when the production of isoleucine is desired, to over-express these particular gene products.
[0103] In addition, because the gene products of the ilvA gene (i.e., threonine deaminase) and the ilvGM (i.e., aceto-hydroxyacid synthetase II) are inhibited, respectively, by L-isoleucine and L-valine, in many circumstances, it will generally be advantageous to use feed-back resistant forms of these enzymes.
[0104] Similar modifications of cells and process of the invention can be readily employed to produce other amino acids generated by pathways related to those for the production of L-threonine and L-isoleucine. Examples of amino acids which can be produced using such modifications include L-lysine and L-glycine.
[0105] The invention also provides microorganisms which express increased amounts of enzymes which catalyze the production of L-methionine, as well as microorganisms which over-produce L-methionine. Examples of such microorganisms are ones which contain at least one met operon on the chromosome (i.e., the metL gene (which encodes AK II-HD II), the metA gene (homoserine succinyltransferase), the metB gene (cystathionine γ-synthase), the metC gene (cystathionine β-lyase) and the metE and metH genes (homocysteine methylase)) that have been subjected to mutagenesis and screening steps described herein. The genes set out in the preceding sentence, including feedback-resistant variants thereof, and, optionally, a non-native promoter can be introduced into the chromosome of the host microorganism according to one or more of the general methods discussed herein and/or known to those skilled in the art.
[0106] As indicated above, microorganisms which over-produce lysine can also be prepared by subjecting microorganisms that contain genes encoding lysine biosynthetic enzymes (e.g., a feedback-resistant lysine biosynthetic enzyme encoded by lysC and/or dapA) and, optionally, a non-native promoter to mutagenesis and screening steps described herein.
[0107] Bacterial strains of the present invention may be prepared by any of the methods and techniques known and available to those skilled in the art. Illustrative examples of suitable methods for constructing the inventive bacterial strains include gene integration techniques (e.g., mediated by transforming linear DNA fragments and homologous recombination) and transduction mediated by the bacteriophage P1. These methods are well known in the art and are described, for example, in J. H. Miller, Experiments in Molecular Genetics , Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y. (1972); J. H. Miller, A Short Course in Bacterial Genetics , Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y. (1992); M. Singer and P. Berg, Genes & Genomes , University Science Books, Mill Valley, Calif. (1991); J. Sambrook, E. F. Fritsch and T. Maniatis, Molecular Cloning: A Laboratory Manual, 2d ed., Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y. (1989); P. B. Kaufman et al., Handbook of Molecular and Cellular Methods in Biology and Medicine , CRC Press, Boca Raton, Fla. (1995); Methods in Plant Molecular Biology and Biotechnology , B. R. Glick and J. E. Thompson, eds., CRC Press, Boca Raton, Fla. (1993); and P. F. Smith-Keary, Molecular Genetics of Escherichia coli , The Guilford Press, New York, N.Y. (1989), the entire disclosure of each of which is incorporated herein by reference.
[0108] B. Amino Acid Production
[0109] Bacterial strains of the present invention include strains which are capable of producing substantial quantities of L-threonine or L-isoleucine when grown in culture. In particular, when grown in culture, strains of the invention include strains which are capable of producing at least about 65 g/L of L-threonine in about 36 hours, at least about 75 g/L of L-threonine in about 36 hours, at least about 85 g/L of L-threonine in about 36 hours, at least about 95 g/L of L-threonine in about 36 hours, at least about 105 g/L of L-threonine in about 36 hours, at least about 110 g/L of L-threonine in about 36 hours, at least about 115 g/L of L-threonine in about 36 hours, at least about 120 g/L of L-threonine in about 36 hours, at least about 125 g/L of L-threonine in about 36 hours, at least about 130 g/L of L-threonine in about 36 hours, at least about 135 g/L of L-threonine in about 36 hours, at least about 140 g/L of L-threonine in about 36 hours, at least about 145 g/L of L-threonine in about 36 hours, or at least about 150 g of L-threonine in about 36 hours. Further, the inventive strains include strains which are capable of producing at least about 95 g/L of L-threonine in about 48 hours, at least about 100 g/L of L-threonine in about 48 hours, at least about 105 g/L of L-threonine in about 48 hours, at least about 110 g/L of L-threonine in about 48 hours, at least about 115 g/L of L-threonine in about 48 hours, at least about 120 g/L of threonine in about 48 hours, at least about 125 g/L of L-threonine in about 48 hours, at least about 130 g/L of L-threonine in about 48 hours, at least about 135 g/L of L-threonine in about 48 hours, at least about 140 g/L of L-threonine in about 48 hours, at least about 145 g/L of L-threonine in about 48 hours, or at least about 150 g/L of threonine in about 48 hours.
[0110] Further, the inventive strains include strains which are capable of producing L-threonine at a rate of at least about 2 g/L/hr, at least about 2.5 g/L/hr, at least about 3 g/L/hr, at least about 3.6 g/L/hr, at least about 4.0 g/L/hr, at least about 4.5 g/L/hr, or at least about 5.0 g/L/hr.
[0111] In addition, when grown in culture, the inventive strains include strains which are capable of producing between about 75 and about 95 g/L of L-threonine in about 36 hours, between about 80 and about 100 g/L of L-threonine in about 36 hours, between about 85 and about 105 g/L of L-threonine in about 36 hours, between about 90 and about 110 g/L of L-threonine in about 36 hours, between about 95 and about 110 g/L of L-threonine in about 36 hours, between about 100 and about 115 g/L of L-threonine in about 36 hours, between about 100 and about 120 g/L of L-threonine in about 36 hours, between about 100 and about 125 g/L of L-threonine in about 36 hours, between about 100 and about 130 g/L of L-threonine in about 36 hours, between about 100 and about 135 g/L of L-threonine in about 36 hours, between about 100 and about 140 g/L of L-threonine in about 36 hours, between about 105 and about 120 g/L of L-threonine in about 36 hours, between about 110 and about 120 g/L of L-threonine in about 36 hours, between about 110 and about 125 g/L of L-threonine in about 36 hours, between about 110 and about 130 g/L of L-threonine in about 36 hours, between about 110 and about 135 g/L of L-threonine in about 36 hours, between about 10 and about 140 g/L of L-threonine in about 36 hours, between about 115 and about 130 g/L of L-threonine in about 36 hours, between about 120 and about 135 g/L of L-threonine in about 36 hours, between about 95 and about 115 g/L of L-threonine in about 36 hours, between about 95 and about 120 g/L of L-threonine in about 36 hours, between about 95 and about 135 g/L of L-threonine in about 36 hours, between about 95 and about 135 g/L of L-threonine in about 36 hours, between about 95 and about 145 g/L of L-threonine in about 36 hours, between about 95 and about 150 g/L of L-threonine in about 36 hours, between about 105 and about 125 g/L of L-threonine in about 36 hours, between about 105 and about 130 g of L-threonine in about 36 hours, or between about 105 and about 135 g/L of L-threonine in about 36 hours.
[0112] Further, when grown in culture, the inventive strains include strains which are capable of producing between about 80 and about 100 g/L of L-threonine in about 48 hours, between about 85 and about 105 g/L of L-threonine in about 48 hours, between about 90 and about 110 g/L of L-threonine in about 48 hours, between about 95 and about 110 g/L of L-threonine in about 48 hours, between about 100 and about 115 g/L of L-threonine in about 48 hours, between about 105 and about 120 g/L of L-threonine in about 48 hours, between about 110 and about 125 g/L of L-threonine in about 48 hours, between about 115 and about 130 g/L of L-threonine in about 48 hours, between about 120 and about 135 g/L of L-threonine in about 48 hours, between about 125 and about 140 g/L of L-threonine in about 48 hours, between about 95 and about 115 g/L of L-threonine in about 48 hours, between about 95 and about 120 g/L of L-threonine in about 48 hours, between about 95 and about 125 g/L of L-threonine in about 48 hours, between about 95 and about 135 g/L of L-threonine in about 48 hours, between about 95 and about 145 g/L of L-threonine in about 48 hours, between about 95 and about 150 g/L of L-threonine in about 48 hours, between about 100 and about 120 g/L of L-threonine in about 48 hours, between about 100 and about 125 g/L of L-threonine in about 48 hours, between about 100 and about 130 g/, of L-threonine in about 48 hours, between about 100 and about 135 g of L-threonine in about 48 hours, between about 100 and about 140 g/L of L-threonine in about 48 hours, between about 100 and about 145 g/L of L-threonine in about 48 hours, between about 105 and about 125 g/L of L-threonine in about 48 hours, between about 105 and about 130 g/L of L-threonine in about 48 hours, between about 105 and about 135 g/L of L-threonine in about 48 hours, between about 105 and about 140 g/L of L-threonine in about 48 hours, between about 105 and about 145 g/L of L-threonine in about 48 hours, between about 105 and about 150 g/L of L-threonine in about 48 hours, between about 110 and about 120 g/L of L-threonine in about 48 hours, between about 110 and about 130 g/L of L-threonine in about 48 hours, between about 10 and about 135 g/L of L-threonine in about 48 hours, between about 110 and about 140 g/L of L-threonine in about 48 hours, between about 115 and about 125 g/L of L-threonine in about 48 hours, between about 115 and about 135 g/L of L-threonine in about 48 hours, between about 115 and about 140 g/L of L-threonine in about 48 hours, between about 115 and about 145 g/L of L-threonine in about 48 hours, or between about 115 and about 150 g/L of L-threonine in about 48 hours.
[0113] The bacterial strains of the invention also include strains which produce L-threonine in high yield with respect to the carbon source present in the culture medium. Thus, the strains of the invention include strains which, with reference to the dextrose content of the culture medium, produce L-threonine in the following yields (wt./wt.): about 26%, about 27%, about 28%, about 29%, about 30%, about 31%, about 32%, about 33%, about 34%, about 35%, about 36%, about 37%, about 38%, about 39%, about 40%, about 41%, about 42%, about 43%, about 44%, about 45%, about 46%, about 47%, about 48%, about 49%, or about 50%.
[0114] Strains of the invention include strains which, with reference to the dextrose content of the culture medium, produce L-threonine in the following ranges of yields (wt./wt.): between about 25% and about 40%, between about 30% and about 35%, between about 30% and about 45%, between about 30% and about 50%, between about 35% and about 40%, between about 35% and about 45%, between about 35% and about 50%, between about 40% and about 45%, and between about 40% and about 50%
[0115] Strains of the invention include strains which are capable of producing at least about 65 g/L of T-isoleucine in about 36 hours, at least about 75 g/L of L-isoleucine in about 36 hours, at least about 85 g/L of L-isoleucine in about 36 hours, at least about 95 g/L of L-isoleucine in about 36 hours, at least about 105 g/L of L-isoleucine in about 36 hours, at least about 115 g/L of L-isoleucine in about 36 hours, at least about 125 g/L of L-isoleucine in about 36 hours, at least about 130 g/L of L-isoleucine in about 36 hours, at least about 135 g/L of L-isoleucine in about 36 hours, or at least about 140 g/L of L-isoleucine in about 36 hours. Further, the inventive strains include strains which are capable of producing at least about 90 g/L of L-isoleucine in about 48 hours, at least about 100 g/L of L-isoleucine in about 48 hours, at least about 110 g/L of L-isoleucine in about 48 hours, at least about 120 g/L of L-isoleucine in about 48 hours, at least about 130 g/L of L-isoleucine in about 48 hours, at least about 140 g/L of L-isoleucine in about 48 hours, or at least about 150 g/L of L-isoleucine in about 48 hours.
[0116] Further, the inventive strains include strains which are capable of producing L-isoleucine at a rate of at least about 2 g/L/hr, at least about 2.5 g/L/hr, at least about 3 g/L/hr, at least about 3.6 g/L/hr, at least about 4.0 g/L/hr, at least about 4.5 g/L/hr, or at least about 5.0 g/L/hr.
[0117] In addition, when grown in culture, the inventive strains include strains which are capable of producing between about 75 and about 95 g/L of L-isoleucine in about 36 hours, between about 85 and about 105 g/L of L-isoleucine in about 36 hours, between about 95 and about 115 g of L-isoleucine in about 36 hours, between about 105 and about 125 g/L of L-isoleucine in about 36 hours, between about 115 and about 135 g/L of L-isoleucine in about 36 hours, or between about 125 and about 145 g/L of L-isoleucine in about 36 hours.
[0118] Further, when grown in culture, the inventive strains include strains which are capable of producing between about 80 and about 100 g/L of L-isoleucine in about 48 hours, between about 85 and about 105 g/L of L-isoleucine in about 48 hours, between about 90 and about 110 g/L of L-isoleucine in about 48 hours, between about 100 and about 120 g/L of L-isoleucine in about 48 hours, between about 110 and about 130 g/L of L-isoleucine in about 48 hours, between about 120 and about 140 g/L of L-isoleucine in about 48 hours, or between about 130 and about 150 g/L of L-isoleucine in about 48 hours.
[0119] The bacterial strains of the invention also include strains which produce L-isoleucine in high yield with respect to the carbon source present in the culture medium. Thus, the strains of the invention include strains which, with reference to the dextrose content of the culture medium, produce L-isoleucine in the following yields (wt./wt.): about 26%, about 27%, about 28%, about 29%, about 30%, about 31%, about 32%, about 33%, about 34%, about 35%, about 36%, about 37%, about 38%, about 39%, about 40%, about 41%, about 42%, about 43%, about 44%, about 45%, about 46%, about 47%, about 48%, about 49%, or about 50%.
[0120] Stains of the invention include strains which, with reference to the dextrose content of the culture medium, produce L-isoleucine in the following ranges of yields (wt./wt.): between about 25% and about 40%, between about 30% and about 35%, between about 30% and about 45%, between about 30% and about 50%, between about 35% and about 40%, between about 35% and about 45%, between about 35% and about 50%, between about 40% and about 4.5%, and between about 40% and about 50%.
[0121] The amount of L-threonine or L-isoleucine, as well as other amino acids, present in culture media can be measured by a number of methods. For example, as indicated below in Examples 2 and 5, the amount of L-threonine, as well as other amino acids, present in culture media can be determined using HPLC. L-threonine or L-isoleucine levels can also be determined using methods such as paper chromatography with ninhydrin detection, thin layer chromatography, or microbiological assay.
[0122] C. Preparation of Bacterial Strains Capable of Over-Producing Amino Acids
[0123] As discussed above, bacterial strains well suited for commercial production of amino acids will generally be altered in more than one phenotypic trait related to production/excretion of the particular amino acids as compared to wild-type strains. As also discussed above, bacterial strains of the invention which over-produce ammo acids include strains which contain at least one thr operon which (a) is integrated into the bacterial chromosome the chromosome and (b) is under control of a non-native promoter. These strains will also generally contain phenotypic changes related to one, two, three, four, or more of the following: (1) the elimination or reduction of feed-back control mechanisms for one, two, three or more biosynthetic pathways which lead to production of amino acids or amino acid precursors; (2) the enhancement of metabolic flow by either amplification or increasing expression of genes which encode rate-limiting enzymes of biosynthetic pathways which lead to the production of amino acids (e.g., L-threonine or L-isoleucine) or amino acid precursors (e.g., aspartate); (3) the inhibition of degradation pathways involving either the desired amino acid end product (e.g., L-threonine or L-isoleucine), intermediates (e.g., homoserine), and/or precursors (e.g., aspartate); (4) increased production of intermediates and/or and precursors; (5) when the pathway which leads to production of a desired amino acid end product is branched, inhibition of branches which do not lead the desired end product or an intermediate and/or a precursor of the desired end product (e.g., inhibiting the E. coli methionine pathway, when the desired end product is L-threonine or L-isoleucine); (6) alterations in membrane permeability to optimize uptake of energy molecules (e.g., glucose), intermediates and/or precursors; (7) alterations in membrane permeability to optimize amino acid end product (e.g., L-threonine or L-isoleucine) excretion; (8) the enhancement of growth tolerance to relatively high concentrations of end products (e.g., amino acids), metabolic waste products (e.g., acetic acid), or metabolic side products (e.g., amino acid derivatives) which are inhibitory to bacterial cell growth; (9) the enhancement of resistance to high osmotic pressure during cultivation resulting from increased concentrations of carbon sources (e.g., glucose) or end products (e.g., ammo acids); (10) the enhancement of growth tolerance to changes in environmental conditions (e.g., pressure, temperature, pH, etc.); and (11) increasing activities of enzymes involved in the uptake and use of carbon sources in the culture medium (e.g., raffinose, stachyose or proteins, as well as other components of corn steep liquor).
[0124] The invention also includes methods for screening bacterial cells to identify cells which have been subjected to mutagenesis and have one, two, three, four, or more of the characteristics set out above. Further included in the invention are bacterial strains which have one, two, three, four, or more of the above characteristics.
[0125] As one skilled in the art would recognize, the use of random mutagenesis, followed by screening to identify cells of the invention which over-produce a desired amino acid (e.g., L-threonine or L-isoleucine) results in the selection of cells having phenotypic changes that do not necessarily provide an indication of the mechanism by which the cell over-produces the amino acid. For example, amino acid over-production could be related to pleiotropic effect of an apparent unrelated phenotypic alteration. Thus, the invention is not limited to cells which over-produce amino acids and exhibit one or more of the metabolic alterations set out in the preceding list. In other words, the invention includes cells which are characterized by the ability to produce specified quantities of particular amino acids upon growth in culture for specified periods of time.
[0126] In specific embodiments, the strains of the invention are produced by subjecting bacterial cells containing at least one thr operon on the chromosome under the control of a non-native promoter to one, two, three, four, five, or more cycles of mutagenesis followed by screening to identify cells demonstrating increased production of amino acids (e.g., L-threonine or L-isoleucine).
[0127] A considerable number of methods for performing metagenesis are known in the art and can be used to generate bacterial strains of the invention. In general, these methods involve the use of chemical agents or radiation for inducing mutations.
[0128] Examples of classes of chemical compound used in mutagenic procedures are alkylating and ethylating agents, such as N-methyl-N-nitrosourea N-nitroso-N,N-diethylamine (NDEA) and N-ethlyl-N′-nitro-N-nitrosoguanidine (ENNG), which have been known for some time to induce mutations in nucleic acid molecules (Hince et al., Mutat. Res. 46:1-10 (1977); J. Jia et al., Mutat. Res. 352:39-45 (1996)).
[0129] Intercalating agents, such as ethidium bromide, as well as other agents which bind to nucleic acid molecules, have also been shown to have mutagenic activity. For example, SYBR Green I stain, anon-intercalating nucleic acid stain, has been shown using the Ames test to induce mutations (Singer et al., Mutat. Res. 439:37-47 (1999)).
[0130] Other agents which can be used to induce mutations include hydroxylamine, bisulfites, nitrofurans (e.g., 7-methoxy-2-nitronaphtho [2,1-β] furan (R7000)), and agents which induce oxidative stress (P. Quillardet et al., Mutat. Res. 358:113-122 (1996); G. Wang et al., Mol. Gen. Genet. 251:573-579 (1996)).
[0131] One skilled in the art would understand how to adjust the concentrations of the mutagenic agent and/or the particular conditions to achieve a desired mutation rate. For example, when ionizing radiation is used to produce mutagenized cells, the intensity of the radiation or duration of exposure can be adjusted to induce a particular number of mutations per cell. Further, the intensity of the radiation or duration of exposure can also be adjusted so that a particular percentage (e.g., 5%) of the treated cells survive.
[0132] After cells have been subjected to mutagenesis, they can be screened to determine whether they have particular characteristics. It is noted long these lines that a number of characteristics have been associated with increased production of L-threonine or L-isoleucine by bacterial cells. Example of such characteristics include resistance to cysteine, threonine, methionine, and purine analogs; resistance to isoleucine antagonists; impaired uptake of L-threonine uptake; and altered feedback inhibition of enzymes in the threonine and isoleucine biosynthetic pathways (see, e.g., Takano et al., U.S. Pat. No. 5,087,566; Yamada et al., U.S. Pat. No. 5,098,835; Yamada et al., U.S. Pat. No. 5,264,353; Kino et al., U.S. Pat. No. 5,474,918; K. Okamoto et al., Biosci. Biotechnol. Biochem. 61:1877-1882 (1997); Sahm et al., Annals N.Y. Acad. Sci. 782:25-39 (1996); Hashiguchi et al., Biosci. Biotechnol. Biochem. 63:672-679 (1999)). Other characteristics believed to correlate with increased production of L-threonine include resistance to L-threonine and TRF.
[0133] Further, screening/selection of cells having an L-threonine resistant phenotype may be done in media containing from about 1% to about 15% (weight/volume) L-threonine. For example, microorganisms of the invention can be screened using culture media containing about 1%, 1.1%, 1.2%, 1.3%, 1.4%, 1.5%, 1.6%, 1.7%, 1.8%, 1.9%, 2%, 2.1%, 2.2%, 2.3%, 2.4%, 2.5%, 2.6%, 2.7%, 2.8%, 2.9%, 3%, 3.2%, 3.4%, 3.6%, 3.8%, 4%, 4.2%, 4.4%, 4.6%, 4.8%, 5%, 5.2%, 5.4%, 5.6%, 5.8%, 6%, 6.2%, 6.4%, 6.6%, 6.8%, 7%, 7.2%, 7.4%, 7.6%, 7.8%, 8%, 8.2%, 8.4%, 8.6%, 8.8%, 9%, 9.2%, 9.4%, 9.6%, 9.8%, 10%, 10.2%, 10.4%, 10.6%, 10.8%, 11%, 11.2%, 11.4%, 11.6%, 11.8%, 12%, 12.2%, 12.4%, 12.6%, 12.8%, 13%, 13.2%, 13.4%, 13.6%, 13.8%, 14%, 14.2%, 14.4%, 14.6%, 14.8%, 15%, 15.2%, 15.4%, 15.6%, 15.8%, or 16% L-threonine.
[0134] Strains of the invention may be generated by using multiple cycles of mutagenesis and screening. After each mutagenic treatment, the mutagenized cells can be screened for either (1) increased production of a desired amino acid end product (e.g., L-threonine or L-isoleucine) or (2) one, two, three, four, five, or more characteristics associated with increased production of the end product (e.g., L-threonine or L-isoleucine), followed by screening for increased production of the desired amino acid end product (e go, L-threonine or L-isoleucine).
[0135] As noted above, one characteristic associated with increased threonine production is resistance to TR. Thus, the invention includes bacterial strains which are resistant to TRF, as well as methods for producing and identifying TRF resistant mutants.
[0136] TRF can be prepared, for example, by protocols similar to the following. Particular matter is removed by ultrafiltration from conditioned threonine fermentation broth prepared, for example, as described below in Example 9 using fermentor fermentation medium. The permeate is then evaporated to concentrate threonine. Crystallized threonine is then recovered from the concentrated broth by centrifugation, using, for example, a continuous flow rotor. The liquid separated from the threonine is then processes through an ion exchange chromatographic separation system, such as C-SEP or I-SEP (Advanced Separation Technologies, Inc., St Petersburg, Fla.). The waste effluent obtained therefrom is referred to as a “TRF” solution.
[0137] As one skilled in the art would recognize, separation methods other than C-SEP or I-SEP could also be employed. Ion exchange chromatographic separation systems are commonly known in the art, as exemplified in U.S. Pat. Nos. 4,808,317 and 4,764,276, which are incorporated herein by reference.
[0138] One TRF preparation prepared by the inventors was analyzed and found to contain the following components: aspartic acid (63 ppm), threonine (438 ppm), glutamic acid (24 ppm), proline (<14 ppm), glycine (40 ppm), alanine (16 ppm), cystine (42 ppm), valine (<18 ppm), methionine (232 ppm), isoleucine (297 ppm), leucine (25 ppm), tyrosine (31 ppm), phenylalanine (22 ppm), lysine (152 ppm), serine (<1 ppm), histidine (1 ppm), arginine (<22 ppm), ammonia (1,791 ppm), raffinose (5,036 ppm), sucrose (1,885 ppm), glucose (1,344 ppm), and fructose (725 ppm).
[0139] As can be seen from the above, TRF contains a considerable amount of ammonia sulfate, L-threonine, other amino acids, salts, and carbohydrates. Thus, TRF contains nitrogen sources, such as ammonia sulfate, and nutrients, such as amino acids and carbohydrates, which can be metabolized by microorganisms.
[0140] TRF concentration may be determined by determining the concentration of a reference component present in the TRF. One example of a reference component is ammonium sulfate. Unless otherwise stated herein, the concentration of a TRF solution is based on the percentage of ammonium sulfate present (wt./wt.). For example, a 5% TRF solution would contain 5 grams of ammonium sulfate per 100 milliliters of solute.
[0141] The ammonium sulfate concentration of a solution can be determined using a number of methods. For example, an ion selective probe can be used to measure the concentration of ammonium ions (e.g., ORION Research, Inc., 500 Cummings Center, Beverly, Mass. 01915, Catalog No 931801).
[0142] When TRF is used to either (1) generate bacterial strains which over-produce L-threonine or (2) identify TRF resistant bacterial strains, the TRF will generally be prepared as described below in Example 10.
[0143] Raffinate solutions may be sterilized by any number of means prior to use in protocols for generating and screening raffinate resistant bacterial strains. The inventors have determined that sterilization of raffinate containing media, especially at high concentrations of solutes, using heat treatment produces amino acid derivatives and other metabolic antagonists which inhibit culture growth. However, heat sterilized TRF containing medium may be used to select mutants that are resistant to amino acid derivatives, especially L-threonine derivatives, through the improvement of their threonine production. To avoid alterations in raffinate properties associated with heat sterilization, culture media may be sterilized, for example, by ultrafiltration.
[0144] Strains of the invention include strains having an improved raffinate resistant phenotype, which is determined by the concentration of raffinate, as measured by ammonium sulfate content, in the selection medium employed. As discussed above, selection for raffinate resistant mutants may be done in a culture media containing raffinate. The particular concentration of raffinate present in the selection medium will vary with factors such as the medium itself, the cells being screened for raffinate resistance, and the raffinate preparation itself. For example, TRF resistant E. coli may be selected using minimal medium E (see Examples 6 and 7) containing from about 0.2% to about 0.5% raffinate. As one skilled in the art would understand, the TRF concentrations used will also vary with factors such as the genus and species of bacteria used and the initial sensitivity of the bacterial strain to TRF.
[0145] Bacterial strains of the invention may be made by performing mutagenesis on a parent bacterial strain followed by selection for cells exhibiting a TRF-resistant phenotype. Parent microorganisms may be selected from any organism useful for the fermentative production of amino acids (e.g., L-threonine); however, in most instances, the organism will be a strain of E. coli.
[0146] Screening/selection of cells having a TRF-resistant phenotype may be performed in culture media containing from about 0.05% to about 5% TRF. For example, microorganisms of the invention can be screened using culture media containing about 0.05%, 0.1%, 0.15%, 0.2%, 0.25%, 0.3%, 0.35%, 0.4%, 0.45%, 0.5%, 0.55%, 0.6%, 0.65%, 0.7%, 0.75%, 0.8%, 0.85%, 0.9%, 0.95%, 1.0%, 1.1%, 1.2%, 1.3%, 1.4%, 1.5%, 1.6%, 17%, 1.8%, 1.9%, 2.0%, 2.2%, 2.4%, 2.6%, 2.8%, 3.0%, 3.2%, 34%, 3.6%, 3.8%, 4.0%, 4.2%, 4.4%, 4.6%, 4.8%, or 5.0% TRF. As noted above, the TRF concentration is determined by with respect to the amount of ammonium sulfate present.
[0147] In one specific embodiment of the invention, E. coli strain 472T23, which requires threonine for growth, may be converted to a threonine producer using P1-mediated transduction to introduce the threonine operon of E. coli strain ATCC Deposit No. 21277, which may be obtained from the American Type Culture Collection, 10801 University Blvd., Manassas, Va. 20110-2209, USA. This thr operon composed of a feedback resistant aspartate kinase-homoserine dehydrogenase gene (thrA), a homoserine kinase gene (thrB), and a threonine synthase gene (thrC). This strain may then be subjected to one, two, three, four, or more cycles of mutagenesis, as described above, followed by screening to identify cells which produce increased quantities of L-threonine or L-isoleucine.
[0148] To increase threonine production, the defective threonine dehydrogenase gene from E. coli strain CGSC6945 (relevant genotype: tdh-1::cat1212; obtained from the E. coli Genetic Stock Center, 355 Osborne Memorial Laboratory, Department of Biology, Yale University, New Haven, Conn. 06520-8104, USA) may be introduced into the cells by P1 transduction. Again, the resulting threonine producer may be further improved by mutagenesis followed by the identification of cells which produce increased amounts of L-threonine or L-isoleucine.
[0149] Plasmids carrying an antibiotic resistance marker gene, such as kan (which encodes for kanomycin resistance), and a strong promoter, such as P L or tac, optionally flanked by DNA upstream of thrA and a few hundred base pairs of the wild-type thrA gene (i.e., not the whole thrA gene), may be constructed and used as a vehicle to deliver the desired DNA fragment into the chromosome. The DNA fragment may be isolated by digestion with a suitable restriction enzyme and purified, and then introduced, through transformation or electroporation, into a strain to remove the control region of threonine operon and replace it by homologous recombination with the desired fragment (e.g., a fragment containing an antibiotic resistance marker gene and a strong promoter at the beginning the thrA gene). The fragment may then be transferred into the cells of the strain by P1 transduction.
[0150] When increased production of L-threonine is desired, the isoleucine requirement of the strain of the one specific host, 472T23, may be eliminated, for example, by introducing a wild-type allele of the marker through P1 transduction. Unwanted nutritional requirements of other hosts may be removed in a similar manner or according to other methods known and available to those skilled in the art.
[0151] Borrelidin- or CPCA-resistant strains of the invention may contain one or more recombinant plasmids as desired. For example, the inventive microorganisms may contain recombinant plasmids that encode biosynthetic enzymes of the threonine pathway. The inventive bacterial strains may likewise contain recombinant plasmids encoding other enzymes involved in threonine biosynthesis, such as aspartate semialdehyde dehydrogenase (asd), or enzymes which augment growth.
[0152] Additionally, the Borrelidin- or CPCA-resistant strains may be modified as desired, for example, in order to increase threonine production, remove nutritional requirements, and the like, using any of the methods and techniques known and available to those skilled in the art. Illustrative examples of suitable methods for modifying Borrelidin- or CPCA-resistant E. coli mutants and variants include, but are not limited to: mutagenesis by irradiation with ultraviolet light or X-rays, or by treatment with a chemical mutagen such as nitrosoguanidine (N-methyl-N-nitro-N-nitrosoguanidine), methylmethanesulfonate, nitrogen mustard and the like; gene integration techniques, such as those mediated by transforming linear DNA fragments and homologous recombination; and transduction mediated by bacteriophages such as P1. These methods are well known in the art and are described, for example, in J. H. Miller, Experiments in Molecular Genetics , Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y. (1972); J. H. Miller, A Short Course in Bacterial Genetics , Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y. (1992); M. Singer and P. Berg, Genes & Genomes , University Science Books, Mill Valley, Calif. (1991); J. Sambrook, E. F. Fritsch and T. Maniatis, Molecular Cloning: A Laboratory Manual, 2d ed., Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y. (1989); P. B. Kaufman et al., Handbook of Molecular and Cellular Methods in Biology and Medicine , CRC Press, Boca Raton, Fla. (1995); Methods in Plant Molecular Biology and Biotechnology , B. R. Glick and J. E. Thompson, eds., CRC Press, Boca Raton, Fla. (1993); and P. F. Smith-Keary, Molecular Genetics of Escherichia coli , The Guilford Press, New York, N.Y. (1989).
[0153] The present invention also includes the use of borrelidin- or CPCA-resistant bacterial strains in fermentation processes for the production of L-threonine (e.g., borrelidin- or CPCA-resistant mutants of E. coli ). Specific embodiments of the invention include mutant derivatives of E. coli strain ADM Kat13, which was deposited at the Agricultural Research Service Culture Collection (NRRL), 1815 North University Street, Peoria, Ill. 61604, USA, on Jun. 28, 1996 and assigned accession number NRRL B-21593 and is described in Wang et al., U.S. Pat. No. 5,939,307. Thus, strain ADM Kat13 may be subjected to one, two, three, four, or more cycles of mutagenesis, as described above, followed by screening to identify cells which produce increased quantities of L-threonine or L-isoleucine.
[0154] Borrelidin or CPCA resistance may be determined by any of the accepted methods known to those skilled in the art. For example, borrelidin- or CPCA-resistant stains can be isolated by plating the candidate strains on minimal medium containing about 139 μM borrelidin or CPCA, as described in G. Nass and J. Thomale, FEBS Lett. 39:182-186 (1974). In addition, borrelidin or CPCA resistance in certain strains is manifested as a change in one or more phenotypic characteristics of the cells. For example, borrelidin-resistant mutants of E. coli strain 6-8 and its derivatives appear round, rather than as rods. In such cases, evidence of a change in a phenotypic characteristic may be sufficient to adequately identify borrelidin-resistant strains.
[0155] The borrelidin- or CPCA-resistant mutants useful in this embodiment of the present invention are capable of producing threonine. The genes that encode the threonine biosynthetic enzymes may be present on the chromosome or contained in plasmids or mixtures thereof. Multiple copies of these genes may also be present. For example, the genes that encode the threonine biosynthetic enzymes may be resistant to attenuation control and/or encode feedback-resistant enzymes.
[0156] Further, borrelidin- or CPCA-resistant mutants may also be subjected to one or more cycle of mutagenesis, followed by screening to identify cells having desired characteristics, as described above. Thus, the invention also includes borrelidin- or CPCA-resistant mutants of E. coli which are also resistant to TRF.
[0157] In one embodiment the borrelidin- or CPCA-resistant mutants of the present invention are modified so as to include a non-native promoter upstream from and in operable link with one or more of the genes that encode the threonine biosynthetic enzymes, regardless of whether these genes are on the chromosome and/or contained in plasmids.
[0158] D. Strains of the Invention
[0159] Examples of organisms, in addition to E. coli , which can be used to prepare strains of the invention which produce increased quantities of amino acids include Brevibacterium flavum, Brevibacterium lactofermentum, Brevibacterium divaricatum, Brevibacterium saccharolyticum, Corynebacterium glutamicum, Corynebacterium acetoacidophilum, Corynebacterium lilium, Corynebacterium melassecola, Microbacterium ammoniaphilum , and Serratia marcesens.
[0160] In many instances, the inventive bacterial strains are strains of E. coli . Further, as noted above, the invention includes bacterial strains (e.g., E. coli stains) which exhibit resistance to the macrolide antibiotic borrelidin or cyclopentanecarboxylic acid. Specific examples of bacterial strains of the invention include E. coli strains ADM Kat69.9 (NRRL B-30316), ADM TH14.97 (NRRL B-30317), ADM TH21.97 (NRRL B-30318), and ADM TH-25.79 (NRRL B-30319), each of which were deposited at the Agricultural Research Service Culture Collection (NRRL), 1815 North University Street, Peoria, Ill. 61604, USA, on Jul. 27, 2000.
[0161] Strains of the invention also include strains which have the characteristics of the deposited strains assigned accession number NRRL B-30316, NRRL B-30317, NRRL B-30318, and NRRL B-30319. Particular characteristics these strains are set out below in Example 7
[0162] Further included within the scope of the invention are bacterial strains that do not require any recombinant plasmids containing one, two or more genes that encode threonine biosynthetic enzymes for threonine production (i.e., strains capable of producing threonine without the need for one or more of the threonine biosynthetic enzymes to be encoded by genes contained in a recombinant plasmid).
[0163] The inventive strains may, of course, optionally contain recombinant plasmids as desired. For example, while such plasmids are generally not required for threonine production, the inventive strains may nevertheless contain recombinant plasmids that encode for threonine biosynthetic enzymes in order to increase threonine production. The inventive strains may likewise contain recombinant plasmids encoding other enzymes involved in threonine biosynthesis, such as aspartate semialdehyde dehydrogenase (asd).
[0164] Strains of the invention also include strains which are resistant to TRF and other agents resistance to which correlates with increased threonine production (e.g., cysteine, threonine and methionine analogs; isoleucine antagonists; and purine analogues).
[0165] In certain embodiments, the strains of the invention do not include one or more of the following strains of E. coli : KY10935, ADM TH1.2, BKIIM B-3996, H-8460, ADM Kat13, tac3, 6-8, 6-8tac3, and 6-8tac3ile+. In other embodiments, the strains of the invention do not include Serratia marcescens strain T2000.
[0166] In many instances, the novel bacterial strains also have no amino acid nutritional requirements for fermentative production of threonine (i.e., the cells do not require amino acids supplements for growth and threonine production). Alternatively, bacterial strains of the invention may require methionine or isoleucine for growth.
III. USE OF THE STRAINS OF THE INVENTION TO PRODUCE AMINO ACIDS
[0167] The present invention is also directed to the use of the above-described bacterial strains in fermentation processes for the production of amino acids, amino acids of the aspartate family in particular. L-threonine and L-isoleucine, for examples, may be obtained by culturing the inventive bacterial strains in a synthetic or natural medium containing at least one carbon source, at least one nitrogen source and, as appropriate, inorganic salts, growth factors and the like.
[0168] Illustrative examples of suitable carbon sources include, but are not limited to: carbohydrates, such as dextrose, fructose, sucrose, starch hydrolysate, cellulose hydrolysate and molasses; organic acids, such as acetic acid, propionic acid, formic acid, malic acid, citric acid, and fumaric acid; and alcohols, such as glycerol and ethanol.
[0169] Illustrative examples of suitable nitrogen sources include, but are not limited to: ammonia, including ammonia gas and aqueous ammonia, ammonium salts of inorganic or organic acids, such as ammonium chloride, ammonium phosphate, ammonium sulfate and ammonium acetate; and other nitrogen-containing, including meat extract, peptone, corn steep liquor, casein hydrolysate, soybean cake hydrolysate and yeast extract.
[0170] Culture media suitable for use with the present invention include the following:
1 Mammal Medium E (described below in Example 1). 2. Yeast extract 2 g/L, citric acid 2 g/L, (NH 4 ) 2 SO 4 25 g/L, KH 2 PO 4 7.46 g/L, CaCO 3 20 g/L, dextrose 40 g/L, and MgSO 4 .7H 2 O 2 g/L, supplemented with trace metals, pH 7.2. 3. Yeast extract 5 g/L and tryptic soy broth 30 g/L.
[0174] Amino acids may be commercially produced using strains of the invention in, for example, batch type or fed-batch type fermentation processes. In batch type fermentations, all nutrients are added at the beginning of the fermentation. In fed-batch or extended fed-batch type fermentations one or more nutrients are supplied (1) continuously to the culture, (2) right from the beginning of the fermentation or after the culture has reached a certain age, or (3) when the nutrient(s) which are fed are exhausted from the culture medium.
[0175] A variation of the extended batch of fed-batch type fermentation is the repeated fed-batch or fill-and-draw fermentation, where part of the contents of the fermentor is removed at a particular time (e.g., when the fermentor is full) while feeding of a nutrient is continued. In this way a fermentation can be extended for a longer time as compared to when such methods are not used.
[0176] Another type of fermentation, the continuous fermentation or chemostat culture, uses continuous feeding of a complete medium, while culture fluid is continuously or semi-continuously withdrawn in such a way that the volume of the broth in the fermentor remains approximately constant A continuous fermentation can in principle be maintained for an infinite period of time.
[0177] In a batch fermentation, the cultured organism grows until either one of the essential nutrients in the medium becomes exhausted or fermentation conditions become unfavorable (e.g., the pH decreases to a value inhibitory for microbial growth). In fed-batch fermentations measures are normally taken to maintain favorable growth conditions (e go, by using pH control) and exhaustion of one or more essential nutrients is prevented by feeding these nutrient(s) to the culture. Thus, the cultured microorganism will normally continue to grow at a rate determined by the rate of nutrient feed.
[0178] In most instances, a single nutrient, very often the carbon source, will become limiting for growth. The same principle applies during continuous fermentation, usually one nutrient in the medium feed is limiting and all of the other nutrients are in excess. After the microorganisms have stopped growing, the limiting nutrient will generally be present in the culture fluid in an extremely low concentration.
[0179] While different types of nutrient limitation can be employed, carbon source limitation is used most often. Other examples are limiting nutrients include the nitrogen, sulfur, phosphorous, trace metal, and oxygen sources. Vitamins and amino acid (in cases where the microorganism being cultured is auxotrophic for the limiting amino acid) can also be limiting nutrients.
[0180] After cultivation, amino acids (e.g., L-threonine or L-isoleucine) that have accumulated in the culture broth can be separated according to a variety of methods. For example, ion-exchange resins according to purify L-threonine according to methods described in U.S. Pat. No. 5,342,766. This method involves first removing the microorganisms from the culture broth by centrifugation and then adjusting the pH of the broth to about 2 using hydrochloric acid. The acidified solution is subsequently passed through a strongly acidic cation exchange resin and the adsorbent eluted using dilute aqueous ammonia. The ammonia is removed by evaporation under vacuum, and the resulting solution is condensed. Addition of alcohol and subsequent cooling provides crystals of L-threonine. As similar method for the purification of L-isoleucine from culture media is described in U.S. Pat. No. 5,474,918.
[0181] Other amino acids of the aspartate family can be produced by methods similar to those described above Isoleucine, for example, can be prepared from the inventive bacterial strains containing, on the chromosome or on a plasmid, an amplified ilvA gene or tdc gene, both of which encode threonine deaminase, the first enzyme involved in the bioconversion of threonine to isoleucine. Amplification of this gene, for example, by use of a ilvA gene encoding a feedback-resistant enzyme, leads to increased biosynthesis of isoleucine.
[0182] Similarly, methionine can be prepared by microorganisms such as E. coli that contain at least one met operon on the chromosome (i.e., the meet gene (which encodes AK II-HD II), the metA gene (homoserine succinyltransferase), the metB gene (cystathionine γ-synthase), the metC gene (cystathionine β-lyase), and the metE and metH genes (homocysteine methylase)). These genes, including feedback-resistant variants thereof, and, optionally, a non-native promoter can be introduced into the chromosome of the host microorganism according to general methods discussed above and/or known to those skilled in the art. Lysine can likewise, be prepared by microorganisms that contain a gene encoding the lysine biosynthetic enzymes (e.g., a feedback-resistant lysine biosynthetic enzyme encoded by lysC and/or dapA) and, optionally, a non-native promoter.
[0183] The present invention also includes the use of borrelidin- or CPCA-resistant bacterial strains in fermentation processes for the production of L-threonine (e.g., borrelidin- or CPCA-resistant mutants of E. coli ).
[0184] In specific embodiments of the present invention, L-threonine or L-isoleucine is obtained by culturing borrelidin- or CPCA-resistant microorganisms in a synthetic or natural medium containing at least one carbon source, at least one nitrogen source and, as appropriate, inorganic salts, growth factors and the like, as described above. Amino acids which accumulate in the culture media can be recovered by any of the methods known to those skilled in the art.
[0185] The following examples are illustrative only and are not intended to limit the scope of the invention as defined by the appended claims. It will be apparent to those skilled in the art that various modifications and variations can be made in the methods of the present invention without departing from the spirit and scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
[0186] All patents and publications referred to herein are expressly incorporated by reference.
Example 1
Preparation of E. coli Strain ADM Kat13
[0187] A. Transfer of the Threonine Operon of E. Coli Strain ATCC Deposit No. 21277 into the Chromosome of E. Coli Strain 472T23.
[0188] E. coli strain ATCC Deposit No. 21277 (U.S. Pat. No. 3,580,810), available from the American Type Culture Collection, 10801 University Blvd, Manassas, Va. 20110-2209, USA, is amino-β-hydroxyvaleric acid (AHV) resistant but requires proline, thiamine, isoleucine, and methionine to grow in a minimal medium, ATCC Deposit No. 21277 is reported to accumulate 6.20 g/L of threonine in a fermentation process. The threonine operon of ATCC Deposit No. 21277 is composed of an aspartate kinase I-homoserine dehydrogenase I gene (thrA) that encodes a feedback-resistant enzyme, a homoserine kinase gene (thrB), and a threonine synthase gene (thrC).
[0189] E. coli strain 472T23, which is deposited in the USSR Collection of Commercial Microorganisms at USSR Antibiotics Research Institute under Reg. No. BKIIM B-2307, is reported to require threonine and isoleucine and to grow in a minimal medium which contains glucose, ammonia, vitamin B1, and mineral salts. This strain cannot produce threonine because it carries a defective thrC gene, an essential gene for threonine biosynthesis. The strain 472T23 also carries a defective threonine deaminase gene, ilvA, which codes for the first enzyme in isoleucine biosynthesis.
[0190] Bacteriophage P1 lysate was prepared by growing phage on ATCC Deposit No. 21277. Strain 472T23 was then infected with this P1 lysate, in which a smaller number of the phage particles cared the threonine operon of ATCC Deposit No 21277. Following infection, bacterial synthesizing threonine were selected by spreading on minimal medium E (glucose 0.05 g/L; MgSO 4 7H 2 O 0.2 g/L; citric acid H 2 O 2.0 g/L; K 2 HPO 4 10.0 g/L; NaHNH 4 PO 4 4H 2 O 3.5 g/L; agar 15.0 g/L) agar plates supplemented with 0.25 g/L isoleucine. Several threonine prototrophic transductants, which carried the threonine operon of ATCC Deposit No. 21277, were now able to grow in a minimal plates supplemented only with isoleucine.
[0191] These transductants were screened by shake-flask fermentation for threonine production as described below in Example 2. One of them, G9, producing threonine, was selected for further strain development.
[0000] B. Transfer of a Defective Threonine Dehydrogenase (Tdh) Gene Inserted with a Chloramphenicol Acetyltransferase (cat) Gene into the Chromosome of E. Coli Strain G9.
[0192] Strain CGSC6945, carrying a defective threonine dehydrogenase gene (tdh), was obtained from the E Coli Genetic Stock Center, 355 Osborne Memorial Laboratory, Department of Biology, Yale University, New Haven, Conn. 06520-8104, USA. The threonine dehydrogenase gene is defective because inserted into it is the chloramphenicol acetyltransferase (cat) gene. To transfer this defective gene to G9, P1 phase were grown on CSCG6945, and the lysate was used to infect G9. Several chloramphenicol-resistant transductants of G9 were selected and screened for threonine production with shake-flask fermentation as described below in Example 2. One of them, G909, with a higher threonine titer than G9, was selected for further development.
[0000] C. Insertion of a Non-Native Promoter into the Chromosome of E. Coli Strain G 909
[0193] In order to deliver the tac promoter into the chromosome of G909, homologous recombination between a linear DNA fragment and the chromosome of an exonuclease V minus strain (recD) was employed.
[0194] The linear DNA fragment contained 1.5 kb of the sequence upstream (5′ end) of the threonine operon, a kanamycin resistant marker, the tac promoter sequence, and about 480 bp of the thrA gene. This fragment, which provided 5′ end homology, a selection marker (kanamycin resistance), a strong and controllable promoter to the threonine operon (tac), and 3′ end homology, respectively, was generated as follows.
[0195] The threonine operon of the wild-type E. coli W3110 was cloned into the restriction enzyme SphI site of plasmid pUC19 by using the DNA of the lambda clone 676 from Dr. Yuji Kohara, Department of Molecular Biology, School of Science, Nagoya University, Chikusa-ku, Nagoya, Japan. The DNAs of lambda clone 676 and pUC19 were then digested with SphI. The pUC19 fragment was subsequently dephosphorylated with shrimp alkaline phosphatase (SAP) and agarose-gel purified. The 6.9 kb fragment of threonine operon from lambda clone was also purified. These two fragments were subsequently ligated by T4 DNA ligase to generate plasmid pAD103.
[0196] An upstream flanking region for homologous recombination and kanamycin resistance marker was then constructed pAD103 was digested with restriction enzyme BstEII, XbaI and blunt-ended with klenow fragment treatment. The 1.5 kb fragment containing only the 5′ end (upstream) of the threonine operon (but not the thr operon itself or its control region) was isolated and ligated to the fragment of kanamycin resistance gene from pUC4K (Pharmacia), which was digested with restriction enzyme Sail and klenow fragment treated to fill-in the 3′ overhangs to generate intermediate plasmid pAD106.pAD103 was also digested with restriction enzyme TaqI and blunt-ended with klenow fragment treatment. The fragment containing the native ribosome binding site and about 480 bp of the coding sequence of the thrA gene was isolated and then ligated to a fragment of pKK233-3 (Pharmacia), which had been digested with restriction enzyme SmaI and dephosphorylated with SAP, to obtain plasmid pAD115, which contained the DNA sequence of the tac promoter, the ribosome binding sites and a few hundred bases of the thrA gene.
[0197] pAD115 was subsequently digested with restriction enzyme BamHI and 0.75 kb of the DNA fragment which contained the desired DNA sequences was isolated, pAD106 was also digested with BamHI and then dephosphorylated with SAP. The two fragments were then ligated to provide plasmid pAD123, which contained the DNA sequence upstream of the threonine operon, a kanamycin resistance marker gene, the tac promoter, and about 480 bp of the beginning of the thrA gene.
[0198] pAD123 was then digested with SpeI, BglI and the fragment containing the desired DNA sequences was isolated.
[0199] The exonuclease V minus strain (recD) was prepared by growing P1 phage on E. coli strain KW251 (relevant genotype: argA81::Tn10, recD1014, obtained from Pharmacia), which contains a recD gene with a co-transducible transposon Tn10 insertion in argA. The lysate which was prepared from the phage was then used to infect strain G9 and the tetracycline-resistant transductant G9T7 was isolated.
[0200] The DNA fragment from plasmid pAD123 was delivered to E. coli strain G9T7 by electroporation. A kanamycin-resistant strain of G9T7 was isolated and a P1 phage lysate was made by growing phage on this strain. The P1 phage lysate was then used to transduce G909. One of the kanamycin-resistant transductants of G909, tac3, which showed a higher threonine titer in the presence of IPTG in shake-flask study, was isolated.
[0201] P1 phage lysate was subsequently prepared with strain tac3 and then used to infect strain 6-8 (described below). The kanamycin-resistant transductants were selected and one of them, strain 6-8tac3, which produced an even higher titer than tac 3 in a shake-flask study, was isolated.
[0202] D. NTG Mutagensis and the Isolation of Borrelidin-Resistant Mutants from E. Coli Strains G909 and 6-8.
[0203] The cells of strain G909 were mutagenized by N-methyl-N′-nitro-N-nitrosoguanidine (NTG) treatment (50 mg/L, 30 min. at 36° C.) using conventional methods. The resulting cells were then spread on minimal medium E agar plate containing 0.25 g/L of L-isoleucine and 0.1% v/v of CPCA. After incubation for 3-5 days at 36° C., the large colonies that formed on the plate, which included strain 6-6, were selected for testing for CPCA resistance and L-threonine production.
[0204] To test for CPCA resistance, each strain was cultivated in 20 ml of the seed medium SM (32.5 g/L glucose; 1 g/L MgSO 4 7H 2 O; 24.36 g/L K 2 HPO 4 ; 9.52 g/L KH 2 PO 4 ; 5 g/L (NH 4 ) 2 SO 4 ; 15 g/L yeast extract; pH 7.2) at 36° C. for 17 hr with shaking. The cells were harvested and washed with minimal medium E. The cell suspension was then inoculated into a sterilized tube containing 3 ml of minimal medium B and 0, 0.1, 0.5, or 1 mM CPCA. After 24 hr cultivation as 36° C. with shaking, growth was determined by measuring the optical density at 660 nm. The results are shown below in Table 1 relative to growth in the absence of CPCA.
[0000] TABLE 1 CPCA (mM) G909 6-8 0 100.0 100.0 0.1 24.2 134.5 0.5 2.9 141.0 1 0.9 184.5
E. Removal of Isoleucine Requirement and Lactose Repressor Gene (lacI).
[0205] By introducing the non-native tac promoter and a feedback-resistant thrA gene, expression of the thr operon (thrA, thrB, thrC) is no longer controlled by the attenuation mechanism. As a result, starvation for isoleucine and/or the presence of an ilvA auxotrophic marker is no longer required for threonine production.
[0206] Accordingly, the wild-type ilvA marker was introduced by transduction into 6-8tac3 to fix the isoleucine requirement of the strain (i.e., to eliminate the need for isoleucine-supplemented medium for cell growth), P1 phage lysate made from CGSC7334 (relevant genotype: lacI42::Tn10, lacZU118; obtained from the E. coli Genetic stock Center, 355 Osborne Memorial Laboratory, Department of Biology, Yale University, New Haven, Conn. 06520-8104, USA) was used to infect 6-8tac3 and transductants positive for isoleucine biosynthesis were selected. These transductants produced approximately the same amount of L-threonine strain 6-8tac3 in a shake-flask study. One of these transductants, 6-8tac3ile+ was selected for further development.
[0207] Since the threonine operon of 6-8tac3ile is under the control of the tac promoter, isopropyl-β-D-thiogalactoside (IPTG) was necessary to induce the cells to fully express the thr operon.
[0208] Accordingly, to eliminate this unnecessary regulatory hindrance, a defective lac repressor (lacy) gene is introduced by infecting 6-8tac3ile+ with P1 phage made from CGSC7334. The resultant transductants (6-8tac3lacI−) were tested for resistance to tetracycline and tetracycline-resistant colonies were selected.
Example 2
Shake-Flask Fermentation Study of Threonine Production
[0209] A comparison of threonine production among the various E. coli strains was determined by their performance in shake-flask fermentation. The strains being tested were grown on LB agar medium (10 g/L, of tryptone, 5 g/L of extract, 15 g/L agar). After 1 to 2 days of growth, the cells were suspended in 5 ml of seed medium (dextrose 3.25 g/L; K 2 HPO 4 24.35 g/L; KH 2 PO 4 9.5 g/L; yeast extract 15 g/L; (NH 4 )SO 4 5 g/L; MgSO 4 7H 2 O 1 g/L) at pH 7.2. The seed was grown for 24 hours with a stirring speed of 250 rpm at 37° C. 15 ml of fermentation medium (dextrose 40 g/L; yeast extract 2 g/L; citric acid 2 g/L; (NH 4 ) 2 SO 4 25 g/L; MgSO 4 7H 2 O 2.8 g/L; CaCO 3 20 g/L; trace metal solution 2 ml) at pH 7.2 was then added to the seed and the fermentation process performed at 37° C. with a stirring speed of 250 rpm. After cultivation, the amount of L-threonine that had accumulated in the culture broth was analyzed by HPLC (ISCO Model 2353 pump, Rainin Model RI-1 refractive index detector, and aminex Hp87-CA column).
[0210] The amount of L-threonine produced by each of the tested strains is presented in Table 2 below,
[0000]
TABLE 2
Strain
L-Threonine Produced (g/L)
G909
4.95
6-8
11.45
tac3
12.9 (induced by IPTG)
10.6 (non-induced)
6-8 tac3 ile+
12.7 (induced by IPTG)
6-8 tac3 lacI−
13.9
ADM Kat13
14.0
Example 3
Fermentation Study
[0211] The E. coli strains of the present invention and their precursor strains were tested for L-threonine production by fermentation.
[0212] G909 was tested under the following conditions, 0.5 L of aqueous culture medium containing 30 g/L of tryptic soy broth and 5 g/L of yeast extract in a 2 L baffled shake flask was inoculated with 15 ml of G909 and incubated on shaker at 35° C. and 200 rpm for 8.5 hours, 0.9 ml (0.03%) of the mature inoculum was added to a glass fermentator containing 3.0 L of the seed fermentor medium (10 g/L d.s of corn steep liquor, 0.4 g/L of L-isoleucine, 2.5 g/L of KH 2 PO 4 , 2.0 g/L of MgSO 4 7H 2 O, 0.5 g/L of (NH 4 ) 2 SO 4 , 0.192 g/L of anhydrous citric acid, 0.03 g/L of FeSO 4 7H 2 O, 0.021 g/L of MnSO 4 H 2 O and 80 g/L of dextrose). Incubation was conducted under the following conditions: a temperature of 39° C. for the first 18 hours, and then 37° C. for the duration; pH of 6.9 (maintained by addition of NH 4 OH); air flow of 3.5 LPM; agitation of 500 rpm initially, which was then increased to maintain the D.O. at 20%; and back pressure of 1-2 psi. Completion of the seed fermentor stage was determined by depletion of dextrose. 315 ml (15%) of the mature inoculum from the seed fermentor was added to a glass fermentor containing the same medium (main fermentor medium) listed above with the following exceptions: volume was 2.1 L and 0.34 g/L of L-isoleucine was added. Incubation was conducted for 48 hours under the following conditions: temperature of 37° C.; pH of 6.9 (maintained with NH 4 OH); air flow of 3.5 LPM until 20 hours then increased to 4.0 LPM; agitation of 500 rpm initially, which was then increased to maintain the D.O. at 20%; back pressure of 1-2 psi; and dextrose level of 10 g/L (maintained by feeding with a 50% w/w dextrose solution). The fermentation was terminated after 48 hours G909 produced the following results: a final titer of 62<3 g/L of threonine with a total productivity of 274 g and a yield of 23.2%.
[0213] tac3 was tested under the same conditions as described above for G909 with the following exception: 1 mg/L of IPTG was added at the start of the main fermentor stage. With addition of IPTG, tac3 produced a final titer of 85.7 g/L of threonine with a total productivity of 355 g and a yield of 28.8%.
[0214] 6-8 was tested under the same conditions as G909 described above 6-8 produced the following results: a final titer of 74.1 g/L threonine with a total productivity of 290 g and a yield of 28.3%.
[0215] 6-8tac3 was tested under the same conditions as tac3 described above, including the addition of IPTG. 6-8tac3 produced the following results: a final titer of 99.3 g/L threonine with a total productivity of 421 g and a yield of 35.1%.
[0216] 6-8tac3ile+was tested under the same conditions as 6-8tac3 as described above, with the following exception: no L-isoleucine was required in either the seed fermentor stage or the main fermentor stage. Due to an agitation failure at 22.5 hours, only the titer at 22 hours was recorded (62 g/L threonine).
[0217] ADM Kat13 was tested under the same conditions as 6-8tac3 as described above with the following exception: no IPTG was added. Under these conditions, ADM Kat13 produced a final titer of 102 g/L threonine with a total productivity of 445 g and a yield of 33.1%.
[0218] The relevant genotypes of the constructed strains, supplements required for fermentative production of threonine, and the titers recorded are presented in Table 3.
[0000]
TABLE 3
Supplements
Titer at
Relevant
for
Titer at
48
Strain
Genotype
Production
30 Hours
Hours
Yield
G9
ilvA;
Ile
ND
ND
ND
G909
ilvA; tdh::Cm
Ile
53
62.3
23.2
tac3
ilvA; tdh::Cm,
Ile, IPTG
86
85.7
28.8
ptacthrABC
6-8
ilvA; tdh::Cm,
Ile
70
74.1
28.3
Bor-R
6-8tac3
ilvA; tdh::Cm,
Ile, IPTG
75
99.3
35.1
ptacthrABC,
Bor-R
6-8tac3ile+
tdh::Cm, Bor-
IPTG
62 (at 22
NA
NA
R, ptacthrABC
hours)
ADM
tdh::Cm, Bor-
None
92.1
102
33.1
Kat13
R, ptacthrABC
lacI
Bor-R: borrelidin Resistance
ND: Not done
NA: Not available
ptacthrABC: the thrA and the thrC genes under control of the tac promoter
Example 4
Preparation of E. coli Strain ADM Kat69.9
[0219] A. Transfer of the threonine operon from an E. coli strain, ADM Kat26, into the Chromosome of E. coli Strain W3110
[0220] Strain ADM Kat26 has been constructed previously from E. coli ATCC Deposit No. 21277 as shown in Table 4. The native threonine promoter of this strain has been replaced by the tac promoter, at the same time a kanamycin gene was introduced into the chromosome A P1 lysate was prepared by growing phage on ADM Kat26. Strain W3110 (ATCC Deposit No 27325) was infected with this lysate, in which a small number of the phage particles carried the threonine operon of ADM Kat26. Following infection, transfer of the threonine operon was selected for on rich media containing kanamycin. Several of these transductants were screened in shake flask fermentation for threonine production, and inducibility of the threonine operon. One of the transductants, ADM Kat60.6, was selected for further strain development.
[0000] B. Transfer of a Defective Threonine Dehydrogenase (tdh) Gene Inserted with Chloramphenical Acetyltransferase (cat) Gene and an Additional Copy of the Threonine Operon Under the Control of the tac Promoter into the Chromosome of E. coli Strain ADM Kat60.6
[0221] In order to introduce a second copy of the threonine operon into the chromosome, a vector was constructed which knocked out the tdh gene by inserting a copy of the threonine operon. The first step in this process was to construct a vector containing the appropriate genes. The tdh::cat deletion from strain SP942 was cloned by digesting genomic, DNA with EcoRI, isolating the region of approximately 4.8 kb, and cloning into the EcoRI site of plasmid puc18 ( FIG. 6 ). This plasmid was then digested with NaeI and the threonine operon with the kanamycin gene and lac promoter was cloned into the tdh gene ( FIG. 7 ). This new construct was linearized by digest with MluI and HindIII restriction enzymes. The linear piece containing the tdh with the second copy of the thr operon was electroporated into a recD strain, Transformations were selected on rich media containing chloramphenical, A P1 lysate was made from one of these transformants, and was used to infect ADM Kat41, an ATCC Deposit No. 21277 derived threonine producer. A lysate was made from this train, and this lysate was used to infect ADM Kat60.6. The transductants were selected on rich media containing chloramphenical. Shake flask studies were performed to screen for the best producer. One strain, ADM Kat68, was chosen for further manipulations.
[0222] C. Removal of the Lactose Repressor Gene (lacI)
[0223] Since both threonine operons of ADM Kat68 are under the control of the lac promoter, isopropyl-β-D-thiogalactoside (IPTG) was necessary to induce the cells to fully express the thr operon. The use of IPTG to induce expression of the thr operon is less preferred. To eliminate this problem, a defective lac repressor (lacI) gene was introduced by infecting ADM Kat68 with P1 phage made from CAG 18439, All strains involved in the construction of ADM Kat69.9 (NRRL B-30316) and their genotypes were shown in Table 4. The resultant transductants were selected on rich media containing tetracycline, and then screened in shake flask for equal production of threonine with or without IPTG.
[0000]
TABLE 4
W3110
F mrcA mcrB IN(rrnD-rrnE)1 lambda
ATCC 21277
pro, thi, iso, met
SP942
F, tdh-1::cat1212, IN(rrn-rrnE)1
CAG 18439
LacI/Tn10, lacZU118
ADM Kat26
kan-ptac-thrABC from tac3 transduced into Kat17
(ATCC 21277 pro + , met + )
ADM Kat41
Kat36.36 (ATCC 2177 pro + , met + w.kan-ptac-
thrABC from tac3; w.tdh-cm-ptac-thrABC, lacI::Tn10
from pIvir from Kat13) with
homoserine resistance from Kat 13
ADM Kat60.6
W3110 with kan-ptac-thrABC transduced from Kat26
ADM Kat68
Kat60.6 with tdh-cm-ptac-thrABC from Kat41
ADM Kat69.9
Kat68 with LacI::Tn10
Example 5
Shake-Flask Fermentation Study of Threonine Production
[0224] A comparison of various E. coli strains was performed using their production of threonine in the shake flask fermentation. The strains were grown on LB agar media overnight, and then transferred to 20 mls of shake flask media (dextrose 32.5 g/L; K 2 HPO 4 24.35 g/L; KH 2 PO 4 9.5 g/L; yeast extract 15 g/L; (NH 4 ) 2 SO 4 5 g/L, MgSO 4 7H 2 O 1 g/L) at pH 7.2. The seed was grown for 24 hours with a stirring speed of 300 rpm at 37° C. 2 ml of this cultured was transferred to the fermentation media (yeast extract 2 g/L; citric acid 2 g/L; (NH 4 ) 2 SO 4 25 g/L, KH 2 PO 4 7.46 g/L; trace metal solution 2 mL; CaCO 3 20 g/L; Dextrose 40 g/L; MgSO 4 7H 2 O 2 g/L) at pH 7.2. The fermentation was then run for 24 hours at 37° C. and 300 rpm on a shaker. After cultivation, the amount of threonine accumulated in the broth was analyzed by HPLC (as shown in Table 5).
[0000]
TABLE 5
Strain
Threonine (g/L)
Yield %
ADM Kat60.6
4
14
ADM Kat68
7.5
19
ADM Kat69.9
7.5
19
Example 6
Mutagenesis and Selection for Mutants with Improved L-Threonine Production from Strain ADM Kat69.9
[0225] The cells of strain ADM Kat69.9 (NRRL B-30316) or its mutants were harvested from mid-log phase cultures grown in LB, and then mutagenized with N-methyl-N′ nitro-N-nitrosoguanidine (NTG) treatment (50 mg/b, 36° C., 25 minutes) in 3 ml of TM buffer (Tris HCl 6.0 g/L, maleic acid 5.8 g/L, (NH 4 ) 2 SO 4 1.0 g/L, Ca(NO 3 ) 2 5 mg/L, MgSO 4 7H 2 O 0.1 g/L, FeSO 4 7H 2 O 0.25 mg/L, adjusted to pH 6.0 using KOH). After 25 minutes of reaction, the NTG treated cells were pelleted by centrifugation. The treated cells were washed twice in TM buffer and spread on minimal medium E (glucose 0.05 g/L, MgSO 4 7H 2 O 0.2 g/L, citric acid H 2 O 2.0 g/L, K 2 HPO 4 10.0 g/L, Na(HN 4 )PO 4 4H 2 O 3.5 g/L) agar plates containing 4-8% of threonine or 0.2-0.5% of threonine raffinate (TRF) based on grams of ammonia sulfate per liter of medium, as determined using an ion sensitive probe which measures ammonium ions.
[0226] After incubation for 3-5 days at 36° C., colonies growing on these plates were picked and tested for improved L-threonine production in shaker flasks and fermentors Mutants with improved threonine production were subjected to the next cycle of mutagenesis and selection. As shown in FIG. 8 , strain ADM TH21.97 (NRRL B-30318) was developed from ADM Kat69.9 (NRRL B-30316) through the use of selection criterion designed to identify cells could grow faster, produce more L-threonine in the formulated fermentation medium, and tolerate higher concentrations of L-threonine and TRF as compared to their parent strains.
Example 7
Selection of Threonine Raffinate Mutants Strains
[0227] Both ADM TH14.97 (NRRL B-30317) and ADM TH25.79 (NRRL B-30319) are mutants which have been selected from E medium agar plates containing 0.2-0.4% of TRF as described in Example 6 Strain ADM TH14.97 is a TIC mutant of ADM TH8.102 developed from ADM Kat69.9 (NRRL 3-30316) as described in FIG. 8 . And strain ADM TH25.79 (NRRL B-30319) is a TRF mutant of ADM TH1.2 which was developed from ADM Kat13 (NRRL B-21593, U.S. Pat. No. 5,939,307). To study the effect of TRF on culture growth, selected TRF mutants and their parent strains were grown in media containing TRF. About 0.1 ml culture prepared from each tested strains was inoculated to a 250 ml baffled shaker flask containing 20 ml minimal medium E and TRF at 0.1-0.4% based on grams of ammonia sulfate per liter of medium. After shaking at 37° C. and 240 rpm for 24 hours, their growth O.D. was measured at 660 nm. As shown in Table 6, ADM TH14.97 and ADM TH25.79 grew better with higher O.D. in minimal medium E containing TIC than their respective parent strains ADM TH8.102 and ADM TH1.2.
[0000]
TABLE 6
O.D. at 660 nm after growth in minimal medium E at 37° C. and
240 rpm for 24 hours
ADM
ADM TH8.102
ADM TH14.07
ADM TH1.2
TH25.79
TRF (%)
(Parent)
(TRF-R)
(Parent)
(TRF-R)
0.1
0.44
1.18
1.14
1.44
0.2
0.68
2.98
1.60
1.62
0.4
1.28
3.74
1.22
1.90
Example 8
Dextrose Consumption, Growth, and L-Threonine Production in Shaker Flask Fermentation
[0228] The L-threonine produced by E. coli strains was determined by their performance in the shaker flask fermentation. The strains being tested were grown on LB agar medium (tryptophan 10 g/L, yeast extract 5 g/L, yeast extract 5 g/L, NaCl 10 g/L, and agar 15 g/L). After 1 to 2 days of growth, cells were inoculated to 20 ml seed medium A (K 2 HPO 4 24.36 g/L, KH 2 PO 4 9.5 g/L, yeast extract 15 g/L, (NH 4 ) 2 SO 4 5 g/L, MgSO 4 7H 2 O 1 g/L, dextrose 32.5 g/L, pH 7.2) in a 250 ml baffled shaker flask. After growing at 37° C., 240 rpm shaking for 18 hours, 2 ml seed was inoculated into 20 ml of fermentation medium A (dextrose 40 g/L, citric acid 2 g/L, lactose 1 g/L, (NH 4 ) 2 SO 4 25 g/L, KH 2 PO 4 7.46 g/L, MgSO 4 7H 2 O 2 g/L, CaCO 3 20 g/L, trace metal solution 2 mL, pH 7.2) in a 250 ml baffled shaker flask. After cultivation at 37° C., 240 rpm shaking for 24 hours, the amount of L-threonine that had accumulated in the culture broth was analyzed by HPLC.
[0229] Under same incubation conditions indicated above, seed medium B (MgSO 4 7 H 2 O 2 g/L, (NH 4 ) 2 SO 4 25 g/L, FeSO 4 7H 2 O 0.03 g/L, MnSO 4 H 2 O 0.02 g/L KH 2 PO 4 2.5 g/L, citric acid 0.2 g/L, corn steep liquor 20 g/L d.s. (dissolved solid), dextrose 40 g/L, CaCO 3 40 g/L, pH 7.0) and fermentation medium B (MgSO 4 7H 2 O 1.75 g/L, (NH 4 ) 2 SO 4 0.88 g/L, K 2 HPO 4 1.75 g/L, corn steep liquor 1.76 g/L d.s., dextrose 40 g/L, urea 20 g/L, CaCO 3 17.5 g/L, pH 6.8) were also used in these studies to determine the threonine production of selected mutants.
[0000] Results of their L-threonine production and yield % in the shaker flask fermentation were shown in Table 7.
[0000]
TABLE 7
Seed/Fermentation
Strain
Media
L-Threonine (g/L)
Yield %
ADM TH1.2
A/A
9.1
30.7
ADM TH25.79
A/A
13.0
31.4
ADM TH8.102
B/B
11.4
19.7
ADM TH14.97
B/B
11.6
25.1
ADM TH17.166
B/B
13.4
26.6
ADM TH21.07
B/B
15.4
30.7
Example 9
L-Threonine Production in Fermentor Fermentation
[0230] The L-threonine production of E. coli strains was also determined from their performance in fermentor fermentation. The strain being tested was grown in a shaker flask medium containing 30 g/L of tryptic soy broth and 5 g/L of yeast extract. About 1.5 ml of culture was inoculated into a 2 L baffled shake flask containing 0.5 ml shaker flask medium and incubated at 37° C. and 220 rpm for 8 hours. About 0.9 ml of the shaker flask culture was then transferred to a 5 L fermentor containing 3.0 L of the seed/main fermentor medium (corn steep liquor 10 g/L, d.s. (dissolved solids), KH 2 PO 4 2.5 g/L MgSO 4 7H 2 O 0.5 g/L, (NH 4 ) 2 SO 4 0.5 g/L, FeSO 4 7H 2 O 0.03 g/L, MnSO 4 H 2 O 0.021 g/L, anhydrous citric acid 0.192 g/L, dextrose 80 g/L). The cultivation of fermentor seed was conducted under following conditions: temperature at 39° C., air flow at 3.5 LPM, agitation at 500 rpm initially, then increased to maintain the D.O. at 20%, pH at 6.9 maintained by adding NH 4 OH 4 and back pressure at 1-2 psi. After the completion of seed stage based on the depletion of dextrose, 315 ml of seed culture was inoculated to another 5 L fermentor containing 1.6 L of same seed/main fermentor medium as described above. The fermentation was conducted for 48 hours under the following conditions: temperature at 33° C., air flow at 3.5 LPM, agitation at 800 rpm initially, then increased to maintain the D.O. at 20%, pH at 6.9 maintained by adding NH 4 OH, and back pressure at 1-2 psi. The fermentation culture was fed with a 50% w/w dextrose solution to maintain the dextrose level at 10 g/L, in the fermentor. After 48 hours, samples were withdrawn to measure the amount of L-threonine produced using HPLC (Table 8).
[0000]
TABLE 8
Titers L-
Relevant
Threonine
Total L-
Strain
Phenotype
(g/L)
Threonine (g)
Yield %
ADM Kat69.9
Parent
5.1
12.9
2.9
ADM TH8.102
Thr-R
68.4
195.5
25.3
ADM TH14.97
Thr-R, TRF-R
87.6
265.6
30.7
ADM TH21.97
Thr-R, TRF-R
96.2
292.2
35.5
ADM TH1.2
Parent
111.0
412.2
36.8
ADM TH25.79
TRF-R
117.3
442.8
37.4
|
The present invention relates to the fields of microbiology and microbial genetics. More specifically, the invention relates to novel bacteria strains and processes employing these strains for the fermentative production of amino acids such as threonine.
| 2
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to cylinder locks and more particularly to cylinder locks which cannot be opened without a key by any of the known "lock-picking" techniques.
2. Description of the Prior Art
The inventor's U.S. Pat. No. 3,761,193, issued Oct. 2, 1973, discloses a cylinder lock having a plurality of pin assemblies selectively configured to engage a shoulder within the cylinder bore in the event that an attempt is made to pick the lock. Each pin assembly comprises a driver portion, a center portion, and a lower portion. The center and driver portions each contain unique transverse grooving which cooperates with the shoulder in the cylinder bore to prevent pin movement whenever rotational pressure is applied to the plug without first inserting the proper key.
This patent includes the basic components present in most cylinder locks: a key plug, a cylinder surrounding the key plug, a set of tumblers in the form of cylindrical pins mounted in radial bores in the key plug, and a set of driver pins mounted in radial bores in the cylinder corresponding to those in the key plug. When there is no key in the plug, the tumbler and driver bores are in alignment, and the driver pins project across the shear line between the cylinder and key plug into the tumbler bores in the plug, preventing it from being turned within the cylinder. In order to open such a lock, a key is inserted having indentations defining selective recesses and projections which cause each of the tumblers to be held to a definite lifted position such that the dividing line between the drivers and the tumblers in each bore coincides with the shear line between the cylinder and plug. When all pins are appropriately positioned, the plug is free to rotate.
There are two well-recognized techniques for picking conventional cylinder locks. In the first, the plug is forcibly turned relative to the cylinder, to the maximum extent allowed by the slight clearance between the pins and their respective bores. Whie maintaining torque upon the plug, each tumbler is carefully pushed upward so that the driver associated with it moves up into its bore in the cylinder until it comes to rest at the shear line due to the ledge created by the slightly rotated position of the plug. When all drivers have been pushed back into the cylinder bores in this manner, the plug can be freely turned and the lock opens.
In the second familiar technique, the tumblers and associated drivers are all initially pushed upward so that the tumblers enter the driver bores. The plug is then forcibly turned as far as it will go and the tumblers are allowed to drop under the action of the driver springs to their normal positions clear of the driver bores. This occurs because at the beginning of their downward movement, the tumblers are already partly within the plug. On the other hand, the drivers are not capable of following their tumblers because they will be stopped by the ledges that are created at the shear line due to the rotated position of the plug. Here again, the plug can be turned freely after all tumblers have dropped.
Another method of opening a lock for which one does not originally have a key, is the technique of "impressioning". In using this technique, a blank key is inserted into the plug and slight rotational pressure is applied during up and down movement of the key. When the key blank enters the lock it pushes all of the tumblers up into the driver bores and when plug pressure is applied, putting upper and lower bores out of register, these pins become trapped. Subsequently, when the key is raised, the pins being unable to move away, burnish small marks, or impressions, on the edge of the key. The key blank is withdrawn, the impressions lightly filed, and the key reinserted. During succeeding insertions, where filing has been done, the tumbler pins rest lower by a small amount. The process is repeated until one of the pins reaches it shear line. At this point, the pin is no longer trapped in a driver bore and becomes free-floating and incapable of making an impression on the key. This informs the impressionist that the pin is "open" and he simply continues with the procedure until all the remaining pins are open. The end result is a hand-filed key. A very undesirable feature of having a lock that can be breached by impressioning, is the fact that the lock can then be reopened at any future time leaving no clue of the opening.
In addition to the inventor's own work in this field, a large number of lock structures have been developed in an attempt to defeat the picking of locks by the above-described methods. The resulting structures, have included in various combinations the serration or grooving of the cylinder bores, the plug bores, the driver pins, and the tumbler pins. When transverse grooves are provided in the pins and bores, it will be understood that the pins cannot move freely except under prescribed conditions such as when their dividing lines are coincident with the shear line between the cylinder and the plug. This prevents a lock-picker from the simple application of the aforedescribed techniques. On the other hand, with a knowledge of the structure of such locks, a skilled lock-picker can generally "feel" or sense the relative positions of the driver and tumbler pins and given sufficient time will open all of these locks.
A series of locks that are quite effective in their ability to prevent illegal entry, are the Spain locks disclosed in U.S. Pat. Nos. 3,499,302, 3,499,303 and 3,722,240. These locks, in addition to other features, include tumblers in the key plug which must be positioned by a properly bitted key reciprocally to clear the shear line and also rotationally to allow a fence member to be cammed out of engagement with the cylinder shell. Only when the appropriate combination of translational and rotational position of each tumbler is effected, may the key plug be rotated.
SUMMARY OF THE INVENTION
The lock of the present invention is an improved form of cylinder lock wherein the cylinder bores, plug bores, pin structures, and a pin freeze element are each cooperatively designed to prevent forcing, sensing, or impressioning. In embodiments of this invention, all vital working areas can be protected with hardened steel shields to defeat illegal destruction by drilling.
It is an object of the present invention to provide an improved pick and impression-resistant cylinder lock.
It is another object of the invention to provide an improved cylinder lock utilizing pins having selectively disposed and uniquely designed transverse indentations along their surfaces.
Yet another object of the present invention is to provide an improved pick-resistant lock with a minimum of components that can be relatively easily manufactured.
Still another object of the invention is to provide an improved cylinder lock featuring the use of a pin freeze element having increments adapted to engage with corresponding increments on tumbler pins.
Yet another object of the invention is to provide an improved pick and impression-resistant cylinder lock having means to prevent the reading of the proper position of individual pins by means of wire.
Another object of the invention is to provide an improved lock wherein all pins are same-length matched pairs in order to prevent "reading" the spring pressure.
In accordance with a particular illustrative embodiment of the invention, there is provided a lock having cylinder and plug portions, each being radially bored to receive a plurality of pin-pairs of specific design. A pin freeze element is positioned for movement within the plug in a direction substantially orthogonal to the axis of the plug bores. This element is biased outwardly toward the surrounding cylinder. The interface between the pin freeze element and the tumbler pins includes incremental notches of matching configuration such that when the plug is turned, the freeze pin element engages the pins locking them from reciprocal movement.
In further accordance with the invention, the notches in the pin freeze element and tumbler pins must be in registration for the plug to turn at all and they must be perfectly registered and properly aligned for the lock to open. Inasmuch as turning the plug freezes the pins before they contact the respective bore, any attempt to take an impression of the pin positions is thwarted since the tumbler pins will always make impressions on a key blank independent of the fact that they may or may not be trapped in the driver bore.
The objects noted above, as well as further objects and numerous unique features of the invention, will be more fully understood and appreciated from the following detailed description which is made in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view, partially in cross-section, of a cylinder lock embodying the features of this invention;
FIG. 2 is an exploded perspective view of the embodiment shown in FIG. 1;
FIG. 3 is a cross-sectional view taken along the line 3--3 in FIG. 1, illustrating the position of typical pins when a key is inserted but the plug is not under rotational pressure;
FIG. 4 is a cross-sectional view taken along the line 4--4 in FIG. 3, illustrating the location of six typical pins and a pin freeze element;
FIG. 5 is an enlarged cross-sectional view taken along the line 3--3 of FIG. 1 with the key removed, showing the pins down in locked position and the spring-operated pin freeze element in unlocked return position;
FIG. 6 is an enlarged cross-sectional view taken along the line 3--3 of FIG. 1 with a correct key inserted, showing the tumbler pin locked by the pin freeze element at the proper shear line;
FIG. 7 is an enlarged cross-sectional view taken along the line 3--3 of FIG. 1 without a key inserted, during attempted picking with the plug forced into partial rotation in a clockwise direction, effecting locking of the tumbler pin within the upper bore where it is held by the pin freeze element;
FIG. 8 is an enlarged cross-sectional view taken along the line 3--3 of FIG. 1 without a key inserted, during attempted picking with the plug forced into partial rotation in a counter-clockwise direction, effecting locking of the tumbler pin by the pin freeze element with the driver pin projecting into the plug bore; and
FIG. 9 is an enlarged cross-sectional view taken along the line 3--3 of FIG. 3, and showing a second embodiment of the invention having uniquely configured and mating grooves in the tumbler and pin freeze element.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The cylinder 10, shown in FIG. 1, is controlled by a typical key 11, having a shank 12 adapted for translation within a key slot 13. The configuration of the key conforms to axially aligned projections in the key slot, such as 14, and includes indentations of selected depth for correct radial positioning of the various pin assemblies. The cylinder lock includes a cylinder portion 20 and a plug portion 21 adapted for rotation therein. The cylinder portion contains a plurality of axially displaced radially disposed bores 31, 32, 33, 34, and 35. The plug portion includes a similar plurality of bores which are positioned for alignment with the cylinder bores when the lock is in its closed or rest position. The plug bores are designated 41, 42, 43, 44, and 45, respectively. Each pair of related bores in the cylinder and plug establish a radial chamber within which a pin-pair assembly operates. As explained hereinafter, each pin assembly is made up of two components comprising an upper driver pin and a lower tumbler pin.
FIG. 2 is an exploded view of the cylinder lock shown in FIG. 1. Throughout the drawings, like parts are designated by identical numerals. In addition to the basic components previously described, the exploded view of FIG. 2 shows five helical springs 51-55 arranged for positioning above driver pins 61-65 for biasing these pins and the lower tumbler pins 71-75 with which they are related, toward the center of the plug 21 and into the key slot 13. FIG. 2 also discloses pin freeze bar 16 and associated biasing springs 17, 18 adapted to rest within slot 19. The function of this bar and its interrelationship with the tumbler pins 71-75 will be described hereinafter.
While considering FIG. 2, reference should also be made to drill-resistant shield 25, and the protective drill-resistant steel plate 26 positioned in front of the cylinder and pin areas to afford protection against destruction of the lock by means of drilling. To the rear of the cylinder, trip plate 27 with fastening screws 28, 29 are shown. See also, the elongated angular cover plate 30 in exploded illustration from the groove above cylinder bores 31-35.
The assembled condition of a typical pin assembly will be appreciated more fully by consideration of the cross-sectional view of FIG. 3 which is taken along the line 3--3 of FIG. 1. This is a transverse vertical section showing the plug rotationally aligned in a locked position within the cylinder when a key is initially inserted. Enlarged views of the relevant portion of this cross-section are presented in FIGS. 5 through 8 to show the principles in accordance with which this invention effects pick and impression-resistant characteristics.
In particular, FIG. 3 shows a driver pin 61 in contact with a tumbler pin 71 with which it is urged into contact by compressed helical spring 51. The key shank 12 rests within key slot 13 and presses the lower proximate portion of tumbler pin 71 upward to position the combined pin-pair assembly with the parting line between driver 61 and tumbler 71 at the shear line between plug 21 and cylinder 20. It will be appreciated that when all pin assemblies are similarly acted upon by an appropriate key 11, there will be no impedance against rotation of plug 21 and the lock can be opened. This presupposes that the side locking bar 16 is not forced outward into engagement with the slot 37 in the side of the cylinder.
The cross-sectional view of FIG. 4 is taken along line 4--4 of FIG. 3 and shows the relative positions of the pin freeze bar 16, biasing springs 17, 18, and the tumbler bores 41-45 within plug 21.
The enlarged view of FIG. 5 shows that when the cylinder is in its typical locked position, the drive pin 61 projects into the plug bore where it rests on the top of tumbler pin 71. The biasing effects of springs 17 and 18 press the pin freeze bar 16 into the slot 37 in the wall of the cylinder 20. Thus, any attempt to turn the cylinder meets with the opposition of drive pin 61 and the projecting portion of side locking bar 16. Similarly, depending only upon the relative lengths of the drive pins and tumbler pins in the other bores of the lock, the parting lines between these components will also block rotation until a proper key is inserted.
The effect of inserting a proper key 11 is shown schematically in FIG. 6. In this instance, the tumbler pin 71 is pushed upward against the pressure of compressed spring 51 (not shown) which holds driver 61 in a downward position. Since the key is correct, the parting line between drive pin 61 and tumbler pin 71 is in alignment with the shear line between the plug and cylinder and rotation is permitted. Upon commencement of rotation, the pin freeze bar 16 rides up the lower inclined wall of slot 37 and in so doing is pressed inwardly against tumbler 71. The abutting faces of the pin freeze bar and each tumbler pin are selectively grooved and dimensioned for interlock. This can occur in a number of relative positions, one of which is when the parting line between the drive and tumbler pins corresponds with the shear line between the plug and cylinder. Thus, sufficient clearance is provided for the pin freeze bar to move inward within the circumference of the plug and provide no resistance to further rotation.
Attention is now directed to situations where unauthorized entry is attempted by a party who does not have the correct key. As explained above, the initial step in most lockpicking techniques is forced rotation of the plug relative to the cylinder. The manner in which these techniques are thwarted is shown schematically by FIGS. 7 and 8.
In FIG. 7, the tumbler pin 71 has been improperly forced upward into the driver bore 31 of the cylinder. Drive pin 61 rests upon the crown of tumbler 71, but is of no effect because it is within the cylinder itself. When plug 21 is torqued in a clockwise direction, the upper shoulder 76 of tumbler 71 engages against the wall of the driver bore. In so doing, further rotational movement is prevented.
Simultaneously, the partial rotation of plug 21 moves pin freeze bar 16 into a position which forces it to ride up the lower wall of slot 37, moving it inward into engagement with the projections at the lower portion of tumbler 71. Once this engagement has occurred, it is not possible to effect further reciprocating movement of the tumbler pin within the plug bore. As a result, a lock picker is not able to sense how high the tumbler pin projects into the driver bore and will remain completely uninformed regarding the position or relative length of the tumbler 71 with respect to the driver 61.
FIG. 8 shows a contrasting condition when attempted picking is effected by means of counter-clockwise rotation of the plug when the driver 61 projects into the plug bore and rests upon the crown of tumbler 71. In this instance, further rotation of plug 21 is prevented by engagement of the upper edge of the plug bore 41 with the lower shoulder of drive pin 61. During the partial counter-clockwise rotation of the plug, FIG. 8 also illustrates that the distal end of the pin freeze bar has ridden up the upper slope of slot 37 and the bar is urged into interlocking contact with the mating surfaces of tumbler pin 71. Once again, further reciprocating motion of tumbler pin 71 is prevented and a lock picker cannot determine why or how this pin has become frozen in position. He is deprived of the potential knowledge regarding the length of the pin 71 vis a vis the driver 61, and whether or not the further rotation of the plug is prevented by the blocking action of the drivers or the tumblers.
With an understanding of the general principles of this invention, consideration is directed to FIG. 9 wherein a more explicitly dimensioned enlarged cross-sectional view is taken along the line 3--3 of FIG. 1 to show another embodiment. The plug 21 is shown in locked position with driver pin 61 projecting into the tumbler bore, tumbler pin 71 positioned midway within the plug bore, and side locking bar 16 unengaged with the tumbler pin.
First, it should be noted that the driver pin 61 and tumbler pin 71 are preferably dimensioned such that the distance from the top of driver 61 to the bottom tip of tumbler 71, for all pairs, is identical. This is effected by selectively modifying the length 610 of the driver pin shank while conversely modifying the length 711 of the tumbler pin shank. This will assure that each pin-pair within any lock will produce substantially the same overall travel and same overall "feel" when sensed from the bottom of a tumbler pin 71.
The grooves on tumbler 71 and mating projections of side locking bar 16 are each flattened. This assures that, in positions such as shown in FIG. 9, the pin freeze bar 16 is forced into broach 37 in the event the plug 21 is torqued in either direction. Thus, the plug is restrained from further movement not only by the interposition of either the driver or tumbler pins across the parting line of plug 21 and cylinder 20; but also by the fact that pin freeze bar 16 resides within the broached area and prevents rotation.
The angle of walls 370, 371 of the broach 37 is selectively determined with reference to the radius of the corners of pin freeze bar 16, in order to effect transverse movement of the locking bar by the distance "x" when the plug is turned a particular number of degrees either clockwise or counter-clockwise. This assures that any plug rotation while the nose portion 610 of driver pin 61 is in the plug bore, or when the upper portion 711 of tumbler 71 is in the cylinder bore, will permit the same amount of rotational motion and thereby thwart determination of the relative position of these pins within their bores. Of course, when no key is present, the larger diameter portion of the driver pin 61 will be within the plug bore under normal circumstances and no substantial plug rotation would be possible.
Attention is also directed to the slight taper of the upper portion 711 of tumbler pin 71. This taper is provided to yield parallel contact with the upper bore wall in cylinder 20 when the plug is rotated during attempted picking with the tumbler pin 71 residing in the upper bore. By maintaining the upper portion of all tumbler pins of similar taper, irrespective of length, all of the upper portions will contact their respective cylinder bore walls at substantially the same time during attempted picking, thereby preventing any clue regarding pin position based upon degree of plug rotation as various pins within a lock are manipulated.
As a final note regarding the illustration of FIG. 9, it will be seen that the squared peaks 160 of the pin freeze bar 16 are dimensioned "y" equivalent to the lower valleys 712 of tumbler pin 71. Conversely, the flattened peaks 710 of the tumbler pins are dimensioned "z" identically to the valleys 162 of the pin freeze bar.
The foregoing description has dealt both generally and specifically with lock component structures which function in combination to provide a cylinder lock that is difficult, if not impossible, to pick and which prevents effective impressioning. Modifications will be apparent to those skilled in the art. To the extent that such modifications are within the spirit and teaching of the invention and are embraced within the following claims, it is intended that they are covered by this invention.
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A cylinder lock wherein both cylinder and plug are radially bored to receive pin-pairs of specific design. A pin freeze element is positioned for movement within the plug in a direction substantially orthogonal to the axis of the plug bores. The interface between the pin freeze element and the pins includes incremental notches of matching configuration such that when the plug is turned, the pin freeze element engages the pins locking them from reciprocal movement. The mating surfaces of the pin freeze element and pins must be in registration for the plug to turn at all and they must be in perfect registration and properly aligned for the lock to open.
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CLAIM OF PRIORITY UNDER 35 U.S.C. §119
The present application for patent claims priority to Provisional Application No. 60/716,421, entitled “Method for using performance and stress tests on computing and digital storage devices for the purposes of device authentication” filed Sep. 12, 2005, and assigned to the assignee hereof and hereby expressly incorporated by reference herein.
BACKGROUND
1. Field
The present invention relates generally to security in computing environments, and more particularly, to a method and apparatus for using performance and stress testing on computing devices for device authentication.
2. Background
A basic component of any security system is the authentication of not only the sender and receiver of secure communications or data, but also the devices that are used as part of the storage and communications process. Computing and digital storage devices have become commonplace for processing, storing and communicating digital information. In recent years, it has been a focus of the computing industry to make such devices secure.
One approach to securing devices is the introduction of secure components that have had a unique identity intentionally embedded into the components. These secure components are known in the art as “dongles.” Another approach is to embed a unique identifier into the component itself. An example of this in the art is the use of a secure computing platforms where the main central processing unit (CPU), or “processor,” features a hard coded serial number or encryption certificate that cannot be changed or modified after manufacture. Another example that is also currently in the art is hard disk serialization, where a unique number is permanently added or written to the hard disk for reference by the operating system.
One disadvantage of the above approaches to digital security and authentication is that the intentional predetermined identification of a device, such as by the use of a manufactured identifier or serialization number, is a specific and easily traced means of identification. This means that attackers and or reverse engineers have a specific and quantifiable target to initiate an attack on the security system.
SUMMARY OF THE PREFERRED EMBODIMENTS
The present invention provides a method for authenticating a computing device. In one preferred embodiment of the present invention, the method includes the step of measuring at least one performance parameter of the device to obtain a measurement and comparing the measurement of the at least one performance parameter with a previously stored measurement of the at least one performance parameter to determine an identity of the device.
An apparatus for authenticating a device is also disclosed. The apparatus includes a processor and a memory coupled to the processor. In one preferred embodiment, the memory is configured to cause the processor to execute a method including the step of measuring at least one performance parameter of the device to obtain a measurement and comparing the measurement of the at least one performance parameter with a previously stored measurement of the at least one performance parameter to determine an identity of the device.
An article of manufacture including a computer-readable medium having instructions stored thereon for causing a processor to perform a method for authenticating a device is also disclosed. The method including the steps of measuring at least one performance parameter of the device to obtain a measurement and comparing the measurement of the at least one performance parameter with a previously stored measurement of the at least one performance parameter to determine an identity of the device.
Other objects, features and advantages will become apparent to those skilled in the art from the following detailed description. It is to be understood, however, that the detailed description and specific examples, while indicating exemplary embodiments, are given by way of illustration and not limitation. Many changes and modifications within the scope of the following description may be made without departing from the spirit thereof, and the description should be understood to include all such variations.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be more readily understood by referring to the accompanying drawings in which:
FIG. 1 is a block diagram of an identification system configured in accordance with one preferred embodiment of the present invention; and,
FIG. 2 illustrates an identification process that can be used to uniquely identify a computing device in accordance with one preferred embodiment of the present invention.
Like numerals refer to like parts throughout the several views of the drawings.
DETAILED DESCRIPTION
Computing devices, including such devices as processors and digital storage devices, possess a wide range of performance and stress test variations. Such variations are commonly used to evaluate devices for quality assurance purposes and often dictate whether a particular device is of a quality level to be sold or should be discarded/recycled.
Performance and stress tests may also be used to qualify devices for sale within one of many levels of grading of devices. For example, the maximum speed at which a processor operates is often used to classify the processor.
The present invention uses performance and stress test variations to identify a computing device for the purposes of uniquely identifying and authenticating the device. The present invention allows the device itself to be used as part of the authentication process and thereby reduces or eliminates the cost and time involved with adding and securing a separate identity token (e.g., dongle) to the device to be secured or authenticated.
The present invention further capitalizes on the natural occurrence of many and varied irregularities that appear both in the manufacturing process, and during the subsequent usage, of the device, and to use these performance characteristics in identifying a particular device. This in turn represents an ideal opportunity for developing unique identities that are hard to reproduce by attackers of authentication and security systems.
The approach described by the present invention allows a wide and diverse range of identifiers to be used to uniquely identify a protected computing device. The use of a wide and diverse range of identifiers significantly complicates the initial stages of any attacking or tampering process in that there is no central and easily identifiable identification component or serial number to attack.
In one preferred embodiment of the present invention, results from performance and stress tests of computing and digital storage devices are used to develop a unique profile for a device. The unique profile can then be used for authentication in security, copy control and access control applications.
FIG. 1 shows a block diagram of an identification system configured in accordance with one preferred embodiment of the present invention. A control software 12 is used for testing a computing device 10 . In one preferred embodiment, the specific testing is achieved by the control software 12 querying computing device 10 using a list of processor-specific instructions 11 (i.e., the instructions that the computing device 10 can execute). The control software 12 uses a list of processor instructions 13 to explore the capabilities of the computing device 10 . The results of the testing are stored in a database of results 14 . As further described herein, the database of results 14 is also used by the control software 12 in a comparison of the test results obtained from the use of the list of processor-specific instructions 11 for the targeted computing device 10 (e.g., a processor) with other tests previously performed on other separate and unique computing devices (i.e., other processors). The test results that are determined to be separate and unique to the computing device 10 (i.e., the computing device currently being tested) can be used to uniquely identify the computing device 10 .
FIG. 2 illustrates an exemplary process that can be used to obtain unique information from a computing device to be used for the purposes of identifying the computing device. The description of FIG. 2 will be accomplished with reference to the components described in FIG. 1 .
Initially, the control software 12 is executed in step 20 . In one preferred embodiment, the first processor instruction is selected from the list of processor instructions in step 21 and the control software 12 executes the processor instruction as part of a query in step 22 that is executed multiple times in succession. The results from these queries are compared and evaluated for changes in step 23 . If the test results cannot be repeated with sufficient accuracy for delivering a repeatable and consistent result, as determined in step 24 , the control software 12 selects the next processor instruction to be tested 25 from list of processor instructions 13 . In one embodiment, for a test result to be repeated with sufficient accuracy, the measured value returned from each test must be equal from test to test. In another preferred embodiment, the measured value returned from each test must be within a particular range. In other preferred embodiments, various tolerances may be used to indicate that the test result is repeatable or reproducible with sufficient accuracy.
If the test results can be repeated with sufficient accuracy for delivering repeatable and consistent results in step 24 , the control software 12 will compare the results of the test with the database of stored results 14 from other computing devices in step 26 .
If the results from the comparison show that the test results are unique to the computing device being tested (i.e., computing device 10 ) in step 27 , the control software 12 stores the results of the test for use in identifying the computing device in the future. The control software 12 then selects the next processor instruction to be tested in step 25 from the list of processor instructions used by the control software 12 .
Referring still to FIG. 2 , an alternate description of the identification process of the present invention follows, where the test program 12 runs a series of computational processes through the computing device 10 in step 22 . The results of each individual test are evaluated in step 23 . The results are measured in terms of how many times an instruction from, for example, the list of processor instructions 11 is executed by the computing device 10 in a set period of time or, conversely, how long it takes computing device 10 to successfully execute an instruction a preset number of times. These results are then tabulated in step 23 that can be used by an authentication software, which can also be control software 12 , to evaluate the test results for repeatability in step 24 . These results are then compared with the database of stored results from other computing devices in step 26 . If the device test results and timings are unique and repeatable on the device being tested, as determined in step 27 , the authentication software stores the results in step 28 and uses the test results and timings as the foundation of a device identity token that can be compared with the target device in the future to verify the identity of the computing device 10 .
Although the exemplary system and process discussed above was with reference to a processor as computing device 10 , other computing devices such as digital storage devices or other components may be used. For example, in another preferred embodiment of the present invention, the same process is applied to digital storage devices where performance and speed tests of the storage media are performed. Rather than using a series of computational problems as in the evaluation of a computing device, performance and speed tests of digital storage devices could involve the reading, writing and transferring of data across multiple storage device location addresses within the storage device.
It should be noted that the methods described herein may be implemented on a variety of communication hardware, processors and systems known by one of ordinary skill in the art. The various illustrative logics, logical blocks, modules, and circuits described in connection with the embodiments disclosed herein may be implemented or performed with a general purpose processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general-purpose processor may be a microprocessor, but, in the alternative, the processor may be any conventional processor, controller, microcontroller, or state machine. A processor may also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration.
The steps of a method or algorithm described in connection with the embodiments disclosed herein may be embodied directly in hardware, in a software module executed by a processor, or in a combination of the two. A software module may reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, a hard disk, a removable disk, a CD-ROM, or any other form of storage medium known in the art. An exemplary storage medium is coupled to the processor, such that the processor can read information from, and write information to, the storage medium. In the alternative, the storage medium may be integral to the processor. The processor and the storage medium may reside in an ASIC. The ASIC may reside in a user terminal. In the alternative, the processor and the storage medium may reside as discrete components in a user terminal.
The embodiments described above are exemplary embodiments. Those skilled in the art may now make numerous uses of, and departures from, the above-described embodiments without departing from the inventive concepts disclosed herein. Various modifications to these embodiments may be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments, without departing from the spirit or scope of the novel aspects described herein. Thus, the scope of the 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. The word “exemplary” is used exclusively herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as the most preferred or advantageous over other embodiments. Accordingly, the present invention is to be defined solely by the scope of the following claims.
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A method for authenticating a device including the steps of measuring at least one performance parameter of the device to obtain a measurement; and comparing the measurement of the at least one performance parameter with a previously stored measurement of the at least one performance parameter to determine an identity of the device. An apparatus and an article of manufacture for authenticating a device is also disclosed.
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BACKGROUND OF THE INVVENTION
The present invention relates to a process for the decomposition of complexes formed from orthobenzoyl-benzoic acid (OBB acid), hydrogen fluoride (HF) and boron trifluoride (BF 3 ), of the general formula: ##STR1## in which n and m are between 1 and 6.
Such complexes can be obtained according to the European Patent Application No. 0,055,951.
In order to be able to isolate the OBB acid contained in such complexes, with a view essentially to cyclize it into anthraquinone, these must be subjected, for example, to treatment with boiling water or sodium hydroxide. A treatment of this nature has the major disadvantage in that it causes destruction of the HF and of the BF 3 and consequently means that recovery of the HF/BF 3 catalyst used in the synthesis of anthraquinone described in the above-mentioned European Patent Application is not economically viable.
Prolonged heating of the complex at 150° C. to 200° C. makes decomposition possible, but at the same time causes almost total degradation of the OBB acid itself-moreover, the water water formed in the course of this degradation combines with the HF and the BF 3 and thus renders the catalyst unsuitable for direct recycling.
Prolonged heating of the complex under vacuum at a lower temperature, for example 50° C. to 100° C., makes it possible to limit the decomposition of the OBB acid, but allows some of the catalyst to remain in this OBB acid, which renders the process uneconomical.
Heating of the complex at a low temperature in an inert solvent still only leads to incomplete recovery of the catalyst and still causes significant degradation of the OBB acid.
French Patent Application No. 82/14,920 describes a process for the decomposition of the complex in which the complex is subjected to the action of an inert solvent at a temperature of at least 20° C. in a distillation column functioning with vigorous reflux of the solvent. Such a process allows virtually quantitative recovery of the HF and the BF 3 , but has the disadvantage that the OBB acid can be isolated only after it has been separated from the solvent which acts on the complex.
SUMMARY OF THE INVENTION
The process according to the present invention overcomes the disadvantages of the known methods. The present invention, on the one hand, permits recovery of the HF and the BF 3 virtually quantitatively, and, on the other hand, the OBB acid is subjected to virtually no degradation and, simultaneously with the decomposition of the complex, can be cyclized to anthraquinone without being isolated from the medium in which it has been liberated and under the same conditions adopted to carry out the decomposition of the complex.
Briefly, the present invention consists of the process comprising subjecting the complex of the general formula (I) to the action of sulfuric acid in a concentration at least equal to 96% by weight, or to the action of an oleum, under atmospheric pressure or under a pressure lower than atmospheric pressure.
DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic representation of a continuous process for the decomposition of a complex of orthobenzoyl-benzoic acid, hydrogen fluoride and boron trifluoride.
DETAILED DESCRIPTION
By way of example, the amount of sulfuric acid in a concentration equal to 96% by weight is preferably between 1 and 3 parts by weight per part of OBB acid in the complex, and that of oleum containing 20% by weight of SO 3 is 0.5 to 2 parts by weight per part of OBB acid.
The temperature at which the decomposition of the complex and the cyclization of the liberated OBB acid to anthraquinone are carried out is usually between about 100° C. and 180° C., preferably between 120° C. and 150° C.
To facilitate the recovery of the HF and of the BF 3 , it is particularly advantageous to carry out the process in such a temperature range and under a pressure such that it will not be possible to detect escape of water from the reaction mixture. For example, the process will preferably be carried out under a pressure between atmospheric pressure and 4.10 -2 bar.
The duration of the operation, in the context of the other conditions defined above, is generally between 15 minutes and 2 hours.
If the reaction is carried out under a pressure below atmospheric pressure, the use of sulfuric acid is preferred, the temperature chosen is preferably equal to 150° C. or slightly varied from this value and the duration of the operation is about 30 minutes.
If the reaction is carried out under atmospheric pressure or under a pressure below but close to this value, the use of an oleum, for example oleum containing 20% by weight of SO 3 , is preferred to the use of sulfuric acid. The temperature is then about 120° C. and the duration of the operation is of the order of 1 hour.
In the course of the decomposition operation on the complex, the HF and the BF 3 are released in the gaseous state. The HF can be separated from the BF 3 by, for example, condensation. The HF and the BF 3 (the latter after sulfuric washing with the aid of, for example, the sulfuric acid or oleum used for the decomposition of the complex) can thus be re-used to produce the HF/BF 3 catalyst for the synthesis of the same complex.
In a particularly advantageous variant of the process, the HF liberated in the course of the decomposition operation on the complex can be partially or completely converted into BF 3 at the rate at which it is formed, by reaction with boric acid, H 3 BO 3 , which is introduced, for example, as a mixture with the oleum or the sulfuric acid.
The anthroaquinone formed during the decomposition operation on the complex can be easily and economically collected, for example by causing its precipitation by dilution of the final sulfuric mixture and by isolating and purifying the anthraquinone thus precipitated by simple filtration and washing operations. The dilution of the final sulfuric reaction mixture can be carried out with the aid of addition of water, or, more appropriately, with the aid of an aqueous solution of sulfuric acid in a concentration, for example, equal to or about 70% by weight, in a manner such that the concentration of sulfuric acid in the mixture containing the anthraquinone reaches about 80% by weight. The acid washings for the filtration can be reconcentrated for recycling into the decomposition operation on the complex, or they can be used to form the acid solution used to dilute the sulfuric solution of the anthraquinone.
The process according to the invention can be carried out continuously or discontinuously in one or more stirred reactors in series.
The single draiwng shows the schematic representation of the process corresponding to a continuous embodiment of the invention, in two stirred reactors in series: the complex of OBB acid, HF and BF 3 of the general formula (I) is introduced via pipe 1 into the reactor 2. The concentrated sulfuric acid or the oleum led via pipe 3 passes through the washing column 4 before entering the reactor 2 via line 5. The HF and the BF 3 leave the reactor 2 via pipe 6. The sulfuric solution present in the reactor 2 leaves the latter via line 7 and enters the reactor 8. The gaseous HF and BF 3 leave the reactor 8 via pipe 9 and are recombined with the HF and BF 3 circulating in line 6. The gaseous mixture thus formed enters 11, via pipe 10, where the HF is separated from the BF 3 by condensation of the HF. The condensed HF is removed via line 12. The gaseous BF 3 then enters the washing column 4, via line 13, from which it leaves via the BF 3 take-off pipe 14. The sulfuric extract solution of reactor 8 is removed via pipe 15 for the purpose of, for example, the dilution, filtration, and washing operations which are described above and are carried out in apparatuses not shown in the single drawing.
The following examples, which are non-limiting, illustrate the invention according to the variant in which the HF liberated from the complex is converted quantitatively into BF 3 by reaction with boric acid, H 3 BO 3 .
EXAMPLE 1
By a procedure according to the European Patent Application No. 0,055,951, 1 mole of phthalic anhydride and 1 mole of benzene are reacted, in proportion, in 10 moles of HF and 10 moles of BF 3 . After some of the BF 3 is degassed at -40° C., a product is obtained, consisting of, for 1 mole of phthalic anhydride employed, a solution of the complex of the OBB acid in HF containing 203.3 g of OBB acid, 306.7 g of BF 3 , 200 g in total of HF and 22.7 g of impurities from the reaction, and the solution is evaporated in vacuum at 0° C. to give 60 g of final solution, from 100 g of the initial solution.
31.5 g of 96% strength by weight sulfuric acid and 8.5 g of boric acid, H 3 BO 3 are added to these 60 g of solution, in a stirred stainless steel reactor, before then being heated, under a pressure of 4.10 bar, to 150° C., the mixture being maintained at this temperature for 20 minutes.
From the evaluation of the amount BF 3 which leaves the reactor during the operation, it is concluded that the recovery yield of the HF and BF 3 initially contained in the complex is more than 99%, which shows that the efficiency of the decomposition of the complex is virtually quantitative.
After cooling, precipitation, by dilution of the sulfuric mixture with water, of the anthraquinone produced from the OBB acid liberated from the complex, separation by filtration and washing of the anthraquinone thus precipitated, 23.6 g of pure anthraquinone are obtained, corresponding to a recovery of the OBB acid equal to at least 91.2%.
EXAMPLE 2
By treating, in the same apparatus and according to the same procedure as in Example 1, the same amount of the same evaporated solution of the complex as in Example 1 with 31.5 g of oleum containing 20% of SO 3 at 120° C. under atmospheric pressure for 30 minutes in the presence of 8.5 g of boric acid, the recovery yield of the HF and BF 3 initially contained in the complex is even greater than 99%, thus showing a virtually quantitative efficiency of the decomposition. The recovery yield of the OBB acid, calculated from the amount of pure anthraquinone collected after the operations of dilution of the final sulfuric mixture by 70% strength by weight sulfuric acid to precipitate the anthraquinone, filtration and washing of the precipitated anthraquinone, is 79%.
While the invention has been described in connection with a preferred embodiment, it is not intended to limit the scope of the invention to the particular form set forth, but, on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
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Process for the decomposition of complexes of orthobenzoyl-benzoic acid, hydrogen fluoride, and boron trifluoride in which the complex is subjected to the action of sulfuric acid in a concentration of at least about 96% by weight or to the action of an oleum, under atmospheric pressure or under a pressure lower than atmospheric pressure.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to an apparatus for supporting the base of a ladder, and more particularly, to an apparatus for supporting the base of a ladder on a stairway such that the ladder may be rotated to any position where an upper portion of the ladder contacts the walls of the stairwell.
2. Description of the Related Art
In the past, various devices have been suggested in order to safely and conveniently use a ladder within a stairwell. These previous devices typically connect to the base of a ladder and provide adjustable length legs to correct for the uneven surface on which the ladder is to be placed. For example, U.S. Pat. No. 4,671,383 issued June 9, 1987 to Huang, illustrates a ladder leveller wherein the "downhill" leg of the ladder is adjustable to a length which compensates for the pitch of the stairway. The structure of Huang, however, prevents its use on opposite sidewalls without adjusting the leg lengths. Typically, a ladder is constructed with rungs having a flat step portion placed at an angle relative to the siderails of the ladder. Thus, a ladder is intended to be used from a single side and cannot simply be pivoted from one sidewall to the other. Rather, the relative leg lengths must be reversed when an operator desires to move from one sidewall to the other. Obviously, the leg lengths must be equalized when the operator desires to move to the stairwell endwall.
Alternatively, U.S. Pat. No. 4,457,397, issued July 3, 1984 to Schala, discloses a basic platform with adjustable legs that traverse multiple steps to provide a substantially planar base area on which to place the ladder. The platform disclosed in Schala is large and cumbersome, requiring six separate adjustments to properly position the platform within the stairwell. Aside from being difficult to position and adjust, Schala further suffers from the disadvantage of the ladder being unattached to the platform. Accordingly, a ladder placed on the Schala platform risks the possibility that the ladder base would slide rearwardly, causing an operator to fall. Schala has suggested the use of stepped portions on the platform surface which engage the base of the ladder and prevent undesirable movement of the base. However, these steps are necessarily positioned within the area in which an operator is expected to walk and, therefore, a risk exists that an operator will trip and fall. Further, reorienting the ladder to rest against the other sidewall or endwall requires the operator to support and balance the entire ladder. These ladders are typically large, heavy devices which prove difficult to maneuver, particularly within the close confines of a stairwell.
The present invention is directed to overcoming one or more of the problems as set forth above.
SUMMARY OF THE INVENTION
The primary object of the present invention is to provide a ladder support which is easily adjustable to conform to the configuration of a particular staircase.
Another object of the present invention is to provide a ladder support which is secured against undesirable lateral movement on the stairs.
Yet another object of the present invention is to provide a ladder support which freely rotates whereby the ladder is positionable on any one of the stairwell walls.
Still another objective of the present invention is to provide a ladder support which prevents undesirable movement of the base of the ladder relative to the ladder support.
To attain these and other objectives an apparatus is provided for supportively positioning the ladder on a stairway. The apparatus is comprised of a first base which has an upper and lower surface where the lower surface is adapted to frictionally engage a first tread of the stairway. The second base includes an upper and lower surface where the lower surface is similarly adapted to frictionally engage a second tread of the stairway. Means fixedly interconnects the first and second bases at one of a plurality of preselected distances apart. A bracket pivotally connects a base portion of a ladder whereby the ladder is free to pivot in a plane parallel to the ladder longitudinal axis. A rotary coupling interconnects the upper surface of one of the first and second bases and the bracket, whereby the bracket and ladder are free to rotate in a plane substantially parallel to the first and second treads.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings in which:
FIG. 1 is a perspective view of the ladder and ladder support positioned on a stairway;
FIG. 2 a cross-sectional view of the base portion and rotary coupling of the ladder support; and
FIG. 3 is a top view of the base of the ladder support.
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that it is not intended to limit the invention 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 invention as defined by the appended claims.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now to the drawings and referring first to FIG. 1, a perspective view of the apparatus 10 positioned on a stairwell 12 is shown. The apparatus 10 includes a first base 14 which has an upper and lower surface 16, 18 where the lower surface 16 is adapted to frictionally engage a first tread 20 of the stairway 12. A second base 22 also has an upper and lower surface 24, 26 with the lower surface 24 being similarly adapted to frictionally engage a second tread 28 of the stairway 12.
The lower surfaces 18, 26 of each of the bases 14, 24 includes a non-skid material 30. This non-skid material 30 aids the base in maintaining its position on the stairway 12 by increasing the coefficient of friction to inhibit undesirable slipping of the bases 14, 24 across the surface of the treads 20, 28.
The two bases 14, 24 are connected as an integral unit by means for fixedly interconnecting the first and second bases 14, 24 at one of a plurality of preselected distances apart. The means includes the first base portion 14 having a vertical section integrally formed therewith and extending downwardly toward the second base 24. The second base 24 is correspondingly constructed to include a vertical portion 34 which extends upwardly from the second base 24 towards the first base 14. These two vertical portions 32, 34 are connected together by a pair of nut and bolt arrangements 36. The nut and bolt arrangements 36 pass through one of a set of plurality of bores 37 horizontally passing through both of the vertical plates 32, 34.
Proper selection of corresponding bores 37 in the plates 32, 34 allow the bases 14, 24 to be positioned at a plurality of distinct distances apart so as to readily accommodate a wide variety of stairways. The vertical distance between treads 20 and 28 can reasonably be expected to be one of a plurality of standard sizes. Accordingly, as illustrated in FIG. 1, three pairs of bores 37 in each of the plates 32, 34 provide for nine separate and distinct vertical positions.
It should be appreciated that the plates 32, 34 are self adjusting. Since the bases 14, 24 are supported in their desired positions by the treads 20, 28, the proper bores 37 will automatically be aligned.
While the non-skid material 30 generally aids the apparatus 10 by reducing slipping of the bases 14, 24 in all directions, a means further reduces movement of the base by fixing the first and second bases 14, 24 against lateral movement. The means includes a pair of sidewall braces 38, 40. The braces 38, 40 are connected to one of the first and second bases 14, 24 and frictionally engage the sidewalls which form the stairwell.
Each of the sidewall braces 38, 40 includes a threaded rod 42 having first and second end portions. A frictional pad 44 is connected to the first end portion of the rod 42 and a handle 46 is connected to the rod 42 second end portion. The frictional pad 44 preferably includes a non-skid material on its sidewall engaging surface to increase the coefficient of friction and reduce undesirable movement along the sidewall.
A bracket 48 is connected to the first base 14 and includes a vertical portion with a horizontal bore extending therethrough in a direction generally perpendicular to the sidewalls. The bore 50 is threaded in a manner to accept the threaded portion of the rod 42. Therefore, clockwise rotation of the handle 46 causes the frictional pad 44 to move outwardly and engage the sidewall. Conversely, counterclockwise rotation of the handle 46 displaces the frictional pad 44 in a direction toward the base 14 and away from the sidewall. Thus, it can be seen that the combination of the two sidewall braces 38, 40 interact to position the apparatus 10 at the desired location between the sidewall and fixes the apparatus 10 position to prevent undesirable movement thereof.
A bracket 52 is pivotally connected to a base portion of the ladder whereby the ladder is free to pivot in a plane parallel to the ladder longitudinal axis and perpendicular to the ladder rungs. A vertical pipe 54 is connected to a midpoint of a substantially flat ladder support 56. Each end of the ladder support 56 is bent upwardly and has a substantially aligned bore extending therethrough. A bolt 58 passes through the aligned bores within the end portions of the ladder support 56. Within the base portion of the ladder a pair of substantially aligned bores 57 extend through the vertical rails 59 such that the bolt 58 also passes through these rail bores 57, capturing the ladder and preventing undesirable removal from the ladder support 56 yet still allowing pivotal movement of the ladder within the ladder support 56. The ladder support 56 receives additional structural rigidity from a pair of support rods 60 extending from each end portion of the support bracket 56 to the vertical pipe 54. It should be noted that the support rod 60, vertical pipe 54 and ladder support 56 are preferably constructed of a metallic substance and are joined together by a welding process.
A rotary coupling 62 interconnects the upper surface 16 of the first base 14 and the bracket 52. Accordingly, the bracket 52 and ladder are free to rotate in a plane substantially parallel to the upper surface of the first and second stair treads 20, 28. This allows the ladder to be positioned with the upper portion of the ladder engaging one of the sidewalls and the end wall of the stairwell. Construction of the rotary coupling 62 can best be seen and described in conjunction with FIG. 2 wherein a cross-sectional view of the rotary coupling is illustrated. The vertical pipe 54 of the bracket 52 extends into a housing 64. The housing 64 includes a pair of bearings 66, 68 positioned at the top and bottom of the housing 64 and disposed about the vertical pipe 54. The race portion of the bearings 66, 68 is press fit into the housing 64 and the ball bearings are free to rotate with the vertical pipe 54. A gear train 70 is disposed within the housing 64 about the vertical pipe 54 and provides for smooth easy rotation of the bracket 54 and ladder. It should be appreciated that the rotary coupling 62 is also positionable on the upper surface 24 of the second base 22. In either location it is important that the ladder support 56 and support rods 60 be positioned at a height sufficient to clear the immediately higher stair.
A positioning means 72 fixes the rotary coupling 62 against rotation at a plurality of preselected rotary positions. The positioning means 72 includes a plurality of bores disposed about the rotary coupling extending into the upper surface 16 of the first base 14. A lock handle 76 is connected to the bracket 52 and is free to rotate therewith. The handle 76 has an engagement pin 78 and is positionable at a first preselected position with the engagement pin 78 disposed within one of the plurality of positioning bores 74 whereby the bracket 52 is fixed against rotation. In a second position the handle 76 is positioned such that the engagement pin 78 is spaced from the upper surface of the base 14 whereby the bracket 52 is free to rotate.
In FIG. 3, it can be seen that the positioning bores 74 are disposed at 90° rotary positions such that when the engagement pin is located within the positioning bores 74 the bracket 52 and ladder are positioned to respectively contact the sidewalls and endwall. Accordingly, it can be seen that by moving the handle 76 to the second position the ladder and bracket 52 are free to rotate and be appropriately positioned. Once the ladder is positioned to one of the three desired locations, the handle 76 is moved to the first position wherein the engagement pin engages one of the positioning bores 74 and prevents undesirable rotation of the ladder.
Other aspects, objects and advantages of this invention can be obtained from a study of the drawings, the disclosure, and the appended claims.
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An apparatus 10 provides easy, stable positioning of a ladder within a stairwell. The apparatus 10 includes multiple base portions 14, 24 which traverse and rest upon multiple steps 20, 28. Sidewall braces 38, 40 adjustably engage the stairwell sidewalls to inhibit lateral movement of the base portions 14, 24. A bracket 52 is pivotally connected to the base of the ladder and rotatably connected to the base portions 24. Accordingly, the ladder is free to be manually rotated and pivoted to rest against any of the walls forming the stairwell.
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BACKGROUND OF THE INVENTION
This invention relates to spray nozzles, and in particular to a spray nozzle bottle cap for the metered mixing and dispensing of a concentrated carried fluid from the bottle with a primary carrier fluid via a secondary carrier fluid.
Spray nozzles for mixing a concentrated carried fluid with a carrier fluid are known. These devices often include their own reservoir for the carried fluid and are usually adapted to be connected to a garden hose to mix and dispense the carried fluid with water. Such devices are widely used to apply fertilizers, fungicides, insecticides, toxicants, soaps, detergents, and numerous other solutions.
Many of the nozzles are complex and include large number of parts. Consequently these nozzles are relatively expensive, and generally too expensive to be considered disposable. Because of the toxicity of some of the chemicals dispensed and because the complex nozzles can be difficult to clean, a household might have several different nozzle devices for the various different chemicals used around the house. This is expensive and can present difficulties in storing the equipment safely and securely.
The inventor has previously invented a spray nozzle bottle cap which is disclosed in his prior U.S. Pat. No. 3,897,004. This prior spray nozzle was a significant improvement over the available nozzles because it was a very simple one-piece nozzle that was inexpensive enough to provide as a disposable bottle cap. The inventor's prior nozzle thus provided a readily available, easy to use nozzle that eliminated the cleaning and storage problems of the more complicated prior nozzle devices. The nozzle made a variety of common chemical products inexpensively accessible to any household, even to those without spray equipment.
The inventor's prior nozzle, although a significant improvement over the available nozzles, required some precision in manufacture to ensure proper alignment and contact between the stream of carrier fluid and the passageway supplying the carried fluid. This required precision increased the cost of the device. One other disadvantage was that the nozzle had no means for shutting off the flow through the nozzle.
SUMMARY OF THE INVENTION
Among the objects of the present invention is the provision of a simple, inexpensive spray nozzle for the metered mixing and dispensing of a concentrated carried fluid with a carrier fluid; the provision of such a nozzle that does not require precise alignment of the primary carrier fluid stream and the carried fluid supply passage by utilizing a secondary carrier fluid; the provision of such a nozzle that can be made inexpensively to be economically disposable; the provision of such a device that can be provided as a cap for a container of a concentrated fluid to permit the fast and convenient dilution and dispensing of the fluid without special equipment; the provision of such a spray nozzle with a positive air gap anti-suckback feature; the provision of such a spray nozzle that can provide a solid stream discharge or a spray discharge; and the provision of a spray nozzle that can provide a clear water rinse. It is also an object of at least one embodiment of this invention to provide a spray nozzle with means for shutting off the flow of fluid through the nozzle.
Generally, the spray nozzle of this invention comprises first connection means adapted for connecting the nozzle to a source of the carried fluid, a second connection means adapted for connecting the nozzle to a source of a primary carrier fluid under pressure, and a jet passageway in communication with the second connection means for projecting the primary carrier fluid in a stream. The nozzle further comprises a mixing chamber aligned with the jet passageway to receive the stream of the primary carrier fluid, the chamber being separated from the jet passageway by an air gap or recess. A passage extends between the first connection means and the mixing chamber for conducting the carried fluid under gravity from the source to the mixing chamber. The internal dimensions of the mixing chamber are sufficiently larger than the stream of the primary carrier fluid projected through the mixing chamber that the stream of the primary carrier fluid does not contact the walls of the mixing chamber and thus the stream of the primary carrier fluid draws a stream of a secondary carrier fluid from the air gap or recess through the mixing chamber. The secondary carrier fluid stream in the chamber draws the carried fluid from the passage into the chamber to mix with the stream of the primary carrier fluid. In the preferred embodiment the primary carrier fluid is water and the secondary carrier fluid is air.
In an alternate embodiment of the nozzle, the nozzle includes means for selectively shutting off the stream of the primary carrier fluid from the jet passageway. In the preferred embodiment this means comprises a shutoff member received in the air gap or recess between the jet passageway and the mixing chamber, the shutoff member being operable between a closed position wherein the shutoff member blocks the passage of the primary carrier fluid from the jet passageway to the mixing chamber, and an open position wherein the shutoff member does not block the passage of the primary carrier fluid from the jet passageway to the mixing chamber.
Thus, the nozzle of the present invention is simple and inexpensive and provides for the metered mixing and dispensing of a concentrated carried fluid with a carrier fluid. The nozzle utilizes a secondary carrier fluid (air) drawn into the mixing chamber by the primary carrier fluid to educt the carried fluid and therefore does not require precise alignment of the primary carrier fluid stream and the carried fluid supply passage. The nozzle can be made inexpensively to be economically disposable, and can even be provided as a cap for a container of a concentrated fluid. The nozzle provides convenient dilution and dispensing of the fluid without special equipment. The nozzle has an air gap or recess that prevents the carried fluid from being sucked into the primary carrier fluid supply. The nozzle can provide a solid stream or spray discharge. When the nozzle is inverted it mixes the carried fluid with the carrier fluid, when the nozzle is upright it provides a clear rinse. Finally, the nozzle can be provided with means for selectively shutting off the fluid stream.
Other objects and features will be in part apparent and in part pointed out hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation view of a spray nozzle constructed according to the principles of this invention as it would be mounted to a container of a concentrated carried fluid and connected to a hose, showing the spray nozzle inverted;
FIG. 2 is an enlarged front elevation view of the inverted spray nozzle, showing the container in phantom;
FIG. 3 is a longitudinal cross sectional view in the vertical plane of the inverted spray nozzle;
FIG. 4 is a longitudinal cross sectional view in the horizontal plane of a second embodiment of the spray nozzle with a shutoff member in the air gap or recess, showing the shutoff member in the open position;
FIG. 5 is a longitudinal cross sectional view in the horizontal plane of the spray nozzle of the second embodiment, showing the shutoff member in the closed position.
Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first embodiment of a spray nozzle constructed according to the principles of this invention is indicated generally as 20 in FIGS. 1-3. The nozzle 20 is adapted to be mounted on the top of a container 22 filled with a concentrated carried fluid and to be attached to a hose 24, supplying a carrier fluid (typically water) under pressure. In the preferred embodiment the primary carrier fluid is water and the secondary carrier fluid is air, however the invention is not so limited, and it is possible that other primary or secondary carrier fluids could be used. In FIGS. 1 and 2 the container and nozzle are shown inverted, which is their normal operating position for mixing and dispensing the carried fluid.
The nozzle 20 is adpated to be inexpensively made, for example by injection molding from a suitalbe polymeric material. Any number of materials that can be molded and do not react with the chemicals being dispensed can be used. The nozzle could even be cast from metal, but this would increase the cost.
The nozzle 20 comprises first connection means, which in the preferred embodiment is an internally threaded socket 26, for connecting the nozzle to the container 22 filled with the concentrated carried fluid. The nozzle also comprises a second connection means, preferably a second internally threaded socket 28, for connecting the nozzle to the hose 24 supplying the primary carrier fluid. As shown best in FIG. 3, a jet passageway 30 communicates with the second socket and is adapted to project the primary carrier fluid in a solid stream. The jet passageway is preferrably cylindrical, and is long enough to establish a smooth fluid flow therein, establishing a predominantly laminar flow pattern as the jet exits into the air gap or recess. The dimensions of the jet passageway to establish the desired flow depends upon the fluid pressure at the inlet of the jet passageway and the viscosity of the carrier fluid. In the preferred embodiment, where the carrier fluid is water provided at a pressure of between about 35 and about 75 psig, the ratio of length to diameter is between about 1.5:1 and 10:1, and preferably between about 2:1 and 3:1. The inventor has empirically determined that the desired diameter for the majority of the municipal water systems is between about 0.10 inch and 0.2 inches, and preferably between 0.120 and 0.140 inches.
A mixing chamber 32 is aligned with the jet passageway 30 to receive the stream of the primary carrier fluid projected from the jet passageway. The mixing chamber is separated from the jet passageway by the air gap or recess 34. The air gap or recess 34 may be any shape, but as shown in the drawings is preferably square for ease of manufacture.
A passage 36 extends between the first socket 26 and the mixing chamber 32. When the container is inverted to its operating position as shown in FIGS. 1 and 2, the passage 36 conducts the concentrated carried fluid under gravity from the container to the mixing chamber. The passage has the function of metering the carried fluid into the carrier fluid. The appropriate size is empirically determined for a desired mixing ratio. For example, when using a 0.125 inch jet passageway 0.300 inches long, with water at 50 psig as the carrier fluid, mixing ratios of between 15:1 and 30:1 can be obtained with passage diameters of between about 0.090 and about 0.140 inches. These diameters are much larger than used in prior metering devices and can be easily molded, eliminating expensive manufacturing steps. Other mixing ratios can be obtained by varying the passage diameter.
The mixing chamber can be of any cross section, for example, square, octagonal, or oval, but is preferably circular. The internal dimensions of the chamber are sufficiently larger than the stream of the primary carrier fluid projected through the mixing chamber that the stream of the first carrier fluid does not contact the walls of the mixing chamber. In the preferred embodiment, the diameter of the mixing chamber is between about 1.5 and about 5 times the diameter of the jet passageway, and is preferably between about 2 and about 3 times the diameter of the jet passageway. The ratio of the length to the diameter of the mixing chamber is preferably between about 1:1 to about 3:1. The upstream end of the mixing chamber may be provided with a collar 38 to ensure that the carrier fluid does not impinge on passage 36. Collar 38 has a generally central aperture 40 through which the stream of the primary carrier fluid passes. The aperture 40 is sufficiently large that the stream does not splatter on the collar. In the preferred embodiment, aperture 40 has a diameter of between about 50% and about 95% of the diameter of the mixing chamber and is preferably between about 70% and about 85% of the diameter. The downstream end of the mixing chamber can be provided with a member (not shown) as is known in the art for dispersing the stream into a spray, if a spray application is desired.
The stream of the primary carrier fluid draws a stream of air from the air gap or recess through the mixing chamber. The air stream acts as a secondary carrier fluid, that can draw the carried fluid from container 22 through the passage 36 into the chamber to mix with the stream of the primary carrier fluid. When the nozzle 20 and the container 22 are inverted, the suction of the secondary carrier fluid is sufficient to draw the carried fluid from the container 22 into the mixing chamber. An air bleed hole 42 is provided in the nozzle adjacent to the socket 26 to allow air to enter the container to replace the concentrated carried fluid withdrawn, thereby facilitating smooth operation. The hole 42 must be large enough to allow air to enter the container to replace the carried fluid at the rate it is educted, while minimizing fluid leakage. It has been empirically determined that a 1/16 inch hole is satisfactory, although other sizes may be satisfactory depending upon the particular carried fluid.
The sockets 26 and 28 are preferably similarly threaded, complementary to threads on the top of the container 22 so that either of the sockets can be secured over the top of the container. Furthermore, the threads of the second socket 28 are preferably complementary to the threads on a standard garden hose, so that it can be connected to the garden hose.
A second embodiment of the nozzle is shown in FIGS. 4 and 5 and indicated as 20'. Nozzle 20' is similar to nozzle 20, and corresponding parts are identified with the same reference numerals. Nozzle 20' differs from nozzle 20, however, by the provision of a shutoff member 44, which is received in the air gap or recess 34. The shutoff member 44 has a generally channel-shaped cross section with the open top of the channel oriented forwardly with respect to the nozzle. The shutoff member has an aperture 46 therein which, as shown on FIG. 4, can be aligned with the jet passageway 30 to allow the stream of the primary carrier fluid to pass to the mixing chamber 32. The open portions of the shutoff member permit the stream of primary carrier forced to draw the secondary carrier fluid into the mixing chamber. The aperture 46 must be large enough to receive the stream from the jet passageway without any contact by the shutoff member. The aperture is preferably slightly larger than the jet passageway to accommodate misalignments due to molding variations. In the preferred embodiment, the aperture is 1.75 times the diameter of the jet passageway. The shutoff member also has a solid portion 48, preferably provided with a convex boss 50, which as shown in FIG. 5 can be aligned with the jet passageway 30 to block the stream of the primary carrier fluid. The convex boss provides a sealing force sufficient to overcome the fluid pressure. The shutoff member 44 is wedged in the air gap or recess and blocks the jet passageway. The convex boss, which projects into the jet passageway, also provides a positive snap action, confirming that the shutoff member is in the closed position. The shutoff member thus allows the nozzle to be turned off, if desired. The shutoff member also serves to close and seal the container when the second socket is secured over the container, as might be done in shipping.
The opposite ends of the shutoff member 40 are provided with stops 52 and 54 to retain the shutoff member in the air gap or recess. Stops 52 and 54 can be conveniently formed by bending the ends of the shutoff member after it is inserted into the air gap or recess. Stops 52 and 54 may have studs 56 and 58, respectively, for providing a positive positioning of the shutoff member in the closed and open positions.
OPERATION
The nozzle 20 can be provided separately with a container 22 of a concentrated carried fluid, or preferably as the cap for the container. When nozzle 20 is provided as the cap, a gasket (not shown) can be provided to seal the container 22. During shipping, socket 28 is preferably secured over the top of the container. This is particularly true with nozzle 20', since the shutoff member 44 can then provide a closure for the container without a gasket.
To dispense the concentrated carried fluid, socket 28 is detached from the top of the container and socket 26 is attached in its place. A typical garden hose 24, connected to a supply of water under pressure, is then connected to the socket 28 of the nozzle. When the water supply is turned on the nozzle projects the water in a stream. The water stream draws air from the air gap or recess through the mixing chamber. When the container and the nozzle are inverted, the concentrated carried fluid is conducted to the mixing chamber through passage 36 under gravity. The air drawn through the mixing chamber acts like a secondary carrier fluid creating enough suction to draw the concentrated carried fluid from the passage 36 into the mixing chamber. Air to replace the concentrated carried fluid being withdrawn can enter through the air bleed hole 42. Once in the mixing chamber the concentrated carried fluid mixes with the primary carrier fluid (the water) and the nozzle dispenses a mixture of water and the carried fluid. When the container and nozzle are again righted, the nozzle projects a clear stream of water. This gives the nozzle a rinsing capability which is of particular advantage, for example, if the nozzle is being used to dispense a detergent or other cleaning preparation.
If nozzle 20' is used, the shutoff member 40 can be operated to selectively block the flow from the jet passageway. This allows the nozzle to be shut off as desired. The stops provide a positive action between the open and closed positions, to ensure proper operation.
In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.
As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
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A one-piece spray nozzle for the metered mixing and dispensing of a carried fluid with a primary carrier fluid comprising a first connection for connecting the nozzle to a source of the carried fluid and a second connection adapted for carrying the nozzle to a source of the primary carrier fluid. A jet passageway communicating with the second connection projects the primary carrier fluid in a stream. A mixing chamber is aligned with the jet passasgeway but is separated from the jet passageway by an air gap or recess. A passage extending between the first connection and the mixing chamber conducts the carried fluid under gravity to the mixing chamber. The mixing chamber is sized so that the stream of the primary carrier fluid does not contact the walls of the mixing chamber but draws a stream of a secondary carrier fluid from the air gap or recess through the mixing chamber. The stream of the secondary carrier fluid draws the carried fluid into the chamber to mix with the primary carrier fluid.
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This is a continuation-in-part International Application PCT/NL93/00016, filed on 15 Jan. 1993 and which designated the U.S., now WO.93/13,671, published Jul. 22, 1993.
BACKGROUND OF THE INVENTION
The invention relates to a device for conveying slaughtered animals, in particular birds, or a part thereof, hanging by at least one leg, the device comprising a plurality of leg carriers for the animals or parts thereof, which leg carriers are each connected by way of rotatable connecting means to a trolley of a conveyor running through a track past at least one processing station, the connecting means being rotatable about an essentially vertical axis through a predetermined angle relative to the trolley, the connecting means comprising means for fixing the angular orientation of the leg carrier relative to the trolley.
DISCUSSION OF THE PRIOR ART
A prior art device is known from European Patent Application Publ. No. 444,782.
In the known device it is not possible to disregard certain processing operations along the track of the conveyor. Nor is it possible, for example, to make a choice between two processing machines disposed on either side of the track.
A still further disadvantage of the known device is that it is designed to cause a fixed series of processing operations to be carried out on the slaughtered animal; it is not capable of causing the processing range to be adapted depending on certain characteristics of the slaughtered animal.
SUMMARY OF THE INVENTION
The object of the invention is to provide a device having the possibility of taking a slaughtered animal or part thereof into or out of the working range of a processing machine disposed along the conveyance track.
A further object of the invention is to provided a device for controlling the processing of a slaughtered animal being conveyed along a processing station.
According to the invention, the leg carriers are disposed eccentrically relative to the axis of rotation of the corresponding connecting means. Hereby a slaughtered animal may be taken into or out of the working range of a processing machine along the route by rotating the leg carrier. One may thus avoid using parallel transport tracks for processing animals in different ways. The processing equipment can be used more efficiently in one single transport track, processing each animal in a specific manner by selecting the equipment to be used and to be avoided.
According to a preferred embodiment of the inventive device, in which the connecting means have two or more projections which project at right angles to the axis of rotation of the connecting means, and which can interact with projection operating means disposed along the track. Advantageously, the length of at least one of the projections is different from the length of the other projections. This provides the possibility of making all carriers take up the same initial position prior to a processing operation.
In a further preferred embodiment, the inventive device comprises recording means disposed along the track upstream of corresponding projection operating means for recording one or more parameters concerning each slaughtered animal or part thereof being conveyed past the recording means, and means for controlling the projection operating means on the basis of the data recorded with the recording means, in such a way that the projection operating means do or do not interact with the projections of the connecting means.
In a still further advantageous embodiment the leg carrier comprises means for accommodating the legs of the slaughtered animal, and fixing means which, interacting with the accommodating means, are adapted to enclose each leg like a ring. Preferably, the accommodating means are formed by an essentially elongated, plate-shaped element. This has the advantage that the accommodating means can be used in a production line such as that described in European Patent Specification No. 159,731 in the name of applicants. The carriers of the device are in this case guided along the guides 6 mentioned in the patent specification, so that a very stable suspension of the animal is ensured during conveyance.
The claims and advantages will be more readily appreciated as the same becomes better understood by reference to the following detailed description and considered in connection with the accompanying drawings in which like reference symbols designate like parts.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a short section of a conveyor for slaughtered poultry;
FIGS. 2A and 2B show top views, partially in cross-section of a closed and open leg carrier respectively of the conveyor of FIG. 1;
FIG. 3 shows three carriers of the conveyor disposed one after the other, in different positions along the track;
FIG. 4 shows a device from FIG. 1 turned through 90°;
FIG. 5 shows schematically in top view the interaction between a Maltese cross in the connecting means and projection operating elements disposed along the track; and
FIG. 6 shows schematically in top view a processing station for cutting wings of poultry, which is adapted for cooperation with the device for conveying slaughtered poultry.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The conveyor shown in FIG. 1 is formed by a driven chain conveyor 1, provided with trolleys 2 which in a usual manner comprise a fork-shaped element 3 with wheels 4. The wheels 4 are guided along a rail 5, the shape of which determines the track of the conveyor. This track runs in the usual way through one or more processing or inspection stations (not shown). Each trolley 2 is provided with a leg carrier 6, which is suitable for accommodating the leg of a slaughtered animal, here a slaughtered bird 7, or a part thereof, and carrying it along the track of the conveyor. Each carrier 6 is fixed by way of adjustable connecting means 8 to the corresponding trolley 2. These connecting means 6 make it possible for each carrier 6 during operation to be rotatable through a predetermined angle on a vertical axis.
It can be seen in FIGS. 2a and 2b that a carrier 6 is made up of a bearing element 10 and a shut-off device 11, which can pivot relative to each other and relative to the connecting means 8 about an axis 12. The bearing element 10 is provided with two recesses 13, in which the legs of the bird 7 can be accommodated. These recesses 13 have such dimensions that the bird 7 can hang by its tarsal joints. A virtually closed ring, in which the tarsal joint is securely confined, is produced by closing shut-off device 11. The carrier 6 also has two carrier control levers 14, 15, which can produce the rotation of the bearing element 10 and the shut-off device 11 about the axis 12.
FIG. 3 shows how the two carrier control levers 14, 15 interact with guides 16 fitted on a wall (not shown) lying above the plane of the drawing, which interaction will be described below. In order to guarantee good stability in the directions at right angles to the direction of conveyance, the connecting means 8 are guided during operation of the levers 14, 15 between two parallel walls 17 running parallel to the conveyor chain 1, only one of which is shown in the figure.
The lefthand device of the three devices illustrated here shows a carrier 6, in the closed position, in which carrier a bird 7 is hanging by the legs. This situation is identical to that shown in FIG. 1. When the chain conveyor 1 moves to the right in the drawing, the carrier control lever 15 at a given moment comes into contact with guide 16, and said lever will be forced downwards as a result of this intersection, thus opening the shut-off device 11. The carrier assembly will assume the position shown in the centre of FIG. 3 when the slope of the guide 16 ends.
In the carrier on the right in the figure it can be seen how the shut-off device 11 closes again when the carrier control lever 15 goes against a rising guide (groove) 16 on moving further to the right. As a result of this the shut-off device 11 closes again.
The discharging (not shown) of the bird 7 can take place by forcing the carrier control lever 14 upwards when the shut-off device 11 is open, causing the recesses 13 to be directed with their openings downwards, as a result of which the bird 7 can be discharged from them.
FIG. 4 shows a carrier 6 which is turned through 90° relative to the carrier from FIG. 1. The figure shows clearly that the carrier 6 is disposed eccentrically relative to the trolley, which makes it possible to bypass or actually seek the working range of certain processing machines disposed along the route.
In order to be able to rotate the carrier 6 about a vertical axis, the connecting means 8 are provided with a Maltese cross 18 (FIG. 5) which interacts with arm operating elements 19 fitted at the bottom of the wall 17, and in the case of which the wall 17 acts as a guide for the connecting means. The rotation of the carrier 6 is determined by the interaction between a segment of the Maltese cross, and also by the angular orientation fixing means present (not shown) in the connecting means 8.
FIG. 5 shows that the segment with the smallest radial dimensions passes the three arm operating elements 19 undisturbed. It will be clear that no matter what the initial position of the Maltese cross 18 is, after the three arm operating elements 19 have been passed, the cross always takes up the same position, which is advantageous for then making a processing selection.
When a selection of a processing operation on the animal is being made, after said animal has been checked for certain characteristics by a recording station, it is possible with the aid or the result of the check to operate the arm operating elements 19, so that an angular orientation to be achieved by the carrier 6 can be selected. In the same way it is possible to have a processing station bypassed by the carrier 6, through the fact that as a result of its eccentric position outside the working range of the processing station in question the carrier passes said station.
FIG. 6 shows schematically in top view a processing station 101 for cutting wings of slaughtered poultry. Slaughtered poultry 105 is carried by a device according to the invention (not shown) along a transport track 100 of a conveyor (not shown). By means of an eccentrical set up of the carrier relative to the trolley, the poultry can be transported forwardly both in position A and in position B.
The processing station consists basically of a frame 102, rotary driven cutting devices 103 for cutting the wings of poultry and wing guide bars 104 for guiding the wings of poultry so that they may take a proper position when being cut.
Also, the frame 102 carries a guide bar 106. The guide bar 106 will act on the poultry which is forwarded in position B by guiding it sideways outside the working range of the processing station 101. After detouring the processing station the poultry will be guided back into its original position close to the transport track 100.
On the other hand, poultry in position A will not be bothered by guide bar 106 and may proceed into the working range of the station 101. The guide bar 106 is provided at its foremost end with a small rotatable wheel 107 for facilitating the guidance of poultry in position A and poultry in position B.
While the invention has been described and illustrated in its preferred embodiments, it should be understood that departures may be made therefrom within the scope of the invention, which is not limited to the details disclosed herein.
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Device for conveying slaughtered animals or a part thereof, having a number of leg carriers, each of which is connected by way of a rotatable connecting element to a trolley of a conveyor, and runs through a track past at least one processing station. Each leg carrier is disposed eccentrically relative to the vertical axis of rotation of the corresponding connecting element.
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FIELD OF THE INVENTION
The present invention relates to benzazepine derivatives and more particularly concerns such compounds useful as cardiovascular agents.
SUMMARY OF THE INVENTION
In accordance with the present invention a novel class of benzazepine derivatives useful, for example, as cardiovascular agents, are disclosed. These compounds have the general formula ##STR2## including pharmaceutically acceptable salts thereof, wherein R 1 is hydrogen, alkyl, acetyl, aryl, arylalkyl, or --NR 7 R 8 ;
X is oxygen or sulfur, or, is a single bond when R 1 is --NR 7 R 8 ;
R 2 and R 3 are each independently hydrogen, alkyl, cycloalkyl or arylalkyl, or R 2 and R 3 together with the nitrogen atom to which they are attached are pyrrolidinyl, piperidinyl, or morpholinyl;
R 4 , R 5 , and R 6 are each independently hydrogen, halogen, alkyl, alkoxy, aryloxy, arylalkoxy, diarylalkoxy, arylalkyl, cyano, hydroxy, alkanoyloxy, ##STR3## fluoro substituted alkoxy, fluoro substituted alkyl, (cycloalkyl)alkoxy, --NO 2 , --NX 3 X 4 , --S(O) m alkyl, fluoro substituted alkyl, (cycloalkyl)alkoxy, --NO 2 , --NX 3 X 4 , --S(O) m alkyl, --S(O) m aryl, ##STR4## R 7 and R 8 are each independently hydrogen, alkyl, cycloalkyl or arylalkyl, or R 7 and R 8 together with the nitrogen atom to which they are attached are pyrrolidinyl, piperidinyl or morpholinyl;
n is 2 or 3;
m is 0, 1 or 2;
q is an integer from 1 to 5;
X 1 and X 2 are each independently hydrogen, alkyl, aryl or heteroaryl, or X 1 and X 2 together with the nitrogen atom to which they are attached are pyrrolidinyl, piperidinyl or morpholinyl;
X 3 and X 4 are each independently hydrogen, alkyl, alkanoyl, arylcarbonyl, heteroarylcarbonyl, or ##STR5## X 5 is hydroxy, alkoxy, aryloxy, amino, alkylamino or dialkylamino; and
X 6 is alkyl, alkoxy or aryloxy; with the proviso that if R 4 is a 7-alkyl group, it must have a tertiary carbon atom bonded to the ring.
DETAILED DESCRIPTION OF THE INVENTION
Listed below are definitions of various terms used to describe the benzazepines of this invention. These definitions apply to the terms as they are used throughout the specification (unless they are otherwise limited in specific instances) either individually or as part of a larger group.
The terms "alkyl" and "alkoxy" refer to both straight and branched chain groups. Those groups having 1 to 10 carbon atoms are preferred.
The term "alkenyl" refers to both straight and branched chain groups. Those groups having 2 to 10 carbon atoms are preferred.
The term "aryl" refers to phenyl and substituted phenyl. Exemplary substituted phenyl groups are phenyl groups substituted with 1, 2 or 3 amino (--NH 2 ), alkylamino, dialkylamino, nitro, halogen, hydroxyl, trifluoromethyl, alkyl (of 1 to 4 carbon atoms), alkoxy (of 1 to 4 carbon atoms), alkanoyloxy, carbamoyl, or carboxyl groups.
The term "alkanoyl" refers to groups having the formula ##STR6## Those alkanoyl groups having 2 to 11 carbon atoms are preferred.
The term "heteroaryl" refers to an aromatic heterocyclic group having at least one heteroatom in the ring. Preferred groups are pyridinyl, pyrolyl, imidazolyl, furyl, thienyl, or thiazolyl.
The term "cycloalkyl" refers to groups having 3, 4, 5, 6 or 7 carbon atoms.
The term "halogen" refers to fluorine, chlorine, bromine and iodine.
The terms "fluoro substituted alkyl" and "fluoro substituted alkoxy" refer to alkyl and alkoxy groups (as described above) in which one or more hydrogens have been replaced by fluorine atoms. Exemplary groups are trifluoromethyl, 2,2,2-trifluoroethyl, pentafluoroethyl, fluoromethoxy, difluoromethoxy, etc.
The compounds of formula I form acid-addition salts with inorganic and organic acids. These acid-addition salts frequently provide useful means for isolating the products from reaction mixtures by forming the salt in a medium in which it is insoluble. The free base may then be obtained by neutralization, e.g., with a base such as sodium hydroxide. Any other salt may then be formed from the free base and the appropriate inorganic or organic acid. Illustrative are the hydrohalides, especially the hydrochloride and hydrobromide, sulfate, nitrate, phosphate, borate, acetate, tartrate, maleate, citrate, succinate, benzoate, ascorbate, salicylate, methanesulfonate, benzenesulfonate, toluenesulfonate and the like.
The carbon atoms in the 3 and 4-positions of the benzazepine nucleus of the compound of formula I are asymmetric carbons. The compounds of formula I, therefore, exist in enantiomeric and diastereomeric forms and as racemic mixtures thereof. All are within the scope of this invention. It is believed that those compounds of formula I which have the 4R-cis configuration are the most potent and are therefore preferred.
The compounds of formula I can be prepared by first reacting a 2-nitrotoluene having the formula ##STR7## with a benzylidine malonate having the formula ##STR8## wherein Y is alkyl. The reaction can be run in a polar nonprotic solvent (e.g., dimethylformamide), in the presence of a strong base such as sodium hydride, and yields a product having the formula ##STR9##
Reduction of a compound of formula IV yields the corresponding compound having the formula ##STR10## The reduction can be accomplished by catalytic hydrogenation (using, for example, palladium on charcoal as a catalyst) or using a chemical reducing agent (e.g., ferrous sulfate or stannous chloride).
Treatment of an amine of formula V with an alkali metal alkoxide (e.g., sodium methoxide) and an alcohol (e.g., methanol) or with potassium hexamethyldisilazide in a solvent such as tetrahydrofuran or toluene, yields the corresponding benzazepine having the formula ##STR11##
Reaction of a compound of formula VI with a reducing agent, such as lithium aluminum hydride, in a solvent such as tetrahydrofuran, at low temperature yields the corresponding compound having the formula ##STR12##
Compound VII can thereafter be reacted with p-toluenesulfonylchloride or methanesulfonylchloride in the presence of a base, such as pyridine to provide a compound having the formula ##STR13##
Compound VIII can be reacted with a base in the presence of a solvent, such as dichloromethane or dimethylformamide, at room temperature, to provide the corresponding compound having the formula ##STR14##
Reaction of a compound of formula IX with a compound of the formula
M--XR.sub.1 X
where M is a metal, such as lithium, sodium or potassium and X is sulfur or oxygen (such as sodiomethanethiol, where X is sulfur and R 1 is methyl; or, sodium methoxide where X is oxygen and R 1 is methyl) in the presence of a solvent, such as methanol or dimethylformamide, yields the corresponding compound of the formula ##STR15## and its diastereomer ##STR16## The preferred cis isomer (XIa) is generally the predominant isomer formed during the above reaction. The isomers can be separated using art recognized techniques, such as crystallization or chromatography. Alternatively, the reactions described hereinafter can be carried out using the diastereomeric mixture (a mixture of the compounds of formulas XIa and XIb). The isomeric mixture can be separated into its component isomers at any point during the reaction sequence.
Treatment of a compound of formula XIa with a base, e.g. potassium hydrogen carbonate, in the presence of a solvent, e.g. methyl ethyl ketone, followed by reaction with a compound having the formula ##STR17## yields the compounds of formula I wherein X is oxygen or sulfur and q is 1.
To prepare compounds of formula I where X is a single bond, q is 1 and R is NR 7 NR 8 , a compound of formula IX is treated with an amine of formula ##STR18## in a solvent like toluene to obtain a diastereomeric mixture of compounds of formulas ##STR19## The diastereomers can be separated at this stage using art recognized techniques such as crystallization or chromatography. A compound of formula XIIIa can be treated as a compound of formula XIa to provide a compound of formula I where X is a single bond, q is 1 and R 1 is NR 7 R 8 . Alternatively, the reaction described above can be carried out using the diastereomeric mixture (a mixture of the compounds of formulas XIIIa and XIIIb). The isomeric mixture can be separated into its component isomers using art recognized techniques, such as crystallization or chromatography.
To prepare compounds of formula I where q is 2 to 5 and X is oxygen or sulfur or X is a single bond and R 1 is ##STR20## a compound of formula VI in a solvent, e.g., dimethylformamide, in the presence of a base, e.g., sodium hydride is treated with bromomethylmethyl ether to provide a compound having the formula ##STR21##
Compound XIV can be reactedwith a compound having the formula
Br--(CH.sub.2).sub.q-1 CH═CH.sub.2 XV
in a solvent, e.g., sodium hydride, at low temperature to provide a compound having the formula ##STR22##
Treatment of a compound of formula XVI with a strong acid, e.g., sulfuric, in the presence of a solvent, e.g. methanol and anhydrous lithium bromide, provides ##STR23##
Compound XVII in a solvent, e.g., pyridine cotaining 1-2% water or dimethylformamide, can therafter be reacted with lithium bromide, or lithium iodide (in presence or absence of p-amino-thiophenol) to obtain a diastereomeric mixture of compounds of formulas ##STR24## The preferred cis isomer is generally the predominant isomer formed during the above reaction. The isomers can be separated at this stage using art recognized techniques, such as crystallization or chromatography. Alternatively, the reactions described hereinafter can be carried out using the diastereomeric mixture (mixture of compounds of formulas XVIIIa and XVIIIb). The isomeric mixtures can be separated into its component isomers at any point during the reaction sequence using art recognized techniques, such as crystallization of chromatography.
Reaction of the compound of formula XVIIIa in a solvent such as tetrahydrofuran with an ethereal solution of osmium tetroxide followed by treatment with aqueous sodium bisulfite solution provides a compound of the formula ##STR25##
Treatment of compound XIX in methanol with sodium-meta-periodate in water provides a compound of the formula ##STR26##
Compound XX, in an organic solvent such as tetrahydrofuran can be reacted with a reducing agent such as sodium borohydride or lithium aluminum hydride to provide a compound of the formula ##STR27##
The compound of formula XXI can be acylated or alkylated using a conventional techniques to obtain products of formula ##STR28## For example, Compound XXI can be reacted with a halide of the formula
R.sub.1 --halogen XXIII
in the presence of a base. Alternatively, the acylation can be accomplished using an acid anhydride.
Treatment of a compound of formula XXII with an alkali metal hydride (e.g., sodium hydride) in an inert solvent, such as dimethylformamide or dimethylsulfoxide, followed by reaction with a compound of formula XII yields the compound of formula I, wherein X is oxygen and R 1 is acetyl, alkyl, aryl or arylalkyl. Alternatively, compounds of formula XXII, in the presence of a base like potassium hydrogen carbonate can be treated with compounds of formula XII in a solvent, e.g., methyl ethyl ketone, to provide compounds of formula I, where --XR 1 is --OR 1 and q is 2 to 5.
To prepare compounds of formula I, where q is 2 to 5 and --XR 1 is --SR 1 or ##STR29## a compound of formula XXI, in a solvent, e.g., tetrahydrofuran, can be reacted with triphenylphosphine and diisopropyl azodicarboxylate, followed by HSR 1 or ##STR30## to provide compounds of formula ##STR31## where XR 1 =--SR 1 or ##STR32##
A compound of formula XXIV can be treated as compounds of formula XXII to provide compounds of formula I, where q is 2 to 5 and --XR 1 is either --SR 1 or ##STR33##
The resolved enantiomers of the compounds of this invention can be prepared by first hydrolyzing a compound of formula VI to obtain the corresponding carboxylic acid having the formula ##STR34## The hydrolysis can be accomplished, for example, by treating a compound of formula VI with an alkali metal hydroxide in an alcohol (e.g., potassium hydroxide in methanol).
A carboxylic acid of formula XXV can be resolved using a chiral amine. Reaction of the acid and amine in an appropriate solvent yields the diastereomeric salts which can be separated using conventional techniques such as crystallization. Regeneration of the carboxylic acid from the pure diastereomeric salt followed by esterification yields the desired nonracemic form of a compound of formula VI. Alternatively, compounds of formula VI can be generated directly from the diastereomeric salts by treatment with an alkyl halide in dimethylformamide in the presence of an inorganic base (e.g., potassium bicarbonate). This nonracemic compound can be converted to the corresponding nonracemic product of formula I via the nonracemic form of intermediates of formulas VII and VIII using the procedures described above.
Alternatively, the resolved enantiomers of the compounds of this invention can be prepared by the reaction of a compound of formula I with a chiral carboxylic acid in an appropriate solvent. The resulting diastereomeric salts can be separated by recrystallization.
In the reactions described above for preparing the compounds of this invention, it may be necessary to protect reactive substituents (e.g., hydroxy and amino) from involvement in the reactions. Protection of the substituents, and the necessary deprotection, can be accomplished using standard techniques.
Preferred are those compounds of formula I wherein
R 1 is methyl when X is oxygen or sulfur; R 1 is ##STR35## when X is a single bond; R 2 and R 3 are each methyl or R 2 is hydrogen and R 3 is methyl;
R 4 is trifluoromethyl (especially 7-trifluoromethyl and 6-trifluoromethyl);
R 5 is 4-methoxy;
R 6 is hydrogen;
R 7 and R 8 are each methyl; and,
q is 1 or 2.
The compounds of formula I and the pharmaceutically acceptable salts thereof are useful as cardiovascular agents. These compounds act as vasodilators and are especially useful as anti-hypetensive and anti-ischemic agents. By the administration of a composition containing one (or a combination) of the compounds of this invention the blood pressure of a hypertensive mammalian (e.g. human) host is reduced. Daily doses of about 0.1 to 100 mg per kilogram of body weight per day, preferably about 1 to about 50 mg per kilogram per day, are appropriate to reduce blood pressure, and can be administered in single or divided doses. The substance is preferably administered orally, but parenteral routes such as the subcutaneous, intramuscular, or intravenous routes can also be employed.
As a result of the vasodilating activity of the compounds of formula I, it is believed that such compounds in addition to being anti-hypertensives may also be useful as anti-arrhythmic agents, as anti-anginal agents, as anti-fibrillatory agents, as anti-asthmatic agents, and in limiting myocardial infarction.
The compounds of this invention can also be formulated in combination with a diuretic or an angiotensin converting enzyme inhibitor. Suitable diuretics include the thiazide diuretics such as hydrochlorothiazide and bendroflumethiazide and suitable angiotensin converting enzyme inhibitors include captopril.
The present invention will be further described by reference to the following examples, however, it is not meant to be limited by the details described therein.
EXAMPLE 1
(cis)-1-[2-(Dimethylamino)ethyl]-1,3,4,5-tetrahydro-3-(methoxymethyl)-4-(4-methoxyphenyl)-7-(trifluoromethyl)-2H-1-benzazepin-2-one, fumarate (1:1) salt
A. [2-(5-Trifluoromethyl-2-nitrophenyl)-1-(4-methoxyphenyl)ethyl]propanedioic acid, dimethyl ester
To a 2 liter three-neck flask (under nitrogen) was added 67.0 g (0.293 mole) of dimethyl-p-methoxybenzylidene malonate and 450 ml of dimethylformamide. The stirred solution was treated with a 50% sodium hydride dispersion (18.7 g, 0.39 mol). The mixture was treated dropwise with a solution of 3-methyl-4-nitrobenzoic acid (60.5 g, 0.293 mol) in 50 ml of dimethylformamide over a period of 1 hour while maintaining a temperature at about 28°-32° C. This mixture was stirred for 4 hours at room temperature, cooled, treated portionwise with 25 ml of acetic acid and poured onto 2.5 l of ice-water. The mixture was extracted 3 times with 250 ml of methylene chloride. The organic phases were combined, washed 3 times with 500 ml of water, dried over magnesium sulfate, filtered and the solvent evaporated to give 126 g of a pale brown semi-solid. The latter was dissolved in 270 ml of methanol, cooled and filtered to give 72.8 g of a pale yellow product, m.p. 110°-112°. A sample recrystallized from methanol, melted at 111°-113°.
Analysis calc'd for C 21 H 20 NF 3 O 7 : C, 55.39, H, 4.43, N, 3.08; F, 12.52; Found: C, 56.08; H, 4.70; N, 2.96; F, 12.09.
B. [2-(5-Trifluoromethyl-2-aminophenyl)-1-(4-methoxyphenyl)ethyl]propanedioic acid, dimethyl ester
A suspension of 25 g (0.055 mol) of the title A compound in 200 ml of methanol was treated with a cold suspension of 2.5 g of 5% palladium on carbon in 50 ml of methanol (under nitrogen) and placed on the Parr apparatus at 58 psi of hydrogen. After 30 minutes, this mixture was heated to 50°-55° C. for 1 hour to assure that all of the nitro compound had dissolved. The mixture was removed from the Parr and allowed to stand at room temperature overnight. The flask was heated to dissolve the crystallized product and the hot solution was filtered through Celite (under nitrogen) and washed with hot methanol. The colorless filtrate was concentrated on a rotary evaporator to give 22.2 g of a nearly colorless solid. The latter was triturated with 100 ml of hexane and then with 50 ml of hexane. The solvent was decanted and the entrained solvent removed on a rotary evaporator to give 21.3 g of product, m.p. 124°- 127°. A sample of this material, after crystallization from methanol, melted at 125°-127 °.
Analysis calc'd for C 21 H 22 NF 3 O 5 : C, 59.29; H, 5.21; N, 3.29; F, 13.40; Found: C, 59.48; H, 5.26; N, 3.16; F, 13.43.
C. 7-(Trifluoromethyl)-1,3,4,5-tetrahydro-3-(methoxycarbonyl)-4-(4-methoxyphenyl)-2H-1-benzazepin-2-one
A stirred solution of the title B compound (20.0 g, 0.047 mol) in 200 ml of methanol was treated with 13.3 ml of 25% sodium methoxide in methanol and heated to reflux. After 2.75 hours, the mixture was cooled in ice water and 70 ml of 1N hydrochloric acid was added to precipitate the partly gummy product. The latter became granular on rubbing and stirring in an ice water bath for 0.5 hours. The tan solid was filtered, washed with water, and air dried to give 19 g of a pale yellow foam-like material. The latter was suspended in 30 ml of isopropylalcohol, allowed to stand for 1 hour, filtered and washed with isopropylalcohol and hexane to provide 13.64 g of the title C compound, m.p. 161°-163°.
Analysis calc'd for C 20 H 18 NF 3 O 4 : C, 61.07; H, 4.61; N, 3.56; F, 14.49; Found: C, 61.26; H, 4.62; N, 3.41; F, 14.21.
D. 7-(Trifluoromethyl)-1,3,4,5-tetrahydro-3-(hydroxymethyl)-4-(4-methoxyphenyl)-2H-1-benzazepin-2-one
The title C compound (29.16 g, 74.13 mmole) in dry tetrahydrofuran (150 ml) was added dropwise and with stirring to a cooled (0° C.) solution of lithium aluminum hydride (6.41 g, 0.169 mole) in tetrahydrofuran (50 ml). The ice bath was removed and the solution was stirred at room temperature for 4 hours. Saturated sodium sulfate solution was carefully added to neutralize the hydride and the mixture was partitioned between water and ethyl acetate. The organic extract was dried over anhydrous magnesium sulfate, filtered and concentrated. The crude residue was digested in hot isopropyl ether and the precipitated title D compound (10.93 g) was collected by suction-filtration (m.p. 189.5°-190.5° C.).
Analysis calc'd for C 19 H 18 NO 3 F 3 : C, 62.46; H, 4.97; N, 3.84; F, 15.59; Found: C, 62.70; H, 5.25; N, 3.76; F, 15.61.
E. 7-(Trifluoromethyl)-1,3,4,5-tetrahydro-4-(4-methoxyphenyl)-3-(p-toluenesulfonyloxymethyl)-2H-1-benzazepin-2-one
p-Toluene sulfonyl chloride (3.31 g, 17.36 mmole) was added with stirring to a solution of the title D compound (4.2 g, 11.57 mmole) in methylene chloride (75 ml) and pyridine (5 ml). The reaction mixture was stirred at room temperature for 6 hours, whereupon it was diluted with ethyl acetate and washed successively with water, 2N hydrochloric acid solution and water. The aqueous extracts were combined and extracted with ethyl acetate. The combined organic extract was dried over anhydrous magnesium sulfate and concentrated. The yellow residue was dissolved in methylene chloride (10 ml) and isopropyl ether (100 ml), cooled to -20° C. and the white precipitate was filtered to obtain 4.93 g of the title E compound. The mother liquor was concentrated and chromatographed on a silica gel column. Elution with 20-40% ethyl acetate in hexane afforded additional 430 mg of the title E compound for a total yield of 5.36 g, m.p. 170°-172° C.
Analysis calc'd for C 26 H 24 NF 3 O 5 S: C, 60.11; H, 4.66; N, 2.70; F, 10.97; S, 6.17; Found: C, 60.21; H, 4.77; N, 2.59; F, 10.92; S, 5.94.
F. 7-(Trifluoromethyl)-1,3,4,5-tetrahydro-4-(4-methoxyphenyl)-3-methylene-2H-1-benzazepin-2-one
To the title E compound (9.36 g, 18.0 mmole) in dimethylformamide (30 ml) was added diazabicycloundecene (DBU) (5.38 ml; 36 mmole; 2 eq) with stirring at room temperature. After 5 hours, the mixture was diluted in ethyl ether/ethyl acetate, washed three times with 1N hydrochloric acid, dried over magnesium sulfate and concentrated to give 7.08 g of the title F compound as a white solid, m.p. 181°-183° C.
Analysis calc'd for C 19 H 16 NF 3 O 2 : C, 65.70; H, 4.64; N, 4.03; F, 16.41; Found: C, 65.82; H, 4.77; N, 3.99; F, 16.70.
G. (cis)-7-(Trifluoromethyl)-1,3,4,5-tetrahydro-3-(methoxymethyl)-4-(4-methoxyphenyl)-2H-1-benzazepin-2-one
To a solution of 1.4 g of the title F compound (4.06 mmole) in 50 ml methanol was added with stirring 4 ml of a 4.37M solution of sodium methoxide in methanol (18.48 mmole). The suspension of enone went into solution upon addition of sodium methoxide solution. The homogeneous reaction mixture was heated at 60°-65° C. for 4 hours, whereupon it was cooled, diluted with ethyl acetate and thoroughly washed with water. The combined aqueous layer was extracted once with ethyl acetate. The ethyl acetate extract was dried over anhydrous magnesium sulfate, filtered and concentrated under reduced pressure. The residue was diluted with ethyl acetate, filtered over anhydrous magnesium sulfate (to remove some water carried in the ethyl acetate extract with methanol) and concentrated under reduced pressure. The crude residue was diluted with 100 mL ether, cooled to -20° C. overnight and the precipitated cis-methoxymethyladduct (420 mg) was filtered and washed with ether. The mother liquor was concentrated and chromatographed on a silica gel column. Elution with 10-50% ethyl acetate in hexane afforded an additional 153 mg of the title G compound, m.p. 220°-228° C.
Analysis calc'd for C 20 H 20 NF 3 O 3 .0.65H 2 O: C, 61.42; H, 5.49; N, 3.58; F, 14.57; Found: C, 61.31; H, 5.15; N, 3.57; F, 14.94.
H. (cis)-1-[2-(Dimethylamino)ethyl]-1,3,4,5-tetrahydro-3-(methoxymethyl)-4-(4-methoxyphenyl)-7-(trifluoromethyl)-2H-1-benzazepin-2-one, fumarate (1:1) salt
The title G compound (400 mg, 1.05 mmole) was dissolved completely in refluxing methyl ethyl ketone (10 ml) under argon. Potassium hydrogen carbonate (0.42 g, 4.2 mmole, 4 eq) was added to the solution, followed by dimethylformamide (3 ml) while maintaining the oil bath temperature at 85°-90° C. After stirring for 15 minutes, a 2.15M toluene solution of N,N-dimethyl-2-chloroethylamine (0.98 ml, 2.1 mmole) was added and heating was continued for 5 hours. The mixture was cooled, diluted with ethyl acetate, washed with water and sodium hydrogen carbonate, dried over magnesium sulfate and concentrated. The crude free amine material was purified over a silica gel eluting with 10% methanol in methylene chloride to yield 260 mg of pure cis free amine product. This material was dissolved in methanol and treated with an equivalent of fumaric acid to give 320 mg of the title compound, m.p. 152°-157° C.
Analysis calc'd for C 28 H 33 N 2 F 3 O 7 .0.32H 2 O: C, 58.76; H, 5.92; N, 4.90; F, 9.96; Found: C, 58.88; H, 5.97; N, 4.86; F, 10.12.
EXAMPLE 2
(cis)-1-[2-(Dimethylamino)ethyl]-1,3,4,5-tetrahydro-4-(4-methoxyphenyl)-3-[(methylthio)methyl]-7-(trifluoromethyl)-2H-1-benzazepin-2-one, fumarate (1:1) salt
A. 7-(Trifluoromethyl)-1,3,4,5-tetrahydro-4-(4-methoxyphenyl)-3-[(methylthio)methyl]-2H-1-benzazepin-2-one
To the title F compound of Example 1 (1.00 g, 2.88 mmole) in dimethylformamide (5 ml) was added sodiumthiomethoxide (300 mg, 4.28 mmole, 1.5 eq) with stirring at room temperature under an argcn atmosphere. After 15 minutes, the mixture was diluted with ether and washed twice with water, followed by saturated sodium chloride. The ether layer, which contained a white solid emulsion, was suction-filtered and the solid was rinsed twice with ether, and vacuum dried to yield 760 mg of the title A compound, m.p. 224°-226.5° C. (contains 90% cis and 10% trans).
B. (cis)-1-[2-(Dimethylamino)ethyl]-1,3,4,5-tetrahydro-4-(4-methoxyphenyl)-3-[(methylthio)methyl]-7-(trifluoromethyl)-2H-1-benzazepin-2-one, fumarate (1:1) salt
The title A compound (750 mg, 1.9 mmole) was dissolved in refluxing methyl ethyl ketone (20 ml) under argon. Potassium hydrogen carbonate (0.76 g, 7.6 mmole, 4 eq) was added to the solution while maintaining the oil bath temperature at 85°-90° C. After stirring for 15 minutes, a 2.15M toluene solution of N,N-dimethyl-2-chloroethylamine (1.8 ml, 3.8 mmole) was added, and heating was continued for 5 hours. The mixture was cooled, diluted with ethyl acetate, washed with water and 1N sodium hydrogen carbonate, dried over magnesium sulfate, and concentrated. The crude free amine product obtained after workup (960 mg) was crystallized from isopropyl ether/hexane. The pure cis product obtained from crystallization was dissolved in methanol and treated with one equivalent of fumaric acid with stirring and then concentrated and vacuum dried to yield 520 mg of the title compound as a white solid, m.p. 130°-134° C.
Analysis calc'd for C 28 H 33 N 2 F 3 O 6 S: C, 57.72; H, 5.71; N, 4.81; S, 5.50; F, 9.78; Found: C, 57.71; H, 5.86; N, 4.78; S, 5.47; F, 9.55.
EXAMPLE 3
(cis)-3-[2-(Acetyloxy)ethyl]-1-[2-(dimethylamino)ethyl]-1,3,4,5-tetrahydro-4-(4-methoxyphenyl)-7-(trifluoromethyl)-2H-1-benzazepin-2-one, monohydrochloride
A. 7-(Trifluoromethyl)-1,3,4,5-tetrahydro-3-methoxycarbonyl)-1-(methoxymethyl)-4-(4-methoxyphenyl)-2H-1-benzazepin-2-one
To a suspension of sodium hydride (360 mg, 7.5 mmole, 50% in oil dispersion/prewashed with dry ether several times) in dry dimethylformamide (30 ml), cooled at 0°-5° C. was added dropwise a solution of the title C compound of Example 1 (1.9 g, 5 mmole) in dry dimethylformamide (15 ml). The mixture was stirred for an additional 20 minutes at 0°-5° C., whereupon bromomethylmethyl ether (800 μl, 10 mmole) was added dropwise, and stirring was continued at this temperature for another hour. Excess sodium hydride was destroyed by the addition of water. The mixture was diluted with ether and washed with water. The aqueous layer was extracted three times with ethyl ether and the combined organic extracts were dried over magnesium sulfate and concentrated. The crude oily residue was flash chromatographed to obtain 1.67 g of the title A compound as a colorless oil.
B. 3-Allyl-1,3,4,5-tetrahydro-3-(methoxycarbonyl)-1-(methoxymethyl)-4-(4-methoxyphenyl)-7-(trifluoromethyl)-2H-1-benzazepin-2-one
To a suspension of sodium hydride (384 mg, 8 mole, 50% in oil dispersion) in dry dimethylformamide (35 ml), cooled in an ice-water bath, was added a solution of the title A compound (917 mg, 21 mmole) in dimethylformamide (8 ml) with stirring. After 30 minutes at 0°-5° C., allylbromide (1.5 ml) was added in one portion. The mixture was allowed to stand at 0°-5° C. for 3 additional hours, whereupon excess hydride was destroyed by the addition of water. The mixture was diluted with ether and washed with water. The aqueous layer was extracted three times with ether, and the combined ethyl ether extracts were dried over magnesium sulfate, and concentrated. The crude residue was flash chromatographed to obtain 905 mg of the title B compound as a white crystalline material.
C. 3-Allyl-1,3,4,5-tetrahydro-3-(methoxycarbonyl)-1-4(methoxyphenyl)-7-(trifluoromethyl)-2H-1-benzazepin-2-one
Concentrated sulfuric acid (8 ml) and anhydrous lithium bromide (720 mg, 8 mmole) were added to a suspension of the title B compound (905 mg, 1.9 mmole) in methanol (40 ml) with stirring. The reaction mixture was heated under reflux for 9 hours, and then allowed to stand overnight at room temperature. The acid was carefully neutralized by the addition of saturated sodium hydrogen carbonate solution and the mixture was extracted three times with ethyl acetate. The combined organic extracts were dried over magnesium sulfate and concentrated giving 858 mg of the title C compound as an off-white solid.
D. (cis)-3-Allyl-1,3,4,5-tetrahydro-4-(methoxyphenyl)-7-(trifluoromethyl)-2H-1-benzazepin-2-one
Lithium iodide (53.34 g, 0.4 mole) was added with stirring to a solution of the title C compound (42.94 g, 0.099 mole) in pyridine (300 ml), containing 1-2% water and the mixture was heated under reflux overnight. Most of pyridine was removed by distillation in vacuo. The residue was dissolved in chloroform and washed with 1N hydrochloric acid solution (4×) and saturated brine. The chloroform extract was dried over anhydrous magnesium sulfate and concentrated to obtain a reddish residue, which was triturated with methanol to obtain the pure cis - title D compound (19.87 g) as a white solid.
E. (cis)-7-(Trifluoromethyl)-1,3,4,5-tetrahydro-3-(2,3-dihydroxypropyl)-4-(4-methoxyphenyl)-2H-1-benzazepin-2-one
To a solution of the title D compound (1.86 g, 5 mmol) in distilled tetrahydrofuran (30 ml) was added 200 μl of osmium tetroxide solution (1 g in 10 ml of ether) with stirring. N-methylmorpholineN-oxide (880 mg, 6.5 mmol, 1.3 eq) in 3 ml of water was then added dropwise. The reaction mixture was allowed to stir at room temperature for 8 hours. The mixture was diluted with ethyl acetate and an aqueous sodium bisulfite solution was added. The biphasic reaction mixture was stirred for 10 minutes to reduce the osmate ester. The organic layer was then separated and the aqueous layer was extracted twice with methylene chloride. The combined organic extracts were dried over magnesium sulfate and concentrated giving 1.97 g of the title E compound as a white solid.
F. (cis)-7-(Trifluoromethyl)-1,3,4,5-tetrahydro-[2-(hydroxy)ethyl]-4-(4-methoxyphenyl)-2H-1-benzazepin-2-one
A solution of sodium metaperiodate (2.14 g, 10 mmol) in 10 ml of water was added dropwise with stirring to a solution of the title E compound (1.97 g, 5 mmol) in 30 ml of methanol cooled in an ice-water bath. A white precipitate formed immediately. After stirring for 30 minutes, the mixture was diluted with water and extracted 4 times with ethyl acetate. The combined extracts were dried over magnesium sulfate and concentrated to obtain the white crystalline aldehyde. This material was dissolved in 40 ml of tetrahydrofuran, cooled in an ice-water bath, and a solution of sodium borohydride (190 mg, 5 mmol) in 2 ml of water was added dropwise. The mixture was allowed to stand at 0°-5° C. for 30 minutes, whereupon excess borohydride was destroyed by dropwise addition of 2N hydrochloric acid. The mixture was diluted with ethyl acetate and washed several times with water. The combined aqueous layers were extracted twice with ethyl acetate. The organic extracts were dried over magnesium sulfate and concentrated. This material was flash chromatographed on silica gel yielding 1.43 g of the title F compound.
G. (cis)-3-[2-(Acetoxy)ethyl]-1,3,4,5-tetrahydro-4-(4-methoxyphenyl)-7-(trifluoromethyl)-2H-1-benzazepin-2-one
To a solution of the title F compound (1.1 g, 2.95 mmol) in methylene chloride (15 ml) and 5 ml of pyridine was added 3 ml of acetic anhydride with stirring. After stirring at room temperature for 8 hours, the mixture was diluted with ethyl acetate and washed with saturated copper sulfate solution. The combined copper sulfate extract was extracted twice with ethyl acetate. The combined organic layers were washed with water, dried over magnesium sulfate and concentrated to give an oily residue, which was flash chromatographed on silica gel using 25-50% ethyl acetate/hexane to give 1.1 g of the title G compound as a white solid.
H. (cis)-3-[2-(Acetyloxy)ethyl]-1-[2-(dimethylamino)ethyl]tetrahydro-4-(4-methoxyphenyl)-7-(trifluoromethyl)-2H-1-benzazepin-2-one, monohydrochloride
Potassium iodide (83 mg, 0.50 mmol) and the title G compound (880 mg, 2.09 mmol) were suspended in 20 ml of methyl ethyl ketone. N,N-dimethylaminoethyl chloride (2.15M in toluene, 1.25 ml, 2.69 mmol) was added and the mixture was refluxed for 8 hours. The mixture was concentrated and the residue dissolved in ethyl acetate and washed twice with water. The organic layer was dried over magnesium sulfate and concentrated leaving 980 mg of an oil which was flash chromatographed on silica gel using 0.1-3.0% methanol in methylene chloride. The pure cis-amine (obtained after a second chromatography on silica gel with 0.7-1.5% methanol in methylene chloride as eluents) was treated with etheral hydrogen chloride to obtain 480 mg of title H compound as a white solid, m.p. 206°-207° C.
Analysis calc'd for C 26 H 31 F 3 N 2 O 4 .HCl: C, 59.03; H, 6.10; N, 5.30; Cl. 6.70; F, 10.77; Found: C, 58.97; H, 6.11; N, 5.25; Cl, 6.68; F, 10.62.
EXAMPLE 4
(cis)-1-[2-(Dimethylamino)ethyl]-3-[(dimethylamino)methyl]-1,3,4,5-tetrahydro-4-(4-methoxyphenyl)-7-(trifluoromethyl)-2H-1-benzazepin-2-one, fumarate (1:2) salt
A. (cis)-3-[(Dimethylamino)methyl]-1,3,4,5-tetrahydro-4-(4-methoxyphenyl)-7-(trifluoromethyl)-2H-1-benzazepin-2-one, fumarate (1:1) salt
To the title F compound of Example 1 (1 g, 2.88 mmol) in 7 ml of toluene was added 5 ml of a 8.87M solution of dimethylamine in water (44 mmole) and 50 mg of benzyltrimethylammonium chloride. The mixture was heated under reflux with vigorous stirring for 2.5 hours, whereupon it was cooled and diluted with ether. The organic layer was separated, washed with water, dried over anhydrous magnesium sulfate and concentrated. The residue was diluted with ether and the precipitated white solid (750 mg) was filtered off. Crystallization from methanol provided 220 mg of pure cis-amine, which was dissolved in warm methanol and treated with one equivalent of fumaric acid to obtain 270 mg of the title A compound as a white solid, m.p. 166°-167° C.
Analysis calc'd for C 25 H 27 N 2 F 3 O 6 : C, 59.05; H, 5.35; N, 5.51; F, 11.21; Found: C, 59.01; H, 5.41; N, 5.84; F, 11.34.
B. (cis)-1-[2-(Dimethylamino)ethyl]-3-[(dimethylamino)methyl]-1,3,4,5-tetrahydro-4-(4-methoxyphenyl)-7-(trifluoromethyl)-2H-1-benzazepin-2-one, fumarate (1:2) salt
A solution of the title A free amine (560 mg, 1.43 mmol) in methyl ethyl ketone (10 ml) was treated with potassium hydrogen carbonate (570 mg, 5.7 mmole) and a 2.15M solution of N,N-dimethyl-2-chloroethylamine (1.33 ml, 2.85 mmole). The reaction mixture was heated under reflux for 4.5 hours, cooled and diluted with ethyl acetate and water. The ethyl acetate layer was separated, dried over anhydrous magnesium sulfate and concentrated. The residue (650 mg, mixture of cis and trans-products) was purified on silica gel plates with 15% methanol in methylene chloride to obtain 141 mg of Title B free amine product, which was dissolved in methanol and treated with 71 mg of fumaric acid (0.61 mmole, 2 eq) to provide 210 mg of the title B product as a white solid, m.p. 67°-69° C.
Analysis calc'd for C 33 H 40 N 3 F 3 O 10 .2.38H 2 O: C, 53.67; H, 6.11; N, 5.69; F, 7.72; Found: C, 53.85; H, 6.04; N, 5.58; F, 7.81.
EXAMPLES 5-28
Following the procedures described above and as outlined in Examples 1-4, the following additional compounds within the scope of the present invention can be made.
__________________________________________________________________________ ##STR36##Ex.No. X R.sub.1 R.sub.2 R.sub.3 R.sub.4 R.sub.5 R.sub.6 q__________________________________________________________________________ 5 S ##STR37## H CH.sub.3 7-CF.sub.3 4-OCH.sub.3 H 1 6 S ##STR38## CH.sub.3 CH.sub.3 6-CF.sub.3 4-OCH.sub.3 H 2 7 S C.sub.2 H.sub.5 CH.sub.3 CH.sub.3 ##STR39## 4-OCH.sub.3 H 1 8 S C.sub.3 H.sub.7 H CH.sub.3 7-CH.sub.3 4-CH.sub.3 H 3 9 S ##STR40## ##STR41## 7-C.sub.2 H.sub.5 4-OCH.sub.3 3-OCH.sub.3 110 S ##STR42## CH.sub.3 ##STR43## 7-CF.sub.3 F H 211 S ##STR44## ##STR45## CH.sub.3 6-CF.sub.3 4-OCH.sub.3 H 412 S CH.sub.3 CH.sub.3 ##STR46## 8-NO.sub.2 NO.sub.2 H 513 -- ##STR47## H ##STR48## 8-CH.sub.3 4-OCH.sub.3 H 114 -- ##STR49## ##STR50## ##STR51## 4-OCH.sub.3 H 215 O ##STR52## ##STR53## ##STR54## C.sub.2 H.sub.5 H 116 O ##STR55## ##STR56## H 7-CF.sub.3 CH.sub.3 H 117 O ##STR57## H CH.sub.3 ##STR58## ##STR59## H 218 O ##STR60## CH.sub.3 CH.sub.3 6-CF.sub.3 ##STR61## H 219 -- ##STR62## CH.sub.3 ##STR63## 7-CF.sub.3 4-OCH.sub.3 H 120 O CH.sub.3 H H 7-CF.sub.3 4-OCH.sub.3 3-OCH.sub.3 221 O C.sub.2 H.sub.5 C.sub.2 H.sub.5 CH.sub.3 7-CF.sub.3 4-OCH.sub.3 H 122 -- ##STR64## ##STR65## 7-CF.sub.3 4-OCH.sub.3 3-OCH.sub.3 223 O ##STR66## H CH.sub.3 8-CN 4-OCH.sub.3 H 124 O CH.sub.3 CH.sub.3 CH.sub.3 8-CH.sub.3 CN H 125 -- ##STR67## H CH.sub.3 8-CF.sub.3 4-CF.sub.3 H 226 -- ##STR68## C.sub.2 H.sub.5 C.sub.2 H.sub.5 7-CF.sub.3 4-OCH.sub.3 H 227 O ##STR69## ##STR70## CH.sub.3 6-CF.sub.3 4-OCH.sub.3 H 128 O ##STR71## ##STR72## CH.sub.3 7-CF.sub.3 4-OCH.sub.3 H 1__________________________________________________________________________
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A new class of benzazepine derivatives having the general formula ##STR1## including pharmaceutically acceptable salts, are disclosed. These compounds are useful as cardiovascular agents, particularly as vasodilators.
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FIELD OF THE INVENTION
The invention relates to the field of circuits for monitoring current flow in a secondary winding of a transformer by sensing current flow in a primary winding of the transformer. In particular, the invention relates to circuits for monitoring current flow in a secondary winding of a transformer which account for a magnetization current of the transformer by integrating a current in the primary winding over time.
BACKGROUND OF THE INVENTION
Fluorescent lamps have "negative resistance." This means that the operating voltage decreases as power dissipation in the lamp increases. Therefore, a circuit for supplying power to a fluorescent lamp requires a controllable alternating current power supply and a feedback loop that accurately monitors a current signal in the lamp in order to maintain operating stability of the circuit and to have an ability to control the lamp brightness. Such a circuit for supplying power to a fluorescent lamp may comprise a transformer wherein the lamp is coupled to a secondary winding of the transformer and is isolated from the rest of the circuit, including the sensing circuit, by the transformer. This makes directly sensing the lamp current signal difficult. Therefore, what is needed is a circuit for accurately sensing the current in a fluorescent lamp that is isolated from the sensing circuit by a transformer.
One such known circuit utilizes a resistor coupled in series with the transformer primary winding. During operation, a voltage signal across the resistor is monitored for utilization by the feedback loop. This voltage signal is multiplied by the resistance value to determine the current signal in the primary winding of the transformer. The current signal in the secondary winding is assumed to relate to the current signal in the primary winding by the ratio of turns between the primary and secondary windings. Therefore, the current signal in the secondary winding of the transformer is sensed indirectly by sensing the voltage signal across the resistor coupled in series with the primary winding.
Transformers, however, suffer from an operational characteristic that the above-described current sensing technique does not take into account. A Magnetization current of a transformer is the current required to produce magnetic flux in the transformer core. FIG. 1 shows a schematic diagram of an approximate equivalent transformer circuit which takes into account the magnetization current. In FIG. 1, the transformer comprises a primary winding Lp and a secondary winding Ls. An inductor Lm coupled in parallel with the primary winding Lp models the effects of the magnetization current Im. It can be seen from FIG. 1 that when an ac voltage signal Vp is applied to the primary winding Lp, the resulting current signal Ip is divided into the magnetization current signal Im and the effective current signal Ie. The magnetization current signal Im lags the voltage signal Vp by 90 degrees. In addition, the magnetization current signal Ie does not directly contribute to inducing current to flow in the secondary winding Ls. Therefore, the above-described technique of sensing current in a secondary winding of a transformer suffers from error caused by not taking the magnetization current into account.
Therefore, what is needed is a circuit for sensing a current signal in a secondary winding of a transformer by monitoring a current signal in a primary winding of the transformer which accounts for the magnetization current of the transformer.
SUMMARY OF THE INVENTION
The invention is a circuit that senses a current signal in a secondary winding of a transformer by monitoring a current signal in a primary winding of the transformer. The monitored current signal contains an effective current component and a magnetization current component. The magnitude of the effective current signal is related to the magnitude of the current signal in the secondary winding by the turns ratio of the transformer. The magnetization current signal produces flux in the transformer core and does not directly contribute to inducing current to flow in the secondary winding of the transformer. Therefore, it is desirable to eliminate the magnetization current from the current signal in the primary winding in order to accurately determine the current signal in the secondary winding. In addition, the magnetization current is 90 degrees out of phase with the effective current signal in the primary winding. The effective current signal in the primary winding is in phase with the voltage signal applied to the primary winding.
The invention integrates the monitored current signal over 0 degrees to 180 degrees of the effective current signal waveform. Since the magnetization current signal is 90 degrees out of phase with the effective current signal, the magnetization current signal component is cancelled from the monitored current signal by the integration operation. Therefore, the result of the integration operation is representative of a current signal in the secondary winding of the transformer and does not contain error caused by failing to take into account the magnetization current of the transformer. The result of the integration operation is used in a feedback loop to control the current in the secondary winding. In a preferred embodiment of the invention, a fluorescent lamp is coupled to the secondary winding of the transformer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic diagram of an approximate equivalent real transformer circuit which takes into account a magnetization current of the transformer.
FIG. 2 shows a schematic diagram of a controller circuit of the present invention.
FIG. 3 shows a schematic diagram of circuits external to the controller circuit of the present invention.
FIGS. 4A-4J show timing diagrams for signals of the circuits shown in FIGS. 2 and 3.
FIG. 5 shows a diagram of the primary current, the magnetization current and the effective current of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 2, a controller 300 of the present invention is shown. The present invention comprises a portion of the controller 300, however, the entire controller 300 is shown for illustrative purposes. The controller 300 preferably comprises an integrated circuit chip, but could be constructed from discrete components. Further, the controller 300 is preferably an integrated circuit chip controller available from Micro Linear Corporation, located at 2092 Concourse Drive, in San Jose, Calif. zip code 95131, under part number ML4878.
The controller comprises a minimum frequency bias circuit 301, a feed forward biasing circuit 302, an over voltage detector circuit 303, an oscillator and sync logic circuit 304, a zero crossing detector circuit 305, a feedback circuit 306, a linear regulator circuit 307, a bias & bandgap reference circuit 308, a negative edge delay circuit 309, a lamp out detector circuit 310, a duty cycle comparator circuit 311, a 50% duty cycle limit circuit 312, a dead time logic circuit 313 and a high side drive correction circuit 314. The controller also comprises a COMP pin 1, a CTLO pin 2, an ISNS pin 3, an RR pin 4, an RT pin 5, an ON/OFF pin 6, a DIM pin 7, a BATT pin 8, an OUTP pin 9, a VCC pin 10, an OUTN pin 11, a GND pin 12, a CHSC pin 13, and a VSNS pin 14.
The VSNS pin 14 is coupled to a non-inverting input to a comparator 315 and to a non-inverting input to a comparator 316. An inverting input to the comparator 315 is coupled to a voltage source of 0.25 volts. An inverting input to the comparator 316 is coupled to the ground node. An output of the comparator 315 is coupled to an S input to an R-S flip-flop 317 and to an S input to an R-S flip-flop 318. A Q output of the flip-flop 317 is coupled to a first input to an OR gate 319. A Q output of the flip-flop 318 is coupled a second input to the OR gate 319.
An output of the comparator 316 is coupled to a gate of an NMOSFET 320, to an input to an inverter 321, and to a first input to an AND gate 322. An output of the inverter 321 is coupled to a clock input to a T flip-flop 323, to a first input to an AND gate 324, and to a first input to an AND gate 325. An X-not output of the T flip-flop 323 is coupled to a second input to the AND gate 324, to a first input to an AND gate 326, to a first input to an AND gate 327, and to a first input to an AND gate 328. The output of the comparator 316 is also coupled to a second input to the AND gate 326. An X output of the T flip flop 323 is coupled to a second input to the AND gate 325, to a first input to an AND gate 329, to a second input to the AND gate 322, and to a first input to an AND gate 330.
An output of the AND gate 325 is coupled to an R input to the R-S flip-flop 318 and to a gate of an NMOSFET 331. An output of the AND gate 324 is coupled to an R input to the R-S flip-flop 317 and to a gate of an NMOSFET 332. An output of the AND gate 326 is coupled to an S input to an R-S flip-flop 333. A Q output of the R-S flip-flop 333 is coupled to a second input to the AND gate 329. An output of the AND gate 322 is coupled to an S input to an R-S flip-flop 334. A Q output of the R-S flip-flop 334 is coupled to a second input to the AND gate 327.
An output of the AND gate 329 is coupled to an inverting input to a transconductance amplifier 335. A non-inverting input to the transconductance amplifier 335 is coupled to a voltage source of 2.5 volts. An output of the transconductance amplifier 335 is coupled to an inverting input to a comparator 336, to a first terminal of a capacitor 337, to a drain of the NMOSFET 331, to an inverting input to a transconductance amplifier 338, and to an inverting input to a comparator 339. A second terminal of the capacitor 337 is coupled to a source of the NMOSFET 331 and to the ground node. A non-inverting input to the comparator 336 is coupled to a voltage source of 0.3 volts. An output of the comparator 336 is coupled to an R input to the R-S flip-flop 333. A non-inverting input to the transconductance amplifier 338 is coupled to a voltage source of 1.9 volts. An output of the transconductance amplifier 338 is coupled to an anode of a diode 340. A cathode of the diode 340 and a first terminal of a current mirror 341 are coupled to the transconductance amplifier 335 to control the gain of the transconductance amplifier 335.
An output of the AND gate 327 is coupled to an inverting input to a transconductance amplifier 342. A non-inverting input to the transconductance amplifier 342 is coupled to a voltage source of 2.5 volts. An output of the transconductance amplifier 342 is coupled to an inverting input to a comparator 343, to a first terminal of a capacitor 344, to a drain of the NMOSFET 332, to an inverting input to a transconductance amplifier 345, and to an inverting input to a comparator 346. A second terminal of the capacitor 344 is coupled to a source of the NMOSFET 332 and to the ground node. A non-inverting input to the comparator 343 is coupled to a voltage source of 0.3 volts. An output of the comparator 343 is coupled to an R input to the R-S flip-flop 334. A non-inverting input to the transconductance amplifier 345 is coupled to a voltage source of 1.9 volts. An output of the transconductance amplifier 345 is coupled to an anode of a diode 347. A cathode of the diode 347 and a second terminal of a current mirror 341 are coupled to the transconductance amplifier 342 to control the gain of the transconductance amplifier 342.
A third terminal of the current mirror 341 is coupled to a collector of an npn bipolar transistor 348. An emitter of the bipolar transistor 348 is coupled to an inverting input to a amplifier 349 and to the RT pin 5. A non-inverting input to the amplifier 349 is coupled to a voltage source of 2 volts. An output of the amplifier 349 is coupled to a base of the bipolar transistor 348. A fourth terminal of the current mirror 341 is coupled to a first terminal of a current mirror 350 and to a first terminal of a current mirror 351. A second terminal of the current mirror 350 is coupled to the RR pin 4. A third terminal of the current mirror 350 is coupled to the ground node. A second terminal of the current mirror 351 is coupled to control the gain of the transconductance amplifier 338. A third terminal of the current mirror 351 is coupled to control the gain of the transconductance amplifier 345.
An output of the OR gate 319 is coupled to a gate of an NMOSFET 352, to an input to an inverter 353, and to a first input to an OR gate 354. The ISNS pin 3 is coupled to a non-inverting input to a transconductance amplifier 355. An inverting input to the transconductance amplifier 355 is coupled to the ground node. An output of the transconductance amplifier 355 is coupled to a drain of the NMOSFET 320. A source of the NMOSFET 320 is coupled to a source of the NMOSFET 352, to a source of an NMOSFET 356, to a cathode of a 1.9 volt Zener diode 357, to a source of an NMOSFET 358, to a noninverting input to the comparator 339, to a non-inverting input to the comparator 346, and to the COMP pin 1. An anode of the diode 357 is coupled to the ground node. A drain of the NMOSFET 356 is coupled to a first terminal of a 5K ohms resistor 359. A second terminal of the resistor 359 is coupled to a voltage source of 0.3 volts. A drain of the NMOSFET 352 is coupled to a first terminal of a 100K ohms resistor 360. A second terminal of the resistor 360 is coupled to a voltage source of 0.4 volts.
An output of the inverter 353 is coupled to a gate of the NMOSFET 358. The DIM pin 7 is coupled to a non-inverting input to a transconductance amplifier 361. An inverting input to the transconductance amplifier 361 is coupled to a voltage source of 0.5 volts. An output of the transconductance amplifier 361 is coupled to a drain of the NMOSFET 358. The ON/OFF pin 6 is coupled to an input to a buffer 362. An output of the buffer 362 is coupled to an ON input to the linear regulator 307, and to an ON input to the bias & bandgap reference circuit 308. The BATT pin 8 is coupled to a power source for the linear regulator 307. The VCC pin 10 is coupled to the linear regulator 307. A REF terminal of the linear regulator is coupled to a REF terminal of the bias & bandgap reference circuit 308. An output UV of the bias & and bandgap reference circuit 308 is coupled to an input to the 40 us negative edge delay circuit 309.
An output of the negative edge delay circuit 309 is coupled to a gate of the NMOSFET 356, to a gate of an NMOSFET 363, to a first input to an AND gate 364, to a first inverted input to an AND gate 365, and to a first input to an OR gate 366. A drain of the NMOSFET 363 is coupled a non-inverting input to a comparator 367, to an output of a transconductance amplifier 368, and to the CTLO pin 2. A source of the NMOSFET 363 is coupled to the ground node. An inverting input to the comparator 367 is coupled to a voltage source of 3 volts. An output of the comparator 367 is coupled to a second input to the AND gate 364 and to a second input to the OR gate 354. An output of the OR gate 354 is coupled to a non-inverting input to the transconductance amplifier 368. An inverting input to the transconductance amplifier 368 is coupled to a voltage source of 2.5 volts. The transconductance amplifier is biased with a current of 1 μA.
An output of the AND gate 364 is coupled to an RS input to the flip-flop 323 and to a first inverting input to an AND gate 369. An output of the comparator 339 is coupled to a second input to the AND gate 330. An output of the comparator 346 is coupled to a second input to the AND gate 328. An output of the AND gate 330 is coupled to a first input to an OR gate 370. An output of the AND gate 328 is coupled a second input to the OR gate 370. An output of the OR gate 370 is coupled to an S input to an R-S flip-flop 371 and to a second input to the AND gate 369. A Q output of the flip-flop 371 is coupled to a third input to the AND gate 369. An output of the AND gate 369 is coupled to a second input to the AND gate 365 and to a non-inverting input to a transconductance amplifier 372. An inverting input to the transconductance amplifier 372 is coupled to a voltage source of 2.5 volts. A fifth terminal of the current mirror 341 is coupled to control the gain of the transconductance amplifier 372.
An output of the transconductance amplifier 372 is coupled to a first terminal of a capacitor 373 and to a non-inverting input to a comparator 374. A second terminal of the capacitor 373 is coupled to the ground node. An inverting input to the comparator 374 is coupled to the ground node. An output of the comparator 374 is coupled to an R input to the flip-flop 371. An output of the AND gate 365 is coupled to a first input to an OR gate 375. An output of the OR gate 375 is coupled to an input to a 100 ns delay circuit 376, to a first input to a NAND gate 377, and to a second input to the NOR gate 366. An output of the delay circuit 376 is coupled to a second input to the NAND gate 377 and to a third input to the NOR gate 366.
An output of the NOR gate 366 is coupled to an input to a buffer 378. An output of the buffer 378 is coupled to the OUTN pin 11. An output of the NAND gate 377 is coupled to an input to a buffer 379. An output of the buffer 379 is coupled to the OUTP pin 9 and to an input to an inverter 380. An output of the inverter 380 is coupled to a gate of an NMOSFET 381. A source of the NMOSFET 381 is coupled to the ground node. A drain of the NMOSFET 382 is coupled to the CHSC pin 13, to a cathode of a 2.1 volt Zener diode 382, and to a non-inverting input to a comparator 383. An inverting input to the comparator 383 is coupled a voltage source of 1.4 volts. An output of the comparator 383 is coupled to an input to a 200 ns positive edge delay circuit 384. An output of the positive edge delay circuit 384 is coupled to a second input to the OR gate 375. An anode of the diode 382 is coupled to the ground node. The GND pin 12 is coupled to the ground node.
FIG. 3 shows a schematic diagram of circuits external to the controller chip 300 of FIG. 2. Referring to FIG. 3, a voltage supply V+, such as a battery, is coupled to the BATT pin 8 of the controller 300, to a first terminal of a resistor 400, to a first terminal of a capacitor 401, to a cathode of a Zener diode 402, to a first terminal of a resistor 403, to a source of a PMOSFET 404 and to a first terminal of a capacitor 405. A second terminal of the resistor 400 is coupled to the RR pin 4 of the controller 300. A second terminal of the capacitor 401 is coupled to the CHSC pin 13 of the controller 300. An anode of the Zener diode 402 is coupled to a second terminal of the resistor 403, to a gate of the PMOSFET 404, and to a first terminal of a capacitor 406. A second terminal of the capacitor 406 is coupled to the OUTP pin 9 of the controller 300. A second terminal of the capacitor 405 is coupled to the ground node.
The DIM pin 7 of the controller 300 is coupled to be controlled by an external circuit for dimming the lamp. The VCC pin 10 of the controller 300 is coupled to a first terminal of a capacitor 407. A second terminal of the capacitor 407 is coupled to the ground node. The RT pin 5 of the controller 300 is coupled to a first terminal of a resistor 408. A second terminal of the resistor 408 is coupled to the ground node. The CTLO pin 2 of the controller 300 is coupled to a first terminal of a capacitor 409. A second terminal of the capacitor 409 is coupled to the ground node. The COMP pin 1 of the controller 300 is coupled to a first terminal of a capacitor 410. A second terminal of the capacitor 410 is coupled to the ground node.
The GND pin 12 of the controller 300 is coupled to the ground node. The ON/OFF pin 6 of the controller 300 is coupled to be controlled by an external circuit for turning the lamp on or off. The OUTN pin 11 of the controller 300 is coupled to a gate of an NMOSFET 411. A drain of the NMOSFET 411 is coupled to a drain of the PMOSFET 404 and to a first terminal of a capacitor 412. A source of the NMOSFET 411 is coupled to the ground node. A second terminal of the capacitor 412 is coupled to a first terminal of an inductor 413. A second terminal of the inductor 413 is coupled to a first terminal of a resistor 414, to a cathode of a Zener diode 415, to a first terminal of a capacitor 416, and to a first terminal of a primary winding 417 of a transformer 418. According to the "dot convention" for determining transformer winding polarities, the first terminal of the primary winding 417 is designated with a dot.
A second terminal of the resistor 414 is coupled to the VSNS pin 14 of the controller 300 and to a first terminal of a resistor 419. A second terminal of the resistor 419 is coupled to the ground node. An anode of the Zener diode 415 is coupled to an anode of a Zener diode 420. A cathode of the Zener diode 420 is coupled to the ground node. A second terminal of the capacitor 416 is coupled to the ground node. A second terminal of the primary winding 417 is coupled to a first terminal of a resistor 421 and to the ISNS pin 3 of the controller 300. A second terminal of the resistor 421 is coupled to the ground node.
A first terminal of a secondary winding 422 of the transformer 418 is coupled to a first terminal of a cold cathode fluorescent lamp 423. According to the "dot convention," the first terminal of the secondary winding 422 is designated with a dot. A second terminal of the secondary winding 422 is coupled to a second terminal of the fluorescent lamp 423.
FIGS. 4(A-J) show timing diagrams for signals of the circuit shown in FIGS. 3 and 4. Referring to FIG. 4(A), BATT is the input signal to the BATT pin 8 of the controller 300 as shown in FIG. 3. VSNS is representative of the signal applied to the fluorescent lamp 423 shown in FIG. 4(B) and is the signal applied to the VSNS pin 14 of the controller 300 shown in FIGS. 2 and 3. Recall that an object of the invention is to drive a lamp with a resonant circuit at its resonant frequency by inputting pulses to the resonant circuit wherein the pulses are centered about a zero crossing of the lamp signal VSNS. ZX is the signal at the output of the comparator 316 of FIG. 2. The comparator 316 serves as a zero crossing detector for the signal VSNS applied to the lamp 423. The signal ZX is at a logical high voltage level when the signal VSNS is above zero volts and at a logical low voltage level when the signal VSNS is below zero volts. The X signal of FIG. 4(D) is obtained by the logic circuits coupled to the output of the comparator 316. The RAMPA signal of FIG. 4(F) is the voltage across the capacitor 337 of FIG. 2. The RAMPB signal of FIG. 4(G) is the voltage across the capacitor 344 of FIG. 2.
The DCMP signal is representative of the centered pulse signal used to drive the resonant lamp circuit. The DCMP signal is formed by logic of the duty cycle compare circuit 311 and the oscillator and sync logic circuit 304 which combine the outputs of the comparator 339 and the comparator 346 such that the pulses in the DCMP signal are alternately formed by the RAMPA comparison and the RAMPB comparison, as described above. This is effected by the X and X-not outputs of the flip-flop 323 which are coupled to the AND gates 330 and 328.
Referring to FIG. 4(F), the RAMPA signal, having been discharged by the transistor 331, begins at zero volts prior to a first positive zero crossing 1 of the VSNS signal. When the first positive zero crossing 1 of the VSNS signal is reached, at approximately the time T1, as detected by the comparator 316, the logic circuits of the oscillator and sync logic circuit 304 of FIG. 2 cause the transconductance amplifier 335 to begin charging the capacitor 337 at a rate determined by the biasing signal to the transconductance amplifier 335. The rate of charging the capacitor 337 is represented by the slope of the RAMPA signal. At the next negative zero crossing of the VSNS signal, at the time T3, the logic circuits of the oscillator and sync logic circuit 304 cause the capacitor 337 to begin discharging at the same rate that it was charged. When the voltage on the capacitor 337 reaches approximately zero (actually 0.3 volts as determined by the voltage at the non-inverting input to the comparator 336), at the time T6, the logic circuits of the oscillator and sync logic circuit 304 stop discharging the capacitor 337 and begin charging the capacitor 337.
The RAMPA signal, which represents the voltage stored on the capacitor 337, is compared by the comparator 339 of FIG. 2 to a voltage on the COMP pin 1 of the controller as shown in FIG. 2. The COMP pin 1 voltage level is an error signal formed by the brightness level set on the DIM pin 7 and the feedback signal from the ISNS pin 3. This brightness signal is shown as a horizontal dotted line superimposed on the RAMPA signal of FIG. 4(F). The output of the comparator 339 is shown by the pulse in the DCMP signal of FIG. 4(H) beginning at time T5 and ending at the time T7. This pulse is centered about the zero crossing of the signal VSNS at approximately the time T6 and is used to drive the lamp resonant circuit. At the time T9, the oscillator and sync logic circuit 304 rapidly discharges the capacitor 337 through the transistor 331. The RAMPA signal then remains low until the third positive zero crossing 3 of the signal VSNS at approximately the time T12 and the cycle described above repeats.
The RAMPB signal is the voltage on the capacitor 344. Referring back to approximately the time T3, the capacitor 344 is rapidly discharged by the oscillator and sync logic circuits 304 through the transistor 332. At the second positive zero crossing 2 of the signal VSNS, which occurs at approximately the time T6, the capacitor 344 begins to be charged by the transconductance amplifier 342 at a rate determined by the biasing signal to the transconductance amplifier 342. At the time T9, when the signal VSNS reaches a negative zero crossing, the capacitor 344 is discharged by the oscillator and sync logic circuit 304 at the same rate that it was charged. At the time T12, when the voltage on the capacitor 344 reaches approximately zero (actually 0.3 volts as determined by the voltage at the non-inverting input to the comparator 343), the oscillator and sync logic circuit 304 stops discharging the capacitor 344 and begins charging the capacitor 344.
The RAMPB signal, which represents the voltage stored on the capacitor 344, is compared by the comparator 346 of FIG. 2 to a voltage level on the COMP pin 1 of the controller as shown in FIG. 2. The COMP pin 1 voltage level is an error signal formed by the brightness level set on the DIM pin 7 and the feedback signal from the ISNS pin 3. This brightness signal is shown as a horizontal dotted line superimposed on the RAMPB signal of FIG. 4(G). The output of the comparator 346 is shown by the pulse in the DCMP signal of FIG. 4(H) beginning at time T11 and ending at the time T13. This pulse is centered about the zero crossing of the signal VSNS at approximately the time T12 and is used to drive the lamp resonant circuit. At the time T14, the oscillator and sync logic circuit 304 rapidly discharges the capacitor 344 through the transistor 331. The RAMPB signal then remains low until the fourth positive zero crossing 4 of the signal VSNS and the cycle described above repeats.
Thus, a circuit for centering pulses about a zero crossing without using a phase comparator or phase locked loop has been described. Rather, the signals RAMPA and RAMPB are synchronously interleaved to obtain the object of the invention. Two ramp signals RAMPA and RAMPB are needed, rather than a single ramp signal, because it is not assured that the zero crossings will coincide precisely with the capacitors 339 and 344 being discharged to zero approximately volts (0.3 volts). For this reason, the capacitors 339 and 344 are rapidly discharged at the times T9 and T14, respectively. However, it will be apparent that a single ramp signal could be used to generate all the pulses in the DCMP signal, but with reduced accuracy in centering the pulses about zero crossings of the VSNS signal.
The invention synchronizes the pulses of the DCMP signal to the sinusoidal signal VSNS within only one cycle, whereas, a phase locked loop could take longer or could fail to synchronize at all.
Referring to FIG. 4(F), it can be seen that the RAMPA signal changes slope at the times T2 and T4, and the RAMPB signal changes slope at the times T8, and T10. To achieve the object of centering the pulses about a zero crossing, it is important that each of the capacitors be charged and discharged at the same rates. For example, from the time T1 to the time T6, the RAMPA signal must be symmetrical about the time T3 and from the time T6 to the time T12, the RAMPB signal must be symmetrical about the time T9. As described above, the RAMPA and RAMPB signals are compared to the voltage level shown by the dotted line superimposed on the RAMPA and RAMPB signals shown in FIGS. 4(F and G). Therefore, the level of the voltage on the capacitor 337 or 344 is not important so long as the voltage level on the capacitor 337 or 344 is higher than the voltage COMP represented by the dotted line and so long as the capacitors are charged and discharged at equal rates.
The rate at which the capacitor 337 is charged depends upon the bias current to the transconductance amplifier 335. The bias current to the transconductance amplifier 335 has two components. A first component is provided by the current mirror 341. A second component is provided by the transconductance amplifier 338 through the diode 340. The diode 340 prevents current from entering the output of the transconductance amplifier 338. Similarly, the rate at which the capacitor 344 is charged depends upon the bias current to the transconductance amplifier 342. The bias current to the transconductance amplifier 342 also has two components. A first component is provided by the current mirror 341. A second component is provided by the transconductance amplifier 345 through the diode 347. The diode 347 prevents current from entering the output of the transconductance amplifier 345.
At the time T1, upon the first positive zero crossing of the signal VSNS, the output of the AND gate 329 is a logical low voltage, the voltage on the capacitor 337 is below 1.9 volts, and the transconductance amplifier 335, biased by both the current mirror 341 and the transconductance amplifier 338, charges the capacitor 337. Once the voltage on the capacitor 337 reaches 1.9 volts, at the time T2, the transconductance amplifier 338 stops providing biasing current to the transconductance amplifier 335 so that the capacitor 337 is charged at a slower rate, as shown by the reduced slope of the RAMPA circuit between the times T2 and T3. Then, once the negative zero crossing of VSNS occurs, at the time T3, the capacitor 337 is discharged at the slower rate until the capacitor 337 is discharged to below 1.9 volts. Once the capacitor 337 is discharged to below 1.9 volts, at the time T4, the transconductance amplifier 338 causes the rate at which the transconductance amplifier 335 discharges the capacitor 337 to increase again to correspond to the rate that the capacitor 337 was charged between the times T1 and T2.
Similarly, once the voltage on the capacitor 344 is above 1.9 volts, the rate at which the transconductance amplifier charges and discharges the capacitor 344 is reduced because the transconductance amplifier 345 stops providing an additional biasing current to the transconductance amplifier 342. When the voltage on the capacitor 344 is below 1.9 volts, the rate at which the transconductance amplifier 342 charges the capacitor 344 is increased because the transconductance amplifier 345 provides the additional biasing current.
A benefit of this technique is that the voltage headroom required for the signals RAMPA and RAMP3 is reduced (i.e. lower supply voltage levels are required) while maintaining a relatively high gain when the RAMPA and RAMPB signals are below the 1.9 volt threshold. This relatively high gain increases the accuracy of the pulse widths and the ability to control the slope of the RAMPA and RAMPB signals increases the ability to control the pulse widths of the DCMP signal.
If voltage on the external resistor 400, illustrated in FIG. 3 increases, current into the RR pin 4 of the controller 300 will increase, as shown in FIG. 4 by the transition in the signal BATT at the time T15 to the time T16, and the capacitors 337 and 344 will be charged even more rapidly than described above. This results in a steeper slope in the RAMPA and RAMPB signals. Thus, the pulses in the DCMP signal are narrower to reflect the reduced duty cycle required to maintain a given lamp brightness. This is achieved by the current mirrors 350 and 351 increasing the biasing current to the transconductance amplifiers 338 and 345. Thus, when the RAMPA and RAMPB signals are below 1.9 volts, the slope is increased in comparison to the slope which results when BATT is at the lower level. When the RAMPA and RAMPB signals are above 1.9 volts, the slope is the same as when BATT is at the lower level because the bias current provided by the current mirror 341 is not increased when BATT is at the higher level. Thus, another means for controlling the slope of the RAMPA and RAMPB signals is disclosed. It will be apparent that any number of different slopes which are selected based on any criteria could be employed, or a constant slope could be employed.
FIG. 5 shows a diagram of the primary current signal Ip, the magnetization current signal Im and the effective current signal Ie of FIG. 1. The magnitude of the magnetization current signal Im is exaggerated in FIG. 5 for illustrative purposes. Recall that an object of the invention is to determine the value of the effective current signal Ie by monitoring only the primary current signal Ip. The value of the secondary current signal Is (FIG. 1) can then be determined by multiplying the effective current signal Ie by the ratio of turns of the primary winding to the secondary winding. The invention achieves this object by integrating the primary current signal Ip from the time TA to the time TB which is 0 to 180 degrees of the effective current signal Ie. This removes the effect of the magnetization current signal Im from the primary current signal Ip because the magnetization current Im is 90 degrees out of phase with the voltage Vp across the primary winding Lp. As can be seen from FIG. 5, the magnetization current Im crosses the zero axis half-way between the time TA and the time TB. Therefore, integrating the magnetization current signal Im over the period TA to TB has zero as a result.
As stated previously, VSNS is representative of the signal applied to the fluorescent lamp 423 shown in FIG. 4 and the signal applied to the VSNS pin 14 of the controller 300 shown in FIG. 2. Therefore, the signal VSNS in FIGS. 2 and 3 is represented by the signal Vp in FIG. 1. The signal across the resistor 421 of FIG. 3 which is coupled to the ISNS pin 3 of the controller 300 is proportional to the current through the primary winding 417 of FIG. 3 and is represented by the current Ip in FIG. 5. Therefore, a magnetization current can be eliminated from the circuits of FIGS. 2 and 3 by integrating the signal coupled to the ISNS pin 3 during periods when the signal VSNS is above the ground level.
Referring to FIGS. 2 and 3, the voltage at the VSNS pin 14 of the controller 300 is compared to ground by the comparator 316. As can be seen from FIG. 5, the output ZX of the comparator 316 is at a logical high voltage when the signal VSNS is above the ground level. The periods during which the signal VSNS is above the ground level (when ZX is a logical high voltage) correspond to the periods during which it is desired to integrate the signal coupled to the ISNS pin 3 of the controller 300. Therefore, the integration occurs during periods when the signal ZX is a logical high voltage. As can be seen from FIG. 2, the signal coupled to the ISNS pin 3 of the controller is coupled to the non-inverting input of the transconductance amplifier 355. The inverting input to the transconductance amplifier is coupled to the ground node. Therefore, the transconductance amplifier 355 will source current when the signal on the ISNS pin 3 of the controller 300 is above the ground level and will draw current when the signal on the ISNS pin 3 is below the ground level.
When the signal ZX is a logical high voltage, the transistor 320 is turned on so that the output of the transconductance amplifier 355 charges or discharges the capacitor 410 coupled to the COMP pin 1 of the controller 300 (FIG. 3). A portion of the voltage on the capacitor 410 is proportional to the result of the integration operation and is coupled to the non-inverting inputs to the comparators 339 and 346 of FIGS. 2 and 3. The voltage on the DIM pin 7 also contributes to the voltage on the capacitor 410. The comparators 339 and 346 comprise a feedback loop for controlling a current in the lamp 423. As explained in reference to FIG. 5, the level of the dotted lines superimposed on the RAMPA and RAMPB signals is applied to the non-inverting inputs of the comparators 339 and 346. The level of the dotted lines is controllable from the DIM pin 7 of the controller.
The present invention has been described in terms of specific embodiments incorporating details to facilitate the understanding of the principles of construction and operation of the invention. Such reference herein to specific embodiments and details thereof is not intended to limit the scope of the claims appended hereto. It will be apparent to those skilled in the art that modifications may be made in the embodiments chosen for illustration without departing from the spirit and scope of the invention.
Specifically, it will be apparent to one of ordinary skill in the art that the device of the present invention could be implemented in several different ways and the apparatus disclosed above is only illustrative of the preferred embodiment of the invention and is in no way a limitation. For example, it would be within the scope of the invention to vary the values of the various components and voltage levels disclosed herein. It will be apparent that transistors of one type, such as NMOS, PMOS, bipolar pnp or bipolar npn can be interchanged with a transistor of another type, and in some cases interchanged with diodes, with appropriate modifications, and so forth. Also a switch may be implemented with a transistor of any type. Further, the logic circuits of the oscillator and sync logic circuit 304 could be implemented in many different ways while remaining within the spirit and scope of the invention.
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A circuit that senses a current signal in a secondary winding of a transformer by monitoring a current signal in a primary winding of the transformer. The monitored current signal contains an effective current component and a magnetization current component. The magnitude of the effective current signal is related to the magnitude of the current signal in the secondary winding by the turns ratio of the transformer. The magnetization current signal produces flux in the transformer core and does not contribute to producing current in the secondary winding of the transformer. In addition, the magnetization current is 90 degrees out of phase with the effective current signal in the primary winding. The effective current signal in the primary winding is in phase with the voltage signal applied to the primary winding. The invention integrates the monitored current signal over 0 degrees to 180 degrees of the effective current signal waveform. Since the magnetization current signal is 90 degrees out of phase with the effective current signal, the magnetization current signal component is cancelled from the monitored current signal by the integration operation. Therefore, the result of the integration operation is representative of a current signal in the secondary winding of the transformer and does not contain error caused by the magnetization current of the transformer. The result of the integration operation is used in a feedback loop to control the current in the secondary winding. In a preferred embodiment of the invention, a fluorescent lamp is coupled to the secondary winding of the transformer.
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BACKGROUND OF THE INVENTION 1. Field of the Invention
This invention relates generally to concrete building structures and more particularly is directed to an improved method and apparatus for precasting concrete building elements in vertical molds and to a building construction utilizing as the principal structural elements a plurality of similar concrete L-shaped wall units and flat roof slabs precast thereby. 2. Description of the Prior Art
In order to reduce labor costs and save time in erecting and dismantling the forms required in poured concrete wall and roof construction, various means and methods have been devised to precast concrete wall units usually at remote manufacturing facilities requiring expensive equipment as well as costs for transporting and handling the precast units in delivery to the building site. Although precasting has been performed in molds disposed both horizontally and vertically, both methods require in excess of twelve hours for the concrete to be sufficiently cured to permit vertical lifting out of the mold for the latter's reuse. Steam curing and/or use of additives to the concrete mix reduces this time to between six to eight hours, but is a much more costly procedure.
Likewise, to reduce building costs and improve efficiency, particularly in erecting bungalow type single family dwellings, various units, precast and prefabricated as entire room units, entire wall units, made in a wide variety of sizes and configurations, as segmental units and as individual panels, have been proposed and used. Each of these units has its own disadvantages and drawbacks, including requirements for costly manufacturing plant facilities, special on site erecting equipment and transportation means from point of manufuacture. There is, therefore, a need, particularly in low cost housing, which this invention satisfies, for a durable concrete building capable of being erected by taking advantage of the economy of precast units while eliminating costly plant and transportation facilities and also having an inexpensive system for assembling the precast units into a completed structure.
SUMMARY OF THE INVENTION
Among the objects of the invention is to provide a method and apparatus for precasting poured concrete building units on an accelerated time schedule producing at least three unit per mold per day yet eliminating costly steam curing and concrete mix additives. The precasting apparatus shall utilize readily constructable plywood faced, vertically disposed mold forms mounted for easy handling, separation and reuse. The method, utilizing such separable mold forms shall be capable of being performed at the building site having conventional concrete mixing and pouring facilities.
The apparatus and method embodying the invention is particularly adapted to precasting freestanding L-shaped wall units and pairs of relatively flat roof slabs. The apparatus essentially comprises a mold having three separable parts, namely, a mold bottom and two opposite vertical sidewalls, each mounted on wheels for transport on a horizontal surface. The wheeled mold bottom is sized and shaped to support a molded unit freestanding in vertical position as cast and the opposite side walls are adapted to separate from a closed position in operative engagement with the mold bottom to an open position spaced a sufficient distance from each other to enable the mold bottom carrying a partially cured concrete molded unit to be wheeled horizontally on the surface to a position completely free of the vertical sidewalls to complete the curing of the unit and to be replaced by another wheeled mold bottom for reuse of the mold.
The method, embodying the invention, maximizes utilization of relatively inexpensive molding equipment whereby unit production is increased on the order of three times while maintaining labor costs at a minimum. The method comprises pouring mixed concrete of any conventional formulation, that is, without special additives for accelerating the curing time, into the mold cavity which has been assembled from the hereinbefore described three separable and wheel mounted parts. The concrete is maintained in the mold for a period of 21/2 to 3 hours at which time the molded unit will have sufficiently cured, that is, set, to be capable of freestanding without the aid of the mold sidewalls. The mold is then disassembled by wheeling the opposite vertical walls apart to release the bottom support bearing the partially cured concrete unit for rolling horizontally on its wheels to a position clear of the sidewalls where the unit completes its curing to a condition for handling by vertical lifting. During this final curing time interval, which may be upwards of 10 hours, other wheeled bottoms are sequentially assembled with the vertical sidewalls into immediately usable molds and the cycle repeated.
The precast L-shaped units serve as the sole vertical support means for a building and are arranged on a poured concrete foundation in a predetermined relation. One L-shaped unit is located at each of the corners of the building providing adjacent exterior wall portions. Spaced between the corners, one section of one or more L-shaped units provides an intermediate exterior wall portion, while the other right angularly disposed section, when extending inwardly, forms part of an interior wall or partition, or when projecting outwardly may serve as a wind breaker, decorative wall or part of an outside utility shed.
The freestanding characteristics of the L-shaped units contribute to the simplicity of their attachment to the foundation requiring a single anchoring means for each section of the unit. Such anchoring means, located in a cutout formed in the bottom of each section, comprises a pair of threaded tie rods, one embedded in the section wall, the other in the foundation, projecting into the cutout in substantially axial alignment so that the free ends thereof are spaced from each other. The free ends of the tie rods are interconnected by projecting through aligned openings formed in opposite parallel arms of a U-shaped bracket and have nuts threaded thereon and tightened against the interior surface of the bracket.
A metal H-beam extends the length of each exterior wall as an upper coplanar border thereof and seats on the top edges of the exterior wall sections of the L-shaped units, which top edges extend into the downfacing trough of the H-beam. The upfacing trough of the H-beam provides a permanent form for reinforced poured concrete combining therewith as a strengthened reinforced composite structure which carries the roof and serves as lintels across the spaces between the wall sections. The poured concrete in the H-beam also receives tie rods extending up from the wall sections and has other tie rods embedded therein to extend upwardly between the roof slabs as anchoring means therefor.
The reinforced concrete roof slabs are of a length to extend between and overlap a pair of opposite exterior walls of the building and have upfacing sides with thickened peripheral edge borders. The slabs are placed side by side longitudinally with flat downfacing sides resting on the concrete filled H-beams. A metal channel has a cross-section which conforms to the width of two adjacent upper flat surfaces and the two downwardly extending interior sides of the thickened edge borders and rests thereon as part of a tie-down joint. The tie rods, which are embedded in the concrete of the H-beams and extend upwardly between the adjacent thickened edge borders, have threaded ends extending through aligned openings in the metal channel and are engaged by nuts which complete the tie-down joint anchoring means for the roof slabs.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a one story building embodying the invention showing L-shaped wall units positioned on the foundation and having interconnecting H-beams extending across the tops thereof preparatory to completing the roof, two roof slabs being shown in place on the H-beams.
FIG. 2 is a vertical sectional view taken through one of the intersecting sections of an L-shaped mold embodying the invention for precasting an L-shaped wall unit similar to those shown in FIG. 1, the mold being in closed position and filled with poured concrete.
FIG. 2A is a diagrammatical plan view of the mold shown in FIG. 2 illustrated in open position preparatory to wheeling the partially cured concrete L-shaped unit from between the separated vertical mold sections.
FIG. 3 is a vertical sectional view of a mold for the roof slabs shown in closed position and filled with poured concrete.
FIGS. 4 and 5 are vertical sectional views taken on lines 4--4 and 5--5, respectively, in FIG. 1, but with all roof slabs in position.
FIG. 6 is an enlarged fragmentary sectional view of the roof and top portion of the wall taken on a line similar to FIG. 5, parts being broken away to show details of the H-beam and the attachment of the roof slabs to the wall units.
FIG. 7 is a sectional view taken on line 7--7 in FIG. 6.
FIG. 8 is an enlarged fragmentary elevational view as seen along line 8--8 in FIG. 1 showing details of the means for anchoring the L-shaped wall units to the foundation, and
FIG. 9 is a sectional view taken on line 9--9 in FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring in detail to the drawings, 10 denotes a vertical L-shaped molding apparatus for precasting wall units 20, each having two wall sections 20a and 20b integrally formed in right angular, L-shaped, relation. Molding apparatus 10 is shown in FIGS. 2 and 2A to have inner and outer separable, vertical sidewall forms 11 and 12, each comprising a pair of wall sections 11a, 11b and 12a, 12b, respectively, disposed in right angular relation and having plywood mold surfaces 11c and 12c supported by a suitable framework in an upstanding position on a plurality of spaced wheels 13, which may be mounted as castors for omnidirectional and independent transport of the forms 11 and 12 on a horizontal surface S. The supporting framework for each of the wall sections 11a, 11b and 12a and 12b, as seen in the drawing, may include horizontally extending and vertically spaced beams or timbers 14, vertically extending and horizontally spaced beams or timbers 14a and one or more vertically extending trusses 14b. Additional structure (not shown), including timbers 14, 14a and trusses 14b spaced closer together along each wall section, may be provided for the framework as required by the weight of the concrete unit 20 to be poured and bracing means (not shown) may also be used for retaining each pair of wall sections 11a, 11b and 12a, 12b in proper right angular relation.
The bottom 15 of molding apparatus 10 has an L-shaped configuration and is also mounted on wheels 13 for omnidirectional transport on surface S independently of sidewall forms 11 and 12. As seen in FIG. 2, mold bottom 15 may be formed as a pair of U-shaped steel channels arranged at right angles and mounted in an inverted position on wheels 13 to provide a flat surface for the bottom wall of the mold. A plurality of threaded rods 16, terminating at opposite ends in nuts 16a, serve to releasably secure the wheeled bottom wall 15 between the wheeled sidewall forms 11 and 12 as a closed operative mold. To avoid passing through the concrete structure, rods 16 may be located to extend through the space below the U-shaped channels provided by wheels 13 and above the level of the concrete when poured and may engage sidewall forms 11 and 12 by extending through opposite ends of the vertical timbers 14a.
End walls for the mold may be provided by any suitable means, which, in FIG. 2A, are indicated as vertical timbers 11d carried on the mold face of wall sections 11a and 11b. In practice, end closure timbers 11d, or the like, may be separate and removable from engagement between sidewall forms 11 and 12 prior to opening the mold. Readily removable clamps (not shown, but conventional in the art) may be located beyond end closure timbers 11d or any other end wall structure to secure sidewall forms 11 and 12 together in closed position.
A modified form of apparatus 10 is shown in FIG. 3 as molding apparatus 50 for precasting substantially flat and elongated concrete roof slabs 25, each having, as seen in FIGS. 1, 6 and 7, a flat bottom side 25a and an upfacing side formed with a thickened peripheral border 26 and an intermediate transverse rib 25c. Roof slabs 25 may be cast in pairs, each standing on a longitudinal side with the plane of the bottom side 25a disposed vertically and facing each other in back-to-back relation.
Molding apparatus 50 comprises a pair of vertical sidewall forms 51, having plywood mold surfaces 51a which are suitably contoured to mold peripheral border 26 and transverse rib 25c in the upfacing side of each slab 25, and a mold bottom plate 55 which supports a vertically extending spacer 54 having opposite plywood mold surfaces 54a to mold the flat bottom side 25a of each of the back-to-back roof slabs 25. Plywood mold surfaces 51a are each suitably supported by a framework 52 which is mounted on a plurality of spaced wheels 53 for independent and separate transport of forms 51 on horizontal surface S. The bottom plate 55 is supported on a pair of longitudinally extending parallel spaced channels 55a, one beneath each mold cavity provided between mold surfaces 51a and 54a and mounted on a plurality of spaced wheels 53 for transport of bottom plate 55 on surface S independently of sidewall forms 51. A plurality of spaced threaded rods 56, each terminating at opposite ends in nuts 56a, serve to releasably retain wheeled bottom plate 55 between wheeled sidewall forms 51 as a closed operative mold, and, in the same manner as rods 16 in apparatus 10, may be located above and below the poured concrete. Removable end walls (not shown) are suitably mounted at opposite ends between sidewall forms 51 to complete the double cavities for molding roof slabs 25. A bracing means (not shown) may also be mounted on wheels and project in angular relation from the framework 52 as part of each sidewall form 51 to add stability to and retain the latter in vertical upright position when wheeled apart to an open mold position.
The operation of apparatus 10 and 50 in the manufacture of precast concrete wall units 20 and roof slabs 25, respectively, involves the method embodiment of the invention as will now be apparent. Molding apparatus 10 is assembled as shown in FIG. 2 and preparatory to pouring a concrete mix of any conventional formulation, but without any setting time accelerators to increase the cost thereof, a latticework of reinforcing rods 20c and various tie rods, as hereinafter more fully described, and conventional lifting rings or hooks (not shown) are properly positioned within the mold cavity. Also, suitably shaped and dimensioned wood blocks (not shown) may be positioned on bottom 15 to provide the cutouts 21 from the bottom edges of wall sections 20a and 20b as seen in FIGS. 8 and 9. After pouring the mixed concrete through the open top of the mold cavity and, with the aid of vibrators (not shown), filling the mold to the proper level to form wall unit 20, all of which is performed in the manner and by equipment well known in the art, molded wall unit 20 is permitted to remain in the closed mold until capable of freestanding without the aid of mold sidewalls 11 and 12. This capability requires a time interval of 21/2 to 3 hours, after which time rods 16 are removed, enabling sidewall forms 11 and 12 to be separated from bottom 15 and rolled apart on wheels 13 to a relative position as indicated in FIG. 2A. Bottom 15, carrying partially cured wall unit 20, may now be rolled on its wheels 13 to a location on horizontal surface S completely clear of the separated sidewall forms 11 and 12. A replacement bottom 15 is then rolled into position and assembled with sidewall forms 11 and 12 to ready the mold cavity for immediate installation of the reinforcing rod latticework and the tie rods and the pouring of concrete for the next wall unit 20. Several concrete pourings, utilizing the same sidewall forms 11 and 12 with different bottoms 15, are performed and partial curings achieved while each wall unit 20 remains in its freestanding position on its wheeled bottom 15 completing its curing process requiring upwards of 10 additional hours until completely set and ready for vertical lifting by conventional crane equipment from bottom 15 and transporting to a location on the building foundation to serve in the manner hereinafter described as a vertical structural wall element.
Molding apparatus 50 is assembled as shown in FIG. 3 with spacer 54 mounted on bottom plate 55 and preparatory to pouring the concrete mix, latticework of reinforcing rods 25b, and if required, lifting rings or hooks (not shown), are properly positioned within the back-to-back mold cavities. The method whereby roof slabs 25 are precast in apparatus 50 being similar to that hereinbefore described for wall unit 20. Thus, after an elapse of 21/2 to 3 hours for partial curing of roof slabs 25, rods 56 are removed and sidewall forms 51 are rolled apart on wheels 53 permitting bottom 55, bearing the two partially cured roof slabs 25 in back-to-back relation, to be wheeled clear of sidewall forms 51 for final curing while the latter are reused with another bottom 55.
Building 30 is shown in FIGS. 1, 4 and 5 to be constructed on a reinforced concrete, ground level foundation slab 31 having a flat upfacing surface 31a providing the floor of the building and having downwardly extending sidewalls providing a peripheral footing 31b for the exterior walls of the building. Various thickened portions of slab 31 in a predetermined arrangement provide footings 31d for the interior walls of the building or for outwardly projecting exterior wall sections. The upfacing surface of footing 31b has a peripheral ledge 31c and footings 31d have depressed seats 31e, the latter and ledge 31c being stepped down from floor surface 31a a uniform predetermined distance. Seats 31e have widened areas 31f at predetermined locations in the manner and for the purpose hereinafter more fully described.
All the structural walls of building 30 comprise precast L-shaped wall units 20 or a left orientated version thereof. Thus, wall units 20 are positioned on peripheral ledges 31c at the four corner locations I of foundation slab 31 and at intermediate locations II, III, IV, V and VI where one wall section of each of the units 20 is positioned on peripheral ledge 31c and spaced between corner locations I. The other wall sections are positioned on seats 31e of footings 31d which intersect at right angles with peripheral ledge 31c. Those wall units 20 serving solely as interior wall structure are positioned on L-shaped seats 31e of footings 31d and are seen at locations VII, VIII, IX, X and XI. Locations IX and X are left orientated L's, that is, the short section 20b extends toward the left rather than towards the right of long section 20a.
To anchor each of the L-shaped wall units 20 in its location on foundation slab 31, a cutout 21 is precast in a midportion of each wall section 20a and 20b to extend as a recess from the bottom edge thereof. A tie rod 22 having a threaded end is precast and embedded in each wall section 20a and 20b and extends vertically downwardly into a midportion of each cutout 21. Likewise, footings 31b and 31d have tie rods 32 suitably embedded therein with threaded ends extending vertically upwardly above ledge 31c and seats 31e to vertically align in spaced relation with each tie rod 22 when the respective wall unit 20 is vertically lowered into its predetermined position. The gap separating the respective ends of each tie rod 22 from 32 is bridged by an interconnecting U-shaped bracket 33 having opposite parallel sides 33a horizontally disposed, each formed with an opening through which the threaded ends of tie rods 22 and 32 project and mount nuts 22a and 32a, respectively, which are tightened against the inner surface of bracket 33.
Cutouts 21, which may have a height equivalent to the depth of ledges 31c and seats 31e from upfacing surface 31a, are readily accessible from the exterior sides of foundation 31 for mounting brackets 33 and tightening nuts 22a and 32a. Seats 31e which would ordinarily obscure cutouts 21 have widened areas 31f in foundation 31 located to register with the cutouts 21 and provide working accessibility thereto. After the brackets 33 are secured and nuts 22a and 32a are tightened, areas 31f and cutouts 21 are filled with concrete, finishing the floor and wall structure.
A feature of the invention which materially contributes to the saving of time and labor in the construction of building 30 is the use of a composite beam 34 to extend across the tops of each group of wall sections 20a and/or 20b positioned in a common vertical plane. For example, a composite beam 34 extends the length of each of the four exterior walls of building 30 and bridges the open spaces between the wall sections of each corner wall unit 20 and the one or more intermediate wall section as lintels to which the tops of door and window frames (not shown) are mounted. Composite beams 34 serve in a similar manner with respect to interior wall structure where the spaces between coplanar wall sections may mount door frames or partition walls (not shown).
With the L-shaped units 20 in position, an H-beam 35 made of a suitable metal, such as extruded aluminum, is placed across the tops of each coplanar group of wall sections so that the top edges of sections 20a and/or 20b extend into the downfacing channel 35a and supportingly engage the horizontal cross-piece 35b. Where required, the side wall of the H-beam forming channel 35a may be cut out to accommodate the intersecting companion right angularly extending wall section and insure a level fit. Preparatory to mounting a composite beam 34, each of the wall sections 20a and 20b of units 20 has been precast with one or more embedded vertical tie rods 23 at predetermined locations having ends projecting above the top edges thereof a distance to terminate short of the top edges of H-beam 35 when mounted thereon as seen in FIGS. 6 and 7. Horizontal cross-piece 35b has openings cut therein through which tie rods 23 extend into the upfacing channel 35c.
With H-beams 35 in position and prior to pouring the concrete into upfacing channel 35c, suitable reinforcing rods (not shown) and vertically extending threaded tie rods 36, which have their lower ends threaded into collars 37a of winged anchor fittings 37, are installed in channels 35c. Tie rods 36 are placed in predetermined positions to extend between adjacent roof slabs 25, the latter being installed to rest upon composite beams 34 after the poured concrete filling channels 35c sets, embedding tie rods 23 and 36 therein and completing composite beam 34. As will be clear from FIG. 1, at intersections of H-beams 35 appropriate portions of sidewall forming upfacing channel 35c may be cut out to provide an uninterrupted channel for receiving the poured concrete therein which will unite all composite beams 34 by an integral concrete structure.
As seen in FIGS. 1, 4 and 5, the dimensions of precast roof slabs 25 are of a length sufficient to extend the width of building 30 and overhang the opposite exterior walls as eaves. Likewise, roof slabs 25 are of a width permitting a plurality of uniform sized slabs to cover building 30 in longitudinal side-by-side relation and have the endmost slabs overhang the front and rear exterior walls as eaves similar to those overhanging the exterior side walls.
Tie rods 36 are arranged in parallel rows of three spaced to accommodate a roof slab 25 therebetween and are located in those composite beams 34 which are seen in FIG. 1 to extend along the exterior opposite side walls of building 30 providing end anchoring means for adjacent roof slabs 25. Midportion anchoring means are provided by the location of tie rods 36 in beams 34, seen to extend along interior walls which also serve to support the midportion of roof slabs 25. After being lifted into position by well known crane equipment so that flat bottom sides 25a rest on composite beams 34 and the thickened peripheral borders 26 of the longitudinal sides align against the rows of tie rods 36 extending vertically between adjacent roof slabs 25, a tie-down joint is effected by suitable means, such as metal elongated strips 38, each seen in FIGS. 4, 5, 6 and 7 as being channel shaped and having a cross-section which conforms to the width of the upper flat surfaces 26a and the downwardly extending interior sides 26b of adjacent thickened peripheral borders 26. Strips 38 have registering openings through which the ends of tie rods 36 extend for receiving nuts 36a which secure strips 38 in engagement with thickened peripheral borders 26, midportions of each strip 38 being cutout to accommodate transverse ribs 25c. Suitable roofing material, such as roofing paper, tar and gravel (not shown), is applied to cover roof slabs 25, strips 38 and nuts 36a providing a weather proof roof for building 30.
Suitable washers (not shown) may be used on the threaded ends of rods 22, 32 and 36 to underlie and reinforce nuts 22a, 32a and 36a in building 30 as well as on rods 16 and 56 under nuts 16a and 56a in apparatus 10 and 50, respectively.
The method and use of wheeled sidewall forms 11 and 12 are well adapted to precast units of L-shape or other configuration in a variety of thicknesses including units having sections of different thicknesses by providing bottoms 15 of comparable width. Also, the length of the respective sections of the unit may be varied by providing bottoms 15 of comparable length or by placement of end walls 11d to shorten the effective length of an existing section of bottom 15.
The precast concrete molding apparatus and method and the building construction utilizing precast L-shaped structural units and roof slabs are seen to achieve the several objects of the invention and to be well adapted to meet conditions of practical use. As various possible embodiments might be made in this invention, and as various changes might be made in the disclosed apparatus, method and building construction, it is to be understood that all matter herein set forth and shown in the accompanying drawings are to be interpreted as illustrative and not in a limiting sense.
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A tripling or more in the production rate of precast concrete building units utilizing reusable mold forms is achieved by casting the units vertically on a wheeled base between separable vertical mold forms. The partially cured poured concrete unit is horizontally transported on the wheeled base from between the separated molds to complete the curing independently thereof, the forms being immediately serviceable with another wheeled base for molding another unit.
A building is erected on a concrete slab foundation using a plurality of precast concrete units in the form of L-shaped walls positioned as corner structure and spaced intermediate exterior wall elements and as interior partitions and roof supports. The L-shaped walls are bolted to the foundation by anchoring means located in cutout portions along the bottom of each wall and H-beams are placed to extend across the tops of the walls and are filled with concrete to serve as support and anchoring means for precast concrete roof slabs and to bridge the spaces between the concrete walls as lintels for doors and windows which complete the exterior wall enclosure of the building.
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BACKGROUND OF THE INVENTION
1. Technical Field
This device relates to vehicle lift mechanisms that are mounted in the truck bed of a pick-up type truck that converts the truck into a tow truck for towing vehicles at reduced cost.
2. Description of Prior Art
Prior Art devices of this type have relied on a variety of different designs to convert pick-up trucks into tow trucks, see for example U.S. Pat. Nos. 3,716,152, 4,473,237, 4,473,334, 4,534,579, 4,586,866 and 3,599,811.
In U.S. Pat. No. 3,716,152 a towing means is disclosed having a pivoted bar with a hydraulic cylinder secured thereto.
U.S. Pat. No. 4,473,237 has a lift and tow bar extending from the vehicles axle.
U.S. Pat. No. 4,473,334 discloses a towing device having a pair of pivoted arms within the truck bed that is lifted by a hydraulic piston cylinder assembly.
In U.S. Pat. No. 4,534,579 a wheel lift of a tow truck is disclosed having a horizontally extended vehicle engagement arm and a vertical pivot member to which the hook from the truck's boom is secured via a cable for raising.
U.S. Pat. No. 4,586,866 discloses a towing apparatus having pivoted arms within a cable lift secured to the outer most arm engaging the vehicle.
U.S. Pat. No. 3,599,811 shows a towing apparatus with multiple arm sections which is pivoted upwardly from a single pivot point then lifted by a cable extending from the tow trucks winch or boom.
Still a further modification of a lift device can be seen in U.S. Pat. No. 3,137,401 in which a vertically positioned adjustable mast is used as a lift support by a pair of secondary wheels secured thereto. The vehicle is lifted by the cable and hook extending from a winch in the tow truck.
SUMMARY OF THE INVENTION
An automobile wheel lift device for use in converting pick-up trucks to tow trucks comprises a truck bed mountable support frame and vertically aligned lift tube with a pivoted inner-connected horizontally extensible automobile engagement arm all activated by a pair of hydraulic lift cylinders.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side plan view of an auto wheel lift device;
FIG. 2 is a top plan view of the auto wheel lift device;
FIG. 3 is a side plan view of the auto wheel lift device in raised position; and
FIG. 4 is an end plan view of the auto wheel lift device on lines 4--4 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An automobile wheel lift device 10 can be seen in Figures 1, 2, and 3 of the drawings positioned within a truck 11 having a truck bed 12, a truck frame 13, and a rear axle and wheel assembly 14. The automobile wheel lift device 10 comprises a generally rectangular support frame 15 having spaced parallel side rails 16 with inner-connected oppositely disposed end rails 17. A boom support member 18 is secured to the support frame 15 and has a pair of spaced angularly disposed boom members 19 and 20 extending therefrom the free ends of which are pivotally secured to an adjustable alignment bracket 21. A pair of vertically aligned spaced extension support frame members 22 from the respective ends of said parallel side rails 16 and are inner-connected by a lift support plate 23. A lift tube 24 is movably secured to the boom alignment bracket 21 by a threaded adjustable inner-connect 25.
A lift bracket 26 is secured to and extends from the upper end of the lift tube 24 and has pairs of oppositely disposed apertured tube T extending therefrom. A pair of spaced hydraulic piston and cylinder assemblies 27 and 28 are pivotally mounted to the lift support frame 23 on opposite sides of the lift tube 24 best seen in FIGS. 1 and 4 of the drawings, piston rods 27A and 28A are connected to the tabs T. The lower end of the lift tube 24 has a telescopically extensible automobile engagement element 29 pivotally secured thereto via a pin 29A extending through said lift tube 24 and support plates 30. A pair of horizontally spaced auto tire engagement frames 31 are positioned on either end of a tubular support arm 32 which is centrally secured to the automobile engagement element 29 as seen in FIG. 2 of the drawings. An L-shaped support beam member 33 is welded to and extends between said support beam members 22 below the truck frame 13 adjacent the lift plate and has spaced apertured angled mounts 34 removably secured thereto so as to provide apertured mounting surfaces abutting a portion of the trucks frame 13. A supplemental wheel and axle assembly 35 is comprised of a pair of spaced air springs 36 affixed to a spring mount support angle 37 mounted to and abutting the trucks frame 13 by fasteners 36A. A supplemental axle 38 is secured to the trucks rear axle 39 via a pair of trailing arms 40 and associated clamps 41 and to the air springs 36 by spring mount plates 42 as will be known to those skilled in the art.
Referring now to FIG. 4 of the drawings a roller 43 is shown in broken lines mounted to the end rail 17 between the support frame members 22 and is aligned to engage the lift tube 24. A pair of lift tube guides 44 are positioned between the lift frame 23 to the end rail 17 on either side of the lift tube 24 and are aligned to selectively engage retraction levers 45 mounted on the pivot pin 29A.
In operation the piston and cylinders assemblies 27 and 28 are inner-connected to a fluid pressure supply source via supply lines (not shown for clarity) and control valve 46 mounted on the rail 16. The air springs 36 are connected to an air pressure source via supply lines (not shown for clarity) with a selective control valve 47 and are activated when a vehicle V shown in broken lines is to be towed.
Referring to FIG. 1 of the drawings the lift tube 24 has been lowered by the piston and cylinder assemblies 27 and 28 and the support arm 32 with its tire engagement frames 31 are on the ground G. The vehicle V is positioned on the frames 31 and the piston and cylinder assemblies 27 and 28 are activated raising the lift tube 24 against the roller 43 vertically and slightly angularly due to the arcuate travel of the top of the lift tube 24 imposed by the boom members 19 and 20 that are of fixed lengths and have fixed pivot points. As the lift tube 24 ascends it tips inwardly slightly raising the vehicle V higher than the relative lift height of tube 24 due to the angular inclination of the tube 24 and connected auto engagement element 29 and associated tire engagement frames 31 as seen in FIG. 3 of the drawings.
The threaded adjustment inner-connect 25 can increase the distance between the lift bracket 26 and the alignment bracket 21 thereby allowing the lift tube 24 when in down position and connected tire engagement frames 31 to tip downwardly away from the bottom members 19 and 20 lowering same to compensate for vehicles on even ground to be towed.
The retraction levers 45 can be moved into position for selective engagement by the tube guides 44 which will pivot the auto engagement element inwardly and upwardly towards the lift tube 24 as same is raised, see broken lines in FIG. 3 of the drawings.
Thus it will be seen that a new and useful automobile wheel lift device has been illustrated and described and it will be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the spirit of the invention. Therefore,
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An automobile wheel lift device for use on pick-up trucks or the like to convert the truck to a tow truck for vehicles. The wheel lift device comprises a support frame secured to the truck, a vertical disposed lift bar and outwardly extending vehicle engagement arms. A secondary wheel and axle assembly stabilizes the truck during towing.
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RELATED APPLICATIONS
[0001] This application is related to and claims priority to Chinese Application No. 200610162067.0 filed Dec. 8, 2006 entitled “SYSTEMS AND METHODS FOR ACHIEVING REDUCED INTER-SECTOR PILOT INTERFERENCE IN A MOBILE COMMUNICATION SYSTEM”, the disclosure of which is hereby incorporated herein by reference.
TECHNICAL FIELD
[0002] This invention relates to wireless cellular systems and more particularly to wireless systems for arranging a cellular network so as to reduce the interference from pilot communications both within each cell and between cells.
BACKGROUND OF THE INVENTION
[0003] Wireless communications rely on transmissions (air interfaces) between a transmission point and a number of mobile communication devices that are located at various locations with respect to the transmission point. These air interfaces include: single carrier; Orthogonal Frequency Division Multiplexing (OFDM); Orthogonal Frequency Division Multiple Access (OFDMA); Wideband Code Division Multiple Access (WCDMA); and Universal Mobile Telecommunications System (UMTS). The OFDM and OFDMA interfaces are now often used in broadband wireless networks (WiMAX) that are based on the IEEE 802.16 standard. Scalable OFDMA (sOFDMA), and Flash OFDM, are also now either being considered or actually being used in some networks. For purposes of discussion herein, these air interface systems will be called modulation schemes.
[0004] As the number of simultaneous communication connections increases so does the probability of interference between the connections. Various frequency reuse schemes have been used over the years with one of the most popular being to divide a physical area into cells (usually, but not always) with a single transmission point at the center of each cell. The transmission point is typically divided into sectors with each sector pointed in a different direction. Various modulation schemes are employed to be sure that transmission in each sector does not interfere with each other. Within a sector, different channels and/or modulation is used to prevent interference between mobile devices in that sector. The frequency reuse pattern between cells is selected so as to reduce the probability of interference across sectors.
[0005] Some air interface systems use a “pilot” signal between the transmission point and a potential connection to a wireless device so as to establish certain parameters with respect to the upcoming connection. These parameters can be, for example, power level, channel number timing information, etc. Currently, these pilot signals are selected for a given transmission point on an “as available” basis and broadcast from the transmission point or points. All mobile devices must monitor all pilot frequencies or channels in order to be able to know how to communicate with any particular transmission point. Again, as transmission traffic increases so does the probability of interference among pilots from adjacent cells or sectors.
BRIEF SUMMARY OF THE INVENTION
[0006] The pilots of a wireless system are arranged to reduce inter-sector interference by establishing a systematic assignment of pilots across the system. In one embodiment, the pilots are differently coded and directionally positioned within a cell such that the same pilot from adjacent cells do not overlap. In one embodiment, Walsh codes are used to modulate pilot signals.
[0007] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawing, in which:
[0009] FIG. 1 illustrates one embodiment of pilot assignments to reduce interference; and
[0010] FIG. 2 is a chart showing one embodiment of differentiating the pilot codes using a Walsh code of length four.
DETAILED DESCRIPTION OF THE INVENTION
[0011] FIG. 1 illustrates one embodiment of pilot assignments to reduce interference. As shown, wireless network 10 consists of a plurality of wireless transmission points, such as transmission point 111 shown at the center of cell area 11 - 1 . Each of the other cell areas, such as cell areas 11 - 2 through 11 - 7 and 12 - 1 through 12 -N, also have one or more transmission points (not shown). Communications connections are made between mobile devices, such as devices 14 - 1 through 14 -N, and the transmission point in the cell serving the mobile device at any point in time. Note that while a single transmission point is shown in a cell there can, and often are, multiple transmission points serving one or more sectors of a cell.
[0012] For each cell in the embodiment of FIG. 1 , such as cell 11 - 1 , the pilot code which otherwise would be available though an air interface to any mobile device within transmission range is divided into three differentiated pilot codes. These three codes are used to form pilot sectors A, B, and C. The pilot sectors from all adjacent cell areas are set up so that the pilot frequency (or channel) used for a first sector is not the same as a for an adjacent second sector into which the pilot from the first sector can penetrate.
[0013] For example, the A sector of cell 11 - 1 “faces” the C sector (and possibly the B sector) of cell 11 - 2 . Likewise the A sector of cell 11 - 1 faces the C sector of cell 11 - 3 and faces the B sector of cell 11 - 7 . While it is possible that pilot signals from outlying cells could be the same as one of the pilots in cell 11 - 1 , the relative signal strength between them should eliminate interference.
[0014] In one embodiment, a Walsh coding technique can be used to create the differentiation between the pilot codes. Walsh codes, which is also known as “Walsh-Hadamard codes,” are generated by an algorithm that establishes statistically unique sets of numbers for encrypting modulation signals. Known as “pseudo-random noise codes,” Walsh codes are “orthogonal” mathematical codes and as such, if two Walsh coded frequencies (signals) are correlated, the result is intelligible only if the signals are coded using the same Walsh code. As a result, a Walsh-encoded signal appears as random noise to a mobile terminal, unless that terminal uses the same code as the one used to encode the incoming signal.
[0015] FIG. 2 shows chart 20 based on a Walsh code of length 4 yielding four possible code sequences called 0 , 1 , 2 , 3 . Code 1 can be used, for example, to generate the A pilot, code 2 can be used to generate the B pilot and code 3 can be used to generate the C pilot. Walsh codes of even longer length can be used and if desired the different codes that come from a longer Walsh code can be used to reduce the repeating of codes in adjacent cells. Thus, for example, code 1 can be used for the A pilot in sectors 11 - 1 and 11 - 4 while code 5 (assuming a Walsh code of length 7 ) can be used for pilot A in cells 12 - 1 and 12 - 2 .
[0016] Walsh codes of longer length, such as length 8 or 16 , may also be used. Walsh codes of length 8 yield 7 usable code sequences, with 0 reserved for macro cell use. Longer sequences may reduce the inter-sector interference even further, since the reused code may be further away than with a shorter code. However, such a benefit has a trade-off. Longer Walsh codes decrease system tolerance to channel impairment. Further, mixed lengths of Walsh codes may be used, as well as adaptive lengths, based on planning needs or channel conditions. Changing a Walsh code, though, may require informing the mobile devices of the change.
[0017] In operation, each mobile device would be equipped with a list of Walsh codes so that as the mobile device passes in proximity to a transmission point (or points) the pilots from the various possible transmission points in the vicinity of the mobile device are received by the mobile device. The mobile device then can select which transmission point it will communicate with based on criterion established by the various cells or network. The pilots for each cell would contain information relevant to that cell and thus the information contained in the pilots for different cells will contain different information which will then be used by the mobile device to establish and maintain a proper air interface between the device and the proper transmission point.
[0018] In many situations, the mobile device will receive several different pilots, such that, for example mobile device 14 - 1 positioned in cell 11 - 1 may “see” pilot signals from many cells, such as from cells 11 - 1 (pilot A), 11 - 3 (pilot B, C) and 11 - 2 (pilot C). Since the A, B, and C pilots are differentiated (in this embodiment by the orthogonal Walsh coding technique) the mobile device can “listen” to each pilot without interference from the other pilots even though the device is receiving multiple pilots and even if the pilots are close enough to the same strength that interference would occur but for the differentiated coding.
[0019] Note that while the Band C pilots from multiple cells, such as from cells 11 - 2 and 11 - 3 might be broadest in the direction of device 14 - 1 , interference is mitigated by the use of different coding between pilot A versus pilot C and between pilot A versus pilot B. The same situation prevails with respect to any device in any sector of network 10 . The A pilot from remote cells, such as from cell 12 - 2 , even if it did extend to mobile device 14 - 1 , would be so diminished in strength as to not cause any interference with the A pilot from cell 11 - 1 . If desired, a Walsh coding using more codes can be used such that the next nearest cell can have different coding from its neighbors.
[0020] If desired, one of the codes, for example the zero code, can be used as the pilot of a macro cell that fills in gaps in coverage between regular cells. Thus, the zero coded pilot can be made available across the entire network or only in selected locations that are known to have poor coverage under the differentiated scheme as discussed above.
[0021] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.
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The pilots of a wireless system are arranged to reduce inter-sector interference by establishing a systematic assignment of pilots across the system. In one embodiment, the pilots are differently coded and directionally positioned within a cell such that the same pilot from adjacent cells do not overlap. In one embodiment, Walsh codes are used to create the differently coded pilot signals.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to document image analysis for security reasons, and more specifically to a method and system for shuffling an Asian-language document image to render it unreadable for an ordinary viewer.
BACKGROUND OF THE INVENTION
[0002] An Asian language document contains Asian characters, each of which is generally of a square block shape. Some Asian documents are confidential in nature, and thus it is desirable to provide a method and system for encoding or encrypting such documents.
[0003] In some situations, it is further desired that each individual character included in the Asian document, even after the document as a whole is encoded, is still recognizable or identifiable. For example, when a confidential Asian document is scanned into a computer, not all the characters included in the document may be correctly recognized due to limitations in OCR (Optical Character Recognition) software. Thus, a human operator may need to read the scanned-in and OCR-processed document to see if there is any wrongly-recognized (e.g., incomplete) character and, if so, manually replace it with a correct character by typing in the correct character.
[0004] The present invention is directed to addressing the need for encoding an Asian document, while maintaining each of the individual characters included in the document recognizable even after the document as a whole is encoded to thereby become unreadable.
SUMMARY OF THE INVENTION
[0005] A method, system, and computer-readable medium containing computer-executable instructions are provided, for randomly relocating text character images of a scanned-in Asian character document to produce a shuffled image, wherein the meaning of text in the shuffled image is not understandable although individual characters forming the text in the shuffled image are recognizable. In one embodiment, the method includes generally four steps: (1) dividing an Asian character document image into a text image portion and a non-text image portion; (2) structuring the text image portion into a multiple resolution-level pyramid; (3) extracting shuffleable character images by analyzing the multiple-resolution-level pyramid; and (4) shuffling some or all of the extracted shuffleable character images to create a shuffled image. The shuffled (e.g., encoded) image can thereafter be reshuffled (e.g., decoded) back to the original text image portion of the Asian character document image, and combined with the non-text image portion to thereby restore the Asian character document image.
[0006] In accordance with one aspect of the present invention, the step of dividing an Asian character document image into a text image portion and a non-text image portion further includes performing one or more sub-steps of: skew correction, noise removal, and non-character image finding.
[0007] In accordance with another aspect of the present invention, the step of structuring the text image portion into a multiple resolution-level pyramid further includes sub-steps of: (1) forming a multiple resolution-level pyramid having resolution levels ranging from 2 0 ×2 0 to 2 N ×2 N where N is a positive integer; (2) finding all islands at each resolution level, wherein each island is associated with its attributes (e.g., the location and size); and (3) constructing a tree structure representing a nodal relationship between islands of adjacent resolution levels.
[0008] In accordance with yet another aspect of the present invention, the step of shuffling some or all of the extracted shuffleable character images to create a shuffled image further includes sub-steps of: (1) creating a plurality of holding spaces in computer memory; (2) randomly selecting the extracted shuffleable character images and placing them in the holding spaces; and (3) associating each shuffleable character image with attributes of island(s) forming the shuffleable character at the highest resolution level of 2 0 ×2 0 .
[0009] In accordance with a still further aspect of the present invention, a computer-readable medium is provided for shuffling an Asian character document image to change its appearance so that the meaning of a resulting shuffled document image cannot be understood while individual characters contained in the shuffled document image are still recognizable. The computer-readable medium includes: (1) a data structure for organizing an Asian character document image in a multiple resolution-level tree, wherein the tree is formed from a multiple resolution-level pyramid of a text portion of an Asian character document image; and (2) a data structure for shuffling and reshuffling the text portion of the Asian character document image.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
[0011] FIGS. 1-3 show Asian characters, respectively, each consisting of a plurality of glyphs;
[0012] FIG. 4 is a block diagram depicting a system suitable for use in practicing a method of the present invention;
[0013] FIGS. 5 and 6 are flowcharts depicting various aspects of a method of shuffling an Asian document image according to one embodiment of the present invention;
[0014] FIGS. 7A-7F schematically illustrate a method of constructing a multiple resolution-level pyramid structure in accordance with one embodiment of the present invention;
[0015] FIG. 8 schematically illustrates a method of progressively lowering the resolution level of an image so as to construct a multiple resolution-level pyramid structure in accordance with one embodiment of the present invention;
[0016] FIG. 9 is a sample Asian character document, which may be scanned in and shuffled according to a method of the present invention;
[0017] FIG. 10 is the sample Asian character document of FIG. 9 after imaging preprocessing has been performed to obtain only a text portion thereof; and
[0018] FIG. 11 is the sample Asian character document of FIG. 10 after it has been shuffled and thus become unreadable as text, with each of its characters being still recognizable as such, according to a method of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] The text in an Asian document, such as the document shown in FIG. 9 , consists of lines 12 , with each line 12 in turn consisting of a plurality of Asian characters 14 . Each Asian character is generally of a square block shape. Though each Asian character has its own meaning, one cannot understand Asian text unless a plurality of Asian characters are arranged in a meaningful sentence. Thus, if the characters from two different sentences are shuffled (e.g., if the first, third, and fifth characters of the first sentence are exchanged with the first, third, and fifth characters of the second sentence), a reader can no longer understand the meaning of either the first or second sentence, even though the reader could still recognize the individual Asian characters forming these sentences. In other words, if an Asian document is shuffled, then a reader can still recognize individual Asian characters contained therein, but the meaning of the document will be completely lost. This becomes particularly true if shuffling is performed multiple times.
[0020] The Asian document image shuffling method according to the present invention may be particularly useful in the case when a classified or proprietary document needs to be processed (e.g., typed) by an outside party. In such a case, a classified document can be scanned and shuffled, so that the shuffled document with new sentences (which are no longer understandable) can be sent, for example, through a network connection to an outside party. At this time, the outside party can still recognize all of the individual characters included in the shuffled document so as to perform, for example, typing a correct character to replace a wrong (e.g., incomplete) character that may have been incorrectly recognized due to limitations in OCR software. The outside party can perform such task because each individual character is visually recognizable and identifiable, even though the meaning of the sentences is not understandable. Thereafter, the outside party sends the shuffled and further processed document back to the owner of the document. The owner can then reshuffle the document back to the original, understandable text.
[0021] Another application of the Asian document image shuffling method of the present invention is as a document encoding (or encrypting) method. When it is desired to protect a document from potential interception by an unauthorized party, the sender of the document can shuffle (i.e., encode) the document and send the shuffled document. The authorized receiver of the shuffled document then reshuffles (i.e., decodes) the document back to the original, understandable text.
[0022] The success of the Asian document image shuffling method of the present invention depends on how well individual characters can be separated for shuffling purposes so that the shuffled document, though not understandable, still consists of individual characters that are recognizable as such. In this connection, a difficulty arises because correctly separating (or demarcating) two or more Asian characters that appear next to each other is no small task in computer image processing.
[0023] Referring to FIG. 1 , a Chinese character is shown in a box 5 . As is typically the case with Chinese characters, this character consists of two glyphs, which are separated from each other and thus are included in two separate bounding boxes 1 and 2 , respectively. Since this character is therefore recognized as two separate glyphs as contained in the bounding boxes 1 and 2 (as opposed to being correctly recognized as a single character contained in the box 5 ), these glyphs will be shuffled separately and consequently the resulting shuffled document will not include the correct character as originally included in the box 5 .
[0024] On the other hand, as shown in FIG. 2 , if one bounding box 3 is included in another bounding box 4 , then the larger bounding box ( 4 , in this case) can be recognized as containing one character. Also, if there is no gap or separation between two or more glyphs forming a character, as shown in FIG. 3 , then such is correctly recognized as one character. FIG. 3 shows the same Chinese character as the character included in the box 5 of FIG. 1 , except that the character in the bounding box 5 ′ of FIG. 3 has its two glyphs touching each other and thus these glyphs are not recognized as two separate elements. Therefore, there remains a need for a method for correctly identifying a character even when it consists of two or more separate glyphs, as in the case of FIG. 1 .
[0025] FIG. 4 illustrates a typical computing environment, in which various methods of the present invention may be implemented. An Asian character document on paper 10 is scanned in by an image scanner 21 , as image data, into a general purpose digital computer 22 . Other types of computing systems, such as networked or mainframe-based systems, may also be used to carry out methods of the present invention, as apparent to those skilled in the art. The Asian character document image data are then “shuffled” according to shuffling program instructions, which are stored in the computer 22 and will be described in detail below. The shuffled Asian character document image data are sent via a network 30 to a third party computer 40 , which includes suitable OCR software. Using the OCR software, the third party computer 40 converts the shuffled Asian character document image data into editable text data. At this time, the third party computer 40 may further permit manual editing or correction of the text data. The text data are thereafter sent via the network 30 back to the original computer 22 and reshuffled so that the characters return to their original positions. In this embodiment, an Asian character image shuffling system 20 consists generally of the image scanner 21 and the computer 22 .
[0026] In another application of the Asian character image shuffling system 20 , an Asian character document 10 of confidential nature can be shuffled (i.e., encoded or encrypted) and sent to a receiver computer 50 via the network 30 . In this application, the receiver computer 50 includes reshuffling program instructions to carry out reshuffling (i.e., decoding) of the received shuffled Asian character document image data so as to restore the original Asian character document image data. In other words, since reshuffling is possible only with the reshuffling program instructions, any unauthorized party without such reshuffling program instructions cannot decode (or understand) the shuffled Asian character document image data even if he/she can intercept such data on the network 30 .
[0027] FIG. 5 is a flowchart depicting a method of shuffling Asian character document image data in accordance with various exemplary embodiments of the present invention. In step S 10 , an Asian character document on paper 10 (for example, the document shown in FIG. 9 ) is scanned in by the image scanner 21 as an image. The scanned-in image includes a text portion consisting of Asian characters (including some western alphabet characters and numbers, as shown in FIG. 9 ) and a non-text portion including, for example, a logo 16 and a table frame 18 . (The text inside the table frame 18 forms part of the text portion.) Thus, in step S 20 , a text portion is separated from a non-text portion in the scanned-in Asian document image, using suitable software as will be apparent to one skilled in the art. At this time, any desirable image preprocessing may also be performed, such as correction of any skew (due to the original Asian character document on paper 10 being fed into the image scanner 21 at an angle), noise removal (due to some smear or stain on the Asian character document on paper 10 ), and detecting and removing any underlining or table framing. Such image preprocessing can be carried out using various functions found in conventional OCR software, for example. FIG. 10 shows only the text portion of the scanned-in Asian character document image of FIG. 9 after the image undergoes step S 20 and various other image preprocessing.
[0028] In step S 30 , a multiple resolution-level pyramid structure is constructed for the text portion image as obtained in step S 20 . This step is performed so as to extract each Asian character from the text portion image without erroneously extracting two or more glyphs forming each Asian character as two or more “characters” for shuffling purposes, as discussed above. As such, this step is important for the purpose of shuffling only genuine characters such that the shuffled image still contains recognizable characters, even though the order in which the characters are arranged is changed and thus the meaning of the sentences is lost. In step S 30 , the image resolution level of the scanned-in text portion image is progressively lowered, with the thickness of a line forming each character becoming progressively increased, as shown in FIGS. 7A-7F . FIG. 7A illustrates an input image of an Asian sentence line, whose image resolution level is lowered from the original 2 0 ×2 0 level ( FIG. 7B ), to 2 1 ×2 1 level ( FIG. 7C ), to 2 2 ×2 2 level ( FIG. 7D ), to 2 3 ×2 3 level ( FIG. 7E ), and to 2 4 ×2 4 level ( FIG. 7F ). As used herein, “2 K ×2 K ” signifies the number of original pixels in relatively high resolution, which is represented by one pixel at a particular resolution level, as will be more fully described below in reference to FIG. 8 . At each resolution level, an island is found for each connected component, as shown in FIGS. 7B-7F . In the present application, the term “island” is used interchangeably with the term “bounding box” as used in reference to FIGS. 1-3 . In FIG. 1 , two bounding boxes (i.e., islands) 1 and 2 are found; in FIG. 2 , two bounding boxes (or islands) 3 and 4 are found (with the island 3 completely included in the island 4 ); and in FIG. 3 , only one island 5 ′ is found. Each island may be defined, for example, with the coordinates of two diagonal corner points.
[0029] FIG. 6 is a flow chart illustrating detailed steps to be performed in step S 30 of FIG. 5 . In step S 31 , the image resolution level of the scanned-in text portion image is progressively lowered to thereby construct a multiple resolution-level pyramid structure. In one example, the multiple resolution-level pyramid structure may be constructed in five levels as shown in FIGS. 7B-7F , though in other applications more or less number of resolution levels may be sufficient or required. The pyramid structure for an original image having 2 K ×2 K pixels would consist of (K+1) number of images, which have different resolution levels, respectively, ranging from 2 0 ×2 0 to 2 K ×2 K . FIG. 8 illustrates the relationship between these (K+1) number of images, wherein I 0 represents an image at 2 0 ×2 0 resolution level, I 1 represents an image at 2 1 ×2 1 resolution level, I 2 represents an image at 2 2 ×2 2 resolution level, and I 3 represents an image at 2 3 ×2 3 level. As noted above, “2 K ×2 K ” signifies the number of original pixels represented by one pixel at each resolution level. In other words, starting with I 0 , the numbers of pixels along X and Y axes, respectively, are halved so that if I 0 at 2 0 ×2 0 resolution level has 64 pixels, I 1 at 2 1 ×2 1 resolution level has 16 pixels, I 2 at 2 2 ×2 2 resolution level has 4 pixels, and I 3 at 2 3 ×2 3 resolution level has 1 pixel. As the number of pixels used to represent the original image having a specific size decreases (i.e., as the size of the pixel increases), the resolution level of the image is lowered. Other methods of progressively lowering the resolution of an original image may also be used, as will be apparent to one skilled in the art.
[0030] Referring back to FIG. 6 , in step S 32 , in each resolution level in the constructed pyramid structure, all the islands each containing a connected component are found, as in FIGS. 7B-7F .
[0031] In step S 33 , a tree structure is formed to represent the relationship between the islands at different resolution levels. Referring to FIGS. 7B-7F , as the resolution level is lowered, previously adjacent glyphs (and also characters) may touch or merge with each other so as to have previously adjacent islands merge into one island. As such, the islands found at 2 K ×2 K level necessarily include all the islands found at 2 (K−1) ×2 (K−1) level. For example, island 1 at the root level of FIG. 7F includes islands 2 , 3 , and 4 of level 1 of FIG. 7E , and island 2 in level 1 of FIG. 7E in turn includes islands 5 , 6 , and 7 of level 2 of FIG. 7D . In this example, island 1 in the root level of FIG. 7F becomes a root node, from which islands 2 , 3 , and 4 in level 1 of FIG. 7E depend as “child” nodes of island 1 . In turn, island 2 at level 1 of FIG. 7E becomes a “parent” node with respect to islands 5 , 6 , and 7 of level 2 of FIG. 7D (i.e., islands 5 , 6 , and 7 become “child” nodes of island 2 ).
[0032] In step S 34 , in association with each “parent” node, attributes (the position and size, as represented by the coordinates of two diagonal corner points for example) of its one or more “child” node(s) are stored. For example, in FIGS. 7B-7F , the attributes of islands 9 and 10 at level 4 of FIG. 7B are stored in association with island 8 at level 3 of FIG. 7C . Thus, the computer is aware that island 8 consists of islands 9 and 10 .
[0033] Referring back to FIG. 5 , in step S 40 , the multiple resolution-level pyramid structure or, more specifically, the tree structure constructed as in FIG. 6 in which attributes of child-node island(s) are stored with its (or their) parent-node island, is analyzed to extract “shuffleable” islands, i.e., islands that represent actual Asian characters (as opposed to mere glyphs, or a combination of a character and a glyph from an adjacent character, for example).
[0034] In one embodiment, traversing from a higher resolution level to a lower resolution level, if a parent-node island includes only one child-node island, which is greater than a predefined minimum size for an island to qualify as a character, then such a parent-node island may be extracted as a shuffleable island. For example, referring to FIGS. 7B-7F , islands 5 , 6 , 7 , 11 , 12 , 13 , 14 , 15 , 16 , 17 , 18 , and 19 may all be identified as shuffleable islands because they each contain only one child-node island. Islands that do not meet the minimum size requirement, such as island 20 that bounds a comma and island 21 that bounds a glyph of a character 22 , are not extracted as shuffleable islands even when their parent-node island includes only one child-node island. In this method, the character 22 and the comma 20 cannot be extracted until island 1 in the root level of FIG. 7F is analyzed. At this time, islands 5 , 6 , and 7 at level 2 of FIG. 7D have already been extracted as shuffleable islands. Thus, island 1 at the root level of FIG. 7F is assumed to include shuffleable islands 5 , 6 , and 7 , plus an unknown island which may or may not be shuffleable. In this example, the unknown island consists of the character 22 and the comma 20 , but for the purpose of shuffling, the combination of the character 22 and the comma 20 can be treated as a shuffleable island. Likewise, a character 23 cannot be extracted until a parent-node island 24 at the root level of FIG. 7F is analyzed. At this time, islands 11 , 12 , 13 , 14 , 15 , 16 , and 17 have already been extracted as shuffleable islands. Thus, island 24 at the root level of FIG. 7F is assumed to include these shuffleable islands 11 , 12 , 13 , 14 , 15 , 16 , and 17 , plus an unknown island that may or may not be shuffleable. In this example, the unknown island consists of the character 23 , and for the purpose of shuffling the document image, the unknown island (in fact properly containing the single character 23 ) is treated as a shuffleable island.
[0035] Referring back to FIG. 5 , in step S 50 , some or all of the extracted shuffleable islands are randomly selected and shuffled. Various methods of shuffling are possible, as would be obvious to one skilled in the art. In one shuffling method, first, multiple holding spaces are created in computer memory for holding the islands (or character images) to be shuffled. Second, the islands to be shuffled are selected randomly from the extracted shuffleable islands and placed into the holding spaces. At this point, the actual islands (or character images) to be shuffled should be the islands (or character images) represented at the original image resolution level. For example, referring to FIGS. 7B-7F , though the character 23 is extracted as a shuffleable island at the root level of FIG. 7F , the actual island (or character image) to be shuffled is taken at the original image resolution level of FIG. 7B , which can be found by traversing the tree structure down from the resolution level of FIG. 7F . Thus, in this example, the attributes (e.g., the size and location) of the actual island to be shuffled consist of attributes of the two glyphs 25 and 26 forming the character 23 at level 4 of FIG. 7B , and what is actually shuffled will be a combination of the images of the glyphs 25 and 26 at level 4 of FIG. 7B . Maintaining the attributes of the islands at the original resolution level is also necessary so that any shuffled islands (or character images) can be thereafter reshuffled back to the original positions. FIG. 11 is the sample text portion of the Asian character document of FIG. 10 , after it has been shuffled and thus become unreadable as text, though each of its characters is still recognizable as such.
[0036] Referring back to FIG. 5 , steps S 10 through S 50 described above are directed to shuffling an Asian character document image. The shuffled Asian character document image data can then be sent to a third party computer 40 for conversion into text data (followed by manual verification and correction of text erroneously recognized by OCR software), or may be sent to an authorized receiver computer 50 for reshuffling (i.e., decoding), as previously described in reference to FIG. 4 . When the shuffled text data are returned from the third party computer 40 to the original computer 22 , the returned text data need to be reshuffled. Also, at the authorized receiver computer 50 , the shuffled Asian document image data need to be reshuffled. Thus, in FIG. 5 , step S 60 , reshuffling is performed, i.e., the shuffled islands are returned to their original positions based on the attributes (e.g., the location and size) of the islands at the original resolution level as previously stored. Finally in step S 70 , the reshuffled text portion image is combined with the non-text portion image to thereby restore the original Asian document image.
[0037] While the preferred embodiments of the invention have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.
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A method, system, and computer-readable medium containing computer-executable instructions are provided, for randomly relocating text character images of a scanned-in Asian character document to produce a shuffled image, wherein the meaning of text in the shuffled image is not understandable although individual characters forming the text in the shuffled image are recognizable. In one embodiment, the method includes generally four steps: (1) dividing an Asian character document image into a text image portion and a non-text image portion; (2) structuring the text image portion into a multiple resolution-level pyramid; (3) extracting shuffleable character images by analyzing the multiple-resolution-level pyramid; and (4) shuffling some or all of the extracted shuffleable character images to create a shuffled image. The shuffled (e.g., encoded) image can be reshuffled (e.g., decoded) back to the original text image portion of the Asian character document image, and combined with the non-text image portion to restore the Asian character document image.
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[0001] This application claims priority under 35 U.S.C. §120 as a continuation-in-part of U.S. patent application Ser. No. 11/450,985, filed Jun. 12, 2006, entitled “Container Lid and Holder and System and Method for Attaching a Lid and Holder to a Container,” that claims priority to U.S. provisional application Ser. No. 60/690,248, filed Jun. 14, 2005, entitled “Lid and Holder for Disposable Cups,” which is referred to and incorporated herein in its entirety by this reference.
FIELD OF THE INVENTION
[0002] The present invention generally relates to closures for containers, and more particularly to a closure and handle configured for attachment to a conventional cup.
BACKGROUND OF THE INVENTION
[0003] Most parents of infants and young children are very familiar with drinking cups often referred to as “sippy” or “sip” cups. Sip cups as currently known in the art typically comprises a cup portion which is fabricated from a plastic material and formed in the same general shape as a conventional paper drinking cup. In addition to this cup portion, the sip cup includes a lid which is engageable with the top rim of the cup portion. The lid itself typically includes an elongate spout which protrudes from a peripheral portion of the top surface thereof and includes a flow opening therein which fluidly communicates with the interior of the sip cup. In certain sip cups, the lid is threadably engaged to the cup or to a collar holding the cup. In other sip cups, the lid is frictionally engaged to the cup portion or to an annular collar holding the cup. Unfortunately, these lids are expensive to make and often do not provide an adequate fluid seal. In take-out eating establishments such as coffee shops, fast-food restaurants, amusement park concession stands, etc., beverages are often provided in a paper or plastic drinking cup. The drinking cup is typically provided with a plastic lid enclosure on one end thereof to contain the liquid within the cup, the lid enclosure including a short spout for drinking. If held by hand, the temperature of the drink can make the person's hand uncomfortably hot, or cold, as the case may be. If a holder is provided, it must usually be disposable or else it risks becoming soiled with use. But disposable cup holders are expensive and create liter. There is thus a need for a way to hold disposable drinks in a cost effective manner.
[0004] A number of coffee shops sell refillable cups, especially to regular customers who buy coffee or other drinks on a regular basis. But the coffee or other beverages leave a residue in the cup and thus require cleaning. There is thus a need for a cup holder that reduces the need for cleaning.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a sectional view showing a disposable cup, a first embodiment of a cup lid, and a first embodiment cup holder;
[0006] FIG. 2 is a sectional view of a portion of the disposable cup, a portion of the cup lid, and a portion of the cup holder illustrated in FIG. 1 ;
[0007] FIG. 3 is a perspective view of a collar and handle constructed according to one embodiment of the present invention;
[0008] FIG. 4 is an elevation view of the embodiment illustrated in FIG. 3 ;
[0009] FIG. 5 is a perspective view of a cup lid constructed according to one embodiment of the present invention;
[0010] FIG. 6 is a sectional view of a cup lid constructed according to another embodiment of the present invention;
[0011] FIG. 7 is a sectional view showing a disposable cup, a cup lid as illustrated in FIG. 1 , and an embodiment of the present invention in the form of a cup with an integrated collar;
[0012] FIG. 8 is a perspective view of cup holder comprising a partial collar and handle constructed according to a further embodiment of the present invention;
[0013] FIG. 9 is a partial elevation view of the cup holder comprising a partial collar and handle constructed according to a yet another embodiment of the present invention;
[0014] FIG. 10 is a perspective view of another embodiment cup holder comprising a partial collar, projections on the collar and a handle constructed according to yet another embodiment of the present invention;
[0015] FIG. 11 is a second perspective view of the cup holder illustrated in FIG. 10 , comprising a partial collar, projections on the collar and a handle constructed according to an embodiment of the present invention; and
[0016] FIG. 12 is a side elevation view of the cup holder illustrated in FIGS. 10 and 11 , comprising a partial collar, projections on the collar and a handle constructed according to an embodiment of the present invention.
[0017] It will be recognized that some or all of the Figures are schematic representations for purposes of illustration and do not necessarily depict the actual relative sizes or locations of the elements shown. The Figures are provided for the purpose of illustrating one or more embodiments of the invention with the explicit understanding that they will not be used to limit the scope or the meaning of the claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] In the following paragraphs, the present invention will be described in detail by way of example with reference to the attached drawings. While this invention is capable of embodiment in many different forms, there is shown in the drawings and will herein be described in detail specific embodiments, with the understanding that the present disclosure is to be considered as an example of the principles of the invention and not intended to limit the invention to the specific embodiments shown and described. That is, throughout this description, the embodiments and examples shown should be considered as exemplars, rather than as limitations on the present invention. As used herein, the “present invention” refers to any one of the embodiments of the invention described herein, and any equivalents. Furthermore, reference to various feature(s) of the “present invention” throughout this document does not mean that all claimed embodiments or methods must include the referenced feature(s).
[0019] One embodiment of the present invention may be employed with a conventional disposable cup, or other type of fluid, or beverage container having a bead located about the periphery of an opening of the cup. A cup lid having a first annular recess engages with the cup bead. A second annular recess in the cup lid engages with a second bead that is located on a collar that is positioned adjacent to the cup bead. In a preferred embodiment, the collar includes a handle, thereby eliminating the need for a consumer to grasp the hot, or cold cup.
[0020] In another embodiment of the present invention, a substantially cylindrical container only includes the second bead, with the cylindrical container sized to receive a conventional disposable cup having a bead located about the periphery of the cup. The conventional cup is positioned within the cylindrical container, and the cup lid having the first and second annular recesses engages with the cup bead and the second bead, respectively, on the cylindrical container. In this embodiment, the cylindrical container may or may not include a handle, and it may be open at both ends, or it may include a base that closes one end. An alternative embodiment may include a gripping surface, such as a dimpled surface, or a rubber or other suitable plastic surface on the cylindrical container.
[0021] Referring to FIGS. 1-7 , a cup 10 has a bottom 14 , sidewalls 16 and a bead 18 around the opening or open top of the cup 10 . The sidewalls 16 are typically tapered at a slight angle to allow stacking of the cups, although the present invention may be employed in cups that do not have angled sidewalls 16 . The cup 10 may be of the disposable type, which are typically made of paper with a rolled bead 18 as shown, or they can be made of various plastic materials with a rolled bead or solid bead. Disposable cup beads 18 typically have a generally circular cross-section, and that includes beads 18 with an oval shape as formed or as deformed during stacking and shipping, and that includes beads 18 with a rounded upper edge and a slightly flattened outer facing edge, or even a slightly flattened bottom edge. In addition, the present invention may be used with cups having beads 18 that comprise a flange, projection, or any non-circular cross-section, and with cups may not be disposable.
[0022] A collar 20 is provided with an inner surface shaped to engage the cup sidewalls 16 . The inner surface is thus usually circular. In embodiments for use with angled cup sidewalls 16 , the collar inner surface 22 is preferably, but optionally tapered at an angle that corresponds to the angle of taper of the cup sidewalls 16 . The collar 20 also includes a projection, or locking surface 25 that may comprise several shapes. As shown in FIGS. 1 and 2 , the locking surface 25 comprises a shape similar to the bead 18 on the cup 10 , that is, a shape having a generally circular cross-section. An alternative shape for the locking surface 25 is shown in FIG. 9 , which comprises a shape that does not have a circular cross-section. It will be appreciated that the shape of the locking surface 25 may comprise a flange, a projection, a lip, or any protruding rim, edge, or rib that is used to hold a lid 40 in place.
[0023] The collar 20 also includes an extension 30 on its upper end. The extension 30 engages the bead 18 when the collar 20 is placed about the cup 10 . In one embodiment, a tip area of the extension 30 engages the lower inner quadrant of the generally circular cup bead 18 , as shown in FIG. 2 . One feature of the collar extension 30 is that by engaging under the cup bead 18 , the cup bead 18 is supported, which prevents the cup bead 18 from collapsing during use. For example, a child may squeeze the cup 10 , which without the support of the collar 20 and collar extension 30 , may cause the cup 10 to collapse. Another feature of the present invention is that it now allows very large cups to be made of paper, rather than plastic. This is because large paper cups generally collapse due to the cup bead 18 weakness. For example, paper cups generally do not exceed 18 ounces in capacity. Larger capacity cups are made from plastic, which is more expensive to manufacture than paper cups. Because the collar extension 30 supports the cup bead 18 , preventing collapse of the cup 10 , large capacity paper cups can now be manufactured.
[0024] The collar 20 may optionally includes a handle 36 , and may have more than one handle 36 if configured for use by infants or persons with impaired manual dexterity. Instead of a handle 36 , a textured gripping surface or a surface shaped to increase the ease and/or efficiency of gripping (e.g., vertical or horizontal ridges) may be employed. As shown in FIG. 4 , the collar 20 may also include a handle hinge 38 , which allows the handle 36 to pivot as shown by the arrow. This embodiment allows the handle 36 to pivot toward the collar 20 , making the collar 20 and handle 36 easy to carry in a purse, backpack, briefcase, or other type of handbag. In another embodiment the handle hinge 38 may include a locking feature, or element that keeps the handle 36 positioned adjacent to the collar 20 and/or in the deployed position, as illustrated in FIG. 4 . The locking feature may comprise a notch, or detent, or other arrangement within the handle hinge 38 that increases the effort required to rotate the handle hinge 38 away from the collar 20 into the position illustrated in FIG. 4 . Another embodiment collar 20 may include a handle 36 that has a tip, or distal end that contacts the cup sidewalls 16 when the collar 20 is positioned around the cup 10 (not shown). In this embodiment, the distal end provides support against the cup sidewalls 16 , thereby stabilizing the handle 36 and collar 20 . Yet another embodiment of the collar 20 , whether it includes the handle 36 , or not, is that it may be manufactured from biodegradable material, as well as and other materials, such as polymers, polyesters, polyolefins, polycarbonates, polyamides, polyethers, polyethylene, polytetrafluoroethylene, silicone, silicone rubber, polyurethane, polyvinyl chloride, polystyrene, stainless steel, aluminum alloys, and metal alloys.
[0025] As used herein, inner or inward refers to a direction toward a longitudinal axis of the cup 10 , and outer or outward refers to the opposite direction. Upper refers to a direction along the longitudinal axis from the cup 10 toward the lid 40 , and lower refers to the opposite direction, and above or below are with reference to the relative positions along the longitudinal axis of the cup 10 using the same orientation as “upper” and “lower.”
[0026] A closure or lid 40 fastens to the top of the cup 10 . In a preferred embodiment, the lid 40 is made of thin, vacuum formed plastic, typically styrene, and is typically about 0.015-0.020 inches thick. However, it will be appreciated that the lid 40 may be made of biodegradable materials, and other materials, such as polymers, polyesters, polyolefins, polycarbonates, polyamides, polyethers, polyethylene, polytetrafluoroethylene, silicone, silicone rubber, polyurethane, polyvinyl chloride, polystyrene, stainless steel, aluminum alloys, and metal alloys.
[0027] In one embodiment, as shown in FIG. 5 , the lid 40 has a raised area 44 with at least one aperture 42 that allows fluid passage or is sized to receive a drinking straw (not shown). The aperture 42 allows liquid within the cup 10 to pass outside the cup 10 . In another embodiment, the raised area 44 forms a spout, or other shaped opening which places the aperture 42 above the rim of the cup 10 . For example, in one embodiment, a spout sized for a child is envisioned. For a child, the spout is preferably a defined spout small enough to fit in a child's mouth. For an adult, the spout may form an annular ring extending around the entire periphery of the cup adjacent the bead 18 , with drinking apertures 42 located at one, or more places for drinking. Other embodiment lids 40 may include apertures 42 that have covers (i.e., flapped covers) which can be deflected, or otherwise moved, or removed, to allow passage of fluid. In another embodiment, the lid 40 may be shaped allow a user to both drink directly from the lid 40 , and also to drink from a straw (not shown) that may be located in another aperture, or opening in the lid 40 . For example, the lid 40 may include a first opening sized to receive a straw, and a second, larger opening sized to receive the lips of a user, so that a user would have the option of drinking from a straw, or drinking directly from the lid 40 . This feature may be helpful when consuming “frozen” drinks, that comprise ice cubes, or smaller ice particles in the form of crushed ice, or a blended slush made of partially melted ice or very small particles of crushed ice.
[0028] Referring again to FIG. 5 , in one embodiment, the lid 40 has an inner or interior recess 45 within the raised area 44 (both forming a cap), and an outer or exterior recess 46 outward of the raised area 44 . The interior recess 45 has a bottom which is located so it is above the rim of the cup bead 18 when the lid 40 is fastened on the cup 10 . A vent opening 48 is optionally located opposite the lid aperture 42 to allow air pressure to equalize between the inside and outside the cup 10 when the lid 40 is on the cup 10 , in order to allow liquid to flow smoothly through the lid aperture 42 . The interior recess 45 can also collect liquid that may spill from the lid aperture 42 . The interior recess 45 may be a larger depression, as shown in FIG. 5 , or in other embodiments, can be a localized depression in the lid 40 adjacent to a spout (not shown).
[0029] In the embodiment shown in FIG. 5 , the outer recess 46 preferably extends around the entire circumference of the lid 40 , so that when it is placed on the cup 10 , the outer recess 46 is immediately adjacent to the bead 18 . Referring to FIG. 2 , in this embodiment, the outer recess 46 extends below the rim of the cup 10 and preferably below the center of the bead 18 . In the illustrated embodiment, the outer recess 46 extends below the bottom of the bead 18 , but other embodiments may not extend as far. This embodiment of the lid 40 that includes an outer recess 46 may be suitable for larger size cups 10 , as the outer recess 46 , in conjunction with the collar extension 30 , support the cup bead 18 , and keep it from collapsing. However, smaller cups 10 may not need an outer recess 46 (and the support it provides) and thus it will be appreciated that an outer recess 46 may not be included in all embodiments of the present invention. As shown in FIGS. 1 and 2 , the support provided by the outer recess 46 is from a cup wall 50 that supports the cup bead 18 , and the adjacent upper cup portion. The cup wall 50 , and inner wall 52 form the outer recess 46 .
[0030] Referring now to FIGS. 2 and 6 , the cup wall 50 of the lid 40 extends past the upper portion of the cup 10 , forming a first recess, or bead recess 32 . The first recess 32 is sized to receive the cup bead 18 , as shown in FIG. 2 . In a preferred embodiment, the first recess 32 engages the cup bead 18 in a “snap-fit” caused by the first recess 32 elastically deforming slightly when the cup bead 18 is inserted into the first recess 32 . As illustrated in FIGS. 2 and 6 the first recess 32 is substantially circular and describes a truncated circle of about 220 degrees (where 360 degrees is a complete circle). However, it will be appreciated that the shape of the first recess may vary to correspond to different cup bead 18 shapes. It will also be appreciated that the shape of the first recess 18 may vary even if the cup bead 18 does not vary from the illustrated shape. For example, the first recess 18 may be substantially “U-shaped,” thus describing only a 180 degree truncated circle, or it may not be circular at all, but may comprise two walls sized to capture the cup bead 18 . In one embodiment, the first recess 32 provides a resilient gripping force (i.e., a first lock, or locking area or a first engaging area) to the cup bead 18 that prevents fluid within the cup 10 from escaping (i.e., a fluid tight seal).
[0031] Adjacent to the first recess 32 is the second recess, or second engagement area 34 . In the embodiment illustrated in FIG. 2 , a portion of the lid 40 extends past the first recess 32 and forms the second recess 34 . Similar to the first recess 32 , the second recess 34 is substantially circular and describes a truncated circle of about 180 degrees (where 360 degrees is a complete circle). In the embodiment illustrated in FIG. 6 , the second recess 34 includes a non-circular area, which is illustrated as flat, or planar, but may comprise other shapes, such as angled, or curved, or any combination of straight, angled or curved. For example, the shape illustrated in FIG. 6 is sized to receive a locking surface 25 that is not circular in cross-section, but instead may be a flange, a projection, a lip, or any protruding rim, edge, rib, or other shape.
[0032] Similar to the first recess 32 , the second recess 34 is sized to form a “snap-fit” with the locking surface 25 . However, this snap-fit may be caused by the second recess 34 elastically deforming slightly when the locking surface 25 is inserted into the second recess 34 , or the second recess 34 itself may not deform, but the section of the lid 40 that extends from the first recess 32 to the tip of the lid 40 may deform. For example, as illustrated in FIG. 2 , the tip of the lid 40 ends in a flange 35 . As the collar 20 with the locking surface 25 is inserted into the lid 40 , the flange 35 , as well as the second recess 34 may deflect slightly to receive the collar 20 and locking surface 25 . In a preferred embodiment, the second recess 34 provides a second locking, or engaging surface (in addition to the first recess 32 ) that additionally secures the lid 40 to the cup 10 . In the illustrated embodiment (shown in FIG. 2 ), the diameter of the locking surface 25 is greater than the diameter of the cup bead 18 . It will be appreciated that other embodiments may have the diameter of the locking surface 25 substantially equal to the diameter of the cup bead 18 .
[0033] One feature of the present invention is that the lid 40 now has two locking surfaces (first recess 32 and second recess 34 ) that provide additional locking, or engaging force (when compared to conventional lids that only employ one engaging surface with a cup bead). This substantially eliminates instances where a cup full of liquid is lifted, or grasped by the lid only, and the lid separates from the cup, spilling the liquid, due to the weak engagement between the lid and cup. The double locking feature of the present invention virtually eliminates inadvertent separation of the lid 40 from a cup 10 . This feature is especially helpful with children who attempt to pry a lid from a cup, often spilling the contents. Another feature of the present invention is that threading engagement between the cup and lid is eliminated and is replaced with a “snapping” engagement between the lid 40 and the cup 10 , greatly increasing ease, and quickness of engagement between the lid 40 and the cup 10 . Yet, the two locking surfaces (first recess 32 and second recess 34 ) provide the same fluid-tight capability and secure engagement offered by threads, but with less effort, and with substantially less manufacturing cost. For example, embodiments of the present invention may be vacuum formed, a process that is very cost effective, but which cannot be used to from threads. In addition, without threads, embodiments described herein comprising the collar 20 and handle 36 , may rotate about the circumference of cup 10 freely, without “unthreading” or becoming separated from the cup 10 .
[0034] As mentioned above, the lid 40 terminates in a flange 35 that is extends away from the cup 10 , so as to ease removal of the lid 40 from the cup 10 . That is, in one embodiment, the flange 35 angles away from the cup 10 sidewalls, providing an easily graspable surface for a person's fingers. It will be appreciated that the flange 35 may not be included in all embodiments of the present invention.
[0035] Referring now to FIG. 7 , which illustrates another embodiment of the present invention in the form of a non-disposable cup 60 that includes an integral collar 20 . In one embodiment, the non-disposable cup 60 is sized to receive a disposable cup 10 having a bead 18 . The non-disposable cup 60 may have a bottom, or the bottom may be eliminated, thus the non-disposable cup 60 may only include sidewalls. In a preferred embodiment, the non-disposable cup 60 includes an integrally attached collar 20 that may be substantially identical to the collar 20 , or modified. For example, in one embodiment, an integral collar includes an annular locking surface 25 that is sized to engage the second recess 34 on the lid 40 . When a disposable cup 10 is placed into the non-disposable cup 60 , the periphery of the non-disposable cup 60 engages the cup bead 18 , similar to the collar extension 30 . A lid 40 is then placed over the disposable cup 10 and the non-disposable cup 60 . The first recess 32 on the lid 40 engages the cup bead 18 , and the second recess 34 on the lid 40 engages the locking surface 25 on the non-disposable cup 60 . In this fashion, two separate locking, or engaging regions provide double security from fluid leakage as well as doubly securing the lid 40 to the cups 10 and 60 .
[0036] As shown in FIG. 7 , another embodiment non-disposable cup 60 may include a modified collar 20 that includes grasping elements 62 . As illustrated, the grasping elements 62 may be projecting dimples, or alternatively, the grasping elements 62 may be circular depressions, or they may be projecting ridges, depressed channels (not shown) or other suitable features that provide additional purchase for gripping the non-disposable cup 60 . In addition, the collar 20 , and/or the locking surface 25 , as well as the grasping elements 62 may be constructed of a material having a high friction coefficient, such as rubber, plastic, a polymer, or any equivalents. The non-disposable cup 60 may be constructed of plastic, stainless steel, metal, metal alloys, aluminum alloys or other suitable materials. That is, the non-disposable cup 60 and its integral collar 20 may or may not be manufactured from the same material. In addition, another embodiment non-disposable cup 60 may include a handle 36 that may or may not include a handle hinge 38 that may or may not include the locking features described above in connection with FIGS. 3 and 4 . In another embodiment, the non-disposable cup 60 may, in fact, be disposable. That is, the cup 60 may be made from paper, or other material so that the cup 60 would be disposable.
[0037] In use, a cup 10 is placed in the collar 20 , with or without liquid already in the cup 10 . If the cup 10 contains hot liquid, such as coffee, the purchaser can now grasp the handle 36 , and thereby directly avoid holding the hot cup 10 . With the collar 20 and collar extension 30 now positioned adjacent to the cup bead 18 , as described above, the lid 40 can be placed over the cup 10 . The first recess 32 on the lid 40 engages the cup bead 18 , and the second recess 34 on the lid 40 engages the locking surface 25 on the collar 20 (in a “snap-fit” as described above). In this fashion, two separate locking, or engaging regions provide double security from fluid leakage as well as doubly securing the lid 40 to the cup 10 . In addition, the collar 20 provides support to the cup 10 , preventing collapse of the cup 10 . When the fluid is consumed, the user can pull the collar 20 down toward the base of the cup 10 , unlocking the collar 20 from the lid 40 , or the lid 40 can be removed from the cup 10 by grasping the flange 35 . The disposable cup 10 and lid 40 may then be discarded, and the collar 20 can be re-used. Or, in another embodiment, the collar 20 (with or without handle 36 ) may also be disposable, that is, designed for a one-time-use.
[0038] Alternatively, the lid 40 may be snapped onto the bead 18 of the cup 10 , and the cup is then inserted through the opening of the collar 20 until the lid snaps onto the collar 20 . Specifically, the first recess 32 on the lid 40 engages the cup bead 18 , and the second recess 34 on the lid 40 engages the locking surface 25 on the collar 20 . In this fashion, two separate locking, or engaging regions provide double security from fluid leakage as well as doubly securing the lid 40 to the cup 10 . The collar 20 also supports the cup bead 18 , preventing collapse of the cup 10 . When the fluid is consumed, the user can remove the lid 40 from the cup 10 by grasping the flange 35 . Once the lid 40 is removed, the cup 10 and collar 20 are easily separated. The disposable cup 10 and lid 40 may then be discarded, and the collar 20 can be re-used.
[0039] Referring now to FIGS. 8 and 9 , another embodiment of the present invention in the form of a partial collar 65 is illustrated. As shown, the partial collar 65 does not comprise a complete ring like collar 20 , but instead comprises a curved ¼ arc, ⅓ arc, ½ arc, or other sized arc. That is, instead of a collar 20 that completely circumscribes, or encircles a container as illustrated in FIGS. 3 and 4 , this embodiment of the invention does not extend completely around the perimeter of a container or cup 10 . This embodiment of the invention may be sized to fit any cup, and the fingers 69 which extend from the handle 36 around the cup (not shown) may deflect to fit different cup circumferences. It will be appreciated that this embodiment of the invention includes any length of fingers 69 , ranging from fingers 69 that would only circumscribe less than ¼ of a cup's perimeter, or circumference, to fingers 69 that would almost meet, thereby circumscribing all but a small portion of the cup's circumference (for example, a ¼ inch or less). The partial collar 65 includes many of the features found in the collar 20 , and also functions similarly. The partial collar 65 includes a collar extension 30 , that when placed against a cup 10 , abuts the cup bead 18 as shown in FIG. 2 . In addition, the partial collar 65 also includes the locking surface 25 that engages the second recess 34 on the lid 40 , as also illustrated in FIG. 2 , and described above.
[0040] Referring to FIG. 9 , this embodiment of the partial collar 65 includes a hinge 38 so that the handle 36 can pivot as shown by the arrow. In addition, this embodiment includes a locking surface 25 that is not circular in cross-section, but instead includes a small shelf, or planar projection that aids in securely engaging with the lid 40 . It will be appreciated that the shape of the locking surface 25 may comprise a flange, a projection, a lip, or any protruding rim, edge, or rib that is used to hold a lid 40 in place. As shown in both FIGS. 8 and 9 , the partial collar 65 may include an optional brace, or extension 67 , that projects downward from the base of the handle 36 . This optional element may provide additional stability and support when the partial collar 65 is positioned against a cup sidewall 16 , as the brace 67 contacts the cup sidewall 16 . Because the fingers 69 of the partial collar 65 do not extend around the entire circumference of a cup 10 , the method of installing and removing the partial collar 65 is simpler than the collar 20 , described above. For example, one method comprises attaching the lid 40 to the cup 10 , and then positioning the partial collar 65 against the cup sidewall 16 and moving the partial collar 65 upward so that the locking surface 25 engages with the second recess 34 on the lid 40 . The collar extension 30 functions as described above in connection with the collar 20 , supporting the cup bead 18 , thereby preventing the collapse of the cup 10 . In addition, the locking surface 25 , in conjunction with the second recess 34 , provides an additional locking, or engaging region (the first being the bead 18 and the first recess 32 ) to provide double security from fluid leakage as well as doubly securing the lid 40 to the cup 10 . Alternatively, the partial collar 65 may be installed by first placing the collar extension 30 underneath the cup bead 18 , as shown in FIG. 2 , and then snapping the cup lid 40 over both the cup bead 18 and the locking surface 25 , thereby engaging the first recess 32 and the second recess 34 with the cup bead 18 and the locking surface 25 , respectively. As described above, this provides two separate locking, or engaging regions that provide double security from fluid leakage as well as doubly securing the lid 40 to the cup 10 .
[0041] Another embodiment of the present invention includes an integral lid 40 and handle 36 (not shown). In this embodiment, the handle 36 with fingers 69 may be pivotally attached (by a hinge, or other means) to the lid 40 so that when the lid 40 is positioned over a cup 10 , the handle 36 and fingers 69 may be rotated downward, with the locking surface 25 on the fingers 69 engaging the second recess 34 on the lid 40 . This embodiment may, or may not be disposable, and the hinge, or pivoting means may or may not include a locking feature as described above.
[0042] Both the collar 20 and the partial collar 65 may include additional features. For example, either embodiments 20 or 65 may include more than one handle 65 , which may be helpful for senior citizens or children. Another feature may be a barcode or other type of identifier (and may also include a BLUETOOTH® functionality) that may be permanent, or temporary, and which may be located on the handle 36 , or elsewhere. For example, a person may purchase either the collar 20 or partial collar 65 from a coffee, or other beverage purveyor, who places information on the collar 20 or partial collar 65 , such as the consumers coffee preference. The information, in the form of a barcode, RF tag, or other information source, may be manufactured into the handle 36 , or the collar 20 or partial collar 65 , or the purveyor may provide a barcode dispenser, with stamp-like barcodes, that can be affixed to the handle 36 , or collar 20 or partial collar 65 , with different barcodes identifying different beverages.
[0043] Referring now to FIGS. 10-12 , yet another embodiment of the present invention in the form of a partial collar 65 with projections 70 is illustrated. As shown, the partial collar 65 does not comprise a complete ring-like collar 20 , but instead comprises a curved ¼ arc, ⅓ arc, ½ arc, or other sized arc. That is, instead of a collar 20 that completely circumscribes, or encircles a container as illustrated in FIGS. 3 and 4 , this embodiment of the invention does not extend completely around the perimeter of a container or cup 10 . This embodiment of the invention may be sized to fit any cup, and the fingers 69 which extend from the handle 36 around the cup (not shown) may deflect to fit different cup circumferences. It will be appreciated that this embodiment of the invention includes any length of fingers 69 , ranging from fingers 69 that would only circumscribe less than ¼ of a cup's perimeter, or circumference, to fingers 69 that would almost meet, thereby circumscribing all but a small portion of the cup's circumference (for example, a ¼ inch or less). The partial collar 65 includes many of the features found in the collar 20 , and also functions similarly. The partial collar 65 includes a collar extension 30 , that when placed against a cup 10 , abuts the cup bead 18 as shown in FIG. 2 . In addition, the partial collar 65 also includes the locking surface 25 that engages the second recess 34 on the lid 40 , as also illustrated in FIG. 2 , and described above.
[0044] Referring again to FIGS. 10-12 , this embodiment includes a locking surface 25 that is circular in cross-section that aids in securely engaging with the lid 40 . It will be appreciated that the shape of the locking surface 25 may comprise a flange, a projection, a lip, or any protruding rim, edge, or rib that is used to hold a lid 40 (as shown in FIG. 2 ) in place. As shown in FIGS. 10-12 , the partial collar 65 may include a projection 70 that extends outward from the fingers 69 . In the illustrated embodiment, each finger 69 has its own projection, or tab 70 . The projections 70 are sized to receive a user's finger, thumb or other digit to aid in removing the partial collar 65 from a cup 10 . That is, when the partial collar 65 is firmly located about a cup 10 , a user can push on the projections 70 to remove the partial collar 65 from a cup 10 . It will be appreciated that the projections 70 may comprise a tab, or an outward extending flange, and comprise shapes other than illustrated in FIGS. 10-12 .
[0045] Referring again to FIGS. 10-12 , this embodiment includes the features of other embodiments described herein, for example, because the fingers 69 of the partial collar 65 do not extend around the entire circumference of a cup 10 , the method of installing and removing the partial collar 65 is simpler than the collar 20 , described above. For example, one method comprises attaching the lid 40 to the cup 10 , and then positioning the partial collar 65 against the cup sidewall 16 and moving the partial collar 65 upward so that the locking surface 25 engages with the second recess 34 on the lid 40 . The projections 70 can be grasped by a user to aid in moving the partial collar 65 upward.
[0046] Also, the collar extension 30 functions as described above in connection with the collar 20 , supporting the cup bead 18 , thereby preventing the collapse of the cup 10 . In addition, the locking surface 25 , in conjunction with the second recess 34 , provides an additional locking, or engaging region (the first being the bead 18 and the first recess 32 ) to provide double security from fluid leakage as well as doubly securing the lid 40 to the cup 10 . Alternatively, the partial collar 65 may be installed by first placing the collar extension 30 underneath the cup bead 18 , as shown in FIG. 2 , and then snapping the cup lid 40 over both the cup bead 18 and the locking surface 25 , thereby engaging the first recess 32 and the second recess 34 with the cup bead 18 and the locking surface 25 , respectively. As described above, this provides two separate locking, or engaging regions that provide double security from fluid leakage as well as doubly securing the lid 40 to the cup 10 .
[0047] For example, one embodiment of a partial collar 65 may comprise an apparatus for holding a container having a bead around an opening, the apparatus comprising a partial ring comprising an annular locking surface extending outwards from the partial ring, an annular extension located above the annular locking surface, the annular extension having a distal portion that tapers to a distal end, a projection located below the annular locking surface, the projection extending outwards from the partial ring and a handle extending from the partial ring. The annular locking surface may comprise a substantially circular cross-section, with the substantially circular cross-section extending outwards from the partial ring. The partial ring may comprise two curved elements that extend more than one-half of a circumference of the container. The projection may comprise two outward extending elements, each located at a respective distal end of two curved elements that comprise the partial ring. A hinge may be located substantially between the partial ring and the handle, the hinge allowing a distal end of the handle to pivot toward the ring.
[0048] In one preferred embodiment, the embodiment described immediately above is constructed to operate in conjunction with a lid for a container having a bead around an opening. The lid comprises a cap with an aperture, an annular base depending from the cap, the base having a first recess sized to engage the bead of the container to provide a first fastening engagement with the container and a second annular recess adjacent to the first recess, the second recess sized to engage a second bead, and provide a second fastening engagement with the container. The second bead may be located on the container, or it may be located on an element that is positioned about the perimeter of the container. The lid may further include an annular cup wall that abuts a container sidewall when the lid is positioned on the container. The container bead may be selected from a group consisting of: a bead having a substantially circular cross-section, a projection, a flange, and a locking surface. The aperture may be selected from a group consisting of: an opening, a opening covered with a moveable flap, an opening covered with a removable element, a spout, an opening sized to receive a straw, and an opening sized to receive a users lips. Also, the bead-engaging surface may be sized to be positionable adjacent to the container bead, and the locking surface is sized to engage a recess on a lid.
[0049] Thus, it is seen that lid, collar and handle for a beverage container are provided. One skilled in the art will appreciate that the present invention can be practiced by other than the above-described embodiments, which are presented in this description for purposes of illustration and not of limitation. The specification and drawings are not intended to limit the exclusionary scope of this patent document. It is noted that various equivalents for the particular embodiments discussed in this description may practice the invention as well. That is, while the present invention has been described in conjunction with specific embodiments, it is evident that many alternatives, modifications, permutations and variations will become apparent to those of ordinary skill in the art in light of the foregoing description. Accordingly, it is intended that the present invention embrace all such alternatives, modifications and variations as fall within the scope of the appended claims. The fact that a product, process or method exhibits differences from one or more of the above-described exemplary embodiments does not mean that the product or process is outside the scope (literal scope and/or other legally-recognized scope) of the following claims.
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An apparatus, system and method for attaching a lid to a beverage container is provided. In one embodiment a lid is positioned over the container opening and fastened to a first bead located around the opening. The lid also fastens to a second bead that is either located on the container, or located on a partial ring that is positioned adjacent to the first bead. The partial collar may only extend partway around the container. The partial collar may be removable and may also include a handle. This Abstract is provided for the sole purpose of complying with the Abstract requirement rules that allow a reader to quickly ascertain the subject matter of the disclosure contained herein. This Abstract is submitted with the explicit understanding that it will not be used to interpret or to limit the scope or the meaning of the claims.
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TECHNICAL FIELD OF THE INVENTION
The present invention relates in general to the field of nasal surgery and more specifically to a method and apparatus for the removal of blood during nasal septal reconstructive surgery and stoppage of blood from the nasal cavity to the throat.
BACKGROUND OF THE INVENTION
Nasal septal reconstructive surgery has many facets. Often it will involve autogenous cartilage drafting and external nasal reconstruction. This is accomplished by going inside the nasal cavity and cutting and removing tissues as part of the reconstructive activity. This type of surgery has several inherent features that impede a physician's ability to perform the procedure. Obviously during the course of the operation, the procedure for nasal reconstructive surgery causes a flow of blood both into and out of the nasal cavity.
The flow of blood during nasal septal reconstruction creates several difficulties associated with the procedure. The blood flows into the nasal cavity in two different directions, both deeper into the nasal cavity from the point of laceration and, in the opposite direction, out of the patients nose. Blood flowing further into the nasal cavity causes choking action and breathing difficulties on the part of the patient which in turn triggers certain autonomic reflexes that are potentially hazardous and can otherwise be obstructive to the patient's well being. Blood flowing forward can obviously be an obstruction to the physician's ability to perform the surgery.
Another solution to the problem of blood flow during nasal septal reconstruction has been the use of a nasal tampon designed to control nasal hemorrhage. Unfortunately, the nasal tampon requires the use of an absorptive sponge that must be moistened prior to insertion. The sponge portion of the nasal tampon must also be compressed prior to insertion, and regains its sh ape as the tampon portion is being inserted, causing abrasions to the inner surfaces to the nose. Finally, the nasal tampon only serves to remove blood from the area and has no control capabilities as to the extent of pressure on the walls of the nasal cavity or the amount of damage that can happen during its retraction.
Therefore, what is needed is a method for simultaneously blocking the flow of blood from going further into the patient's nasal cavity while withdrawing blood flowing in the opposite direction. By performing these two steps simultaneously the physician reduces the likelihood of the patient suffering breathing and choking difficulties caused by the flow of blood and prevents the blood flowing out the patient's nose from obstructing the procedure being performed by the physician.
In the past physicians primarily used gauze to remedy the problem of blood draining out of the nasal cavity. A physician would pack the gauze into the nasal cavity. The gauze was used to absorb the flow of blood. This would help reduce the blood's interference with the physician's operation. However, the use of gauze in nasal septal reconstruction created other problems.
First, the use of gauze had certain limitations. Depending on the size of the surgery, one may not be able to utilize enough gauze to stop the flow of blood because the physician needs space to operate. In addition, gauze does not fully contain the flow of blood in all procedures. This means the physician has to change the gauze several times during the operation. This need to change gauze during a procedure interferes with the operation and increases the time the patient is under anesthesia. It is desirable to limit the time a patient is under anesthesia to as short a time as possible. Yet another limitation involved another type of interference. In using gauze as a sponge, the gauze would be placed in the nasal cavity during the operation and removed afterward. Often times it was found that when the gauze was removed after an operation some of the reconstructed tissue would deform. This is because it had been supported by the gauze during the reconstruction. This created the need to repeat the reconstructive procedure, reinforcing work that had already been done, so that it could exist independently of the support of the gauze. Other than attempting to be more skilled at recognizing the problem, there was little a physician could do to alleviate it. There were various attempts but none that offer the benefits of the instant invention.
SUMMARY OF THE INVENTION
The invention provides a way to prevent the flow of blood deeper into a nasal cavity while simultaneously, quickly and non-obstructively removing the blood flowing out of the nasal cavity toward the exterior of the patient's nose. This is accomplished by inserting a catheter having an inflatable balloon at a forward end into the nasal cavity. Once inserted, inflating the balloon to seal off the rear portion of the nasal cavity. Blood is then suctioned out of the forward portion of the nasal cavity through a series of holes in the catheter and into an interior duct for quick and efficient removal.
The catheter is constructed of an outer tube, an inner duct and a plurality of holes that connect the duct with the outer surface of the tube. Inside the tube is a lumen used for transporting a substance, such as gas or liquid, into the balloon. The substance is used to inflate the balloon from a remote location. Blood is drawn into the duct while the balloon seals the nasal cavity, preventing any flow of blood further into the cavity.
In one embodiment the catheter is made of an elastomeric material. The material would have qualities that allow flexibility and strength. In addition it must have smooth surfaces, both inside and outside. The inner surface of the duct must be smooth so that blood can flow through it to be carried away from the nose.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts and in which:
FIG. 1 illustrates a cutaway view of a human head with a catheter inserted therein;
FIG. 2 shows a cutaway view of the invention;
FIG. 3 illustrates a plurality of holes in a portion of a catheter;
FIG. 4 shows a cross section of a catheter;
FIG. 5 shows a cross section of a catheter;
FIG. 6 illustrates a portion of a catheter attached to a pump and a suction device;
FIG. 7 shows a balloon in one embodiment;
FIG. 8 shows a balloon in an alternative embodiment;
FIG. 9 shows a portion of a catheter having a non-inflated balloon;
FIG. 10 shows a portion of the catheter prior to insertion; and
FIG. 11 shows the catheter inserted in a nasal cavity.
DETAILED DESCRIPTION OF THE INVENTION
The invention disclosed is for a method and apparatus for simultaneously isolating the flow of blood in a nasal cavity and withdrawing the blood from a nasal cavity. A catheter having a balloon near one end and two channels contained inside is inserted into a nasal cavity. The first channel forms a lumen for the flow of a liquid to inflate the balloon. Once properly in place, the balloon is inflated to form a seal with the cavity wall. The catheter has a plurality of holes in it. The holes lead to the inner channel, or duct. Blood is drawn into the duct through the holes and in this way is removed from the body.
In one embodiment of the invention is shown in FIG. 1. The illustration 10 shows a cutaway of a human head 36. Head 36 has a nose 12 having a nasal cavity 14. It may be seen from FIG. 1 that nasal cavity 14 is characterized by a tubular shape that extends from a rear portion 42 of nasal cavity to a forward portion 40 for purposes of our illustration. The tubular shape of nasal cavity 14 is irregular and varies in diameter at different points. The shape of nasal cavity 14 varies in diameter within a given head but also varies from head to head. Each nasal cavity 14 has a distinct shape. That shape is dictated by the individual's genetic code and any direct physical changes that may have occurred. Examples of such cavity 14 shaping events would include prior surgical operations or physical mishaps, such as sports injuries, that directly affect the shape of nasal cavity 14. This factor is important when choosing a method to stem the flow of blood in nasal cavity 14 while simultaneously removing the flowing blood from nasal cavity 14.
Inside nasal cavity 14 is a catheter 16. A catheter, being a slender, flexible tube that is inserted into the body, comes in a variety of shapes and sizes depending upon its specific purpose. In the present invention catheter 16 has unique features that are key to the invention. Overall, catheter 16 is slender, flexible and is inserted into the human body, see FIG. 1. It is slender enough so that it may be slidably inserted into a nasal cavity 14. This means that the diameter of catheter 16 must be small. It must also be long so as to be able to be connected to other devices outside of nasal cavity 14. The exterior of catheter 16 must be smooth and composed of such a material that ease of entry into nasal cavity 14 is enhanced by the surface contact. There are several potential materials catheter 16 may be made from, silicon, natural or synthetic rubber, polymer and elastomeric polymers. Combinations of all of these are well known in the art. They may be used to create an exterior surface that will facilitate the ease of entry of a catheter 16 into nasal cavity 14.
Catheter 16, illustrated in FIG. 2 is composed of a tube 24 having an external surface area which makes up catheters' 16 outer surface and an internal surface area that forms the interior of the tube 24. The interior of tube 24 forms a duct 22. The duct 22 must also be made of a material having a smooth surface. A smooth surface will aid the passage of blood through duct 22 to a point of ultimate disposal. Duct 22 will generally be cylindrical in shape and have a large enough diameter to allow the flow of blood. Duct 22 is for most of its length coextensive with tube 24 and is used to transport blood, and potentially other bodily fluids, from one end of catheter 16 to another. Duct 22 is defined by an exterior surface that is also generally coextensive with the interior surface of tube 24 but spaced apart from tube's 24 interior surface.
FIG. 2 shows a view of catheter 16 outside of nasal cavity 14. It is a cutaway view of catheter 16 and all the components that it consist of. FIG. 2 provides a cutaway view of the internal as well as external structure. Catheter 16 shows a balloon 18 in its inflated state. The balloon 18 may be formed of a part of catheter 16 that has certain elastic properties that are not found in the rest of catheter 16. These properties would include the ability to deform and then return to its original shape. This may be accomplished by mechanically attaching a different type of material at the point where balloon 18 is to be placed. The recommended material would be more elastic and have the capability of being inflated. In addition, once inflated it must have enough elasticity to return to its original shape with little or no distortion from the initial shape. The more elastic material will inflate when put under pressure before the rest of tube 24. Another way to accomplish the construction of balloon 18 is to have a thinner diameter at the point where balloon 18 is to be located. The thinner diameter must be of sufficient diameter to not tear when placed under pressure, such as when in an inflated state. The length of balloon 18 is also a factor that must be considered. In FIGS. 7 and 8 other potential balloon 18 shapes are disclosed. FIG. 7 shows an elongated balloon 18a structure. This structure may be used to seal surface areas that are irregular and may not be engaged at a more narrow juncture. FIG. 8 shows a shortened balloon 18b. This structure may be used in places where nasal cavity 14 is convoluted and/or congested and there is not enough room for larger sized balloons 18. Obviously the size of balloon 18 depends on several factors. These factors include the size of nasal cavity 14, the amount of space within cavity 14, the types of obstructions that may be found inside nasal cavity 14 and the other geometry specific considerations. The factors for the shape of balloon 18 should also include take into consideration the properties of the material(s) that will be used to construct balloon 18. The physical properties may dictate to a certain degree the extent to which balloon 18 may be inflated and deflated and over what surface area.
Balloon 18 is inserted into a nasal cavity 14 in it's rest position, or deflated state. Once positioned, balloon 18 is then inflated so as to expand and engage the interior walls of nasal cavity 14. Balloon 18 is expanded until it is sealably engaged with nasal cavity 14 walls so as to prevent the flow of blood from the operating area to the forward portion 40 of nasal cavity 14 and into the patient. Balloon 18, when inflated, will assume a shape that will generally conform to the contours of the interior of nasal cavity 14. Catheter 16 is connected to a device that is used for drawing blood through holes 20 into duct 22 and out of nasal cavity 14, as herein described.
FIGS. 2, 4 and 5 disclose a lumen 26. Lumen 26 is contained entirely within the interior of tube 24. Lumen 26 in the embodiment described herein is completely contained within the interior of tube 24. It consist of a cylindrical shape whose external walls are coextensive throughout most of catheter 16 with the interior walls of tube 24. It can be seen from FIG. 2 that lumen 26 is coaxially aligned with catheter 16 for a portion of its length. The extent to which the two are coextensive depends upon a number of factors, including the types of devices attached to catheter 16 and the functional requirements of catheter 16. For example, the pumping device 30 that is attached to lumen 26 may have physical characteristics that cause it to severely lose pressure per unit length of lumen 26. In that situation, it would be desirable to have as short of a lumen 26 as possible. This would mean lumen 26 may be shorter in length than duct 22. Again, depending on the type of equipment that may be used, the opposite may be true. In general, lumen 26 and duct 22 are fairly coextensive except for slight differences dictated by operational needs.
FIGS. 4 and 5 show two different configurations of the physical relationship between holes 20, duct 22 and lumen 26. In both embodiments, lumen 26 and duct 22 are coexistent. It is through lumen 26 that a substance, gas or liquid, is pumped. In the invention described herein, water is the substance that is used. The water in turn inflates and deflates balloon 18 according to the needs of the physician.
FIG. 4 shows a dissectional cross view of catheter 16 having a lumen 26 within the interior of tube 24 at a particular portion. This configuration essentially places a pipe shaped lumen 26 inside the interior of tube 24. The remaining channel in the tube 24 serves as duct 22 to be used for the removal of the flow of blood from nasal cavity 14. There is one hole 20 placed opposite lumen 26.
FIG. 5 shows a dissectional cross view of catheter 16 having a tube 24 and a lumen 26 that is circumferentially coextensive with tube 24. In this embodiment lumen 26 is composed of space created between the exterior wall of a duct 22 and the interior wall of a tube 24. Here, there are two holes 20, in the same plane, at angles to lumen 26.
Returning to FIG. 2, the physical relationship between a balloon 18 and a lumen 26 is also disclosed. Balloon 18 is the terminal point for lumen 26. In the most general designs, duct 22 terminates at a point near balloon 18 allowing the passage that defined lumen 26, between duct 22 and the wall of tube 24, to expand and open into balloon 18. Duct 22 closes upon itself in a completely sealed fashion at this end of catheter 16 so that it does not extend into balloon 18. One purpose of this seal is to insure that any blood that enters duct 22 flows in only one direction. This necessarily means that the space that previously defined lumen 26 now empties into balloon 18. The terminal point for this space may be nipple 38, after having passed through balloon 18. This is clearly illustrated in FIG. 2. In an alternative form, the termination of the space may be the end of balloon 18.
FIGS. 3, 4, 5 and 9 illustrate various placements of a plurality of holes 20 at the distal end of catheter 16. In all the embodiments the plurality of holes 20 go through the outer surface of catheter 16, through the inner surface of catheter 16 and connects through to duct 22. It is through these holes 20 that blood is drawn and passes through associated duct 22 and out to a point removed from nasal cavity 14.
FIGS. 4 and 5 show holes 20 in different configurations in cross sectional views. In the cross sectional view, FIG. 4 shows a single hole 20. Holes 20 in this embodiment feed directly into a duct 22, thus providing for transport of a patient's blood from the nasal cavity 14 to said duct 22.
FIG. 5 discloses holes as being circumferentially displaced along the axis of catheter 16. They are open at the exterior surface of a tube 24, pass through tube 24 and through the interior surface of tube 24. From there holes 20 pass through the interior walls of tube and continue on, defined by a cylindrically enclosed space, into the exterior surface of duct 22, through to the interior surface. It is at this point that blood flowing into duct 22 joins the stream of blood that is being directed to a rear position for disposal. Holes 20 may be placed in an infinite number of arrangements and sizes. These are but two examples.
FIG. 3 shows an embodiment wherein holes 20 are linear spaced in the direction of the length of catheter 16. FIG. 3 provides another illustration of plurality of holes 20. The placement of holes 20 in a tube 24 depends upon a number of different factors. Holes 20 must be positioned so as to enable blood withdrawal from within nasal cavity 14. One consideration in the placement of holes 20 is the desire to maximize holes' 20 ability to keep up with the rate of blood flow stemming from a patient's nasal cavity 16. If the type of surgery to be performed anticipates the need to remove an abnormally high flow of blood, there will be a need to increase either the number of holes or the size of the holes. The working requirements of suctioning device 28 to be attached would also be a consideration. The drawing power of suctioning device would dictate the number of openings. Another consideration would need to be the structural integrity of tube 24. It is desirable to avoid having so many holes 20 that tube 24 becomes structurally weakened. Other factors to be considered include the type of the material used to make tube 24, the number of holes 20 that are desired for the particular job and the type of device that will be used with catheter 16 to bring the blood into duct 22 through holes 20. The size of holes 20 will also be determined by these factors. Five (5) holes 20 are illustrated in FIGS. 2 and 3. In the one embodiment, holes 20 are equally spaced.
Nipple 38 is located at a far end of catheter 16 followed by an inflatable balloon 18 in its inflated state. Balloon 18 is slidably inserted into a nasal cavity 14 at a forward portion 40 of nasal cavity 14 as shown in FIG. 11.
Balloon 18 is followed by a plurality of holes 20 that go through outer tube 24 of catheter 16. Holes 20 lead to a duct 22 within catheter 16. The holes 20 are used to remove blood from the rear portion 42 of nasal cavity 14. This is accomplished by coercing the blood into holes 20 and into duct 22.
One form of coercion is to apply a suction force at the opening of holes 20 to draw the blood into duct 22. This may be accomplished by attaching a suctioning device to duct 22. This creates a suction force at the entrance of holes 20 . This suction would draw blood into duct 22 through holes 20. The suction force created by suction device 28 is spread out over the area of holes 20. In this way the blood is disposed quickly and effectively by being drawn into duct 22 as a result of the suction force at holes 20. The suction force should be sufficient to not only draw blood from an external source and into duct 22, but to also be able to be able to draw the blood along duct 22 unto it reaches a point where it will be disposed. This suction action should also be sufficient to overcome any obstructions that may occur. It is important that the suction force that is applied is not overly strong. If the force is too strong it will be hazardous to the surgery by drawing in, or at least pulling at, tissues that may become loosed during the procedure. This would exacerbate the work done by the physician because the placement of tissue, before, during and after an operation, is crucial.
Balloon 18 may be inflated by a pumping device, as shown at 30. The pumping device 30 must have the ability to inflate and deflate balloon 18 via the use of some substance that has the capability of flowing through lumen 26. As mentioned above, balloon 18 may be inflated by a gas or a liquid. The preferred embodiment would inflate balloon 18 with a gas because it is lighter than liquids. Air is a natural choice because of its availability. The pump 30 may have an associated device 32, or cut off valve, that can be releasably engaged allowing the user to either inflate or deflate balloon at will. Cutoff valve 32 is in an open position to allow gases or liquids to flow in or out and in the closed position to maintain gas in lumen 26 and balloon 18 at a desired pressure. Pump 30 should allow for variable control over the inflation pressure so that balloon 18 may expand only as much as needed and not cause any undue pressure in nasal cavity 14.
In combination, a catheter 16 is slidably inserted into a nasal cavity 14, as illustrated in FIG. 10. Once positioned, a pumping device 30 is used to inflate a balloon 18 on catheter 16. A balloon 18 is inflated to engage the side walls of cavity 14. A suctioning device 28 attached to another end of catheter 16 is then activated creating a suction force within a duct 22 inside said catheter 16. The suction force is dispersed in duct 22 and applied at the openings of holes 20. Blood is suctioned into holes 20 and into duct 22 to be disposed of at a distant end. The physician then performs nasal reconstructive surgery relatively free of the flow of blood in either direction in nasal cavity 14.
After the operation is completed, balloon 18 is deflated. The entire catheter is then removed from nasal cavity 14.
While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention will be apparent to persons skilled in the art upon reference to the description. It 15 , therefore, intended that the appended claims encompass any such modifications or embodiments.
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A method for simultaneously isolating the flow of blood in a nasal cavity and withdrawing the blood from the nasal cavity is disclosed. The method comprises the steps of inserting a catheter into the nasal cavity. The catheter is composed of a tube and a duct and a forward end capable of being enlarged to form a balloon. Once the catheter is positioned in the nasal passage, air is pumped into the catheter through the tube to inflate the balloon. The inflated balloon forms a seal within the nasal cavity that prevents the flow of blood beyond the seal.
Simultaneously, blood is drawn into the catheter by applying a suction force to the duct. Suction may be accomplished by attaching a vacuum at the opposite end of the catheter and connecting it to the duct. The blood is drawn into the duct through a plurality of holes that connect the periphery of the catheter with the duct. The blood thus drawn into the duct is removed from the nasal cavity and disposed away from it.
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This is a national stage of PCT/DK09/000072 filed on 26 Mar. 2009 and published in English, which has a priority of European Patent Appln. No. 08388012.0 filed 26 Mar. 2008, hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to exercise equipment or training devices allowing the user to perform a specific physical activity aimed to improve for example strength, stamina or agility of the user. The training device may be designed to train certain parts of the body or to improve the general fitness of the user. Training devices range from simple lifting weights, exercise balls and the like to more complex treadmills, exercise bikes and the like.
BACKGROUND OF THE INVENTION
Individuals recovering from a surgery or injury may speed up their recovery by the use of training devices. Such individuals typically need small and light training devices suitable for use in hospital or home environments. Training devices suitable for physical therapy should preferably be flexible, adjustable and work in a controlled manner to be usable for different patient groups needing different training. Depending on the body part in need of training a different training program may be required. Additionally, some patients are in need of frequent rest periods while others may train for a longer time period.
Most training devices provide a rather monotonous training without any intellectual stimulation and tend to bore the user within a few minutes of activity. Additionally, most exercise systems are quite heavy and therefore cannot be moved over a very far distance and provide very little portability.
SUMMARY OF THE INVENTION
It is an object according to the invention to provide a device and a method for indoor physical activity, which gives the user increased intellectual stimulation and thereby motivation during the training exercise. It is a further object of the invention to provide a system, which is both modular and flexible to allow it to be transported and assembled in any location.
The above object together with numerous other objects, advantages and features which will be evident from the below detailed description of the presently preferred embodiments of the invention according to a first aspect of the present invention are according to the teachings of the present invention obtained by a therapeutic training device comprising a shallow housing of a specific shape having a quadratic top surface, a quadratic bottom surface and four thin rectangular side surfaces, the housing comprising: an upwardly open cavity in the top surface, a flexible and transparent cover enclosing the cavity at least partially, the flexible and transparent cover having a size in the range between the size of a human fist and the size of a human foot, and defining a central part, a force sensor placed inside the cavity and communicating with the central part, the force sensor measuring the force applied on the flexible and transparent cover and generating a response signal, a light source placed inside the cavity, the light source being visible through the flexible and transparent cover, a central processor placed inside the housing for activating the light sources in accordance with a specific software and evaluating the response signal from the force sensor in accordance with the specific software, and a plurality of communication means located on the side surfaces controlled by the central processor and communicating with adjacent devices.
A user may interact with the therapeutic training device by applying a hand or a foot onto the flexible and transparent cover and the underlying force sensor. The flexible and transparent cover having a size between a human fist and a human foot should be understood to mean the flexible and transparent cover having a diameter preferably between 5 to 30 cm and most preferably around 15 cm. The flexible and transparent cover may be divided into one flexible but non-transparent part and one transparent but rigid part. The flexible part may preferably be made of a material of sufficient strength and shock resistance to be durable and at the same time the flexible part should be soft not to injure the user. Preferably, a plastic material is used. The light source may be used for giving instructions and information to the user. Alternatively, providing a sound pervious cover, the light source may be substituted with a sound source or a sound source may be used in addition to a light source.
The therapeutical training device is based upon modern artificial intelligence and robotics. It is applicable for different forms of physical activities, for example therapeutic rehabilitation, exercise, physiotherapy, sports, fitness and entertainment. At the same time it gives unique possibilities for documentation of the physical activity for use in for example a therapeutic treatment. It is highly motivating due to immediate feedback and fun, interesting exercises. Several therapeutical training devices may be put together in a therapeutical training system forming an electronic, interactive surface on a floor or wall and each activity or therapeutic treatment may have its own appropriate control program or exercise. The use of the therapeutical training system motivates the user to perform physical activities by providing immediate feedback based upon physical interaction with the system and the user is able to make new physical set-ups within less than a minute.
Processing in electronic devices is traditionally based on central control. This is the case in VCRs, televisions, mobile phones, industrial robots, toy robots, etc. In such cases, the device is controlled by an electronic system with a central control. If just a small part of the central control breaks down, the whole system/device may break down. The invention challenges the traditional central control, and allows processing to be distributed among a number of processing units that can connect together to form a larger, collective system. The individual therapeutical training device includes both processing capabilities and communication capabilities. The therapeutical training system comprising a number of therapeutical training devices allows the user to define the physical shape and the functionality of the therapeutical training system and to interact with the therapeutical training device.
By enumeration of neighbours, the individual therapeutical training device is able to communicate with other specified therapeutical training devices in the system. The detection of neighbours and the overall structure can be done automatically by the system itself at run-time, which facilitates easy modification of the physical form by the user. With neighbour is meant any device adjacent to the side surfaces of the therapeutical training device and communicating with the therapeutical training device. Four neighbours are possible, designated north, south, east and west.
User interaction and capabilities of constructing electronic devices are enhanced by particular processing methods. The invention allows construction of both the physical shape and functionality through the physical construction with no necessary computer skill or need for a personal computer, external programming station, monitor or the like.
Exercises may be run as software on the therapeutical training system. The exercises may adjust themselves to fit any physical configuration constructed by the user. Each exercise may be adjusted to fit particular user groups and levels, such as therapeutic patients, fitness trainees, gamers, etc.
The therapeutical training system may preferably be used for rehabilitation of cardiac patients. For cardiac patients, the exercises on the therapeutical training system may motivate a rise in pulse to appropriate levels. Due to the intellectually stimulating nature of the exercises, the patients find the rehabilitation activity fun and interesting.
Use of the therapeutical training system is not limited to certain patient groups. For instance, exercises that demand the correct movement of the knee and the correct force exerted onto the force sensor will be suitable for knee operated patients. For hip patients the exercises may include walking paths that demand the appropriate weight and force applied on each of the therapeutical training devices, for elderly exercises that stimulate balance training, etc.
Additionally, the therapeutical training system may be used for cognitive rehabilitation. Cognitive tasks may be implemented on the therapeutical training system and feedback (light & sound) may be given to the user based upon the performance of the user on the cognitive tasks. Users may be challenged with different cognitive exercises and the exercises may be easily adjustable to the different capabilities of different users. This may for example be imitation exercise for autistic children.
Further, the therapeutical training system may be used for fitness training and sports training. For example, the therapeutical training system can be set up for precision shooting in football or handball training. Exercises may provide light patterns of different velocity with the purpose of the sport trainee to hit the light and receive feedback (light & sound) from the therapeutical training system when doing so, e.g. to obtain an overall score. Fitness training is often a repetitive and individual activity. The therapeutical training system provides fitness training in the form of fun and challenging exercises that adapt the training level according to the capability of the trainee.
Additionally, the exercises may be of social type by allowing a plurality of users to compete against each other in different exercises on a single therapeutical training system. Hence, the therapeutical training system may be used for individual training by a single user or for simultaneous training by a group of users. Exercises may be designed to allow rehabilitation activities to be performed by a plurality e.g. two, three or four patients at the same time. In this way the rehabilitation exercise may become a competitive exercise between patients. Other user groups such as e.g. fitness trainees, sports trainees, etc. may also use the social type exercises. In activities such as physiotherapy and fitness training the invention provides a unique opportunity for such social activities and challenges for instance in therapeutic rehabilitation practices. With other tools used for such training sessions such social use is often lacking and/or impossible.
Additionally, the therapeutical training system may be used to define musical expressions for music composition and live music performances. For instance, the physical interaction may control different MIDI sequences and thereby, for instance, allow music composers to play music on the therapeutical training system or allow a music concert audience to participate in live music concerts by interacting with the therapeutical training system or allow home users to interact with music albums.
The therapeutical training system may be easily set up on the floor or wall within one minute. The therapeutical training devices may simply attach to each other with magnets or alternatively another attachment mechanism. Preferably, infrared communication means are used to avoid having to connect any wires. The therapeutical training system may register whether it is placed horizontally or vertically, and may by itself make the software exercises behave accordingly.
Additionally, a plurality of therapeutical training systems may be put together in a group and communicate with each other wireless. For instance, an exercise may be running distributed on a group of therapeutical training systems on the floor and a group of therapeutical training systems on the wall, demanding the user to interact physically with both the floor and the wall. A master device or a personal computer may be used for communication between the therapeutical training systems.
The special features of the currently preferred embodiment of the invention include the modularity, the possibility for users to modify the physical shape, the easy setup, the possibility of exclusion of an external host computer, the self-contained energy source, the wireless communication (local and global), and the individual exercises.
Additionally, the therapeutic therapy system may include means of logging response signals from the force sensor on a memory unit and displaying the response signals or a result derived from the response signals on a display unit, monitor, personal computer or by means or light and/or sound signals. The memory unit may preferably be a RAM, hard disk or CD/DVD unit. The memory unit may be communicating with the therapeutic training device and/or the master device. The memory unit may alternatively be a part of the therapeutic training device and/or the master device.
The present invention also relates to a method of performing a physical therapy on a patient or person by providing the therapeutic training system as described above, loading the software comprising an exercise program on the therapeutic training system, the exercise program comprising a series of predefined exercises, wherein each exercise comprises at least the following steps: instructing the patient by activating the light source and/or sound source of a specific therapeutic training device to apply a force onto the central part of the specific therapeutic therapy devices, and logging the response signal of the force sensor of the specific therapeutic training device.
The word patient should in this context be interpreted in its broadest sense and not limit the users to therapeutical users. Thus, the word patient also includes all possible professional and leisure users of the therapeutical training system such as for example sports trainees, gamers and the like.
It is further evident that numerous variations of the exercise program described in the method above may be realized. It follows a comprehensive but not limiting description of alternative methods according to the present invention:
The method of performing a physical therapy as described above, wherein the exercise program comprises a precision game, wherein an object is used for applying a force on the central part of the specific therapeutic therapy device, the object being for example a football, a soccer ball, a basketball, a tennis ball or a handball.
The method of performing a physical therapy as described above, wherein the exercise program comprises a balance game, wherein the therapeutic training system is located in a horizontal position preferably on a floor and the patient is instructed by the light sources and/or sound sources to walk according to a specific path on the therapeutical therapy system and thereby sequentially applies a force onto the central part of a plurality of the therapeutical therapy devices.
The method of performing a physical therapy as described above, wherein the exercise program comprises a musical game, wherein the therapeutic training devices each trigger a different music sequence, allowing e.g. a music composer to compose a concert or interact with a music album by applying a force onto the central part of a plurality of the therapeutical therapy devices.
The method of performing a physical therapy as described above, wherein the exercise program comprises a memory game, wherein the patient must memorize a sequence of light or sound signals and subsequently apply a force onto the central part of a plurality of the therapeutical therapy devices according to the sequence.
The method of performing a physical therapy as described above, wherein the exercise program comprises a dancing game, wherein the therapeutic training system shows a light sequence and plays a music sequence and the patient moves his/her feet to apply a force onto the central part of the therapeutic training device in a sequence according to the light sequence and the music.
The method of performing a physical therapy as described above, wherein the exercise program comprises a color game, wherein each color is representing a specified body part, a therapeutical training device showing a randomly selected color and the patient is applying a force onto the central part of the therapeutic training device using the designated body part.
The method of performing a physical therapy as described above, wherein the exercise program comprises a multiplayer game, wherein a plurality of patients are interacting with one or more therapeutic training systems, thereby the number of therapeutical training devices is at least the same number as the number of patients.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a plurality of therapeutical training devices.
FIG. 2 illustrates a single therapeutical training device.
FIG. 3 illustrates an exploded view of a single therapeutical training device.
FIG. 4 a is a 3D view of a front of a single therapeutical training device.
FIG. 4 b is a different 3D view of a front of a single therapeutical training device.
FIG. 4 c is a different 3D view of a front of a single therapeutical training device.
FIG. 4 d is a rear view of a single therapeutical training device.
FIGS. 5 a - 5 d illustrate a transparent view of a single therapeutical training device from different angles.
FIGS. 6 a - 6 j illustrate a flow chart of a printed circuit board of a single therapeutical training device.
FIG. 7 is a layout of a circular printed circuit board.
FIGS. 8 a - 8 d illustrate a flow chart of a PLB add-on chip.
FIG. 9 illustrates a physical layout of a PLB add-on chip.
FIGS. 10 a 1 , 10 a 2 and 10 b are charts of component parts.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A detailed description of the figures of a presently preferred embodiment of the invention follows below.
FIG. 1 shows a 2D view of a therapeutical training system ( 10 ) according to the invention. The therapeutical training system ( 10 ) comprises a number of therapeutical training devices ( 12 ) of quadratic shape oriented side-by-side forming a planar and flat structure. Each therapeutical training device ( 12 ) is oriented in a specific orientation juxtaposed to at least one other therapeutical training device ( 12 ) and has a user interface oriented in a certain direction towards the user. The therapeutical training device ( 12 ) further has communicating features for communicating with other therapeutical training devices ( 12 ). The master device ( 12 ′) has all the features and abilities of a therapeutical training device ( 12 ) and additional features, which will be described in detail later. The shown embodiment of the therapy system ( 10 ) includes 12 therapeutical training devices ( 12 ) and one master device ( 12 ′). The number of master devices ( 12 ′) must be one, whereas the number of therapeutical training devices ( 12 ) may vary.
FIG. 2 shows a 3D view of a therapeutical training device ( 12 ) having a shallow and quadratic casing ( 20 ). The casing ( 20 ) is preferably moulded in a plastic material, such as for example polyurethane. The casing ( 20 ) further encompasses a quadratic front surface ( 14 ), a quadratic back surface ( 16 ) opposite the front surface ( 14 ) and four shallow rectangular side surfaces ( 18 ). The top surface ( 14 ) comprises a user interface having a centrally located circular cover ( 26 ) and an outer ring shaped transparent plate ( 24 ) surrounding a circular cover ( 26 ). The transparent plate ( 24 ) is preferably made of a robust plastic material such as Plexiglas and is fixed onto the casing. The circular cover ( 26 ) is preferably made of a robust plastic material and is flexible in its position. With flexible is in this context meant that the circular cover ( 26 ) either may be placed loosely in the transparent plate ( 24 ) permitting the circular cover ( 26 ) to be moved a certain distance into the casing ( 20 ) or the circular cover ( 26 ) being fixated to the casing ( 20 ) but soft and easily stretchable and able to protrude a certain distance into the casing when applying a force onto the circular cover ( 26 ).
FIG. 3 shows a 3D exploded view of a therapeutical training device ( 12 ). The top surface ( 14 ) comprises a centrally located circular cavity ( 30 ). The cavity ( 30 ) comprises a centrally located raised platform ( 28 ) protruding a distance less than the depth of the cavity. Between the raised platform ( 28 ) and the circular cover ( 26 ) a force sensitive resistor (FSR, not shown) is located sensing the force applied from the outside onto the circular cover ( 26 ). The circular cavity ( 30 ) further comprises a circular printed circuit board (PCB, not shown). Each of the four sides ( 18 ) of the therapeutical training device ( 12 ) comprises two permanent magnets ( 32 ) oriented in view of polarity in such a way that attachment to other therapeutical training devices ( 12 ) is permitted. The strength of the permanent magnets ( 32 ) should be chosen to allow simple attachment and detachment by use of hand force, and still provide sufficient strength to hold the therapeutical training devices ( 12 ) fixated and clustered during use as a therapeutical training system ( 10 ). Electro magnets may in an alternative embodiment replace the permanent magnets. Each side ( 18 ) of the therapeutical training device ( 12 ) further comprises a centrally located communication port ( 34 ) forming a tubular channel extending from the outside into the circular cavity ( 30 ) housing the PCB. The communication port ( 34 ) preferably uses IR (infrared) communication means for exchange of information with other therapeutical training devices ( 12 ). One of the sides of the therapeutical training device ( 12 ) further comprises a battery charging port ( 36 ), used for connecting a battery charger to charge the internal batteries (not shown) located on the PCB (not shown).
FIG. 4 a shows a different 3D view of the front surface ( 14 ) of a therapeutical training device ( 12 ). The circular cavity ( 30 ) is provided with four fixation studs ( 38 ) for fixating the PCB (not shown) inside the circular cavity ( 30 ).
FIG. 4 b shows a different 3D view of the front surface ( 14 ) of a therapeutical training device ( 12 ). The circular cavity ( 30 ) is provided with a data communication port ( 42 ) for communicating to an external PC (personal computer). The data communication port ( 42 ) comprises a JTAG programming plug used for attaching a programming cable allowing the PCB to be configured using e.g. an external PC.
FIG. 4 c shows a different 3D view of the front surface ( 14 ) of a therapeutical training device ( 12 ).
FIG. 4 d shows a different 3D view of the back surface ( 16 ) of a therapeutical training device ( 12 ). The back surface ( 16 ) comprises four wall fixation magnets ( 40 ) for use when the therapy system ( 10 ) is used vertically mounted onto e.g. a wall. The back surface ( 16 ) further comprises the outside end of the data communication port ( 42 )
FIGS. 5 a - 5 d show a 3D transparent view of a therapeutical training device ( 12 ) from a variety of angles.
FIGS. 6 a - 6 j show a flow chart view of a printed circuit board PCB ( 50 ) of a device. In the centre of the PCB ( 50 ) the microprocessor ( 60 ) can be found. The ATmega 1280 microprocessor ( 60 ) is used for controlling all the other components and for running various kind of software such as games. Four IR communication units ( 52 ) communicate to the microprocessor ( 60 ) and further detects if any other device is assembled in any of the four neighbouring positions and if such neighbouring device or devices are present communicating using infrared light to the neighbouring devices. Each IR communication unit ( 52 ) comprise a separate encoder and transceiver. Further connected to the microprocessor are eight LED (light emitting diode) units ( 54 ). The LED unit ( 54 ) each comprise three LED:s of different colors (blue, red and green). The battery unit ( 56 ) holds the three NIMH rechargeable batteries and includes a circuitry for monitoring the charge level of the batteries as well as controlling charging and discharging of the batteries. Low battery level is detected by the battery unit ( 56 ) and indicated to the user by the LED units ( 54 ). The user can recharge the batteries by simply connecting a separate charger unit (not shown) to the battery charging port ( 36 ), which in turn is connected to the battery unit ( 56 ). The time needed to fully charge the discharged batteries is 16-18 hours. For avoid unnecessary battery wear, the PCB ( 50 ) will power down if the therapeutical training device ( 12 ) is left unused for more than 5 minutes or if the therapeutical training device ( 12 ) is removed from the therapy system ( 10 ). The 2D accelerometer ( 58 ) detects horizontal or vertical placement of the device. Additionally, a wireless communication unit ( 62 ) and a force sensitive resistor ( 64 ) are connected to the microprocessor ( 60 ). The FSR preferably has a limiter, thus not reporting very low forces and limiting very high forces. The FSR may be analogue or digital.
FIG. 7 shows a physical layout view of a circular printed circuit board PCB ( 50 ) designed to be fitted in the circular cavity ( 30 ). The four IR communication units ( 52 ) are located close to the edge of the PCB ( 50 ) separated by 90 degrees in such a way that each IR communication unit ( 52 ) match a corresponding communication port ( 34 ) at each side surface ( 16 ) and permit a direct line-of-sight to the communication port and IR communication unit of a connected neighbouring device. The word match should in this context be understood to mean that the IR communication unit ( 52 ) should be positioned in a way to enable IR communication from a specific IR communication unit ( 52 ) through a specific communication port ( 34 ) and further through a communication port ( 34 ) of a neighbouring device to a IR communication unit ( 52 ) of a neighbouring device if such a neighbouring device is available in the present structure of the therapeutical training device ( 10 ). If such a neighbouring device is present between the communicating IR communication units and IR communication can be performed successfully, the software running on the therapeutical training system ( 10 ) will be informed about the position of the neighbouring device. If IR communication cannot be established, the software assumes no neighbouring device in the specific position. Each therapeutical training device ( 12 ) may have up to four neighbouring devices separated by 90 degrees, i.e. a neighbour to the north, south, east and west. The software running on the therapeutical training system will further be updated if any devices are added or removed from the therapeutical training device. In this context device may mean a therapeutical training device ( 12 ) as well as other devices and apparatus compatible with the hardware and software of a therapeutically training device. With IR communication should be understood both sending and receiving of IR data signals. The data signals are preferably digital coded signals, however, analogue communication may be possible as well. The eight LED units ( 54 ) should be positioned to allow light signals from the LED units ( 54 ) to penetrate the transparent plate ( 24 ) and be clearly conceived by a user. For additional clarity and aesthetic appearance the LED units ( 54 ) are preferably distributed to form a circular appearance, i.e. being separated 45 degrees in this case of using eight LED units. The battery unit ( 56 ) includes three battery holders, fitted on top of the PCB ( 50 ) for easy access and designed for AA rechargeable batteries.
FIGS. 8 a - 8 d show a flow chart view of the PCB add-on chip ( 70 ) used in the master device ( 11 ′) only. The PCB add-on chip ( 70 ) comprises a radio communication unit ( 74 ) (XBee) used by the master device to enable wireless communication with other master devices of other therapy systems. Such wireless communication may be utilized for combining two therapeutical training systems into one therapeutical training system without the need of a physical connection. Further use involves running specific software on the master device such as for example comparing results of different patient running the same exercise simultaneously or controlling the therapy system from an external PC. A display unit ( 76 ) for showing text messages and an array of buttons ( 72 ) comprising four buttons are provided on the master device ( 70 ) for direct user interaction. The buttons are used to setup the software. The charge pump ( 78 ) (TPS60130) is used to provide power to the circuitry.
FIG. 9 shows a physical layout view of the PCB add-on chip ( 70 ). The PCB add-on chip ( 70 ) is mounted on the circular printed circuit board PCB ( 50 ). The array of buttons ( 72 ) is located such as to be operated from the outside of the device in a convenient way. The casing ( 20 ) for the master device ( 12 ′) is to be modified in a way to fit the array of buttons ( 72 ) in a convenient and user-friendly way. The buttons are used to interact with the software running on the therapeutical training device. The radio communication unit ( 74 ), the display unit ( 76 ) and the charge pump ( 78 ) are located on the PCB add-on chip ( 70 ) as well.
Upon assembling the therapy system, the hardware will detect the physical structure of the therapeutical training system as described above. The software will use the information of the physical structure in setting up a therapeutical training program and evaluating the result of the patient. Below numerous embodiments of therapeutic exercises or games will be described in detail.
On the presently preferred embodiment of the invention, software can run on the ATmega 1280 microprocessors in the therapeutical training devices. If the game “Chasing Colors” is chosen on the master device, the master device will ask for number of participants (1-6), and thereafter duration of play (0.5, 1, 1.5, 2, 2.5, 5 minutes). The physical structure of the therapeutical training device is checked and then the master device asks for start: when the down button is pressed the game will start. According to the number of players, that number of colors will show up at random therapeutical training devices on the therapeutical training system. For instance, if three players are selected, there will be one therapeutical training device lighting up in red, one therapeutical training device lighting up in blue, and one therapeutical training device lighting up in yellow. When one of the therapeutical training devices which is lightened up in a specific color is pressed, the information will be sent to the master device by IR communication. The master device counts up a variable of that color with one, the color will be turned off on the current therapeutical training device and shown at another randomly selected therapeutical training device. When the selected time has passed (e.g. 1 minute), the master device will check the different color variables and the color that was pressed most times (the winner) will be shown on all therapeutical training devices (i.e. the master device sends information to the therapeutical training devices to show that color). After 10 seconds of showing the winning color, the game will restart.
Hence, in the presently preferred use of this game, the users will select the number of participants and duration of games, and then chase one color each. The user who hits most therapeutical training devices showing his/her color within the selected duration of a game will win the game, indicated by his/her color lighting up on all therapeutical training devices for 10 seconds, before a new game starts again. Users compete at the same time on one therapeutical training system and have to navigate around each other to “catch” the colors. In physiotherapy, sports and fitness training, this activity is used to create a rise in pulse amongst the participants.
For instance, if the therapeutical training system is put as a structure on the floor, the participant will be walking, running or jumping around on the therapeutical training system to hit the ones with their individual color with the feet. Alternatively, some users may choose to crawl on the therapeutical training system and hit the therapeutical training devices with their hands or knees. If the therapeutical training system is put as a structure on a wall, the users will be moving around to hit the therapeutical training devices with their hands.
The system, through the master device, checks the size of the structure using the IR communication units of each therapeutical training device in order not to allow more participants than there are therapeutical training devices available in the structure. The master device is always keeping track of number of therapeutical training devices in the structure (see description above).
The game motivates to perform physical activities because it is fun, challenging and social. Similar games with similar attributes can be made on the therapeutical training system.
In the game “Floor and Wall”, the user builds two therapeutical training systems, each having a master device. The two therapeutical training systems, designated “floor”-structure and “wall”-structure are physically separated (e.g. one structure is on the floor and one structure is on a wall or alternatively they are located in two different rooms or the like. The user selects “Floor” on one master device, number of players and duration of game, in the same way as for the Chasing Colors game described above. On the other master device, the user selects “Wall”. When start is indicated by pushing the down button on the “Floor” master device, the game will start on both “floor”-structure and “wall”-structure. The game is similar to the Chasing Colors game: a specific color appears either on the “floor”-structure or on the “wall”-structure. The two master devices communicate with each other by radio communication (XBee), and thereby the “floor” master device can send colors to randomly chosen therapeutical training devices either the “floor” structure or the “wall” structure. Other games using distributed therapeutical training systems that communicate with radio communication may be implemented.
In the “Simon says” game, the user only has to press start. When the game starts, one therapeutical training device will light up for 3 seconds and then turn off. The user now has to repeat by pressing on that specific therapeutical training device to make it light up. If the user presses the therapeutical training device that lighted up before, then it is correct, and all therapeutical training devices will light up in green for 3 seconds. If the user presses any other therapeutical training device, then all therapeutical training devices will light up in red, and the game will end. In the case of the correct action, the game will now show the first therapeutical training device light up again, turn off, and show a second therapeutical training device light up for 3 seconds before it turns off. The user now has to repeat the sequence on pressing the two therapeutical training devices in the order that was shown by the system. If the order that the user presses is correct, then all devices light up in green, else they light up in red and the game ends. The game continues allowing the user to try to repeat 3 lights, 4 lights, 5 lights, 6 lights, etc. until the user makes an error by pressing a therapeutical training device in the incorrect sequence. Users can compete against themselves on how long sequences they can make, and they can compete against each other on how long sequences they can make. The users can build different physical therapeutical training device structures to run the game on, in order to make the game easier or more difficult. Similar cognitive tasks, memory and imitation games can be made and, for instance, used in cognitive rehabilitation with the aspect of being both cognitive and physical games.
In the “Disco” game, a therapeutical training device lights up in a random color when it is pressed. If no therapeutical training device is pressed for 2 seconds, then all therapeutical training devices will turn off. Hence, the user can move around and continuously press the therapeutical training devices to make them change color (e.g. from red to blue to yellow to magenta to green to purple, etc.). The user may choose to play external music along with playing the game. Similar dancing games can be implemented on the therapeutical training system.
There are also one-player games such as “Stepper”. The user selects the duration of game (0.5, 1, 1.5, 2, 2.5, 5 minutes). In Stepper, the master device will investigate the physical structure built by the user and find the longest rectangle with 2 therapeutical training devices on one side (i.e. 2*2, 2*3, 2*4, 2*5, . . . ). It will indicate by color on the first two that the user should place him/herself with a foot on each of these two. On the two therapeutical training devices furthest away, light will show in colors depending on the speed with which the user steps on the two therapeutical training devices where he/she is positioned. The indicator therapeutical training devices will show up in yellow, green and red in this order based on the speed on the stepping.
In the “Reach” game, the start procedure is similar to the Stepper game. Here the user has to reach out and touch the therapeutical training devices that light up. The therapeutical training devices light up in a color that may indicate that the user should use the left or right leg/arm to reach out and touch that therapeutical training device. The user can also select if the touch to activate the therapeutical training devices should be light, middle or hard (which is measured by the analogue FSR sensor). This may, for instance, allow physiotherapists and fitness trainers to select level for specific users. The “Reach” game can, for instance, be used for balance training.
In the “Ball game”, the user selects the level (1, 2, 3) and the duration of the game (0.5, 1, 1.5, 2, 2.5, 5 minutes). The master device will send information to the therapeutical training devices to have a light signal traverse the therapeutical training devices in different patterns (depending on the chosen level), for instance horizontally. The user now has to hit the therapeutical training devices that light up with a ball (e.g. football or handball) from a distance chosen by the user. If the user hits the light a specific number of times (depending on the level) within the duration of the game, all therapeutical training devices will show up in blinking green, indicating that the user has won the game. A similar game may be used for e.g. racket sports.
Additional features of the preferred embodiment of the invention include a battery management system. When the battery level of a therapeutical training device is low, this will be indicated by the lights of the therapeutical training device rotating in red, while in a master device it will be written in the display. A charger can be attached to the block in the charging plug on the side of the therapeutical training devices, and the batteries will be fully recharged within 16-18 hours.
The therapeutical training system consists of a number of therapeutical training devices as described above. The therapeutical training devices can be put together to form different structures. The magnets on the sides of the therapeutical training devices makes the blocks snap and hold together. When a master device is put together with a cluster of one or more therapeutical training devices, the master block will send IR signals to the first neighbouring therapeutical training device, which will receive this IR signal as a wake-up signal and relay the signal to its own neighbours by IR communication to its North, East, South, West side. Where there is a therapeutical training device on the North, East, South or West, that (those) therapeutical training device(s) will then, at its (their) turn, relay the signal to its (their) own neighbours. And those therapeutical training devices will receive and relay the signal, and so forth. When a therapeutical training device receives a signal, it sends back a receipt, so a sending therapeutical training device can obtain knowledge about its own neighbourhood structure by keeping track of from where it receives receipts. For instance, it will have a neighbour to the North if it receives a receipt from North. The neighbourhood structure of a therapeutical training device is sent back to the device from which it received the signal, and so the different neighbourhood structures can be relayed back to the master device. Based on this information, the master device can simply build a tree structure and a map of the layout of the therapeutical training devices. This map of the physical structure, which has been built by the user, is used by the system for the different software games. The therapeutical training devices will continuously send IR signals to their North, East, South, West neighbours and receive receipts from those positions that are occupied by other blocks. If they receive signals from a position, which was not occupied at the previous time stamp, or if they do not receive signals from a position that was occupied at the previous time stamp, then the system recognizes that the structure has been changed (either by the addition of a block or the removal of a block). If this happens, the master block will re-initiate a count of blocks and their positions in order to build an updated tree structure and map of the physical layout. Hence, the recognition of changes in structure happens immediately at run-time. Therefore, it becomes possible for the user to build different structures with the therapeutical training devices, and possible for the system itself to recognize what structure the user has built.
If the therapeutical training devices are not used for 5 minutes, they will power down. Also, if a therapeutical training device is removed from the structure, it will blink three times and then power down.
With the system's knowledge of the physical structure and the continuous update of possible changes to the structure, the software games can utilize the physical structure to make games automatically become appropriate to the individual structures. The softwares (games) can adjust themselves when the structure is changed.
The buttons on the master device can be used to select games. In the prototype implementation, there are four buttons on the master device: home, left arrow, right arrow, down arrow. A small display on the master device will show text information. Initially, it will tell that the structure is being detected and print the number of therapeutical training devices found in the structure. Then the software will ask the user to select a game. By pressing the left arrow or the right arrow, the user may browse backward or forward in the list of games. The down button can be used to select one of the games. When a game is selected, the software may ask for further details from the user such as number of players, which again is selected by the arrows. Other selections to be made may include game level and duration of play.
When a game has been selected on the master device and possibly other options selected, the master device will send this information through the tree structure to all the therapeutical training devices, and the game will start.
Although the present invention has been described above with reference to specific and presently preferred embodiments of a therapy system and other devices and methods also constituting a part of the invention, it will be evident to a person having ordinary skill in the art that the therapy system including all of the devices and methods may be modified in numerous ways.
For example, it would be evident to a person skilled in the art that the invention may be performed using different energy sources, such as solar power or retrieval of energy from the physical activation of the system. Single use batteries or an external AC or DC source may replace the rechargeable batteries. The devices may be moulded in another plastic material and another transparent material could be used for the transparent ring. A flexible film or foil may be used instead of the circular cover and function as buttons or the buttons may be reinforced. The shape of the device may take other forms than quadratic and still allowing the devices to be assembled to form an overall structure (e.g. like a puzzle), and the surface may comprise grooves and be generally uneven. Additionally, light could be emitted in other patterns than a ring, such as for example a square or circle, or sound effects may replace or accompany the light. The electronic components could be substituted for other, similar components. The PCB may be chosen to have a different form in order to minimize the PCB size. The hardware may be fully or to a large extent be replaced by a personal computer. The communication between the devices may be performed by other means than IR, such as for example by radio or wire. Software features may be controlled differently such as for example by pressing on one or more of the devices or an RFID system with RFID tags may be applied for game selection. Additional software features may be implemented, such as other games. For instance, a Music game may allow the user to control MIDI signals by pressing the different therapeutical training devices and a specific sound device may be used for playing the MIDI signals. Such a sound device may include all the features of the before mentioned therapeutical training devices additionally including a sound PCB and MIDI chip add-on. Alternatively, the sounds may be played on a host computer, with the signal being sent preferably by radio communication from the master device.
LIST OF PARTS
10 Therapy system
12 Therapeutical training device
12 ′ Master device
14 Front surface
16 Back surface
18 Side surface
20 Casing
24 Transparent plate
26 Circular cover
28 Raised platform
30 Circular cavity
32 Magnet
34 Communication port
36 Battery charging port (connector)
38 Fixation stud
40 Wall fixation magnet
42 Data communication port
50 Printed circuit board PCB
52 IR communication unit
54 LED unit
56 Battery unit
58 2D Accelerometer
60 Microprocessor
62 wireless communication unit
64 Force sensitive resistor
70 PCB add-on chip
72 Array of buttons
74 Radio communication unit
76 Display unit
78 Charge pump
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A therapeutic training device includes a shallow housing of a specific shape with a quadratic top surface, a quadratic bottom surface and four thin rectangular side surfaces. The housing includes an upwardly open cavity in the top surface and a flexible and transparent cover which encloses the cavity at least partially. The flexible and transparent cover has a size in the range between the size of a human fist and the size of a human foot, and defines a central part. The housing further includes a force sensor placed inside the cavity communicating with the central part. The force sensor measures the force applied on the flexible and transparent cover and generates a response signal. The housing further includes a light source placed inside the cavity, the light source being visible through the flexible and transparent cover, and a central processor placed inside the housing, which activates the light sources in accordance with a specific software and evaluates the response signal from the force sensor in accordance with the specific software. A plurality of communication devices are located on the side surfaces and is controlled by the central processor and communicates with adjacent devices.
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CROSS REFERENCES TO RELATED APPLICATIONS
[0001] This application is a U.S. national stage application of International App. No. PCT/FI2005/050091, filed Mar. 18, 2005, the disclosure of which is incorporated by reference herein, and claims priority on Finnish App. No. 20045093, filed Mar. 23, 2004.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] The present invention relates to the inner elongated structure of the roll of a paper/board machine or finishing machine, such as the shaft of a deflection-compensated roll or the suction box of a suction roll.
[0004] Current production paper machines run at speeds nearing 2000 m/min and machine widths come close to 11 m. The future development trend is to continue increasing these values.
[0005] Increasing both will bring about a changeover to dynamic dimensioning in current deflection-compensated rolls unless new ways are invented for manipulating the specific frequency of the roll so as to prevent the critical specific frequency from falling upon the running zone. A deflection-compensated roll comprises a stationary shaft and a shell arranged to rotate around it, the shell being supported on the shaft by loading elements which exert a loading force against the inner surface of the shell to load the shell towards the backing roll forming a nip with the said roll. In the modem, wider deflection-compensated rolls of calenders, it has been necessary to increase dimensioning by as much as four classes as a result of dynamic dimensioning, which incurs considerable additional expenses. The increase in roll mass also causes problems regarding crane capacity, especially in old mills.
[0006] In a suction roll, a perforated shell rotates fitted with bearings on thrust shafts. Inside the shell may be a single- or multi-chamber suction box, the apertures of which open—limited by sealing strips—onto the inner surface of the shell for directing the suction at a specific sector of the suction roll. At the ends of the roll are aggregates by means of which external negative pressure can be connected to the suction box. While the negative pressure is connected, a vacuum is formed under the paper web through the wire or the felt. The pressure difference formed removes water from the web to the perforations in the shell or holds the web during transfer. The negative pressure in the chambers is determined in accordance with the intended use of the suction roll. A problem with suction rolls is the deflection of the suction box towards the inner surface of the roll shell while negative pressure is connected to the suction box. In this case, external pressure will deflect the suction box in the direction of its suction inlets, whereby the seals of the suction box are pressed more tightly against the inner surface in the central area of the roll shell, thus wearing the seals more in their center than on the edge zone.
[0007] In simplified form, the specific frequency of the roll is determined according to the following formula:
f i = λ i 2 2 · π · L 2 · ( E · I m ) 1 / 2
where
λ is the support constant L is roll width EI is stiffness, and and m is mass.
[0012] From this equation for specific frequency can be seen that its characteristics cannot be efficiently manipulated by any means other than by manipulating stiffness, when the mass remains approximately constant. Another way of eliminating the detrimental effects of the vibrations themselves is to provide so high roll-internal damping that specific frequencies will not be a disadvantage. The aim of the present invention is to provide a solution by means of which the above-mentioned problems can essentially be eliminated.
[0013] To achieve this aim, the solution relating to the invention for realizing the inner elongated structure of the roll of a paper/board machine or finishing machine is characterized in that the structure is comprised at least partly of composite material, including reinforcing fibers in matrix material.
SUMMARY OF THE INVENTION
[0014] According to a preferred embodiment of the invention, the inner elongated structure of the roll is the stationary shaft of a deflection-compensated roll having a frame part essentially of fiber-reinforced composite, on which frame part is formed a support part of steel extending in the longitudinal direction of the shaft for supporting the loading elements bearing the shell on the shaft. According to another preferred embodiment of the invention, the inner elongated structure of the roll is the stationary shaft of a deflection-compensated roll having a frame part essentially of metal, which is coated with fiber-reinforced composite material. According to yet another preferred embodiment of the invention, the structure is a suction box inside the suction roll, which is preferably made completely of composite material.
[0015] Composite material refers to a structure comprising reinforcing fibers, for example, carbon, boron or glass fibers or their mixtures, and a matrix material, which may be polymeric, ceramic or metallic. Ceramic material comprises different oxides and carbides, such as Al—, B—, Cr—, Ti—, Si—, Sn—, W—, Zn—, Zr— oxides and carbides or their mixtures, and different nitrides, such as Bn and Si 3 N 4 .
[0016] The invention is described in greater detail in the following, with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 shows a prior art deflection-compensated roll as a diagrammatic longitudinal section.
[0018] FIG. 2 is a cross-sectional view of the roll of FIG. 1 taken along section line II-II.
[0019] FIG. 3 shows a deflection-compensated roll according to the invention as a diagrammatic longitudinal section.
[0020] FIG. 4 is a cross-sectional view of the roll of FIG. 3 taken along section line IV-IV.
[0021] FIG. 5 shows the end section of the roll of FIG. 3 .
[0022] FIG. 6 shows the end section of FIG. 5 as seen in the direction of arrow VI.
[0023] FIG. 7 shows a diagrammatic longitudinal section of the end section of another deflection-compensated roll realized according to the invention.
[0024] FIG. 8 shows a modification of the embodiment of FIG. 7 .
[0025] FIG. 9 shows a longitudinal section of yet another end section of a deflection-compensated roll according to the invention.
[0026] FIG. 10 shows a view of the roll of FIG. 9 as seen from the end with the roll end removed.
[0027] FIG. 11 shows a diagrammatic cross-section of yet another deflection-compensated roll according to the invention.
[0028] FIG. 11 a is an enlarged fragmentary view of the apparatus of FIG. 11 taken at the circle 11 a.
[0029] FIG. 12 shows a diagrammatic cross-section of yet another deflection-compensated roll according to the invention.
[0030] FIG. 12 a is an enlarged fragmentary view of the apparatus of FIG. 12 taken at the circle 12 a.
[0031] FIG. 13 shows a diagrammatic longitudinal section of a prior art suction roll.
[0032] FIG. 14 shows a diagrammatic cross-section of the suction roll of FIG. 13 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] FIGS. 1 and 2 show diagrammatically a prior art deflection-compensated roll 10 comprising a stationary roll shaft 11 , around which a roll shell 12 is arranged to rotate. The roll shell 12 is supported on the roll shaft 11 by means of hydraulic loading elements 17 . The hydraulic loading elements act in the direction of the nip plane, and by means of them, the nip profile of the roll can be controlled in the longitudinal direction of the roll. The roll shaft 11 is connected to the roll's support structures by means of shaft journals 18 . In the example disclosed, the roll 10 is provided with slide bearings 14 , 14 a acting on the main loading plain of the roll, whereby the bearings 14 act in the direction of the nip, that is, in a direction opposite to the loading direction, and the bearings 14 a act in the opposite direction with respect to these. The roll further comprises lateral slide bearings 15 , 15 a, which act in a transverse direction with respect to the main loading direction, and axial slide bearings 16 , 16 a acting in the axial direction, which rest on the roll ends 13 , and 13 a , respectively, through a lubricant film. Slide bearings 14 , 15 , 14 a, 15 a acting in the radial direction, rest, for their part, against the inner surface of the roll shell 12 through the lubricant film. A roll of this type is known, for example, from U.S. Pat. No. 5,509,883, and is thus not described in greater detail in this connection.
[0034] FIGS. 3 to 6 show a deflection-compensated roll realized according to the invention, where the same or similar parts are referred to by the same reference numerals as in FIGS. 1 to 2 . In this embodiment, the roll shaft 11 is comprised of a beam, essentially I-shaped in cross-section, which is made of composite material, preferably of carbon fiber reinforced material, by lamination. In the upper part of the beam 24 is formed a longitudinal groove, in which a support part 26 of steel or cast iron is positioned by means of an intermediate layer. The intermediate layer 25 evens out differences in thermal expansion and fixes the support part to the fiber-reinforced frame 11 . On the support part 26 are formed bores for hydraulic loading elements 17 . Reference numeral 27 denotes a feed pipe for supplying hydraulic medium to the chamber beneath the loading element 17 . On the bottom part of the I-beam have been added fiber-reinforced plates 21 , 22 , 23 to areas requiring additional stiffness, as determined on the basis of the moment of deflection. The stiffening plates 21 - 23 can be joined together and to the I-beam, for example, by means of gluing with matrix material or by means of a bolted joint. The I-beam is connected to the thrust shaft 40 , for example, in the manner shown in FIGS. 5 and 6 . The thrust shaft 40 comprises an inwards directed roll fixing part 41 to which are formed the protruding ends 11 a, 11 b of the I-beam, and grooves for receiving the web part between them. The interlocking of the I-beam and the thrust shaft is secured by bolted joints 42 , the said bolts extending from the level 43 formed on the upper surface of part 41 to the recesses 45 and 46 , the said recesses being arranged to lighten the thrust shaft. Locking may also be carried out, for example, by gluing instead of by bolted joints. The stresses exerted on the joint are not very high because the moment of deflection is small compared with the central part of the beam. This solution makes possible the relatively simple assembly of the roll. Depending on the loading forces, the upper part 24 of the I-beam may also be made completely of steel or cast iron, in which case no separate intermediate layer 25 or support part 26 will be required. An upper part of steel or cast iron may also be fixed, for example, by gluing with matrix material to the fiber-reinforced frame 11 . It is also conceivable to make the shaft completely of composite material.
[0035] FIG. 7 shows another deflection-compensated roll realized according to the invention, wherein the frame of the roll shaft 11 is steel and forms an integrated structure with the shaft journal 18 . The frame part is lightened in the area between the end sections where it is comprised of a relatively thin support part 11 a, which receives the compressive stresses. Nip loads cause compressive stresses on the shaft on the loading element 17 side, and tensile stresses on the lower part. To receive the tensile stresses, between the end parts of the shaft are arranged fiber-reinforced bars or plates 30 running through the end parts and locked in place by locking means 31 , which is a locking nut in FIG. 7 . The bars or plates 30 are preferably of carbon fiber reinforced composite.
[0036] The embodiment of FIG. 8 differs from that of FIG. 7 only as regards the locking means 32 , which are made by winding of reinforcing fibers and by fixing with matrix material to the bar or plate 30 .
[0037] In the embodiment according to FIGS. 9 and 10 , on the end parts of the roll shaft are formed mounting projections 36 , 38 , and opposite end parts are joined with each other by means of reinforcing fibers dipped in matrix material and wound in the longitudinal direction of the shaft, which form bundles 35 , 37 of composite material which receive the tensile stresses. Using the mounting projections makes it possible to wind the reinforcing fibers into one loop, whereby the strength of the structure is better than when using, for example, the separate locking means according to FIGS. 7 to 8 , where the joint becomes weaker than the basic materials, whereby the structure must be dimensioned according to the strength of the joint. In the solution according to FIGS. 9 and 10 , dimensioning takes place in accordance with the composite material and shaft material, for example, steel or cast iron.
[0038] An additional advantage in the embodiments of FIGS. 7 to 10 is the free space remaining also on the neutral axis which may be utilized in positioning the hydraulic pipes of the loading elements.
[0039] FIGS. 11, 11 a , 12 and 12 a show some further embodiments of the deflection-compensated roll according to the invention, with the elimination of disadvantageous vibration as the starting point. This has been realized by adding a coating 50 of composite material on the existing roll shaft 11 . FIG. 11 shows a diagrammatic, cross-sectional view of a deflection-compensated roll provided with an almost round-profiled shaft 11 , and FIG. 12 shows a deflection-compensated roll with a so-called movable shell, the shaft of which is essentially rectangular in cross-section. Reference numeral 14 b denotes the bearing means of the roll.
[0040] The coating 50 may be formed, for example, by providing the shaft first with a base treatment, for example, with glue, and by then winding a reinforcing fiber layer of, for example, glass fiber or carbon fiber, around the shaft, and by adding the matrix material to the reinforcing fiber layer. The addition of matrix material can be carried out, for example, by dipping the fibers to be wound in matrix material before winding, or by spraying matrix material on the surface of the shaft while winding the fibers. After coating, bores for the loading elements 17 and bearing elements 14 b may be finishing cut on the shaft through the coating, and the means to be fixed on the shaft, such as oil collection means, may be added. Coating made by winding also makes possible relatively easy coating of shafts provided with straight surfaces ( FIG. 12 ).
[0041] FIG. 13 shows a view in principle of a prior art suction roll without an internal suction box. The suction roll comprises a roll shell 111 which is fitted with bearings to rotate on shaft journals 113 A and 113 B which are connected to the roll shell 111 through end flanges 112 A and 112 B. The roll shell 111 has a perforation comprised of numerous apertures 115 extending through the roll shell 111 . FIG. 13 shows only a part of the perforation of the shell 111 . At least one of the shaft journals 113 B comprises aggregates leading to the interior of the roll, to which an external negative pressure source (not shown) can be connected. By means of the negative pressure source, air is sucked out (arrow P 2 ) through the sector formed by the suction box, whereby a corresponding amount of air (arrow P 1 ) will flow inside the roll through the perforation of the roll shell.
[0042] FIG. 14 shows the suction roll of FIG. 13 in cross-section and with the suction box mounted inside it. The suction box 104 and the seal holder part 105 are rigidly fixed to each other. The seals 101 are loaded against the shell 111 by means of loading tubes 103 , whereby the seals are made to press against the shell at approximately constant pressure even when the suction box is in a deflected situation. Because of the seal pressure, water lubrication V is necessary to reduce wear on the inner surface of the roll shell. When negative pressure is switched on in the suction box 104 , it deflects towards the inner surface of the shell. Deflection is strongest in the longitudinal central area of the roll, while the ends of the suction box remain in place. Nowadays, suction boxes are usually made of relatively thin sheet metal, whereby increasing rigidity by increasing thickness would increase weight which is not desirable. The deflection of the suction box can be reduced in accordance with the invention by making, for example, the seal holder part 105 or the entire suction box 104 of composite material, which makes possible greater rigidity with less weight.
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The roll of a paper/board machine or finishing machine has an inner elongated structure ( 11; 104 ) which is at least partly comprised of composite material, including reinforcing fibers in matrix material. The structure is preferably comprised of a combination of metallic material and composite material.
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BACKGROUND OF THE INVENTION
The invention relates to disc brakes and, in particular, to disc brakes for automotive vehicles of the type having a brake carrier mounted stationarily to the vehicle, a brake housing straddling the edge of a rotatable brake disc and which is arranged axially, slidable relative to the brake carrier with two brake linings positioned on either side of the brake disc straddled by the brake housing. The disc brake is of the type also hving a mechanical actuating device provided for moving the brake housing including an actuating shaft rotatably supported ina bore of the brake housing. The actuating shaft acts on at least one of the brake shoes. There is also provided a retaining device to limit the axial slide of the actuating shaft.
A disc brake of this kind is disclosed in the German patent application No. 1,924,024, published without examination. In this apparatus, the retaining device for the actuating shaft is provided with a circlip which engages in a circular groove of the actuating shaft. By means of this retaining device, the actuating shaft is retained in one direction only. No retainment of the actuating shaft in the opposite direction is provided so that an actuating lever secured to the actuating shaft is allowed to strike against the housing upon deformation of an elastic scraper ring. This is a severe disadvantage particularly when there is a relatively large distance between the housing and the actuating lever, for example, in order to prevent contact corrosion.
SUMMARY OF THE INVENTION
It is, therefore, the object of the present invention to provide for an improved disc brake of the kind mentioned in that the actuating shaft is axially retained in a simple manner in both directions of movement.
According to a very important aspect of the invention, this object is achieved by providing in the bore of the brake housing a projection defining a retaining device.
According to another very important aspect of the invention, the actuating shaft is formed with a recess extending over at least a part of its circumference and includes radially extending boundaries adapted to be engaged by the projection.
Another feature of the invention provides that at least one of the boundaries extends over only a part of the circumference of the actuating shaft. In this way, a retaining device, which is comprised of very few components and which provides for easy, quick mounting is created in an extremely simple manner. Owing to the but slight axial tolerance, the efficiency of the disc brake is improved in that no losses of travel come about in the clamping direction and a scraper ring, which will experience only minimal deformation, may be provided.
According to a preferred embodiment of the invention, the projection is circular, ring-shaped with its axis being radially offset with respect to the axis of the bore thereby defining a crescent shaped projection. The circular, ring-shaped projection is preferably formed by a stepped bore which is provided in the housing in an easy manner from opposite sides.
A still further important feature of the invention provides for the recess to also be in the shape of a circular groove, with the boundary of the recess exetending over a part of the circumference of the actuating shaft defining a crescent shaped recess or groove.
Another feature of the invention provides for a substantially cylindrical section of the actuating shaft to be positioned eccentrically relative to the longitudinal axis of the actuating shaft.
A further important aspect of the invention provides for a bushing made of an antifriction metal in the bore of the housing in which the actuating shaft is supported and which provides for ease of motion of the actuation shaft.
According to another advantageous embodiment of the invention, the actuating shaft is provided with a radially extending, eccentrically arranged recess in which one end of a thrust member is accommodated. The other end of the thrust member is in abutment against an axially slidable actuating element providing for movement of the thrust member in an axial direction.
In addition to the mechanical actuating device, the disc brake may, according to the teachings of the invention, moreover be furnished with a hydraulic actuating device.
Advantageously, a cover disc is used to close the bore of the actuating shaft. The cover disc being insertable prior to the mounting of the shaft thanks to the inventive embodiment of the retaining device.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in more detail in the following Detailed Description Of The Preferred Embodiment and will be be better understood when read in conjuction with the drawings in which:
FIG. 1 is a top plan view of a disc brake suitable for combined hydraulic and mechanical actuation;
FIG. 2 is a longitudinal section through the disc brake according to FIG. 1;
FIG. 3 is a cross-section through the mechanical actuating device of the disc brake according to FIGS. 1 and 2; and
FIG. 4 is a view of the mechanical actuating device in the direction of the arrow IV in FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A disc brake 1 illustrated in the drawing is provided with a brake housing 2 having a U-shaped longitudinal section and comprises an internal, radially extending stem 3 and an external stem 4 which also extends in the radial direction. The stems 3 and 4 are interconnected through a substantially paraxially extending bridge portion 5. The brake housing 2 straddles the external edge of a brake disc 6. Two brake linings 7, 8 are positioned on either side of the brake disc 6 which are also straddled by the brake housing 2. The internal stem 3 of the brake housing 2 contains a combined hydraulic and mechanical actuating device 9 which will be described in more detail hereinbelow.
The brake housing 2 is axially, slidably supported at a brake carrier 11 which is stationarily mounted to the vehicle. The brake carrier 11 is substantially comprised of a supporting element 12 arranged parallel to the brake disc 6 and two guide arms 13, 14 extending in an axial direction beyond the edge of the brake disc. The guide pins 15, 16 are screwed into the guide arms 13, 14 on the supporting element side of the brake disc. The brake housing 2 is guided on the pins of the supporting element side of the brake disc 6. For this purpose, the brake housing 2 is furnished with two lateral lugs 17, 18 extending in a circumferential direction and being provided with pores in which the guide pins 15, 16 are guided. Elastic guide elements 19, 20 are arranged in the bores.
On the other side of the brake disc 6, that is, on the side opposite the supporting element 12, a pair of guide grooves 21, 22 are provided in the guide arms 13, 14 for the purpose of guiding the brake housing. The guide grooves 21, 22 engage two lugs 23, 24 on the brake housing 2 which extend in a circumferential direction.
For providing hydraulic actuation of the disc brake 1, the internal stem 3 of the brake housing 2 is provided with a cylinder bore 25 which is oriented parallel to the axis of rotation of the brake disc and axially, slidably accomodates a brake hydraulically operated piston 26. The bottom 27 of the brake piston 26 and cylinder bore 25 form a pressure chamber 28 which is supplied with a pressure medium, such as hydraulic fluid, through a connection 29. The cylinder bore 25 has a stepped configuration with a mechanically actuatable parking brake piston 31 being axially, slidably supported in a section 30 which has a diameter reduced from that of the cylinder bore 25. The parking brake piston 31 is formed with a cylindrical section 32 which is guided within a section 33 of the bore 25 which has a diameter reduced still further from that of the bore 25 and section 30. Coupled to the cylindrical section 32, is a disc-shaped section 34 which is arranged in the section 30 of the cylinder bore and whose front end facing the brake disc 6 is provided with a thrust face being abuttable against the bottom 27 of the brake piston 26.
The parking brake piston 31 forms part of a mechanical actuating device which further includes an eccentric apparatus 35 which acts, through a thrust member 36, on the parking brake piston 31. The eccentric apparatus 35 is provided with an actuating shaft 37 which is supported in a bearing bushing 38 which is in turn accommodated in a bore 39 extending at right angles to the cylinder bore 25. A parking brake lever 40 is secured to one end of the actuating shaft 37 projecting from the bore 39. A helical spring 41 is provided to urge the parking brake lever 40 into its end released position which is defined by means of a pin 42 affixed to the housing. That part of the actuating shaft 37, which is supported in the bushing 38, includes an eccentrically arranged recess 43 within which an end portion of the thrust member 36 is positioned. The opposite end of the thrust member 36 is received in a concentric recess 44 provided in the cylindrical section 32.
The end portion of the actuating shaft 37 which is positioned in the bore 39, is also provided with a circular groove-shaped recess 45 which extends over a portion of the circumference of the shaft 37 defining a cresecent shaped groove when viewed toward the lef end of the shaft in FIG. 3 and a cylindrical section 46 having a reduced diameter in comparison to the main part of the actuating shaft, is provided adjacent to the recess 45. Adjacent to the cylindrical section 46, another cylindrical section 47 is provided and arranged in an eccentrically offset position with respect to the cylindrical section 46. The circular, ring-shaped front face 48 at the transition between the main part of the actuating shaft 37 and the cylindrical section 46 thus forms a first axial boundary wall of the recess 45, whereas the second axial boundary wall is defined by the section 49 of the front face of the cylindrical section 47, which is crescent-shaped when viewed in the axial direction.
Due to this arrangement, the recess 45 extends over only a part of the circumference of the actuating shaft 37 and terminates tangentially toward the ends as viewed in the circumferential direction. A projection 50 extends into the recess 45 and is formed by a section 52 of the bore 39 having a reduced diameter and being arranged eccentrically with respect to the bore 39 defining a crescent shaped projection when viewed toward the left end of the shaft in FIG. 3. As best seen in FIG. 3, a counterbore 53 around the bore 39 accommodating the cylindrical section 47 of the shaft 37 is arranged adjacent to the reduced diameter section 52 of the bore 39. The counterbore section 53 of the bore 39 is succeeded, in its turn, by another counterbore section 54 around the bore 39 in which a cover lid 55 is inserted.
Owing to the fact that the recess 45 or, rather, the axial boundary formed by the cylindrical section 47 extends only over a part of the circumference of the actuating shaft, the actuating shaft can be brought into a position by rotation in which the axis of the cylindrical section 47 is congruent with the axis of the section 52 of the bore 39. In this position of the actuating shaft 37, the projection 50 no longer engages in the recess 45, and the actuating shaft may be pulled out of the bore in the axial direction. The actuating shaft 37 may also be inserted in the bore 39 when in the same angular position. The projection 50 is engaged in the recess 45 by rotating the actuating shaft which engagement effects an axial retainment of the actuating shaft in both directions. Suitable stops can be provided in order to limit rotation of the actuating shaft 37 to a range of rotation in which an axial motion of the shaft is not possible. The stops may, for example, be formed by a pin 42 which engages in a corresponding recess 51 of the parking brake lever 40, which recess 51 limits the rotation of the lever and shaft to a determined angle of rotation.
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A disc brake for use in automotive vehicles is disclosed including a hydraulic brake actuating and a mechanical brake actuating device comprising a thrust member for axially operating a hydraulic piston in response to manual rotation of an actuating shaft in a bore in the brake housing. The shaft is axially retained in the bore by an eccentrically positioned recess in the shaft and projection on the bore extending over only a portion of the shaft circumference and bore. The recess defines radial boundaries for engaging the projection to prevent axial movement and the eccentric relationship causes axial movement of the thrust member for operation of the brake piston.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13,004,955 filed Jan. 12, 2011, which was a divisional application of U.S. patent application Ser. No. 12/005,032 filed on Dec. 21, 2007, which is incorporated by reference herein for all it discloses.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention is directed to top drive systems; parts thereof; and methods of their use.
[0004] 2. Description of Related Art
[0005] The prior art discloses a variety of top drive systems; for example, and not by way of limitation, the following U.S. patent application and U.S. patents present exemplary top drive systems and components thereof: U.S. Pat. Nos. 4,458,768; 4,589,503; 4,753,300; 4,800,968; 4,807,890; 4,813,493; 4,872,577; 4,878,546; 4,984,641; 5,433,279; 6,007,105; 6,276,450; 6,536,520; 6,679,333; 6,705,405; 6,913,096; 6,923,254; 7,186,686; and 7,270,189 all incorporated fully herein for all purposes.
[0006] Certain typical prior top drive drilling systems have a derrick supporting a top drive which rotates tubulars, e.g., drill pipe. The top drive is supported from a traveling block beneath a crown block. A drawworks on a rig floor raises and lowers the top drive. The top drive moves on a guide track.
[0007] Certain prior systems include a top drive with a gear system with a lower or second stage planetary carrier which rotates with respect to multiple (e.g. two) vertically spaced-apart bearings which are secured in place and which do not float radially (or axially).
BRIEF SUMMARY OF THE INVENTION
[0008] The following presents a simplified summary of the present disclosure in order to provide a basic understanding of some aspects of the invention. This summary is not an exhaustive overview of the disclosure, nor is it intended to identify key or critical elements of the subject matter disclosed here. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is discussed later.
[0009] The present disclosure is generally directed to certain illustrative aspects of a top drive system that may be used during wellbore operations. In one exemplary embodiment, a system is disclosed that includes a gear system having a gear housing and a lower planetary carrier disposed in the gear housing, the lower planetary carrier being adapted to rotate relative to the gear housing. The illustrative system also includes, among other things, a top drive system that is operatively coupled to the gear system, the top drive system having a top drive shaft that is adapted to be driven by the gear system. Additionally, a single bearing is positioned between the gear housing and the lower planetary carrier, the single bearing being adapted to facilitate a rotation of the lower planetary carrier relative to the gear housing. Furthermore, a motor apparatus is operatively coupled to the gear system, the motor apparatus being adapted to drive the gear system by rotating the lower planetary carrier relative to the gear housing, wherein a rotational axis of the single bearing is adapted to move in a lateral translational direction with respect to the gear housing while the motor apparatus is rotating the lower planetary carrier and while the gear system is driving the top drive shaft.
[0010] In another embodiment of the present disclosure, a system is disclosed that includes a gear system having a gear housing and a lower planetary carrier disposed in the gear housing, the lower planetary carrier being adapted to rotate relative to said gear housing. The system further includes, among other things, a single bearing positioned between the gear housing and the lower planetary carrier, the single bearing being adapted to facilitate a rotation of the lower planetary carrier relative to the gear housing, and a bearing cartridge that is adapted to maintain the single bearing in position between the gear housing and said lower planetary carrier. The bearing cartridge includes an outer part that is releasably secured to the gear housing and a radially movable inner part that is encompassed by the outer part, wherein the single bearing abuts the radially movable inner part. Furthermore, the system also includes a motor operatively coupled to the gear system, the motor being adapted to rotate the lower planetary carrier relative to the gear housing, wherein a rotational axis of the single bearing and a centerline axis of the radially movable inner part are adapted to move in respective lateral translational directions during the rotation of the lower planetary carrier relative to the gear housing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The disclosure may be understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements, and in which:
[0012] FIG. 1A is a back view of a top drive system according to the present invention.
[0013] FIG. 1B is a side view of the top drive system of FIG. 1A .
[0014] FIG. 1C is a front view of the top drive system of FIG. 1A .
[0015] FIG. 1D is a cross-section view along line 1 D- 1 D of FIG. 1C .
[0016] FIG. 2A is a perspective view of a top drive system according to the present invention with a motor/gear apparatus according to the present invention.
[0017] FIG. 2B is a partially exploded view of the top drive system and motor/gear apparatus shown in FIG. 2A .
[0018] FIG. 2C is a cross-section view of the system of FIG. 2A .
[0019] FIG. 2D is a side view of the system of FIG. 2A .
[0020] FIG. 2E is a front view of the system of FIG. 2A .
[0021] FIG. 3 is a rear view of a top drive system of according to the present invention.
[0022] FIG. 4A is a perspective view of a gear apparatus for a top drive system according to the present invention.
[0023] FIG. 4B is a side view partially in cross-section of the apparatus of FIG. 4A (along line 4 B- 4 B of FIG. 4C ).
[0024] FIG. 4C is a top of the apparatus of FIG. 4A .
[0025] FIG. 4D is a bottom view of the apparatus of FIG. 4A with part in cross-section (along line 4 D- 4 D of FIG. 4B ).
[0026] FIG. 4E is an enlargement of part of the apparatus of FIG. 4B .
[0027] While the subject matter disclosed herein is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION
[0028] Various illustrative embodiments of the present subject matter are described below. In the interest of clarity, not all features of an actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.
[0029] FIGS. 1A-1D illustrate a top drive system 10 according to the present invention which has a plurality of components including: a gooseneck 11 , a bonnet 12 , brakes 13 , a motor 14 , a gear system 15 , a drive shaft 16 , a bearing system 17 , a swivel body 18 , a pipe handler lock assembly 19 , a link support 22 , a swivel ring 23 and a load (or landing) collar 29 . The components can be collectively suspended in a typical derrick from a typical traveling block for up and down movement in the derrick.
[0030] During certain operations, the motor 14 within a housing 14 a rotates the drive shaft 16 which, in turn, rotates a drill string and a drill bit to produce an earth bore. Fluid pumped into the top drive system through the gooseneck 11 passes through the drive shaft 16 , a drill string, and a drill bit and enters the bottom of an earth bore.
[0031] In certain aspects, the motor housing 14 a (e.g. made of sheet metal or aluminum) includes a series of tie rods 14 b which are secured to a top member 14 c and a bottom member 14 d to strengthen the housing 14 a. In certain particular aspects the housing 14 a is made of metal such as aluminum or steel. In one particular aspect the motor 14 is a motor as disclosed in U.S. Pat. No. 7,188,686. In another particular aspect the motor 14 (as may be any motor herein) is a salient pole permanent magnet motor.
[0032] The gear system 15 is located above a bearing retainer 21 which serves to maintain the drive shaft 16 in place (radially and axially) e.g. during drilling, and houses an upper race of a thrust bearing system 16 b. As shown in FIG. 1D , the bearing retainer is a separate item secured to and below the housing of the gear system 15 . As discussed in detail below, in one embodiment of the present invention, a bearing retainer is made integral with the gear system housing. A load flange 16 a of the drive shaft 16 moves on bearings 16 c.
[0033] An encoder/resolver 24 (see FIG. 1D ) measures the position and speed of the motor 14 and provides a signal indicative of the position of the drive shaft 16 . With certain salient pole motors, the encoder/resolver 24 can be deleted since motor controls for salient pole permanent magnet motors indicate the position of the rotor of the motor and, therefore, the position of the drive shaft 16 (e.g., the position of the drive shaft during tubular connection make-up and break-out and during drilling). Certain typical salient pole motors (with embedded tangential or radial rotor magnets) have relatively higher inductance than non-salient motors and provide smoother starting from a standstill.
[0034] The top drive system 10 has a motor control system 20 (shown schematically, FIG. 1A ) which, in certain aspects, includes an output reactor 20 a (also called an “inductor”) which insures efficient operation by increasing the inductance applied to the motor. This inductor is used with certain low inductance motors. In other aspects, by using a relatively high inductance motor, e.g. a relatively high inductance salient pole motor, the inductor 20 a is eliminated since the high inductance motor applies a sufficient amount of inductance.
[0035] FIG. 2A-2D shows a top drive system 30 according to the present invention which, in some aspects, is like the system 10 , FIG. 1A (and like numerals indicate like parts). A motor 14 m (like any of the motors 14 ) is above a gear system 25 (instead of the gear system 15 ) has a housing 14 h.
[0036] Parts of the housing 14 h including sides 14 s, top 14 t, and bottom 14 v following assembly are not connected together by tie rods (as are housing parts in the top drive of FIG. 1A ). In one aspect the housing 14 h is made of steel and is sufficiently strong so that a portion of it is threaded to threadedly connect the bonnet 12 thereto. A steel housing motor can be relatively larger than a motor with a weaker (e.g. aluminum) housing. This novel elimination of tie rods allows a motor of a greater diameter (larger size) to be used in a similar space. This relatively larger diameter means that the motor provides relatively greater horsepower with greater efficiency.
[0037] A lower portion 48 of a gear housing 46 serves as a bearing retainer to retain bearing 44 . FIGS. 2A-2D are exploded views or views that show parts not assembled together.
[0038] When assembled, the bearing 44 is within a bearing retainer 48 . The bearing retainer, a lower portion 48 of the housing 46 is releasably secured to the housing 46 , e.g. with bolts.
[0039] FIG. 3 shows a top drive system 50 (partially exploded view) according to the present invention. A motor 60 has a brake system 54 and an output shaft 56 . The output shaft 56 is connected to a gear system 100 . The gear system 100 driven by the motor 60 , drives a main drive shaft 70 . Bearings 58 (thrust bearings) are retained in place by a bearing retainer 80 which is bolted to or integral with the gear system 100 . An attachment frame 90 (a “swivel body”) provides for the connection of a torque track for conducting torque from the system to the torque track. The swivel body 90 is, typically, suspended from a block in the derrick by bails.
[0040] FIGS. 4A-4D show the gear system 100 of the top drive system 50 . A housing 102 has a motor mounting surface 104 on which the motor is positioned. A part 107 is releasably secured to the housing with bolts 107 b. Gear reducer system 110 within the housing 102 includes a gear reducer 111 and a bearing 116 . The gear reducer system 110 includes a first stage carrier 112 ; a second stage sun pinion 113 ; a second stage carrier 114 ; and a bearing cartridge 115 . The cartridge 115 with the bearing 117 is held in place by bolts 115 x. Removing the bolts 107 b and the bolts 115 x permits removal of the cartridge 115 for bearing replacement, in one aspect, with a single bearing 117 .
[0041] There are three first stage planetary gears 127 (see FIG. 4C ). The gear system 100 has a bottom surface 130 (see FIG. 4D ). A temperature gauge 134 can be inserted in a tapped thread portion 132 . A tip of the gauge sits in the oil flow path and dynamically measures the temperature of the oil flow.
[0042] A lower portion 120 of part 107 of the housing 102 serves as a bearing retainer to retain in place the bearing 44 (see FIG. 4E ). An inline flow meter 121 which measures oil flow to the housing has an oil inlet port 122 . Magnetic plugs 123 are positioned in holes 124 to attract and hold metal shavings and debris. An air breather 125 is in communication with the interior of the housing 120 .
[0043] As shown in FIGS. 4B and 4E , the cartridge 115 has a part 115 b which is adjacent a part 115 a. The part 115 a includes an upper part 115 g and a side 115 f. The part 115 b is encompassed within structure of the part 115 a (upper part 115 g and side 115 f ) and a top surface 107 a of the part 107 . The part 115 a rests on a top surface 107 b of the part 107 and against a side 107 c of the part 107 . In one aspect, the top surface 107 a is lower than top surface 107 b.
[0044] Due to the tolerances between the part 115 b and the part 115 a some slight movement is possible of the part 115 b with respect to the part 115 a. An interface between the parts 115 b and 115 a is sealed by one or more seals--two o-ring seals 115 c are shown in corresponding recesses 115 d in the part 115 b. These seals are sized, configured, and positioned to accommodate the movement of the part 115 b with respect to the part 115 a.
[0045] The bearing 117 is held in place by a holder 114 c bolted to the second stage carrier 114 by bolts 114 b and rests partially on a ledge 115 e of the part 115 b and under a shoulder 114 d of the carrier 114 . The bearing 117 can move radially (and/or axially) the extent that the part 115 b can move radially (and/or axially), thus permitting the bearing 117 when it is movable radially to “float” horizontally. This inhibits interference in the horizontal plane between the bearing 117 and the bearing 44 (which can cause excessive bearing wear and premature failure). The bearing 117 does not float so much that the second stage carrier 114 moves too far axially, i.e., so far that splines on the periphery of the second stage carrier 114 would not properly mesh with corresponding splines on the main shaft of the motor.
[0046] The present invention, therefore, provides in some, but not in necessarily all, embodiments a top drive system for wellbore operations, the top drive system including: a main body; a motor apparatus; a main shaft extending from the main body, the main shaft having a top end and a bottom end, the main shaft having a main shaft flow bore therethrough from top to bottom through which drilling fluid is flowable; a quill connected to and around the main shaft; and, in one aspect, the quill is part of a gearbox of a gear system; a gear system interconnected with the quill, the gear system driven by the motor apparatus so that driving the gear system drives the quill and thereby drives the main shaft, the main shaft passing through the gear system; upper components connected to the main body above the top end of the main shaft.
[0047] The present invention, therefore, provides in some, but not in necessarily all, embodiments a top drive system for wellbore operations, the top drive system including a motor and gearing system including a motor housing, a motor within the motor housing, and the motor housing comprising a top and a bottom and a plurality of rods interconnected between the top and bottom to connect the top and the bottom together.
[0048] The present invention, therefore, provides in some, but not in necessarily all, embodiments a top drive system for wellbore operations, the top drive system including: a main body; a top drive shaft; a motor apparatus; a motor shaft extending from the motor; a gear system driven by the motor shaft, the gear system driven by the motor apparatus so that driving the gear system drives the top drive shaft, the gear system including a lower planetary carrier; the gear system including gear apparatus enclosed within a gear housing; a single bearing adjacent and in contact with the lower planetary carrier; a bearing cartridge connected to the gear housing; and the bearing cartridge abutting the single bearing and in contact with and holding the single bearing in position with respect to the lower planetary carrier. Such a system may have one or some, in any possible combination, of the following: the bearing cartridge including an outer part secured to the gear housing, and an inner part within the outer part, the inner part movable radially with respect to the outer part; the single bearing abuts the inner part and the inner part is movable radially with the single bearing; the single bearing maintains the lower planetary carrier in radial position; a shaft bearing around the top drive shaft, and a bearing retainer portion on a lower part of the gear housing for retaining the shaft bearing; wherein the inner part and the single bearing are movable to inhibit interference in the horizontal plane of the single bearing with the shaft bearing; wherein the motor apparatus is a salient pole permanent magnet motor apparatus; at least one seal on the inner part, the at least one seal projecting from the inner part and abutting the outer part, and the at least one seal accommodates movement of the inner part with respect to the outer part; there are two spaced-apart seal recesses on the inner part, and the at least one seal is two seals, one seal in each seal recess; wherein the bearing cartridge is releasably secured to a first part of the gear housing; and/or wherein the first part is releasably secured to the gear housing.
[0049] The present invention, therefore, provides in some, but not in necessarily all, embodiments a top drive system for wellbore operations, the top drive system including: a main body; a top drive shaft; a motor apparatus; a motor shaft extending from the motor; a gear system driven by the motor shaft, the gear system driven by the motor apparatus so that driving the gear system drives the top drive shaft, the gear system including a lower planetary carrier; the gear system including gear apparatus enclosed within a gear housing; a single bearing adjacent and in contact with the lower planetary carrier; a bearing cartridge connected to the gear housing; the bearing cartridge abutting the single bearing and in contact with and holding the single bearing in position with respect to the lower planetary carrier; the bearing cartridge including an outer part secured to the gear housing; an inner part within the outer part, the inner part movable radially with respect to the outer part; the single bearing abuts the inner part and the inner part is movable radially with the single bearing; wherein the single bearing maintains the lower planetary carrier in radial position; a shaft bearing around the top drive shaft; a bearing retainer portion on a lower part of the gear housing for retaining the shaft bearing; and wherein the inner part and the single bearing are movable to inhibit interference in the horizontal plane of the single bearing with the shaft bearing.
[0050] The present invention, therefore, provides in some, but not in necessarily all, embodiments a method for facilitating rotation of a lower planetary carrier of a gear system of a top drive system, the top drive system having a motor and gearing system including a motor housing, a motor within the motor housing, and the motor housing being a top and a bottom and a plurality of rods interconnected between the top and bottom to connect the top and the bottom together, the method including: rotating the lower planetary carrier with respect to the single bearing, and holding the single bearing in position with the bearing cartridge. Such a method may have one or some, in any possible combination, of the following: the bearing cartridge including an outer part secured to the gear housing, and an inner part within the outer part, the inner part movable radially with respect to the outer part, wherein the single bearing abuts the inner part and the inner part is movable radially with the single bearing, the method further including allowing the single bearing to move radially to an extent of possible radial movement of the inner part; wherein the single bearing maintains the lower planetary carrier in radial position, the method further including maintaining the lower planetary carrier in position with the single bearing; the top drive system having a shaft bearing around the top drive shaft, and a bearing retainer portion on a lower part of the gear housing for retaining the shaft bearing, the method further including retaining the shaft bearing in position with the bearing retainer portion; wherein the inner part and the single bearing are movable to inhibit interference in the horizontal plane of the single bearing with the shaft bearing, the method further including inhibiting interference in the horizontal plane between the single bearing and the shaft bearing; and/or the top drive system having at least one seal on the inner part, the at least one seal projecting from the inner part and abutting the outer part, the at least one seal accommodates movement of the inner part with respect to the outer part, the method further including with the at least one seal accommodating movement of the inner part with respect to the outer part.
[0051] The present invention, therefore, provides in some, but not in necessarily all, embodiments a method for inhibiting interference in the horizontal plane between a single bearing in a gear housing adjacent a lower planetary carrier of a gear system of a top drive system and a shaft bearing around a top drive shaft of the top drive system, the top drive system having a main body, a top drive shaft, a motor apparatus, a motor shaft extending from the motor, a gear system driven by the motor shaft, the gear system driven by the motor apparatus so that driving the gear system drives the top drive shaft, the gear system including a lower planetary carrier, the gear system including gear apparatus enclosed within a gear housing, a single bearing adjacent and in contact with the lower planetary carrier, a bearing cartridge connected to the gear housing, and the bearing cartridge abutting the single bearing and in contact with and holding the single bearing in position with respect to the lower planetary carrier, the method including allowing the single bearing to move radially with respect to the gear housing in a controlled manner.
[0052] In conclusion, therefore, it is seen that the present invention and the embodiments disclosed herein and those covered by the appended claims are well adapted to carry out the objectives and obtain the ends set forth. Certain changes can be made in the subject matter without departing from the spirit and the scope of this invention. It is realized that changes are possible within the scope of this invention and it is further intended that each element or step recited in any of the following claims is to be understood as referring to the step literally and/or to all equivalent elements or steps. The following claims are intended to cover the invention as broadly as legally possible in whatever form it may be utilized. The invention claimed herein is new and novel in accordance with 35 U.S.C. 102 and satisfies the conditions for patentability in section. 102 . The invention claimed herein is not obvious in accordance with 35 U.S.C. 103 and satisfies its conditions for patentability. This specification is in accordance with the requirements of 35 U.S.C. 112. The inventors may rely on the Doctrine of Equivalents to determine and assess the scope of their invention and of the claims that follow as they may pertain to apparatus not materially departing from, but outside of, the literal scope of the invention as set forth in the following claims. All patents and applications identified herein are incorporated fully herein for all purposes.
[0053] Whereas the present invention has been described in particular relation to the drawings attached hereto, it should be understood that other and further modifications apart from those shown or suggested herein, may be made within the scope and spirit of the present invention.
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A system includes a gear system having a gear housing and a lower planetary carrier disposed in the gear housing, the lower planetary carrier being adapted to rotate relative to the gear housing. A top drive system is operatively coupled to the gear system, the top drive system having a top drive shaft that is adapted to be driven by the gear system. A single bearing that is adapted to facilitate rotation of the lower planetary carrier is positioned between the gear housing and the lower planetary carrier. A motor apparatus is operatively coupled to and adapted to drive the gear system by rotating the lower planetary carrier relative to the gear housing, wherein a rotational axis of the single bearing is adapted to move in a lateral translational direction with respect to the gear housing while the motor apparatus is rotating the lower planetary carrier.
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FIELD OF THE INVENTION
The present invention relates to the SKS semi-automatic rifle, and more particularly to a replacement gas tube therefor.
BACKGROUND OF THE INVENTION
The SKS rifle, also known as the Simonov, is a semi-automatic rifle developed for the Soviet army in the 1940's. SKS type rifles have been in widespread use by military services around the world since that time, and are widely available as military surplus for civilian use in the U.S.
The firing mechanism of the SKS is automatically cocked each time a round of ammunition is fired by means of a piston which is actuated by the gas propelling the bullet out of the gun barrel. A small portion of the propellent gas exits the gun barrel through a port penetrating the barrel a short distance from the muzzle and enters a gas tube located above the barrel. The piston is located inside the gas tube and is driven in a rearward direction by the gas against a bolt carrier, momentarily driving the carrier rearwardly against a recoil spring to eject the spent shell casing and cock the hammer. The force of the gas is spent at this point, and the recoil spring drives the bolt carrier forward to introduce a new round from the magazine into the firing chamber.
The standard gas tube produced for SKS rifles is an assembly of several parts. The tube itself is formed in two pieces, the first being a piston tube having a relatively large interior diameter to permit sliding passage of the gas piston head therein, and the second being a rod tube having a smaller inside and outside diameter than the piston tube, with the inside diameter sized to permit passage of an operating rod attached to the gas piston head and the outside sized to permit it to be press fit into the bore of the piston tube. A hand guard, usually made of wood or metal, is attached to the gas tube assembly via end bands to cover the rod tube portion of the gas tube, which becomes hot during continuous firing of the rifle and which is located along the upper surface of the fore end of the stock where a hand may rest while holding a rifle. Standard hand guards comprise three separate pieces: a semi-cylindrical guard, and two end caps or bands which connect the guard to the gas tube.
The overall result of this multi-piece construction is a gas tube assembly that, while functioning adequately in its primary task of converting the energy of propellant gas into piston motion to actuate the firing mechanism, is relatively flexible over its longitudinal axis. This flexibility has several adverse consequences, the most significant being a reduction in firing accuracy of the rifle. The accuracy of firearms can generally be improved by increasing the stiffness or rigidity of the barrel and receiver group components, including the gas system components connected to the rifle barrel.
It is believed by the inventor that the multi-piece construction of the prior art gas tube also leads to the assembly having an increased number of harmonic natural frequencies that are excited when the rifle is fired. During rapid fire these harmonic vibrations may propagate throughout the rifle, decreasing accuracy and possibly causing metal fatigue that may lead to failure of any number of the rifle's components.
Additionally, the multi-piece gas tube has inherently poor heat transfer characteristics. The interface between the two tube patterns impedes heat transfer therebetween and so reduces the overall rate of heat dissipation from the unit.
Another limitation of the standard SKS gas tube assembly is that the hand guard portion cannot be readily detached from the gas tube. The hand guard may need replacement due to damage, or the gun owner may wish to install a different style or color hand guard. It may also be desirable to remove the hand guard from the gas tube assembly for cleaning. Currently, removal of the handguard from the gas tube cannot be accomplished without access to a well equipped machine shop.
The position of the gas tube assembly on the SKS rifle assembly is a prime spot for the mounting of non-standard rifle accessories, such as sighting devices, flashlights, or cameras. The construction of the standard gas tube, however, does not permit the secure mounting of such accessories. No provisions are made on the standard gas tube for mounting accessories, detachably or otherwise.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved gas tube for an SKS rifle formed from a single piece of metal. The increased stiffness of the unitary gas tube improves the overall rigidity of the rifle when the gas tube is operatively attached to the rifle, thereby increasing firing accuracy and reducing vibration during firing. The heat transfer characteristics of the unitary tube are also improved.
It is a further object of the present invention to provide an SKS rifle gas tube to which a hand guard or other accessory may be securely yet removably attached. This objective is achieved by providing an axial segment of the gas tube in the handguard region with a mounting site, for example by increasing wall thickness enough to allow the formation therein of mounting holes. By the use of bolts or other fastening means, a hand guard or other accessory can be securely attached to the gas tube and thereby to the rifle as a whole and may be easily removed for repair or replacement.
It is yet another object of the present invention to provide an SKS rifle gas tube of unitary construction having increased axial rigidity wherein cooling of the gas tube is enhanced by a plurality of integrally formed, axially spaced cooling fins.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a right side view of an SKS rifle of the type toward which the present invention is directed;
FIG. 2 is a perspective view of a prior art gas tube and handguard assembly shown with cooperating parts of the rifle and the gas piston removed;
FIG. 3 is an exploded view of a prior art gas tube and handguard assembly for an SKS rifle;
FIG. 4 is an exploded view of an SKS gas tube and handguard assembly embodying the present invention; and
FIG. 5 is a side view of an SKS gas tube according to an alternate embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As depicted in FIG. 1, an SKS rifle 10 generally comprises a barrel 12, a stock 14, a receiver 16, and a gas tube assembly 20. The receiver 16 houses several parts which together make up the rifle firing mechanism (partially shown). A small diameter hole (not shown) passes through the upper wall of barrel 12 and is covered by gas cylinder 22. When rifle 10 is fired, a small portion of the combustion gas which propels a bullet along barrel 12 escapes through the gas port and into the gas cylinder after the bullet has passed thereby. Gas cylinder 22 is in communication with a gas tube 24 such that the gas enters gas tube 24 and acts on a gas piston 26 slidingly contained therein. Gas piston 26 has a rod portion 42 which extends out the rear end of gas tube 24 and into receiver 16 where it operatively engages the firing mechanism in known manner. Each time rifle 10 is fired, the vented propellant gas forces gas piston 26 rearwardly in gas tube 24 and this motion actuates the firing mechanism to eject a spent shell casing, cock the firing mechanism, and load a new shell into the chamber of barrel 12.
Gas tube assembly 20 is retained in its operative position by engaging gas cylinder 22 at its forward end and a gas tube lock lever 28 at its rearward end. Gas tube assembly 20 may be removed from rifle 10 by moving gas tube lock lever 28 to an unlocked position and moving gas tube assembly 20 upwardly and rearwardly to disengage it from gas cylinder 22.
A standard gas tube assembly for an SKS rifle exemplifying the prior art is shown in FIGS. 2 and 3. The prior art gas tube assembly comprises a piston tube 30, a rod tube 32, a hand guard 34, and forward and rear gas tube bands 36 and 38, respectively. Piston tube 30 has an interior bore of a diameter sized to receive piston head portion 40 (FIG. 2) of gas piston 26. Rod tube 32 has a smaller internal bore diameter than piston tube 30 for passage of rod portion 42 of gas piston 26. The external diameter of rod tube 32 is also substantially less than that of piston tube 30, and rod tube end 32a is press fit into the internal bore of piston tube 30 such that the respective piston and rod tube bores communicate in coaxial fashion.
Gas tube bands 36, 38 engage opposite ends of hand guard 34, with forward gas tube band 36 being press fit over forward assembly lug 44a on rod tube 32 and abutting piston tube 30, and rear gas tube band 38 being welded and/or pinned to an assembly lug 44b formed at the rearward end of rod tube 32. Handguard 34 is held between bands 36, 38 and assembly lugs 44a, 44b to cover rod tube 32 and prevent it from directly contacting a user's hand during firing. Handguard 34 is perforated with holes 34a to keep it cool.
The two-piece nature of the prior art gas tube reduces its strength and rigidity, particularly where rod tube 32 and piston tube 30 are joined. Additionally, the press-fit and braze/weld attachment of handguard 34 to rod tube 32 via bands 36, 38 and assembly lugs 44 makes removal of handguard 34 from the gas tube very difficult without special tools or machinery. Finally, the three-piece band/handguard assembly 34, 36, 38 adds additional non-unitary structure to the gas tube when assembled therewith.
In the improved gas tube of the present invention shown in FIG. 4, gas tube 50 is unitary, formed from a single piece of metal, preferably carbon steel. The forward end of unitary gas tube 50, that being defined as the end which engages gas cylinder 22, comprises a piston tube portion 52 having a bore 52a of a diameter sized to receive the head 40 of gas piston 26. The balance of gas tube 50 defines a rod tube portion 54 having a bore 54a of a diameter smaller than that of piston tube portion 52 and sized to receive the rod 42 of gas piston 26. The rearmost end of rear tube portion 54 includes an assembly lug 66 which is similar to lug 44b in FIG. 3; i.e., it is engaged by gas tube lock lever 28 to hold gas tube 50 securely in its operative position on rifle 10.
The one piece, unitary construction of gas tube 50 according to the present invention increases its rigidity, thereby increasing accuracy of the rifle to which it is connected. In particular, the two piece plug fit of the prior art rod tube 32 and piston tube 30 is replaced with a unitary rod tube 54 and piston tube 52, in which the junction of rod bore 54a and piston bore 52a is strengthened by a unitary region of increased wall thickness 56 which overlies the forward end of rod bore 54a and is integral with piston tube 52. At the same time, the increased wall thickness of rod tube region 56 provides a solid, convenient mounting site for an accessory such as handguard 64. In the illustrated embodiment at FIG. 4, forward mounting lug region 56 is provided with a threaded hole 60 for receiving a set screw 62 for securing handguard 64 directly to the gas tube 50, without the need for structure such as bands 36, 38.
In a preferred form the rearward end of rod portion 54 of gas tube 50 includes an enlarged diameter region or lug 58 which provides a rearward mounting site for the rear end of handguard 64, also using a threaded hole 60 and set screw 62.
The intermediate region of rod tube portion 54 between mounting lugs 56, 58 has a reduced diameter to lighten the overall weight of gas tube 50. In the illustrated embodiment, however, the diameter of the intermediate portion of rod tube portion 54 is greater than the wall thickness of prior art rod tube 32 to increase rigidity and add a desirable, recoil-reducing heft near the mid-section of the rifle. It will be understood that various wall thicknesses can be used for the intermediate portion of rod portion 54, and it is possible to manufacture rod portion 54 with a constant diameter such that the entire gas tube 50 has a constant outside diameter. However, in the handguard region of rod tube portion 54 (i.e., the portion from the rear end of mounting lug 58 to the front end of mounting lug 56 covered by handguard 64) handguard 64 only contacts the gas tube in the region of mounting lug 56, 58. It is desirable to reduce the intermediate portion of rod portion 54 between mounting lugs 56, 58 to maintain an air gap with handguard 64; otherwise, handguard 64 might become uncomfortably hot through conductive, metal-on-metal heating along its entire length.
While in the illustrated embodiment of FIG. 4 a handguard 64 is the accessory attached to mounting lug regions 56, 58 of rod portion 54 of the gas tube, other accessories can be mounted to one or both of the mounting lug regions for example a flashlight bracket, a telescopic sight, a night sight, or a camera. And while the illustrated handguard 64 comprises a perforated metal, the handguard could be solid and/or made from other materials such as wood or heat-resistant plastics.
While the structure used for mounting the handguard accessory 64 to mounting lug regions 56, 58 comprises a threaded hole 60 and set screw fastener 62 in the illustrated embodiment, it will be apparent to those skilled in the art that mounting lug regions 56, 58 provide a strong base for other types of fastening or mounting structure to connect accessories to the gas tube assembly. The set screw fastened handguard 64 in the illustrated embodiment of FIG. 4 illustrates a preferred accessory, and a method for making it easily removed from gas tube 50 using only hand tools and without the need for removing gas tube 50 from rifle 10.
A further embodiment of the present invention is depicted in FIG. 5 and comprises a unitary gas tube 50' having an overall configuration similar to that of the above-described first embodiment. Unitary gas tube 50' comprises a piston tube portion 52' and a rod tube portion 54' having mounting lug regions 56', 58' and a series of cooling fins 70 formed integrally therewith. Cooling fins 70 serve to increase the rate of heat transfer away from unitary gas tube 50' and also provide additional material to increase gas tube rigidity and serve as a heat sink. Gas tube 50' can be used with or without a handguard; however, where the diameter of fins 70 is equal to that of regions 56', 58', it may be preferable to dispense with a handguard for the reasons described above.
Many modifications and variations of the present invention will be apparent to those skilled in the art in light of the above teachings, and the described embodiments are not intended to limit the present invention beyond the scope of the claims.
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A replacement gas tube for an SKS rifle features unitary construction to provide increased rigidity and improved vibrational and heat transfer characteristics. The gas tube also features at least one area of increased wall thickness in the handguard region in which is formed a mounting hole to permit the detachable mounting of a hand guard or other accessories.
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BACKGROUND OF THE INVENTION
Fishing spearguns have not changed dramatically over the last century in that they continue to enjoy spearpoint shafts that are biased into a trigger release mechanism by a plurality of rubber bands, and a string line is provided for retrieving the spearpoint and shaft after firing.
Of course, modern manufacturing techniques have made improvements which have somewhat affected the appearance of the speargun, its safety and ease of cocking and trigger pull. For example, the grip assembly now includes, in one case, a one-piece plastic housing that forms the handle grip, the trigger guard, the butt support, the forepiece support and the housing for the trigger assembly.
The trigger assembly has been improved by providing it with a removable frame that permits the trigger assembly to be easily removed from the grip housing. This prior trigger assembly includes a one-piece plastic frame having an upper spearpoint shaft guide and spaced parallel lower frames that pivotally support both the trigger and a shaft latching bar.
The trigger assembly is also provided with a safety pawl operated by a knob on the outside of the grip housing.
Since these spearguns have remained basically unchanged, performance improvements, although they may appear small, contribute greatly to the popularity of the speargun in this fascinating, competitive and still somewhat esoteric sport.
In these prior trigger assemblies, the latch bar and the trigger slidably engage one another and are constructed of the same material and after a period of use, the interengaging surfaces become scored causing trigger pull to become erratic which results in a jerking movement of the gun during firing throwing the spear off target.
Another problem in these prior trigger assemblies is that the safety mechanism requires the use of the fisherman's other hand, or more particularly, with the fisherman's left hand on the grip housing handle, he either has to operate the safety release with his right hand or take his left hand off the grip to release it.
In my U.S. Pat. No. 4,962,747, issued Oct. 16, 1990, I disclose and describe a speargun that includes a trigger assembly that has a left-right reversible safety operable with the trigger hand while on the grip, and an improved trigger pull achieved by engaging bearing surfaces on the latch bar and trigger.
That speargun was provided with a one-piece grip housing in the general shape of the housing of an automatic pistol that has an upper slot into which a trigger assembly is insertable. The trigger assembly has a plastic frame with an integral top tube that receives the proximal end of the spearpoint shaft, and parallel spaced depending walls that pivotally support the trigger, the latch bar, and a safety pawl.
The latch bar has an upwardly projecting shaft locking pawl substantially in line with the pivotal axis of the locking pawl, and this location has the effect of reducing the outward shaft torque on the latch bar, and hence the trigger, reducing trigger pull effort by at least 32%.
The latch bar has an elongated arm that rests on a shoulder on the trigger in the set or firing position. The latch bar is constructed of hardened 17-7 stainless steel, while the trigger is constructed of 302 stainless, or equivalents thereof, resulting in a significant difference in hardness and creating a bearing effect between the latch bar arm and the trigger shoulder eliminating the prior problem of scoring on these surfaces and thereby smoothing out trigger pull substantially.
The safety pawl is operated by a knob and shaft assembly projecting through the grip housing and the trigger frame. The knob has a radially extending finger that is positioned so that when the safety is "on" with the latch bar holding the spearpoint shaft in a firing position, this finger depends over the trigger blocking movement of the fisherman's index finger toward the trigger. This is important in spearguns because underwater conditions make it difficult to visually observe whether the safety is "on" or "off".
After recognizing a safety "on" condition, the fisherman, with his trigger hand on the housing grip, releases the safety with this index finger of his trigger hand by rotating the knob finger clockwise toward a horizontal position away from the trigger, rotating the safety pawl away from the trigger creating a firing condition.
The safety knob and shaft assembly is insertable through the safety pawl from either the right or left side of the grip housing permitting the safety to be used with the trigger hand on the grip for both right or left side spear fishermen.
While my prior speargun has worked well and been extremely successful, it does have several disadvantages that are addressed in the design of the speargun according to the present invention.
Firstly, the safety assembly is journaled in the frame of the removable trigger assembly, and since the width of the frame is fairly narrow, the shaft supporting the safety assembly tends to rock somewhat during use, creating a feeling of uncertainty in operation. And oxidation caused by salt water and foreign matter in my prior gun had a deleterious effect on the metal bearings. This prior safety assembly also includes a spring for urging the safety assembly to its appropriate axial position. The spring is mounted externally of the grip housing, which requires the safety assembly shaft to project a significant distance from the grip housing. This design has resulted in some cases in the safety assembly shaft bending which sometimes prompts the spear fisherman to completely remove the safety assembly.
My prior speargun also included a line holding and release assembly mounted in the grip housing that included a shaft with an hexagonal head, a torsion spring, and a finger bar. The torsion spring was seated at one end in the hexagonal shaft head, and the other end seated in the line holding finger bar. As these parts are assembled to the grip housing, it was necessary to rotate the hexagonal head to tension the spring prior to pushing the head into a mating hexagonal hole in the grip housing. This was an extremely difficult assembly procedure that required repetitive attempts to locate the parts properly and at the same time rotate the head to tension the finger bar. Also in this design the spring was carried by the shaft inside the housing, without any support during initial assembly, and tended to push the shaft out of the housing sometimes causing these parts to be lost.
The third problem with my prior speargun, as well as all of the spearguns that I am aware of, is the necessity for the spearpoint shaft to be threaded completely through the muzzle both when loading the spearpoint shaft and when removing the spearpoint shaft from the gun after an incomplete fire when the spearpoint shaft fails to clear the muzzle.
It is a primary object of the present invention to ameliorate these problems noted above both in the prior art and in my prior speargun, as shown and described in my U.S. Pat. No. 4,962,747, issued Oct. 16, 1990.
SUMMARY OF THE PRESENT INVENTION
In accordance with the present invention, an improved spear fishing gun is provided having a receiver assembly that has a grip housing containing a removable trigger assembly with a spearpoint shaft latch bar, trigger, and a safety pawl, the latter mounted on a shaft extending through the grip housing with an external operator, with the shaft being supported in the grip housing to increase its stability. The grip housing has a line holding and release assembly that is automatically tensioned as it is assembled to the grip housing, and a muzzle assembly is provided that permits the lateral insertion and removal of the spearpoint shaft.
Toward these ends, the safety pawl assembly includes a square pivot shaft that is supported by plastic bearings in the grip housing, rather than in the trigger assembly frame. Since the walls of the grip housing are spaced apart a far greater distance than the corresponding walls in the trigger assembly frame, the entire safety assembly has far greater stability than in my prior construction. The bearings for this safety shaft include a boss integrally formed on the safety assembly operator that fits closely in an aperture in the grip housing. The other end of the safety assembly shaft is supported in the other side of the grip housing by a small annular plastic bearing that is engaged in an aperture therein. This reduces the oxidation problems in my prior gun.
A spring is provided on the shaft inside the grip housing for urging the shaft and the operator to their appropriate positions. This eliminates the need for a long extension of the shaft from the grip housing as in my prior speargun described in my U.S. Pat. No. 4,962,747.
The line holding and release assembly includes a main support shaft for a pivotal finger bar and a coil spring. One end of the coil spring is held in a fixed position relative to the grip housing by a small offset pin, and the other end of the spring is bent laterally and is received in an offset aperture in the finger bar. During assembly the spring is positioned first in the grip housing over the small pin, and the other end is threaded into the finger bar aperture before the main shaft is threaded through the finger bar. When the main shaft is then threaded through the finger bar, the finger bar is automatically appropriately tensioned in the grip housing without requiring any additional tensioning as in prior designs.
The muzzle assembly is a one-piece plastic molding that has a band aperture and an integral line holding finger. The top of this molding has a spearpoint shaft receiving opening that has an adjacent lateral slot formed by deformable fingers that permit the spearpoint shaft to be laterally snapped in and out of the muzzle, thereby eliminating the prior necessity of completely threading the spearpoint shaft through the muzzle both when loading the spearpoint shaft and when removing the shaft from the gun after a misfire.
A further feature of the present invention is the provision of a knuckle guard which not only achieves the function of protecting the fisherman's knuckles from injury, but also keeps the grip housing from spreading near the line holding and release assembly, thereby eliminating the problem of the line holding and release assembly parts becoming disoriented.
Other objects and advantages of the present invention will appear more clearly from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the fishing speargun according to the present invention;
FIG. 2 is an exploded sub-assembly perspective of the grip housing, trigger assembly, and line assembly shown in FIG. 1;
FIG. 3 is a left side exploded perspective similar to FIG. 2;
FIGS. 4, 5 and 6 are longitudinal sections of the trigger assembly respectively in the loading, safety "on" and firing positions;
FIGS. 7 and 8 are a side views, partly fragmented, of the muzzle end of the present speargun according to the present invention as the spearpoint shaft is snapped into its loaded position;
FIG. 9 is a left side end view of the muzzle assembly;
FIG. 10 is a cross section through the grip housing illustrating the safety assembly according to the present invention taken generally along line 10--10 of FIG. 2, and;
FIG. 11 is a cross section through the grip housing illustrating the line holding and release assembly taken generally along line 11--11 of FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings and particularly FIGS. 1 to 3, a speargun assembly 10 is illustrated according to the present invention generally including a grip housing 12, a trigger assembly 14, a butt rest 16 supported in grip housing 12 by butt extension 17, a wooden forepiece 19 supported in the forward end of grip housing 12, a muzzle piece 21 supported on forepiece 19, and a pair of bands 23 of natural rubber shown in their relaxed positions which are adapted to engage spearpoint shaft 24 in preparation for firing, which carries a spearpoint 26 at its distal end.
Bands 23 carry metal loops 28 adapted to engage in grooves 30 in the top of spearpoint shaft 24 as seen clearly in FIG. 4.
Referring again to FIG. 1, a line assembly 32 is provided for retrieving the spearpoint 26 and shaft after firing.
As seen in FIGS. 2 and 3, the grip housing 12 is a one-piece plastic molding including a clamshell design of two substantially mirror image half portions 12a and 12b in the general shape of an automatic pistol having a hollow handle 35, a trigger guard 36, and a tubular upper receiver 37, whose forward end supports forepiece 19 and rear end supports butt extension 17 and a knuckle guard 15. Trigger assembly 14 is insertable into an elongated slot 38 in the top of receiver 37.
The trigger assembly 14 and the grip housing 12 support a safety assembly 40 and a line holding and release assembly 42.
The trigger assembly 14 includes a reinforced nylon plastic frame 43 seen more clearly in FIGS. 4 to 6. Frame 43 is a one-piece plastic injection molding having an integral upper guide tube 44 that slidably receives proximal end 45 of spearpoint shaft 24. Frame 43 has a pair of parallel spaced depending side walls 46 and 47 that laterally support trigger 50, latch bar 51, and safety pawl 52.
The latch bar 51 is a one-piece 17-7 hardened stainless steel part pivotally supported between walls 46 and 47 by a pin 53 that extends through walls 46 and 47 but not through receiver side walls 54 and 55, as seen in FIGS. 2 and 3 so that it does not have to be removed to remove trigger assembly 14 from receiver 37.
The latch bar 51 has a rectangular recess hat defines a reset pawl extending into guide tube 44 through slot 58. Pawl 57 is engaged by the proximal end 45 of the spearpoint shaft as the shaft is loaded into the guide tube 44.
Recess 57 also defines a second pawl 59 on the latch bar that in its set position illustrated in FIG. 5 engages a shoulder 60 in a recess in the bottom of spear-point shaft proximal end 45 to hold the spearpoint shaft in a firing reading position.
One-piece trigger 50 is constructed of 302 stainless steel and is pivotally mounted between trigger frame walls 46 and 47 by pin 61, and a leaf spring 63 is provided which engages shoulders on the latch bar and trigger to maintain them in engagement after firing as seen in FIG. 6.
The latch bar 51 has a forwardly extending arm 64 that engages a generally horizontal shoulder 65 on trigger 50 in the firing position of the latch bar illustrated in FIG. 5.
Because the latch bar 51 and the trigger 50 are constructed of substantially disparate hardness materials, the interengaging surfaces of shoulder 65 and the bottom surfaces of latch bar arm 64 create a bearing condition between the surfaces that substantially eliminates scoring of these surfaces and yields a vastly enhanced trigger pull.
As seen in FIGS. 2 and 3, a safety assembly 40 is provided that includes the pawl 52, spacing ring 68, spring 69, shaft 70 and operator knob 71.
The shaft 70 is square throughout its length and is received in a corresponding rectangular aperture in safety pawl 52 so that the pawl is rotationally fixed to the shaft.
The operator knob 71, as seen in FIGS. 2, 3 and 10, has an integral tubular boss 73 with a rectangular aperture therein for non-rotatably receiving shaft 70, and boss 73 is seated in a circular aperture 74 in the grip housing side wall 55, that provides the appropriate bearing support (as assembled in FIG. 2), for the safety assembly 40. The opposite end of square shaft 70 receives a short plastic annular bearing segment 76 that has a square aperture therein that non-rotatably receives that end of shaft 70. Bearing or bushing 76, as seen in FIG. 10, is rotatably supported and received in aperture 78 in grip housing side wall 54 to provide the bearing support for the left side of the safety assembly 40. The wide spacing between bearing walls 54 and 55 provides greater stability for the shaft 70 and the trigger assembly 40. The trigger assembly is maintained in its appropriate axial position in the housing by a coil compression spring 80, which reacts between segment 76 and spacer 68 which engages the side of 46. This action also urges the operator knob 71 toward its seated position in the grip housing. This assembly eliminates the extension of shaft 70 from the grip housing.
As seen in FIG. 11, the line holding and release assembly 42 is mounted between the portions of the grip housings 12a and 12b of the one-piece housing defining the trigger guard 36, and these have been designated as 36a and 36b in FIG. 11. Holding and release assembly 42 includes a boomerang-shaped finger bar 84 pivotally mounted on a cross shaft 85 seated in aligned apertures in housing portions 36a and 36b, a coil compression spring 87, and a small diameter pin 88 also seated in apertures in side walls 36a and 36b. One end of coil spring 87 has a loop 89 that fits around pin 88 to fix one end of the spring 87 with respect to the housing. Spring 87 is seated within a chamber 91 formed in housing side wall 36b. The other end of spring 89 has a lateral projection 93 that fits within an offset aperture or hole in finger bar 84.
During assembly, spring 87 is assembled first by placing it into chamber 91 around pin 88 with main shaft 85 being unassembled at that point. Then the projection 87 is positioned in finger bar 84, and the finger bar is rotated to its holding position as the main shaft is inserted through central aperture 94 in bar 84. Side walls in chamber 91 and recesses in side wall 36a define the limiting positions for the finger bar 84 so that when shaft 85 is inserted through the bar 84, it is automatically preloaded by spring 87.
As seen in FIGS. 7, 8 and 9, the muzzle assembly 21 is a one-piece plastic molding that slides onto and is fastened over the distal end of forepiece 19. Muzzle 21 includes an integral forward line holding finger 100 and a band loop 101 that includes an integral spring finger 102 for permitting the fast and easy entry of the bands 29 into the loop without any separate parts.
The muzzle 21 has a circular axial aperture 105 therethrough that receives spearpoint shaft 24, defined by arcuate segments 106 and 107. The segments 106 and 107 are circumferentially spaced from one another permitting lateral entry of the spearpoint shaft 24. The arcuate segments 106 and 107 have inwardly radially converging shaft entry surfaces 110 and 111 that at their closest point are spaced from one another a distance less than the outer diameter of the spearpoint shaft 24. As seen in FIGS. 7 and 8, the surfaces 110 and 111 angle axially and rearwardly downwardly toward the forepiece 19 to accommodate the angular orientation of spearpoint shaft as it is inserted and removed from the muzzle.
This design permits the spearpoint shaft to be snapped into the muzzle aperture 105 by the application of radial pressure to the upper surface of the spearpoint shaft by the fisherman's thumb, bearing in mind that the muzzle is constructed of an appropriate plastic material so that arcuate segments 106 and 107 are slightly flexible to permit this snap action of the spearpoint shaft into and out of the muzzle. In the event of a misfiring of the spearpoint shaft from the speargun when the spearpoint shaft does not clear the muzzle, the shaft can be pulled away from the gun and snapped out of the muzzle laterally eliminating the necessity that it be axially cleared from the muzzle.
Referring to FIGS. 4, 5 and 6, spearpoint shaft 24 is loaded by inserting it into the guide tube 44 engaging the projection on latch 51, rotating latch bar 51 counter-clockwise against the biasing force of spring 63 away from transverse trigger shoulders permitting trigger 50 to pivot counter-clockwise to its position illustrated in FIG. 5 where a latch bar arm 64 engages transverse trigger shoulders stopping further counter-clockwise movement of the trigger 50. In this position of the latch bar 51, the pawl engages the shaft shoulder preventing outer movement of spearpoint shaft 24 from the guide tube 44.
With his trigger hand forefinger, the fisherman engages safety operator knob 71 and rotates it from its FIG. 4 position to its FIG. 5 "on" position where the safety pawl 52 engages trigger side 115 preventing trigger firing.
When commencing firing, the trigger hand forefinger again engages safety knob 71 and rotates it clockwise back to its horizontal position illustrated in FIG. 6, its "off" position permitting trigger 50 to be pulled to its fired position illustrated in FIG. 6 permitting latch bar 51 to pivot clockwise releasing the locking pawl from the shaft shoulder, permitting bands 23 to fire shaft 24 from the speargun.
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A spear fishing gun having a receiver assembly that has a grip housing containing a removable trigger assembly with a spear point shaft latch bar, a trigger, and a safety pawl mounted on a shaft extending through the trigger assembly and the grip housing with an external operator, with the shaft being supported in the grip housing in a manner to increase its stability. The grip housing has a line holding and release assembly that is automatically tensioned as it is assembled to the grip housing, and a muzzle assembly is provided that permits the lateral insertion and removal of the spearpoint shaft.
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PRIORITY CLAIM
[0001] This application claims the benefit of the provisional patent application Ser. No. 60/844,309 filed Sep. 12, 2006, the contents of which are incorporated herein by this reference.
FIELD OF THE INVENTION
[0002] This invention relates to the reporting and analysis of tabular and graphical data.
BACKGROUND
[0003] Traditional multi-dimensional reporting mechanisms allow the user to change the dimensions of a tabular report (often called a pivot table) or click on a particular cell and “drill down” to see a more detailed view of that data item along the same dimensions as the current report. Current mechanisms allow either:
[0004] 1. The user to change the dimensions of the entire report
[0005] 2. User can take the data in a single cell and show it against two new dimensions
[0006] 2. View details of a single item in the same dimensions
[0007] Neither of these mechanisms allows the user to perform instant analysis on a single data value across multiple dimensions. Therefore, an improved mechanism for multi-dimensional reporting is desirable.
SUMMARY
[0008] Techniques are provided for analyzing data called “pivot points” which allows users to instantly generate a report based on all available dimensions for any cell in a tabular report or any data point in a graphical report. In one embodiment, the techniques involve:
[0009] 1. The system places a unique UI element or menu next to or on each data point
[0010] 2. Clicking on this UI element brings up an automatically filtered list of the valid reports or Dimensions available for just this sub-set of the data.
[0011] Once the user selects which view they want, a report is automatically generated based on those dimensions with just this subset of data
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which:
[0013] FIG. 1 is an example data set that is used to facilitate an explanation of embodiments of the invention;
[0014] FIG. 2 is a simple report displaying all bugs by operating system and priority;
[0015] FIGS. 3A and 3B are block diagrams that illustrate a two step menu list that allows a user to two new dimensions for a new report;
[0016] FIG. 4 is a block diagram that illustrates a report that would be generated if a user selects Product by Assigned to as dimensions from the menu, according to an embodiment of the invention;
[0017] FIGS. 5 a and 5 b are block diagrams that illustrate how valid dimensions would be displayed if a user chose to analyze the issues in an overall total cell, according to an embodiment of the invention;
[0018] FIG. 6 is a block diagram illustrating a report that would result from selecting reporter by assigned to, according to an embodiment of the invention; and
[0019] FIG. 7 is a block diagram illustrating a computer system upon which embodiments of the invention may be implemented.
DETAILED DESCRIPTION
[0020] In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, that the present invention may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to avoid unnecessarily obscuring the present invention.
[0021] The FIGS. 1-4 illustrate how the Pivot Point method works with a very simple data set related to bugs in a software development setting. Software bugs were used for the example data set since it is likely familiar to most professionals working in software field. The approach described works independently of the kind of data being reported upon and could just as easily apply to virtually any data set.
[0022] Techniques described herein relate to how the end-user interacts with the data set in question, not how the data sets are stored or generated. So, the techniques work independently of how the data is stored and how the report itself is generated. The source data itself could be stored in a relational database (RDBMS), a multi-dimensional database, a spreadsheet or any other electronic store. The reports themselves could be generated using any of the many well known reporting techniques.
[0023] FIG. 1 provides an example data set. All other figures are based on this sample data. For simplicity the data set is small, but the techniques work with any multi-dimensional data set.
[0024] FIG. 2 is a simple report displaying all bugs by operating system and priority. Notice the “pivot” icon next to each cell. A “right click” menu (a menu displayed when clicking the right or secondary mouse button in a standard graphical user interface) on the data element itself could also be used instead of the icon.
[0025] Now for example suppose that the user is interested in the “Normal” priority Bugs on “Windows” operating system, by clicking on the “pivot point” next to this cell (Element 1), the system automatically gives the user the ability to select two new dimension for the new report on this subset of the data. This list of dimensions is automatically filtered by the data point in question. In this example, “Priority” is not shown as a valid dimension for further analysis. This is because all data elements in this cell are of a single priority (normal) so a further report on that dimension would not be meaningful. Similarly the “Operating System” dimension is not available because all data elements in this cell are related to a single Operating System, in this case “windows”.
[0026] From the two step menu list in FIGS. 3A and 3B , the user can select two new dimensions for the new report and the system will automatically generate that report based on the data in the active cell (in this case 2 normal bugs for windows). The system automatically filters the subsequent report to include just the data points underlying the cell in question.
[0027] Two step menu could easily be replaced by predefined reports list (which are on appropriate dimensions)
[0028] FIG. 4 shows the report that would be generated if the user had selected Product by Assigned to as dimensions from the menu. Notice that the report generated includes just the 2 normal windows bugs in question.
[0029] A similar approach can be applied to any data value in the report and a similar process is used to display on the meaningful dimensions for that particular data element. To illustrate how this works with different data values in the same report, FIGS. 5A and 5B show the valid dimensions which would be displayed if the user chose to analyze the four issues in the overall total cell. All available dimensions are shown in this case however, since the data elements in question span multiple priorities and operating systems. After making selection in the first popup menu (in this case selecting “reporter”), that selection is no longer available in the second popup menu.
[0030] FIG. 6 shows the report that would result from selecting reporter by assigned to. Notice once again that the data set automatically filtered to the four issues in question.
[0031] The same techniques can be used with by clicking on “pivot points” next to or “right clicking” on data elements in graphical reports such as bar charts, line charts, scatter plots etc.
Hardware Overview
[0032] FIG. 7 is a block diagram that illustrates a computer system 700 upon which an embodiment of the invention may be implemented. Computer system 700 includes a bus 702 or other communication mechanism for communicating information, and a processor 704 coupled with bus 702 for processing information. Computer system 700 also includes a main memory 706 , such as a random access memory (RAM) or other dynamic storage device, coupled to bus 702 for storing information and instructions to be executed by processor 704 . Main memory 706 also may be used for storing temporary variables or other intermediate information during execution of instructions to be executed by processor 704 . Computer system 700 further includes a read only memory (ROM) 708 or other static storage device coupled to bus 702 for storing static information and instructions for processor 704 . A storage device 710 , such as a magnetic disk or optical disk, is provided and coupled to bus 702 for storing information and instructions.
[0033] Computer system 700 may be coupled via bus 702 to a display 712 , such as a cathode ray tube (CRT), for displaying information to a computer user. An input device 714 , including alphanumeric and other keys, is coupled to bus 702 for communicating information and command selections to processor 704 . Another type of user input device is cursor control 716 , such as a mouse, a trackball, or cursor direction keys for communicating direction information and command selections to processor 704 and for controlling cursor movement on display 712 . This input device typically has two degrees of freedom in two axes, a first axis (e.g., x) and a second axis (e.g., y), that allows the device to specify positions in a plane.
[0034] The invention is related to the use of computer system 700 for implementing the techniques described herein. According to one embodiment of the invention, those techniques are performed by computer system 700 in response to processor 704 executing one or more sequences of one or more instructions contained in main memory 706 . Such instructions may be read into main memory 706 from another machine-readable medium, such as storage device 710 . Execution of the sequences of instructions contained in main memory 706 causes processor 704 to perform the process steps described herein. In alternative embodiments, hard-wired circuitry may be used in place of or in combination with software instructions to implement the invention. Thus, embodiments of the invention are not limited to any specific combination of hardware circuitry and software.
[0035] The term “machine-readable medium” as used herein refers to any medium that participates in providing data that causes a machine to operation in a specific fashion. In an embodiment implemented using computer system 700 , various machine-readable media are involved, for example, in providing instructions to processor 704 for execution. Such a medium may take many forms, including but not limited to storage media and transmission media. Storage media includes both non-volatile media and volatile media. Non-volatile media includes, for example, optical or magnetic disks, such as storage device 710 . Volatile media includes dynamic memory, such as main memory 706 . Transmission media includes coaxial cables, copper wire and fiber optics, including the wires that comprise bus 702 . Transmission media can also take the form of acoustic or light waves, such as those generated during radio-wave and infra-red data communications. All such media must be tangible to enable the instructions carried by the media to be detected by a physical mechanism that reads the instructions into a machine.
[0036] Common forms of machine-readable media include, for example, a floppy disk, a flexible disk, hard disk, magnetic tape, or any other magnetic medium, a CD-ROM, any other optical medium, punchcards, papertape, any other physical medium with patterns of holes, a RAM, a PROM, and EPROM, a FLASH-EPROM, any other memory chip or cartridge, a carrier wave as described hereinafter, or any other medium from which a computer can read.
[0037] Various forms of machine-readable media may be involved in carrying one or more sequences of one or more instructions to processor 704 for execution. For example, the instructions may initially be carried on a magnetic disk of a remote computer. The remote computer can load the instructions into its dynamic memory and send the instructions over a telephone line using a modem. A modem local to computer system 700 can receive the data on the telephone line and use an infra-red transmitter to convert the data to an infra-red signal. An infra-red detector can receive the data carried in the infra-red signal and appropriate circuitry can place the data on bus 702 . Bus 702 carries the data to main memory 706 , from which processor 704 retrieves and executes the instructions. The instructions received by main memory 706 may optionally be stored on storage device 710 either before or after execution by processor 704 .
[0038] Computer system 700 also includes a communication interface 718 coupled to bus 702 . Communication interface 718 provides a two-way data communication coupling to a network link 720 that is connected to a local network 722 . For example, communication interface 718 may be an integrated services digital network (ISDN) card or a modem to provide a data communication connection to a corresponding type of telephone line. As another example, communication interface 718 may be a local area network (LAN) card to provide a data communication connection to a compatible LAN. Wireless links may also be implemented. In any such implementation, communication interface 718 sends and receives electrical, electromagnetic or optical signals that carry digital data streams representing various types of information.
[0039] Network link 720 typically provides data communication through one or more networks to other data devices. For example, network link 720 may provide a connection through local network 722 to a host computer 724 or to data equipment operated by an Internet Service Provider (ISP) 726 . ISP 726 in turn provides data communication services through the world wide packet data communication network now commonly referred to as the “Internet” 728 . Local network 722 and Internet 728 both use electrical, electromagnetic or optical signals that carry digital data streams. The signals through the various networks and the signals on network link 720 and through communication interface 718 , which carry the digital data to and from computer system 700 , are exemplary forms of carrier waves transporting the information.
[0040] Computer system 700 can send messages and receive data, including program code, through the network(s), network link 720 and communication interface 718 . In the Internet example, a server 730 might transmit a requested code for an application program through Internet 728 , ISP 726 , local network 722 and communication interface 718 .
[0041] The received code may be executed by processor 704 as it is received, and/or stored in storage device 710 , or other non-volatile storage for later execution. In this manner, computer system 700 may obtain application code in the form of a carrier wave.
[0042] In the foregoing specification, embodiments of the invention have been described with reference to numerous specific details that may vary from implementation to implementation. Thus, the sole and exclusive indicator of what is the invention, and is intended by the applicants to be the invention, is the set of claims that issue from this application, in the specific form in which such claims issue, including any subsequent correction. Any definitions expressly set forth herein for terms contained in such claims shall govern the meaning of such terms as used in the claims. Hence, no limitation, element, property, feature, advantage or attribute that is not expressly recited in a claim should limit the scope of such claim in any way. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense.
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Techniques are provided for analyzing data called “pivot points” which allows users to instantly generate a report based on all available dimensions for any cell in a tabular report or any data point in a graphical report. In one embodiment, the techniques involve placing a unique UI element or menu next to or on each data point, and clicking on this UI element brings up an automatically filtered list of the valid reports available for just this sub-set of the data. Once the user selects which view they want, a report is automatically generated based on those dimensions with just this subset of data.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to an apparatus for alternately releasing and holding a side gear of a differential assembly against rotation relative to a case. More particularly, the invention pertains to electromagnetic actuation of a device for releasing and holding the side gear.
2. Description of the Prior Art
A locking differential is used to prevent relative rotation of one driven wheel with respect to another driven wheel. This is usually accomplished by locking one differential side gear to a differential case, thereby preventing rotation of the side gear with respect to the differential case and preventing a wheel speed differential on any one axle.
A locking differential employs hydraulic pressure or an electromagnet to actuate a mechanism that alternately holds a side gear against rotation and releases the side gear to rotate freely. Due to packaging constraints, however, certain vehicle applications require a small electromagnetic coil whose size and number of windings may not provide an engagement force of sufficient magnitude to lock the differential. In such instances, a technique is required to amplify the actuating force produce by the coil to a magnitude that is sufficient to produce reliable, axial displacement of the coil.
The actuating force produced by the coil varies non-linearly and inversely with air gap. Thus for a given coil size, the initial air gap should be kept as small as possible in order to maximize the force that actuates the differential to the locked condition.
A need exists in the industry for a locking differential actuated by a small axially displaceable electromagnetic coil having a minimum air gap such that displacement of the coil is amplified producing greater displacement for a locking mechanism that secures one of the side gears of the differential against rotation on a differential case.
SUMMARY OF THE INVENTION
A differential mechanism includes a case, a gear rotatable about an axis, a lock ring held against rotation relative to the case, a lever contacting the lock ring, and an electromagnetic coil that is displaced axially when energized, pivoting the lever, engaging the lock ring with the side gear, and preventing the gear from rotating relative to the case.
A method for locking a differential includes supporting a gear for rotation, holding a lock ring against rotation, placing a lever in contact with the lock ring, energizing an electromagnetic coil causing the lever to pivot, engaging the lock ring with the side gear, and preventing the side gear from rotating relative to the lock ring.
The locking differential employs a relatively small coil having a small copper winding, thereby reducing its weight and cost.
The locking differential amplifies displacement of the energized coil, thereby allowing the coil to move a short distance while providing a large movement for the lock ring and ensuring its full engagement with the side gear.
Due to the small coil, a small air gap produces an axial force that is able to move the coil to the engaged or locked position, thereby allowing use of a large return spring, which keeps the differential unlocked when the coil is deenergized.
The moving coil locking differential operates reliably at all normal operating temperatures in a front or rear axle differential or in a center differential, such as those used in 4×4 and AWD vehicles.
The scope of applicability of the preferred embodiment will become apparent from the following detailed description, claims and drawings. It should be understood, that the description and specific examples, although indicating preferred embodiments of the invention, are given by way of illustration only. Various changes and modifications to the described embodiments and examples will become apparent to those skilled in the art.
DESCRIPTION OF THE DRAWINGS
The invention will be more readily understood by reference to the following description, taken with the accompanying drawings, in which:
FIG. 1 is a cross section taken at a diametric plane through a locking differential mechanism;
FIG. 2 is an isometric cross section showing the lock ring, side gear and a lever installed at the inner axial face of the end cap;
FIG. 3 is an isometric view showing the inboard side of the end cap with the lock ring and return spring installed;
FIG. 4 is an isometric view of the inboard side of the end cap showing the lock ring and return spring in spaced-apart relationship;
FIG. 5 are graphs showing the non-linear relation between axial force of the coil and air gap for various magnitudes of electric current applied to the coil;
FIG. 6 is a side view showing the lock ring actuating mechanism when the coil is initially energized;
FIG. 7 is a side view showing the lock ring actuating mechanism in an intermediate position later than that of FIG. 6 ; and
FIG. 8 is a side view showing the lock ring actuating mechanism in a final locked position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2 , a differential mechanism 10 includes a differential case 11 , preferably of cast iron or steel, supported on a stationary housing (not shown) for rotation about a lateral axis 12 . The case 11 is driveably connected through a bevel ring gear (not shown) to the output of a transmission or transfer case. The ring gear, secured to the case 11 at the attachment bolt holes on a flange 13 , is supported for rotation about axis 12 .
The case 11 provides an internal chamber 14 , which contains bevel pinions 16 , 17 . Chamber 14 contains a right-side bevel gear 18 meshing with the pinions 16 , 17 , driveably connected to an output shaft and secured by a spline to side gear 18 , which extends laterally at the right-hand side from the case 11 to a driven wheel of a motor vehicle. Chamber 14 contains a left-side bevel gear 20 meshing with the pinions 16 , 17 , driveably connected to a second output shaft and secured by a spline to side gear 20 , which extends laterally from the case 11 at the left-hand side to a driven wheel of the motor vehicle. A spindle 22 , is secured by a pin 24 to the rotating case 11 , supports the pinions 16 , 17 for rotation about the axis of spindle 22 perpendicular to axis 12 . The pinions 16 , 17 revolve about axis 12 .
Also located in case 11 is a lock ring 26 , which rotates with the case 11 about axis 12 due to contact with a differential case end cap 27 . FIGS. 3 and 4 show that lock ring 26 is formed with angularly spaced arms 28 , each arm extending radially from axis 12 and extending circumferentially between angularly spaced posts 30 , formed on an inner surface of the end cap 27 . Case 11 is secured to the end cap 27 at attachment holes aligned with those on case flange 13 . Contact between the arm 28 and the posts 30 limits or prevents rotation of the lock ring 26 relative to the case 11 and end cap 27 . The axial inner or inboard surface of lock ring 26 is formed with a series of angularly spaced clutch recesses 32 , which are adjacent and face the axial outer or outboard surface of the side gear 20 .
The axial outer surface of side gear 20 is formed with a series of clutch teeth 38 angularly spaced about axis 12 , facing and adjacent the clutch recesses 32 of the lock ring 26 . The clutch teeth 38 of side gear 20 and the clutch recesses 32 of lock ring 26 are mutually complementary such that they can engage and disengage as the lock ring moves toward and away from the side gear.
The lock ring 26 is normally not engaged with the side gear 20 , permitting the side gear to rotate with respect to the differential case 11 and the lock ring, thereby producing an unlocked or disengaged state. When the coil 44 is energized with electric current it moves along axis 12 toward the case 11 , actuating lock ring 26 to engage the side gear 20 , and causing the clutch teeth 38 and recesses 32 mesh or engage mutually, thereby rotatably connecting the side gear to the lock ring and case 11 , preventing the side gear from rotating relative to the case and lock ring, and placing differential 10 in a locked or engaged state. When coil 44 is deenergized, the compression force of an annular Belleville spring 40 , located between the case 11 and lock ring 26 , forces the lock ring axially away from the side gear 20 , thereby returning the differential 10 to the unlocked or disengaged state.
FIGS. 1 and 2 show a coil assembly 42 supported on the case 11 outside chamber 14 . The coil assembly 42 includes an electromagnetic coil 44 , fitted into an annular recess formed in a ring 48 , and a non-magnetic collar 54 press fitted into ring 48 . The coil 44 produces a magnetic field when energized with electric current. The magnetic field produces an axial force on the coil assembly 42 , whose magnitude varies with the width of an air gap between the coil assembly and the end cap 27 .
In operation when the coil 44 is energized, it is attracted to the differential end cap 27 due to the magnetic field generated by the coil. The coil assembly 42 is fixed against rotation with respect to the differential case 11 , but it can translate axially toward and away from the differential case. Axial displacement of the coil assembly 42 is transmitted to a collar 54 , which is secured to the end cap 27 by a snap ring 58 . Collar 54 allows rotation of the differential 10 with respect to the assembly 42 and provides a linear guide for the coil assembly 42 to translate axially.
When the coil 44 is energized, the sliding collar 54 applies an axial force directed rightward to a roller thrust bearing 62 and thrust plate or thrust washer 64 . Bearing 62 and thrust plate 64 are located in an annular recess formed in the end cap 27 . When coil 44 is energized, thrust plate 64 applies axial force to three angularly spaced balls 66 , each ball retained in a hole formed in the end cap 27 . As FIGS. 3 and 4 show, three angularly spaced levers 68 are pinned to lugs 70 formed on the end cap 27 , each lever located at the angular position of a ball 66 .
The mechanism comprising the balls 66 and lever 68 is located axially between the lock ring 26 and the case 11 . The levers 68 are actuated by the energized coil assembly 42 moving axially toward case 11 forcing thrust plate 64 against the balls 66 , causing the levers 68 to pivot about pivot axes 72 . The outboard end of each lever 68 contacts lock ring 26 as the lever pivots, thereby moving the lock ring clutch recesses 32 into engagement with clutch teeth 38 of the side gear 20 . The lock ring 26 moves into mechanical engagement with the side gear 20 to prevent rotation of the side gear relative to the case 11 .
Each ball 66 is located at a distance D 1 from the lever's pivot axis 72 . The lock ring 26 is moved due to contact with the end of the levers 68 , which end is located at a distance D 2 from the lever rotation axis 72 . Axial displacement of the coil assembly 42 due to energizing coil 44 is amplified at the locking ring 28 by the ratio D 2 /D 1 . For example, with an initial coil air gap of 1.0 mm and a final air gap of 0.5 mm when the differential 10 is fully locked, the coil 44 moves through a distance of 0.5 mm. Using a ball and lever D 2 /D 1 ratio of 2.3, the lock ring moves through a distance of 1.15 mm.
FIG. 5 are graphs showing the non-linear relation between axial force of the coil and air gap for various magnitudes of electric current applied to the coil. For a given coil size it is desirable to keep the initial air gap as small as possible in order to maximize the differential lock force, thereby allowing use of a large return spring, which acts to keep the differential 10 unlocked when the coil 44 is deenergized.
FIG. 6 shows the components of the mechanism for actuating lock ring 26 at a position when coil 44 is initially energized. Lever 68 contacts lock ring 26 at point A, which is closer to pivot point 72 than the point of contact between ball 66 and lever 68 at b point B. Therefore, the force applied to lock ring 26 by lever 66 at A is greater than force F 1 , which is applied to lever 66 at B by ball 66 . This arrangement actuates lock ring 26 with a greater force than the force that is applied to the ball 66 due to energizing coil 44 .
FIG. 7 shows the components of the mechanism in an intermediate position later than that of FIG. 6 , wherein lever 68 contacts lock ring 26 at contact points A and B. In their positions in FIG. 7 , coil 44 , ball 66 and lever 68 are in motion. Force applied to lock ring 26 by lever 66 is being transferred from point A to point C as the lever pivots about its pivot axis 72 .
A cam profile surface can be formed between contact points A and C on the upper surface of lever 26 or on the lower surface of lock ring 26 . The surface profile would match the coil force curve of FIG. 5 and the force-displacement relations of the return spring 40 and provide optimal displacement, engagement time and engagement force of lock ring 26 and electric current draw of the coil 44 .
FIG. 8 shows the components of the mechanism in a final locked position later than that of FIG. 7 , wherein lever 68 contacts lock ring at contact point C. Axial displacement of lock ring 26 is greater the axial displacement of coil 44 because the lock ring contact point C is further from pivot axis 72 than ball contact point B.
In accordance with the provisions of the patent statutes, the preferred embodiment has been described. However, it should be noted that the alternate embodiments can be practiced otherwise than as specifically illustrated and described.
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A differential mechanism includes a case, a gear rotatable about an axis, a lock ring held against rotation relative to the case, a lever contacting the lock ring, and an electromagnetic coil that is displaced axially when energized, pivoting the lever, engaging the lock ring with the side gear, and preventing the gear from rotating relative to the case.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to downhole fishing and drilling operations, or removing obstructions to a drilling line when such a line becomes lodged or otherwise stuck in a well bore. Conventional means of downhole retrieval are dubious, and usually involve attempting to actuate the entire work string in the hope of dislodging it or removing an obstruction. Often this is unsuccessful either because the work string cannot jar loose the obstructions, or adequate motion cannot be effected in the well bore. Consequences of this failure to remove the obstruction can be failure of the well to produce at all or in part, also, current methods of removing obstructions can result in line breakage, both of which result in having to relocate the drilling operation, which necessarily involves lost time and money.
[0002] The present invention is able to attempt to actuate a lodged object in the path of the drilling path without moving the work string, which results in reduced trauma and friction and prevents work hardening of the work string. The tool can also have various other applications, such as drilling, retrieving or driving other tools that may be attached to it, or in any application, down hole or otherwise, that may require such a jarring action.
OBJECTS OF THE INVENTION
[0003] One objective of this invention is to provide a device capable of maintaining tensile force on a drilling work string while dislodging an object that may be interfering with the well operation.
[0004] Another objective of the invention is to provide a device that is more efficient at dislodging obstructions interfering with well operations.
[0005] Still another objective of the invention is to provide a device that can be placed into any confined space and perform a jarring action, or drive other tools that require linear input.
[0006] Other objects and advantages of this invention shall become apparent from the ensuing descriptions of the invention.
SUMMARY OF THE INVENTION
[0007] According to the present invention, the down hole jar tool is a tool used to apply jarring forces to objects that may be obstructing the path of a down hole, or above-ground operation that requires a repetitive jarring action to dislodge or remove such objects. The tool is used by providing a linear input to a mandrel portion that draws back against a compressible unit of predetermined resistance until a releasing means abruptly releases the mandrel portion. The mandrel portion then rapidly moves in the direction of the linear input until it encounters a stationary anvil, which produces the desired jarring action. This tool may also be combined with accelerators and/or valves, as well as other tools, to create a more substantial jarring impact.
DESCRIPTION OF THE DRAWINGS
[0008] The accompanying drawings illustrate an embodiment of this invention. However, it is to be understood that this embodiment is intended to be neither exhaustive, nor limiting of the invention. It is but one example of some of the forms in which the invention may be practiced.
[0009] FIGS. 1 A- 1 D show diametrical longitudinal cross-sections of the hammer assembly in the “up” or “fired” position.
[0010] FIGS. 2 A- 2 D show diametrical longitudinal cross-sections of the hammer assembly in the “down” or “re-cock for firing” position.
[0011] FIGS. 3 A- 3 D show diametrical longitudinal cross-sections of the hammer assembly in the “neutral” or “ready to fire” position.
[0012] [0012]FIG. 4 shows an end cross-sectional view of the bearing assembly shown in FIG. 1D.
[0013] [0013]FIG. 4A shows a perspective view of the bearings shown in FIG. 4.
[0014] [0014]FIG. 5 shows an enlarged detail view of a portion of FIG. 1C.
[0015] [0015]FIG. 5A shows a perspective view of the Belleville washers shown in FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] Without any intent to limit the scope of this invention, reference is made to the figures in describing the preferred embodiments of the invention. Referring to FIGS. 1 through 5, FIGS. 1A through 1D show the invention in the “up” or “fired” position. FIGS. 2A through 2D show the invention in the “down” or “re-cock” position, and FIGS. 3A through 3D show the invention in the “neutral” or “ready to fire” position.
[0017] The flow-activated hammer assembly 123 is comprised mainly of six components, outer mandrel 101 , latching and unlatching sleeve 202 , inner mandrel 105 , kinetic energy sleeve 125 , reloading energy sleeve 205 , and latching and unlatching ring 206 . Inner mandrel 105 resides within outer mandrel 101 , and kinetic energy sleeve 125 is disposed between the two. Outer mandrel 101 is stationary, while inner mandrel 105 is free to move telescopically within outer mandrel 101 .
[0018] Outer mandrel 101 can be a cylindrical housing used to contain all the parts of flow-activated hammer assembly 123 . On the inner surface of outer mandrel 101 , there will be re-cock groove 209 and firing groove 210 . These grooves are shaped to receive latching and unlatching ring 206 . The grooves can have various depths and shapes depending upon the characteristics of latching and unlatching ring 206 .
[0019] Inner mandrel 105 is a cylindrical mandrel which at its uppermost end will be connected to a driving force, such as the flow-activated valve assembly 100 discussed below, or by any other linear input, be it mechanical or otherwise. Inner mandrel 105 can be hollow if used in conjunction with a hydraulic tool to permit hydraulic fluid to exit from such a tool, or it can be substantially solid if a mechanical means is used to drive the tool. Where inner mandrel 105 engages latching and unlatching sleeve 202 , there is inner mandrel groove 211 cut to permit inner mandrel 105 to engage latching and unlatching ring 206 . Shortly beyond inner mandrel groove 211 , inner mandrel's 203 diameter decreases to permit accommodation of kinetic reloading sleeve 205 on its outside perimeter. This change in diameter forms retaining lip 214 .
[0020] Kinetic energy sleeve 125 is held in place radially by inner mandrel 105 and outer mandrel 101 , and held in place longitudinally by outer mandrel coupling 206 which provides upper shoulder 207 and by latching and unlatching sleeve 202 . Kinetic energy sleeve 125 can be any type of variably compressible substance or similar assembly, such as belleville washers, stacked chevron washers, springs, nitrogen gas or hydraulic fluid. An example of such a compressible assembly is shown in FIGS. 5 and 5A, where belleville washers 501 are stacked in a manner used to create kinetic energy, namely, face-to-face.
[0021] Latching and unlatching sleeve 202 is also held in place radially by outer mandrel 101 and inner mandrel 105 , and secured longitudinally by kinetic energy sleeve 125 and by reloading energy sleeve 205 . Latching and unlatching sleeve 202 is designed such that latching and unlatching ring 206 can be secured at a selected point along latching and unlatching sleeve's 202 length.
[0022] Examining FIG. 4, latching and unlatching ring 206 is comprised of a retaining ring 401 , as well as bearings 402 , which can either be in a capsule shape as in FIG. 4A, or in a “mushroom” shape, depending upon application.
[0023] Reloading energy sleeve 205 , like the previous two components, is mounted between outer mandrel 101 and inner mandrel 105 . Longitudinally, it is secured by latching and unlatching sleeve 202 , and by an outer mandrel finisher 208 . Reloading energy sleeve 205 can be any type of variably compressible substance or similar assembly, such as belleville washers, stacked chevron washers, springs, nitrogen gas or hydraulic fluid.
[0024] Washers 212 may be implemented at various points between moving parts to reduce friction and/or wear, and o-rings 213 can be used at strategic points to keep the insides of the tool clean, and/or prevent fluid from entering portions of the tool if needed.
[0025] In operation, a driving force will be applied to extending mandrel 124 , such that extending mandrel 124 will be pulled upward, at which point latching and unlatching ring 206 will be located in inner mandrel groove 211 and will be unable to move past retaining lip 214 , thus restricting movement of extending mandrel 124 . As force is maintained on extending mandrel 124 , retaining lip 214 and latching and unlatching ring 206 will begin to travel upward against the force of kinetic energy sleeve 125 . The tool will now be in the “ready to fire” position, illustrated by FIGS. 3A through 3D.
[0026] This force will continue until sufficient energy is applied to extending mandrel 124 to overcome the configured strength of jar energy sleeve 204 , at which point jar energy sleeve 204 will permit a small amount of longitudinal travel of latching and unlatching sleeve 202 , causing latching and unlatching ring 206 to locate in firing groove 210 . At this time, extending mandrel 124 will no longer be restricted in longitudinal movement by latching and unlatching ring 206 and retaining lip 214 , and will rapidly move upward, until it strikes a aft inner shoulder 215 , causing an upward jarring force on the tool, and leaving the tool in the “fired” position, as illustrated in FIGS. 1A through 1D.
[0027] After this upward jar is delivered, the tool will begin to return downward to the starting position. As it does, the retaining lip 214 will encounter latching and unlatching ring 206 , moving it out of firing groove 210 and down the body of the tool, until it reaches re-cock groove 209 . Here, latching and unlatching ring 206 will drop into re-cock groove 209 , permitting retaining lip 214 to move past it. Now, reloading energy sleeve 205 will apply predetermined upward force, typically less than that of kinetic energy sleeve 125 , but sufficient to move latching and unlatching ring 206 forward in re-cock groove 209 . Extending mandrel 124 then begins moving upward again, and latching and unlatching ring will engage inner mandrel groove 211 , thus beginning the firing stroke, illustrated in FIGS. 2A through 2D.
[0028] The tool, in the aforementioned embodiment, will apply an upward jarring force when operating; however, it may also be configured to provide a downward jarring force if needed. This may be accomplished by reconfiguring the kinetic energy sleeve 125 and reloading energy sleeve 205 to provide upward resistance instead of downward resistance, thereby causing the jarring force to impact in the reverse direction from that illustrated above.
[0029] This tool is also intended to be used in conjunction with a flow-activated valve, such as the one in co-pending application entitled “Flow-Activated Valve,” which is hereby incorporated by reference in its entirety. Such a tool would be attached as the driving force of the jar tool by being attached to extending mandrel 124 . The flow-activated valve is described below.
[0030] The “top” of tool assembly 100 starts at the top of FIGS. 1A, 2A, and 3 A. Shown is outer mandrel 101 , which in the embodiment of the above-mentioned FIGS., is threadably separable into several parts to facilitate assembly and maintenance by way of several threaded joints 102 . The tool assembly 100 is shaped to permit connection to a hydraulic source and/or other threaded tool at joint 103 . Outer mandrel 101 also has hydraulic exhaust ports 104 . Located within outer mandrel 101 is the inner mandrel 105 , which, in this embodiment, is threadably attached to outer mandrel 101 and is separable into parts by way of threaded connections 106 . Inner mandrel 105 has hydraulic fore exhaust ports 107 and aft exhaust ports 108 . Hydraulic fluid is also able to exhaust at the lower end of inner mandrel 105 through mill slots 109 . These parts are all stationary while the tool is being operated.
[0031] Some of the parts of tool assembly 100 are moving while tool assembly 100 is operated, the first of which is reciprocating valve 110 . Like outer mandrel 101 and inner mandrel 105 , reciprocating valve 110 has, in the embodiment shown, been cast as separable pieces joined by threadable connections 111 . Reciprocating valve 110 has fore hydraulic exhaust ports 113 and aft hydraulic exhaust ports 114 . Various shoulders are along reciprocating valve 110 and its path of travel, such as aft hammer shoulder 119 , which engages fore inner shoulder 120 of outer mandrel 101 on the down stroke. There also exists a reciprocating sleeve closing shoulder 118 , and a reciprocating sleeve opening shoulder 121 which is used to actuate an impact in the downward direction, as well as marking the end of the downward stroke.
[0032] Simultaneously with the above action, reciprocating sleeve opening shoulder 121 of reciprocating valve 110 , as it slides, will cause reciprocating sleeve 115 to move down the inner mandrel 105 in the same direction, effectively closing aft hydraulic ports 108 of inner mandrel 105 , and opening fore hydraulic ports 107 of inner mandrel 105 . At this time, the fluid will be permitted to exit via the lower end of inner mandrel 105 through mill slots 109 , at which point it may exit from end 122 . This leaves tool assembly 100 in the “down” position.
[0033] At all times during operation, additional fluid is being pumped into joint 103 , but because inner mandrel 105 hydraulic aft exhaust ports 108 are now closed, the fluid exits through the inner mandrel 105 hydraulic fore exhaust ports 107 , which forces reciprocating valve 110 to move in the direction of joint 103 due to fluid pressure being applied to reciprocating valve 110 , that being the path of least resistance. This movement continues until reciprocating valve 110 reaches top shoulder 122 , at which point reciprocating valve 110 engages top shoulder 122 and creates an impact in an upward direction, marking the end of the upward stroke. At this point, reciprocating valve 110 will have traveled far enough to expose outer mandrel's 101 hydraulic exhaust ports 104 so that fluid will exit tool assembly 100 . When reciprocating valve 110 is in this position, reciprocating sleeve closing shoulder 118 will have moved reciprocating sleeve 115 to its original, or “up” position, thus restarting the cycle.
[0034] To assist in the down hole operation, accelerator 123 may be attached to bottom end of tool assembly 100 in order to exaggerate the vibratory motion created by tool assembly 100 . Accelerator 123 is constructed of extending mandrel 124 , which is shaped to fit within outer mandrel 101 , but also to permit a compressible kinetic energy sleeve 125 to fit between the walls of outer mandrel 101 and extending mandrel 124 , and further be connected to reciprocating valve. Kinetic energy sleeve 125 is retained in place by being situated between a fore accelerator shoulder 126 and an aft accelerator shoulder 127 .
[0035] In this manner, when reciprocating valve 110 is performing a downward stroke, it is energizing a compressible kinetic energy sleeve 125 , such as a spring, belleville washer assembly, stacked chevron washer assembly, risked washer springs, hydraulic fluid or other known similar devices. This is accomplished when fore accelerator shoulder 126 is moving downwardly and compresses kinetic energy sleeve 125 . When reciprocating valve 110 reverses direction, it is thrust forward with the contained kinetic energy stored in compressible kinetic energy sleeve 125 , thus creating a more powerful impact on the upstroke. Similarly, compressible kinetic energy sleeve 125 can be configured to have the reverse effect, or to amplify the downward stroke. This can be done by reversing compressibility of the spring to change the direction of the release of kinetic energy.
[0036] Although only a few exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims.
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The down hole jar tool is a tool used to apply jarring forces to objects that may be obstructing the path of a down hole, or above-ground operation that requires a repetitive jarring action to dislodge or remove such objects. The tool is used by providing a linear input to a mandrel portion that draws back against a compressible unit of predetermined resistance until a releasing means abruptly releases the mandrel portion. The mandrel portion then rapidly moves in the direction of the linear input until it encounters a stationary anvil, which produces the desired jarring action. This tool may also be combined with accelerators and/or valves, as well as other tools, to create a more substantial jarring impact.
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FIELD OF THE INVENTION
The present invention pertains generally to razor blade shaving cartridges. More particularly the present invention pertains to multi-blade shaving systems. The present invention is particularly, but not exclusively, useful as a multi-blade shaving system which is easily rinsable to remove debris filling the interblade spaces to maintain the effectiveness of the cutting blades.
BACKGROUND OF THE INVENTION
Twin bladed razor systems for shaving hair form a body surface are well known and widely used. Typically, such razor systems incorporate a razor cartridge on which the two blades are mounted. More specifically, the blades are normally spaced apart from each other and are mounted on the cartridge in parallel. Additionally, the cartridge typically includes a guard bar which provides structure for guiding the blades into contact with the surface to be shaved. The cartridge, in turn, is attachable to a handle which is used to maneuver the cartridge and its blades during a shaving operation. For purposes of establishing nomenclature and structural interaction, it is to be appreciated that the leading blade is commonly referred to as the seat blade, and the trailing blade is commonly referred to as the cap blade. Further, the seat blade is normally positioned so as to be between the cap blade and the guard bar.
One significant disadvantage to presently available twin bladed razor systems is the fact that debris easily accumulates in the space between the blades. The unwanted result is that this accumulation diminishes the efficacy of the blades to cut hair. When compared to the condition where there is no debris in the space between the blades, it has been determined that the build up of debris in the space between the blades can reduce the effectiveness of the cap blade by almost eighty percent (80%). This reduction in efficiency will also result for the seat blade if the space between the guard bar and the seat blade is also allowed to accumulate debris. Further, it is believed that the build up of debris contributes to discomfort during the shaving operation.
In order to alleviate the above mentioned disadvantages, the user normally rinses the razor cartridge during shaving in an attempt to clear debris from the cartridge. If effective, this rinsing will improve the cutting effectiveness of the razor as well as contribute to user comfort. It happens, however, that the spacers which are presently used to stabilize the blades of a typical twin bladed razor cartridge do not permit rinse water to flow easily between the blades. More specifically, because these spacers are normally solid structures, they effectively obstruct the flow of rinse water through the space between the blades in the direction perpendicular to the cutting edges of the blades. The flow of rinse water parallel to the blades does not efficiently contact the accumulated debris and, consequently, debris tends to collect between the blades.
In light of the above, it is an object of the present invention to provide a rinsable twin bladed shaving cartridge which avoids clogging of the space between the blades in order to minimize the accumulation of shaving debris in the cartridge. Another object of the present invention is to provide a rinsable twin bladed shaving cartridge which has improved rinsability to facilitate the removal of debris which accumulates between the blades during a shaving operation. Yet another object of the present invention is provide a rinsable twin bladed shaving cartridge which is comfortable and safe to use. Still another object of the present invention is to provide a rinsable twin bladed shaving cartridge which is simple to use, relatively easy to manufacture and comparatively cost effective.
SUMMARY OF THE INVENTION
A rinsable twin bladed shaving cartridge includes a support which has a cap blade attached to an upper platform, and a seat blade attached to a lower platform. At least one post connects the rear edge of the upper platform to the rear edge of the lower platform. As so connected, the platforms align the cutting edge of the cap blade with the cutting edge of the seat blade and extend both of the cutting edges forward from the cartridge. This connection also holds the blades parallel to each other and establishes a substantially unobstructed passageway through the cartridge to facilitate the rinsing of accumulated debris from between and around the blades.
In one embodiment of the present invention, the cartridge is attachable to a handle which is formed with a guard bar. When this handle is attached to the support, the guard bar is disposed substantially parallel to the seat blade, and on the opposite side of the seat blade from the cap blade. Further, the guard bar is distanced from the support to establish a substantially unobstructed channel between the guard bar and the support. This channel also facilitates the rinsing of accumulated debris from the cartridge.
In another embodiment of the present invention, the cartridge again includes a support which has upper and lower platforms on which a cap blade and a seat blade are respectively mounted. As before, a post connects the upper platform to the lower platform to establish a substantially unobstructed passageway through the cartridge between the blades. Additionally, the cartridge itself includes an elongated guard bar which is formed substantially parallel to both the upper and lower platforms to position the seat blade between the guard bar and the cap blade. Further, the guard bar is distanced from the seat blade to establish a substantially unobstructed channel between the guard bar and the seat blade. With both the passageway and the channel, the cartridge is rinsable to remove debris which accumulates around and between the blades during a shaving operation. For this embodiment, a handle can be attached to either the lower platform or to the guard bar for controlling the cartridge during the shaving operation.
The novel features of this invention, as well as the invention itself, both as to its structure and its operation will be best understood from the accompanying drawings, taken in conjunction with the accompanying description, in which similar reference characters refer to similar parts, and in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferred embodiment of the twin bladed shaving cartridge of the present invention;
FIG. 2 is a front elevational view of the twin bladed shaving cartridge shown in FIG. 1;
FIG. 3 is a cross sectional view of the shaving cartridge of the present invention as seen along the line 3--3 in FIG. 2;
FIG. 4 is a perspective view of a handle for use with the embodiment of the present invention shown in FIG. 1;
FIG. 5 is a perspective view of an alternate embodiment of the twin bladed shaving cartridge of the present invention shown attached to a handle;
FIG. 6 is a front elevational view of the embodiment of the present invention shown in FIG. 5 with portions broken away for convenience;
FIG. 7 is a cross-section view of the shaving cartridge of the alternate embodiment of the present invention as seen along the line 7--7 in FIG. 6; and
FIG. 8 is a perspective view of yet another embodiment of the twin bladed shaving cartridge of the present invention shown attached to a handle.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring initially to FIG. 1, the twin bladed shaving cartridge according to the present invention is shown and is generally designated 10. As shown in FIG. 1, this embodiment of cartridge 10 includes a support 12 which is formed with an upper platform 14 and a lower platform 16. A cap blade 18 is attached to the lower surface of the upper platform 14 with its cutting edge 20 extending in a forward direction from the cartridge 10. The cap blade 18 can be attached to the upper platform 14 in any manner well known in the pertinent art. Similarly, a seat blade 22 is attached to the upper surface of the lower platform 16 with its cutting edge 24 extending in a forward direction from the cartridge 10. Preferably, when blades 18 and 22 are mounted on the support 12, the cutting edge 20 of cap blade 18 is parallel to the cutting edge 24 of seat blade 22.
As perhaps best appreciated by cross referencing FIGS. 1, 2 and 3, a pair of side posts 26a and 26b connect the rear edge of the upper platform 14 to the rear edge of the lower platform 16. As intended for the present invention, this connection establishes an aperture 28 between the side posts 26a and 26b which is sufficiently large to create a substantially unobstructed passageway 30 between the cap blade 18 and the seat blade 22. Additionally, FIG. 1 shows that the support 12 can be formed with a groove 32 which is useful for attaching the cartridge 10 to a handle 34.
FIG. 4 shows a handle 34 which can be used with the embodiment of the cartridge 10 shown in FIGS. 1,2 and 3. Specifically, the version of handle 34 shown in FIG. 4 includes a rib 36 which is matingly engageable with the groove 32 of cartridge 10 to hold the cartridge 10 on the handle 34. It is to be appreciated, however, that the handle 34 and the disclosed connection between this handle 34 and the cartridge 10 are only exemplary. Indeed, the cartridge 10 can be attached to any handle, such as handle 34, by any means well known in the pertinent art.
For the specific handle 34 shown in FIG. 4, it will be seen that a brace 38 extends outwardly from the handle 34, and that the brace 38 holds an elongated guard bar 40 at a distance from the brace 38. Specifically, the distance between the brace 38 and the guard bar 40 establishes a channel 42 therebetween. Thus, when cartridge 10 is attached to the handle 34, guard bar 40 will be distanced from the lower platform 16 of support 12 and the channel 42 will be unobstructed. Consequently, for the combination of cartridge 10 and handle 34, a substantially unobstructed passageway is established between cap blade 18 on upper platform 14 and seat blade 22 on lower platform 16 and, at the same time, a substantially unobstructed channel 42 is established between the lower platform 16 and guard bar 40. As intended for the present invention, the passageway 30 and the channel 42 both allow the flow of water therethrough to effectively rinse the cartridge 10 of any debris which might accumulate on the cartridge 10 during a shaving operation.
For an alternate embodiment of the present invention, a guard bar 46 is attached directly to the support 12 in a manner as shown in FIG. 5 for a cartridge 44. In many respects, this cartridge 44 is similar to the previously disclosed cartridge 10. Impliedly, however, the difference is that guard bar 46 is formed as part of the cartridge 44. Specifically, like cartridge 10, the cartridge 44 has an upper platform 14 with a cap blade 18 attached thereto, and it has a lower platform 16 with a seat blade 22 attached thereto. As before, the cap blade 18 and the seat blade 22 are substantially parallel to each other and the side posts 26 create an aperture 28 which is a continuation of the passageway 30 established between the blades 18 and 22. Unlike cartridge 10, however, cartridge 44 includes side posts 26a' and 26b', which are extensions of the side posts 26a and 26b and, which hold the guard bar 46 in position relative to lower platform 18.
As perhaps best seen by cross referencing FIG. 5 with FIGS. 6 and 7, the cartridge 44 is established with an essentially unobstructed passageway 30 between the blades 18 and 22, as well as an essentially unobstructed channel 42 between the seat blade 22 and the guard bar 46. Further, the cartridge 44 is shown to include a pair of center posts 48 and 48' which can be used to help stabilize the combination of upper platform 14, lower platform 16 and guard bar 46. Though the center posts 48 and 48' are shown specifically for the embodiment of the cartridge 44 illustrated in FIGS. 5 and 6, it is to be appreciated that the cartridge 10 could also include a center post. As shown in FIG. 5, a handle 50 is attachable to the cartridge 44 for guiding the cartridge 44 during a shaving operation. Here, the handle 50 is shown attached to the guard bar 46 portion of the cartridge 44.
FIG. 8 shows yet another embodiment of the present invention wherein a cartridge 52 is formed with an integral guard bar 54. Here, in a slightly different configuration than presented above for the cartridge 44, side posts 26a" and 26b" (not shown) are forward on the lower platform 16. In all important respects, however, the cartridge 52 is functionally similar to the cartridge 44. As before, a channel 42 is formed between the lower platform 16 and the lower guard bar 46 to establish a substantially unobstructed channel 42. Further, the substantially unobstructed passageway 30 is established between the upper platform 14 and the lower platform 16. For this configuration, a handle 56 is shown to be attachable to the lower platform 16 of the cartridge 52. As with the other embodiments disclosed herein, the handle 56 is attachable to the cartridge 52 for guiding the cartridge 52 during a shaving operation.
While the particular twin bladed shaving cartridge as herein shown and disclosed in detail is fully capable of obtaining the objects and providing the advantages herein before stated, it is to be understood that it is merely illustrative of the presently preferred embodiments of the invention and that no limitations are intended to the details of the construction or design herein shown other than as defined in the appended claims.
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A rinsable twin bladed shaving cartridge is attachable to a handle and includes a support having an upper platform on which a cap blade is mounted and a lower platform on which a seat blade is mounted. At least one post connects the upper platform to the lower platform to hold the blades substantially parallel to each other and to establish a substantially unobstructed passageway for rinsing debris from around and between the blades.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to access windows and similar equipment and more particularly to access windows for drive-through fast food service.
The invention especially relates to access windows typically installed on the side of a building adjacent a driveway to facilitate business transactions between a clerk and a customer. The most common use of such windows is for fast-food drive-in establishments.
In a typical commercial environment a drive-in access window must easily permit the clerk to transact business with a customer and yet provide the necessary isolation between the outside environment and the inside environment to satisfy health code requirements.
2. Brief Description of the Prior Art
Prior art access windows typically employ rigid inflexible members on the window openers such as those illustrated and described in U.S. Pat. No. 4,411,102. The windows may be actuated solely be manual force or by electrical motors triggered by such force. In both cases, however, the mechanisms involved rely on mechanisms which transmit forces with essentially no give or flexibility.
The prior art also describes an attempt to employ rigid members in combination with a rubber-toothed transmission belt. An example of such a system is described in U.S. Pat. No. 4,442,630.
The manually-operated service windows depicted in prior art referred to above typically make use of a plunger head with limited surface area for contact by a human operator. The use of such a plunger head in combination with other mechanical aspects of the prior art has resulted in a window which requires substantial force to open, and which requires a significant amount of force to retain it in the open position. In the case of a purely mechanical system, the window requires considerable effort on the part of a clerk to open a window and keep it open.
SUMMARY OF THE INVENTION
The present invention meets the above-mentioned disadvantages by providing an access window which employs a push-bar operator with a substantial surface area to permit a person to push on the surface area with any part of the person's torso. The invention is further characterized by a mechanism which enables a window to be opened with little force or discomfort. The window is capable of opening smoothly without the need of electrical power.
The preferred embodiment of the apparatus comprises a pair of hinged windows with a common unhinged midpoint where they seal against each other. The windows are hinged on vertical axes, and preferably employ an antifriction bearing at the top of each hinge and a machined rotor at the bottom of each hinge. The rotors are coupled to the push-bar operator by means of an elastic coupling system which is adjustable and returns the windows to a closed position when the push-bar is released. In a preferred form, the coupling system incorporates a "locked-window" bias member which absorbs operation of the push-bar whenever the window is locked and averts damaging the overall system.
The coupling system also preferably includes a feature which provides a uniform push-bar resistance as the windows are operated between a fully open and a fully closed position. The feature in a preferred form employs an off-center radius groove on the rotors attached to the lower hinges of the windows.
In a general sense, the present invention resides in a fast food access service window which employs an operator push-bar that can be pushed by any part of a clerk's torso with greatly reduced force and discomfort.
This bar preferably is capable of being easily locked in the open position and then quickly released to permit the window to close. The bar preferably is also capable of absorbing a force applied to open a window when the window is locked shut, without damaging the window or its operator.
The various features and principles of the invention will become obvious to those skilled in the art upon review of the detailed description in conjunction with the appended drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one embodiment of an access service window located in a wall.
FIG. 2 is a detailed, exploded, partially cutaway perspective view of one of the top hinge posts of one of the window members.
FIG. 3 is a detailed, perspective, partially phantom view of the horizontal operator bar outboard-end hinge.
FIG. 4 is a cross-section taken along line 4--4 of FIG. 3 illustrating a top view of the horizontal operator bar outboard-end hinge.
FIG. 5 is a partial perspective view of the horizontal operator bar in the "locked-open" position.
FIG. 6 is an exploded view of the bottom hinge post of one of the window members.
FIG. 7 is a perspective top view of the access window with the top-shelf cut away to illustrate the operator linkage with the access window in the closed position.
FIG. 8 is a bottom view of the access window operator illustrating the horizontal push-bar in access window "open" (in phantom) and access window "closed" positions.
FIG. 9 is a partial detailed development of the access window operator.
FIG. 10 is a top view of one of the access window rotors taken along line 10--10 of FIG. 9.
FIG. 11 is a cutaway top view of one of the access window rotors taken along line 11--11 of FIG. 9.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates an access window 20 attached to a wall 21. Very broadly, the external components of the window include the horizontal operator push-bar 22, the horizontal service shelf 23, the vertical access window frame members 24 and 25, the top horizontal access window frame member 26, left pivoting or swinging window member 27, and right pivoting or swinging window member 28.
Left swinging planar surface or window member 27 comprises a frame with vertical frame members 29 and 30, top frame member 31 and bottom frame member 32. Frame members 29, 30, 31, 32 describe the outer perimeter of a window pane 33 which in the preferred embodiment is glass.
In a similar manner right swinging planar surface or window member 28 comprises vertical frame members 34 and 35, top frame member 36 and bottom frame member 37. Frame members 34, 35, 36 and 37 likewise form the outer perimeter of window pane 38.
In a preferred embodiment of the present invention frame members 29 and 31 are joined together by mitered joints at 45° angles. Similarly, adjacent frame members are likewise joined by mitered joints.
Vertical frame members 29 and 35 provide for offset vertical swinging axes of window members 27 and 28, respectively. In a preferred embodiment window members 27 and 28 swing outward pivoting about their vertical swinging axes. The window members 27 and 28 meet at the access window centerline, as vertical frame members 30 and 34 come into contact when the window is closed.
Alternatively, window members 27 and 28 may be configured to swing inward pivoting about the same vertical swinging axes.
Also illustrated in FIG. 1 is a horizontal window latching bar 39, sliding latch mechanisms 40 and 41 and latching bar slots 44 and 45. Latching bar 39 is used to latch or lock the access window in the closed position. To latch the window in the closed position horizontal bar 39 is first placed in latch bar slots 44 and 45. Sliding latch bars 40 and 41 are then moved slidably outward into suitable slots, holes or like receptacles 42 (not shown) and 43.
FIG. 1 also illustrates a segmented horizontal push-bar 22 which is hinged at outboard ends 50 and 51. The segmented push-bar 22 is also hinged or articulated at piano hinge 52 between the outboard ends 50 and 51. In a preferred embodiment, piano hinge 52 is located equidistant from the outboard ends 50 and 51.
Horizontal push-bar 52 consists of two horizontal segments or members 53 and 54. Horizontal members 53 and 54 have hand holds 53a and 54a, respectively.
Swinging window member 27 pivots about pivot points 55 and 56. In a similar manner right window member 28 pivots about pivot points 57 and 58. A line drawn between pivot points 55 and 56 forms an imaginary vertical pivot axis which is hereinafter referred to as the vertical pivot axis. In a preferred embodiment, the vertical pivot axis is offset from frame members 29 and 35 as shown in FIG. 2.
Referring to FIG. 2, an exploded view of right swinging window member 28 illustrates the mitered joint of top horizontal frame member 36 with right vertical frame member 28, top window member attachment bracket 59, hinge post bracket 63, hinge post 64 and top window frame member 26. Window member attachment bracket 59 is attached to window frame members 35 and 36 by means of screws or other similar devices.
A hinge post bracket 63 is attached to the window corner bracket 59 by brazing or other suitable means. The top hinge post 64 is similarly brazed to the hinge post bracket. The centerline of hinge post 64 is the centerline of vertical pivot axis between pivot points 57 and 58.
Hinge post 64 is inserted through an antifriction device 65 such as a roller bearing. Hinge post 64 is held in its vertical position by means of nut 65a or other suitable means. Bearing 65 is retained in position by a bearing receptacle fabricated from flat bar stock or in any other suitable manner.
It is to be understood that the top of window member 27 is hinged in a manner similar to that described for window member 28.
Referring to FIG. 3, the right outboard hinge 51 of the horizontal operator push-bar 22 is illustrated in detail. Push-bar section 54 has a protruding hinge member 66 which is restrained by angle member 67. Angle member 67 is brazed or welded to the service shelf vertical wall 68. Service shelf vertical wall 68 is attached to the horizontal service shelf 23.
Horizontal tab 70 is also attached to service shelf vertical wall 68 and limits the downward travel of the push-bar section 54 and consequently of the segmented horizontal push-bar 22. The hinge arrangement of push-bar section 53 is similar to that illustrated for push-bar section 54.
Referring to FIG. 4, a top view of the above-described push-bar hinge arrangement is illustrated. The top view is taken along line 4--4 of FIG. 3. As a force pushes on push-bar section 54 as shown by the straight arrow, push-bar section 54 moves inward with a rotating clockwise motion (as illustrated by the rotational arrow). When the push-bar member 54 has been pushed sufficiently inward, i.e., sufficient to open the access window, the rotating motion is partially arrested by contact of edge 67a of angle member 67 with the side wall 69 of push-bar member 54. The side wall of push-bar member 53 also restrains push-bar member 53 in a similar fashion.
Inward motion of push-bar 22 is also partially arrested by travel stop 71 (illustrated in FIG. 8). The design of horizontal shelf 23 likewise aids in arresting the inward motion of push-bar 22. Referring to FIG. 1, the horizontal shelf front surface members or walls 72 and 73 immediately above push-bar 22 recede from points 74 and 75 towards midpoint 76. The members 72 and 73 form in essence an outward-facing V-shaped member. As push-bar 22 flexes inward, the push-bar changes configuration from an inward-facing V-shaped member to an outward-facing V-shaped member. Push-bar 22 travel in essence stops when the push-bar 22 surfaces are flush with the vertical members 72 and 73. Thus, a person operating the access window with the lower part of the torso by pushing on the push-bar 22 will ultimately feel the sensation of relatively rigid members 72 and 73, and thereby know without visual inspection that the access window should be fully open.
The push-bar 22 can be locked to maintain the access window in the open position. This is accomplished by pushing push-bar 22 inwardly past front surface members or walls 72 and 73 (see FIGS. 1 and 5), then sliding push-bar 22 upward behind the members 72 and 73. Sliding push-bar 22 upward is most easily accomplished by inserting one's fingertips in hand-holds 53a and 54b and gently urging push-bar 22 upward behind the surface members or walls 72 and 73.
To unlock push-bar 22 a person must push the push-bar 22 inward slightly and then by inserting the fingertips in hand holds 53a and 54b urge the push-bar 22 downward. Prior to unlocking, as push-bar 22 is pushed inward excessive inward motion is restrained by travel stop 71 (illustrated in FIG. 8). Referring to FIG. 8, as the horizontal push-bar 22 is pushed inwardly (as shown by the arrow), push-bar members or segments 53 and 54 flex inwardly. The inward flexing is permitted by the hinge arrangement depicted in FIG. 4, as well as piano hinge 52. As push-bar 22 flexes inwardly, push-bar travel stop 71 comes to rest on vertical wall 70 and restrains further inward travel.
Cross member 77 is rigidly affixed to the underside of horizontal shelf 23 to provide further support and rigidity to horizontal serving shelf 23.
Referring to FIG. 6, the lower hinge of window members 27 is illustrated in detail; the lower hinge for window member 28 is similar.
Left window bottom corner bracket 62 is attached to the vertical frame member 29 and horizontal frame member 32 using screws or other suitable means. A bottom hinge post bracket 80 is attached to the corner bracket 62 by means of brazing or other suitable means. A hinge post 81 is similarly attached to hinge post bracket 80.
Hinge post 81 is inserted through horizontal shelf 23, bracket 82, an upper antifriction member 83, rotor 84 and a lower antifriction member 86. Antifriction member 83 in a preferred embodiment is a roller bearing which is inserted in a bearing receptacle 83a machined out of bracket 82. In a similar manner, bearing receptacle 86afor bearing 86 is machined out of lower bracket 87. The lower hinge assembly is held together by means of threaded stud 88, nuts 89a and 89b, spacer 90 and nut 89c. Spacer 90 is interdisposed between brackets 82 and 87 to prevent the compressive forces of nuts 89a and 89c from interfering with the rotation of rotor 84.
Brackets 82 and 87 are mounted below shelf 23 and are held in place by securing brackets 82 and 87 to shelf 23 by means of threaded stud 88, nuts 89a, 89b, spacer 90 and nut 89c. Threaded studs 88 are long enough to protrude through horizontal shelf 23 to secure window frame members 24 and 25 in the vertical position.
Rotor 84 is attached to hinge post 81 by means of set screw 84a (see FIG. 7). Set screw 84a is screwed into hinge post 81. Rotor 85 is attached to its respective hinge post in a similar manner.
Various aspects of the elastic and flexible linkage which interconnects push-bar 22 to window rotors 84 and 85 are illustrated in FIGS. 6 through 11. Push-bar bracket 91 is rigidly attached to push-bar segment 53. Push-bar bracket 91 is operatively attached to the right hand rotor 85 by means of a string, typically a 640 lb. test No. 72 nylon string 92. The string 92 is wrapped about groove 93 of rotor 85. Rotor groove 93 is a concentric groove machined out of the cylindrical rotor 85. The groove 93 is high enough to accommodate string 92 and deep enough to permit string 92 to fit within groove 93 without protruding out of the groove.
String 92 is wrapped around rotor 85 in a counterclockwise fashion (from top of rotor 85 looking down). String 92 is anchored in groove 93 by means of a knot in string 92, or other suitable means, in a surface machined to hold the knot without slipping. This orientation permits rotor 85 to turn clockwise as push-bar bracket 91 moves in the direction illustrated by the arrow (see FIG. 9). Push-bar-bracket 91 moves in the direction illustrated by the arrow when push-bar 22 is moved inward.
Rotors 84 and 85 are interconnected by means of a flexible linkage 94. Flexible and elastic linkage 94 comprises counter rotation links 95 and 96. Referring to FIG. 9 counter rotation link 95 is wrapped around the backside of rotor 85 and around the front side of rotor 84. In a similar manner counter rotation link 96 is wrapped around the backside of rotor 84 and around the front side of rotor 85. The counter rotation links 95 and 96 cause rotor 84 to rotate in a counterclockwise direction, whenever rotor 85 rotates in a clockwise direction. They further cause rotor 84 to rotate in a clockwise direction, whenever rotor 85 rotates in a counterclockwise direction. Equal and equidistant rotation is accomplished by adjusting turnbuckles 97 and 98. (See FIG. 7). Turnbuckles 97 and 98 are adjusted in a manner such that the length of interconnecting link 95 is equal to the length of interconnecting link 96.
In a preferred embodiment, interconnecting linkages 95 and 96 are constructed of 10 strands of 80 lb. No. 9 nylon fishing line. The 10 strands are woven on a loom into a flat band. The flat band in the preferred embodiment is very pliable and flexible and provides a significant number of window operations without breakage and without deterioration of adjustment or operation.
Counter rotation link 95 is anchored to rotor 84 at anchor point 99 (shown in FIG. 10). Counter rotation link 96 is anchored to rotor 84 at anchor point 100 (shown in FIGS. 9 and 10). Counter rotation links 95 and 96 are anchored to rotor 85 in a similar fashion. The counter rotation links 95 and 96 rotate about the outer peripheries of rotors 84 and 85.
To close the window members 27 and 28 upon release of push-bar 22, window closer bias member 101 interconnects rotors 84 and 85 by means of bias member linkages 102a and 102b. Window closer bias member 101 in the preferred embodiment is a spring. Bias member linkages 102a and 102b are 150 lb. test No. 36 nylon string. One end of bias member linkage 102a is attached to anchor post 103 on rotor 84, and the other end is attached to bias member 101. Bias member linkage 102b is attached at one end to bias member 101 and at its other end to anchor post 104 of rotor 85.
Bias member linkage 102a fits in bias linkage groove 105 when the access window is open. In a similar manner bias member 102b fits in bias linkage groove 106 when the access window is open.
When the access window is closed the bias member linkage 102b does not fit in bias linkage groove 106 but rather on the outer periphery 106a, of rotor 85. Outer periphery 106a exists because of the off-center groove 106 which is cut in the cylindrical rotor 85.
In a similar manner, bias linkage member 102a fits on the outer periphery of rotor 84 whenever the access window is closed.
Bias linkage groove 105 may be machined in rotor 84 and bias linkage groove 106 may be machined in rotor 85. The grooves 105 and 106 are off-center radius grooves. The configuration of grooves 105 and 106, in rotors 84 and 85 respectively, are illustrated in FIG. 11. The configuration of grooves 105 and 106 results in the sensation, to a person pushing on operator bar 22, of a uniform resistance as an access window travels from the fully closed to the fully opened position. The uniform resistance, sensed by the person operating the window, is created by closer bias member linkages 102a and 102b traveling from the outer peripheries 105a and 106a of rotors 84 and 85 respectively, (with the access window closed) into grooves 105 and 106 of rotors 84 and 85 respectively, as the access window opens. This configuration provides for uniform window closer bias member 101 tension as weather stripping 107 (see FIG. 1) on the common edges of window members 27 and 29 is separated.
Providing a uniform tension on window closer bias member 101 as an access window travels from a fully closed window to a fully opened window is imperative in order to keep the access window from flopping wide open as soon as the weather stripping 107 is separated. Access windows which flop open often startle persons on both sides of the windows.
The use of off-center radius grooves 105 and 106 on rotors 84 and 85 respectively, tends to result in a smooth operating window with equal tension on window closer bias member 101 throughout the complete window cycle, i.e., full closed to full open to full closed.
The use of off-center radius grooves 105 and 106 as disclosed herein tends to create a greater opening torque, for the access window opening cycle, as the window begins to open (when the weather stripping 107 is in contact); then tends to reduce the opening torque when window closer bias links 102a and 102b enter grooves 105 and 106 respectively (after the weather stripping 107 has separated ).
In a similar fashion for the access closing window cycle the off-center radius grooves 105 and 106 tend to create a lesser torque as the window begins to close (when the weather stripping 107 is separated); then increases the closing torque as the window closes as window closer bias links 102a and 102b exit grooves 105 and 106 respectively (as the weather stripping 107 comes into contact).
Grooves 105 and 106 also aid in a uniform closing cycle of access window members 27 and 28, as the members travel from full open to full closed.
Another beneficial aspect of the present invention is the locked window bias member 108 and turnbuckle 109 illustrated in FIG. 9. The locked window bias member 108 absorbs pushing action on push-bar 22 in the event the access window members 27 and 28 have been latched by means of latching member 39 (as illustrated in FIG. 1). Locked window bias member 108 absorbs the forces supplied to push-bar 22 without damaging window members 27 and 28, and further without damaging any parts of the window operators and interconnecting linkage 94.
In the event a person pushes on operator bar 22 while the latching bar 39 is installed, the locked window bias member 108 stretches to absorb the pushing motion. Push-bar 22 can be pushed to its travel limit, at which time travel stop 71 comes in contact with vertical wall 70 of horizontal shelf 23 (see FIG. 8). With the latch bar 39 installed, as push-bar 22 is pushed window bias member 108 stretches; however, rotor 85 does not turn. Since rotor 85 does not turn, rotor 84 likewise does not turn. Consequently, window members 27 and 28 remain closed; rotors 84 and 85 remain stationary; and only push-bar 22 flexes inward and locked window bias member 108 stretches. Locked window bias member 108 must be stiff enough, so that it does not stretch during normal window operation and only stretches when the latch bar 39 is installed.
Locked window bias member 108 also tends to cushion a sudden impact to operator bar 22 when operator bar 22 is pushed abruptly with the latch bar 39 not installed. Thus when the window latch member 39 is not installed, bias member 108 tends to serve as an energy storage device, e.g., stores a sudden impact and then uses the stored energy to open the access window.
One end of the locked window bias member 108 is positioned in one of the push-bar bracket 91 holes (91a,91b, 91c, 91d, 91e, 91f). The push-bar bracket holes are provided to permit a field adjustment, once the window has been installed. The adjustment holes permit the installer to achieve full window travel, as the push-bar 22 is pushed from the window closed position to the window open position.
The opposite end of locked window bias member 108 is affixed to one end of a turnbuckle 109. The other end of turnbuckle 109 is attached to nylon string 92. Turnbuckle 109 permits string 92 to be field adjusted to insure a fully closed window when the push-bar 22 is in the "window closed" position.
As can be appreciated by one skilled in the art, the above detailed description describes only one embodiment of the present invention. The window can be readily adapted from an outwardly opening window to an inwardly opening window by merely varying the operation of nylon string 92 on rotors 84 and 85. Various components may be replaced by other mechanical or electromechanical equivalents to accomplish the same result, particularly in view of the interchangeable nature of such devices and their functions in the present invention. Variations and modifications of the invention will become obvious from the drawings and specification. Accordingly, the present invention should be limited only by the scope of the appended claims.
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An access window for use in fast food establishments and other similar drive-thru business establishments is disclosed. The window broadly comprises an elastic operating mechanism, two planar window members and a segmented articulated push-bar operator which is pushed to open the access windows. The push-bar operator can be locked in the open position. Upon releasing and/or unlocking the operator push-bar assembly the access window returns to its closed position by means of a closer bias member. The access window also comprises a locked window bias member which absorbs the pushing action on the operator push-bar, in the event the access window is latched shut, without damaging the access window and further without damaging the operating mechanism. The operating mechanism employs an off-center groove in the rotor located in the bottom hinge assembly which serves to produce a greater initial opening torque than the opening torque at the end of the opening cycle and conversely produces a greater closing torque at the end of the closing cycle.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This is a divisional application of prior application Ser. No. 09/605,214 filed Jun. 28, 2000.
FIELD OF THE INVENTION
[0002] This invention relates to an arrangement for removing oil from a roll, in which, inside a rotatable shell, there is a fixed axle-beam, supporting loading shoes acting on the inner surface of the shell, and in which roll there are devices for removing oil from the roll, comprising an oil guide attached to the loading shoes, a collector trough, and oil-removal piping, of which the oil guide is arranged to form an oil jet directed into the roll, the removal of the oil from the roll being arranged to take place with the aid of the pressure difference.
BACKGROUND OF THE INVENTION
[0003] Problems with deflection-compensated rolls include oil frothing and poor oil removal from inside the roll. In addition to oil leaking from the loading shoes, oil may be sprayed against the inside of the roll shell to cool or heat it. It is important that the oil is collected as soon as possible from inside the roll, so that frothing of the oil, and thus the air mixed with it, remains as little as possible. When the roll rotates, a film of oil travels around its inner surface, colliding with the stationary loading shoes. In the solution according to U.S. Pat. No. 5,853,359, the lubricating oil colliding with the loading shoes is allowed to flow by gravity to a lower trough, from which it is sucked out of the roll. If the loading shoes are low down, a special scraper is used, from which the oil flows into the trough in a corresponding manner. Such a construction demands a considerable amount of space, which is not available in most rolls. A somewhat similar construction is disclosed in Finnish patent application 982045, in which the gravity-induced flow is directed to a special collection space, which may be located as a low construction on the outer surface of the cylindrical axle. WO publication 98/38381 discloses a special guide, to be attached to the loading shoes, by means of which a jet, directed towards a trough beneath, is formed from the film of oil traveling along the inner surface of the roll. In this case, the oil-removal guide must be set at a higher level, because removal takes place, at least partially, by gravity into the lower trough. A corresponding solution cannot be used in connection with a loading shoe set at a lower level.
SUMMARY OF THE INVENTION
[0004] The present invention provides an arrangement which will permit the removal of oil in any position at all.
[0005] The method for removing oil from a roll, in which, inside a rotatable shell, there is a fixed axle beam, which supports loading shoes directed against the inner surface of the shell, and in which roll there are devices for removing the oil from the roll, comprising an oil guide attached to the loading shoes, a collector trough and oil-removal piping, of which the oil guide is arranged to create a jet of oil directed inside the roll and the transfer of the oil out of the roll is arranged to take place with the aid of a pressure difference, is characterized in that the collector trough is located a short distance from the oil jet and the related auxiliary guide, which, together with the oil guide is arranged to guide and channel the oil jet against the trough, and that the oil is removed to the outlet pipe through a low gap in the bottom of the collector trough.
[0006] The arrangement in a roll equipped with loading shoes, in which, inside a rotatable shell, there is a fixed axle beam, supporting the loading shoes directed against the inner surface of the shell, and in which shell there are devices for removing oil from the roll, comprising an oil guide attached to the loading shoes, a collector trough, and oil-removal piping, of which the oil guide is arranged to form an oil jet directed inside the roll and the transfer of the oil out of the roll is arranged to take place with the aid of a pressure difference, is characterized in that the collector trough includes an auxiliary guide and that it is locates at a short distance from the oil guide of the loading shoe, in such a way that it turns the oil jet to the bottom of the collector trough, and that there is a gap in the bottom of the collector trough leading to the outlet pipe.
[0007] Utilizing the method according to the invention, oil is removed rapidly and with a good degree of control, in a small space. According to one preferred embodiment, each loading shoe incorporates a guide of the same width as the shoe, for creating an oil jet, whereas the collector trough receiving the oil and its auxiliary guide and removal pipe are essentially the same width as the roll shell.
[0008] These and other features and advantages of the invention will be more fully understood from the following detailed description of the invention taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] In the drawings:
[0010] [0010]FIG. 1 shows a cross-section of a roll, in which an oil-removal arrangement according to the invention is attached to the loading shoes;
[0011] [0011]FIG. 2 shows a partly enlarged cross-section at the loading shoe, more precisely of the oil-removal arrangement located at its side;
[0012] [0012]FIG. 2 b shows the operation of the oil-removal arrangement;
[0013] [0013]FIG. 3 shows another oil-removal arrangement according to the invention;
[0014] [0014]FIG. 4 shows an oil-removal arrangement according to the invention, located in an upper position;
[0015] [0015]FIG. 5 shows a variation of the oil guide, attached to one type of loading shoe;
[0016] [0016]FIG. 6 a shows a variation of the oil-removal arrangement of FIG. 2 a; and
[0017] [0017]FIG. 6 b shows an oil-removal arrangement according to the invention, located in the upper position.
DETAILED DESCRIPTION OF THE INVENTION
[0018] In the deflection-compensated roll 10 according to FIG. 1, there is a stationary axle 12 , on which the loading shoes 20 are installed. Here, reference number 20 is used to mark the moving part of the loading shoes, which, in this case, is a cylindrical component. The roll shell 11 is arranged to rotate in a known manner, with the aid of bearing devices ( 14 ). Loading shoes 20 press on roll shell 11 , in a manner that is, as such, known, while the related oil-feed system can be used to load the roll shell from inside, according to the desired profile.
[0019] With reference to FIG. 1, loading shoes 20 and the related oil guide 13 extend to the inner surface of roll shell 11 . According to FIG. 1, oil guides 13 are essentially the same width as loading shoes 20 and, at the shoes, guide the oil traveling along the inner surface of roll shell 11 , as an oil jet essentially in a radial direction to collector trough 19 .
[0020] The construction of the oil-removal devices is shown in detail in FIG. 2 a, in which there is a partly enlarged cross-section at the loading shoe. Loading shoe 20 or more precisely its cylindrical part, move in a radial direction, according to the load of the loading shoe. Oil guide 13 , which throws the oil to collector trough 19 , which is formed by outlet pipe 15 and in this case sheet-metal casing 14 , is attached to this cylindrical part by means of bolts 18 . The end part 14 . 1 of the casing forms an auxiliary guide, which turns the oil jet, in the manner described later, to the bottom of the collector trough, in which there is a gap 16 connecting to outlet pipe 15 . This gap 16 is slightly narrower than the plate-like oil guide 13 and loading shoe 20 . Outlet pipe 15 and collector trough 19 extend continuously over the entire width of the row of loading shoes (see FIG. 1). Oil is led with the aid of connector pipe 17 from outlet pipe 15 to an external outlet channel. The removal of the oil can, as such, take place either by means of excess pressure or a vacuum. Excess pressure is created by feeding compressed air into the roll, whereas a vacuum is created with the aid of a vacuum pump connected to the outlet pipe.
[0021] Oil collection can be further improved by widening the oil guides and correspondingly the gaps of the outlet pipe.
[0022] Most of the collector trough can be formed by machining it into the axle, as shown in FIG. 6 a. The same reference numbers as previously are used for functionally similar components. In this case, a small part of the collector trough is formed by sheet-metal strip 14 . 4 , which carries outlet pipe 15 and which is secured to axle 12 by means of bolts 14 . 3 .
[0023] According to FIG. 2 b, the roll shell, which rotates rapidly in the direction S 1 , brings a flow of oil against loading shoe 20 and oil guide 13 , the kinetic-energy of the oil creating a damming pressure at the intersection of oil guide 13 and roll shell 11 . This creates an oil jet J 1 , which discharges along oil guide 13 , which is aimed in the direction of auxiliary guide 14 . 1 of collector trough 19 , which further leads it to the bottom of the collector trough, the other side of which is formed by outlet pipe 15 . A layer of oil, which prevents air from entering outlet pipe 15 , forms on top of gap 16 in the lower part of outlet pipe 15 . At the same time, this oil layer cancels the remaining kinetic-energy in the jet, calming the flow at this stage at the latest. The depth of the oil layer forming on top of gap 16 is adjusted by controlling the vacuum or excess pressure in outlet pipe 15 . The final cancellation of the jet in the trough can take place in some other way, as long as a layer of oil collects on top of the gap.
[0024] [0024]FIG. 3 shows a variation of the oil guide. This oil guide 13 is formed most simply by a flow surface shaped in the loading shoe, which is vertical in FIG. 3, but which continues as a hole, to which auxiliary guide 14 . 1 of collector trough 19 extends. In this case, oil guide 13 forms an oil jet in the same way, which can be easily directed to auxiliary guide 14 . 1 and from it onwards to the bottom of collector trough 19 . It is always essential for there to be a gap between oil guide 13 and auxiliary guide 14 . 1 , which permits the loading shoe to move radially. Except for the guide surfaces, the oil jet follows this narrow gap, so that its movement is very well controlled.
[0025] The oil-removal arrangement according to FIG. 4 according to the invention can be located in any position at all. In this case, oil guide 13 attached to loading shoe 20 forms the oil jet and turns it nearly as much as required, with auxiliary guide 14 . 1 forming part of the actual oil-removal arrangement only guiding it in a straight form to the bottom of the collector trough. The trough has a spiral shape, with outlet pipe 15 forming its inner part. The opening in its lower part is blocked at regular intervals, thus forming gaps 16 for transferring the oil to the operational outlet pipe. The suction opening 17 ′ in the end of the outlet pipe is shown in the figure by broken lines.
[0026] The oil-removal arrangement according to the invention can also be applied in connection with a shoe press roller, according to FIG. 6 b. In this case, the embodiment corresponds to the oil-removal arrangement shown in FIG. 4. In the shoe press roller embodiment, the shell 11 is the belt casing, which is usually about 3-5 mm thick. Despite the thinness of the belt casing, the oil-removal arrangement works well, as the belt casing is sufficiently stable immediately before loading shoe 20 .
[0027] In the case according to FIG. 2 b, the flow energy of the oil is to a great extent cancelled already against the loading shoe and the guide in it. If a relatively more powerful jet, for example at a lower circumferential velocity, is desired, an oil guide 13 according to FIG. 5, for example, is used in which a curved oil-guide piece is attached to loading shoe 20 , which piece turns the oil layer on the inner surface of the roll shell 11 , with small losses, into an inwardly-directed jet, at which point an oil collector trough with an auxiliary guide is placed in the manner disclosed previously.
[0028] Although the invention has been described by reference to specific embodiments, it should be understood that numerous changes may be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not be limited to the described embodiments, but that it have the full scope defined by the language of the following claims.
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An arrangement is disclosed for removing oil from a roll, in which, inside a rotatable shell, there is a fixed axle beam, which supports loading shoes directed against the inner surface of the shell. An oil guide attached to the loading shoes creates an inwardly-directed jet of oil, next to and at a short distance from which a collector trough is located. The oil guide and an auxiliary guide attached to the collector trough guide and cancel the oil jet against the collector trough. The oil is removed to an outlet pipe through a low gap in the bottom of the collector trough.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application for an invention claims the benefit of U.S. Provisional Application No. 62/157,340, High Temperature Control Knob, filed May 5, 2015.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field of the Invention
[0003] The invention relates to temperature control devices. More particularly the invention relates to temperature control devices for retrofitting appliances in order to prevent the temperature from exceeding a predetermined maximum temperature.
[0004] Even more particularly, the invention pertains to a high temperature control knob which may be utilized on an existing appliance, such as a stove or oven, without the addition of additional electronic wiring to the appliance.
[0005] 2. Prior Art
[0006] The prior art includes devices for regulating temperature using sensors which are found on thermostat type devices. The prior art of record shows a number of devices for controlling the temperature of the surface of an oven.
[0007] A problem with existing technology is that it is not easily adaptable to the numerous models of appliances in the market place to control the temperature of a substance, such as oil in a container. The invention discloses a high temperature control knob that may be used on any existing appliance.
GENERAL DISCUSSION OF THE INVENTION
[0008] The invention addresses the need to have a high temperature control knob which an user could add to an existing appliance, such as an oven or surface heating element of a stove. The invention would prevent a substance from reaching undesired temperatures resulting in disastrous consequences, such as oil reaching its burning point and causing a fire.
[0009] In a simple embodiment of the device described herein, the invention provides an alignment means with at least one stop. The alignment means may be adjusted using an adjusting means to align the at least one stop with a preselected maximum temperature to prevent an arm on a dial from going past at least the one stop, thereby preventing the appliance from exceeding the preselected maximum temperature. The invention can be applied to an existing appliance, such as a stove, over an existing control knob stem. Where the existing appliance dials do not have the arm, a dial with the arm may be applied to the control knob stem to which the replaced existing appliance dials were attached. The alignment means may be mounted around the power control knob stem and may be secured to the face of the appliance using existing screws in threaded apertures that are located around a control knob stem so that at least the one stop of the alignment means can be rotated along an arc aligned with a set of temperatures or the alignment means may be otherwise mounted to the existing appliance using a fixing means, such as screws. The arm contacts at least the one stop when the arm reaches a predetermined power level associated with a preselected maximum temperature for which at least the one stop is aligned to prevent the appliance from going over desirable heat levels.
[0010] One place where this type of technology would be particularly beneficial would be in the rental house market. In these situations an owner of a rental unit may want to provide for additional care in order to protect tenants and may wish to retrofit the appliances so that the appliances will operate in safer temperature ranges, particularly for frying oil.
[0011] The problem with prior art devices is they require a great deal of expense because they are not easily retrofitted onto existing equipment.
[0012] It is the main purpose of the invention as described above to provide a high temperature control knob which is attached to an existing appliance control knob stem and which serves to prevent the temperature of an item on top of a burner or within an appliance from being heated above a predetermined maximum temperature.
[0013] It is a further object of the invention to provide a high temperature control knob for preventing oil on top of a appliance from being heated above the flash point at which it ignites.
[0014] These and other objects and advantages of the invention will become better understood hereinafter from a consideration of the specification with reference to the accompanying drawings forming part thereof, and in which numerals correspond to parts throughout the several views of the invention with like parts be identified by the same numeral.
[0015] One other benefit of the high temperature control knob for the appliance is that it lowers the power consumption while cooking. The percent conception loss is believed to be between 30% & 50% based on laboratory tests.
[0016] Also, one related benefit is that the oil used can be consumed over a longer period of time because the oil is not as badly damaged by high temperature.
[0017] Yet another related benefit is that the oil does not smoke as badly if left for extended period of times as it would without the devise. Less smoke and oil residue are present with the devise than in the situation without it.
[0018] In addition, it is believed that there is not a significant difference in the time required for heating the oil to the temperature of 375°, the approximate desired temperature so that there is both an energy savings, safety savings and a environmental (reduction of smoke and type of smoke) benefit to the devise.
[0019] The oil smoke point is the temperature at which the oil begins to decompose and visible smoke is given off. Typically, once the smoke point is reached, the oil begins to degrade. This is the reason why maintaining the frying temperature of approximately 195° centigrade or 375° Fahrenheit is important. This allows a batter coated surface to quickly form a protective shield from penetrating the cold food and making it greasy.
DESCRIPTION OF DRAWINGS
[0020] For a further understanding of the nature and objects of the invention, reference should be made to the following detailed description taken in conjunction with the accompanying drawings in which like parts are given like reference numerals and wherein:
[0021] FIG. 1 shows show a prospective view of a dial, an adapter, an alignment means, and a rear plate of one embodiment of the invention aligned with a control knob stem of an appliance that does not have a set of temperature markings that are observable;
[0022] FIG. 2 show a prospective view of the dial, the adapter, and the alignment means of FIG. 1 aligned with the control knob stem on an appliance having the set of temperature markings on the face of the appliance;
[0023] FIG. 3 shows a prospective view of the dial, the adapter, the alignment means, and the rear plate of the one embodiment of the invention;
[0024] FIG. 4 shows a rear face view of the dial with a depression for the adapter of the one embodiment of the invention;
[0025] FIG. 5 shows a frontal view of the one embodiment of the invention with the at least one stop at a third temperature marking;
[0026] FIG. 6 shows a frontal view of an original appliance knob having a set of original temperature markings;
[0027] FIG. 7 shows a prospective view of another embodiment of the invention comprising the dial, the adapter, and the alignment means of the one embodiment of the invention aligned with the control knob stem on the appliance with the set of temperature marking on the face of the appliance;
[0028] FIG. 8 shows a prospective view of yet another embodiment of the invention comprising only the alignment means of the of the one embodiment of the invention;
[0029] FIG. 9 shows a frontal view of an alternate alignment means with a plurality of hold apertures; and
[0030] FIG. 10 shows a prospective view of an alternate alignment means with a plurality of hold apertures.
DETAILED DESCRIPTION OF THE INVENTION
[0031] The invention is a high temperature control knob 10 for retrofitting an appliance 11 , such as a stove, having at least one control knob stem 9 as shown in FIG. 1 . The control knob stem 9 extends from a face 11 a of the appliance 11 and the control knob stem 9 is movable (i.e., can be turned or rotated) about a longitudinal axis 9 a of the control knob stem 9 . As can best be seen by reference to FIG. 1 in one embodiment, the high temperature control knob 10 comprises: an alignment means 13 having a disc portion 13 a and a raised portion 13 b ; a rear plate 15 ; a dial 18 ; and an adapter 18 a . The disc portion 13 a disposed generally perpendicular to the raised portion 13 b . The rear plate 15 comprises a set of temperature markings 20 that may include a first temperature 21 , a second temperature 22 , a third temperature 23 , and a fourth temperature 24 , and may be used when the set of temperature markings 20 are not observable on the appliance 11 or will be covered after installing the alignment means 13 . Looking to FIG. 2 , where the set of temperature markings 20 is observable on the appliance 11 , the rear plate 15 is not required. Looking to FIGS. 3 and 4 , the dial 18 has an arm 12 and a rear face 18 b . The rear face 18 b has a depression 18 c sized for the adapter 18 a shown in FIG. 3 . Referring again to FIG. 1 , the disc portion 13 a may comprise an adjusting means 17 , such as at least a first slot 17 a , or at least a second slot 17 b . Although the first slot 17 a as shown is elongated and curved, the first slot 17 a could be a circular through aperture similar to a first rear slot 17 aa of the rear plate 15 . The alignment means 13 further may comprise a center slot 13 c , generally centered in the disc portion 13 a . The alignment means 13 fits around the control knob stem 9 of the appliance 11 by placing (i.e., inserting) the control knob stem 9 through center slot 13 c . The disc portion 13 a may have a diameter D between 1.5 and 3 inches, and a thickness T between 0.1 to 0.3 inches. The raised portion 13 b may be attached circumferentially to the disc portion 13 a as shown in FIG. 1 or may be mounted on (not shown) an outer face 37 of the disc portion 13 a and may have a raised height RH between 0.25 to 1.00 inches, as measured perpendicular the disc portion 13 a and may have a raised thickness RT between 0.1 and 0.2 inches. The raised portion 13 b may have at least one stop 16 on one end and may also have an alternate stop 16 a on an other end configured to contact the arm 12 on the dial 18 when the dial 18 is rotated clockwise and counter-clockwise, respectively. The raised portion 13 b extends perpendicular to the outer face 37 of the disc portion 13 a away the face 11 a of the appliance 11 .
[0032] The adapter 18 a may be similar to a type commonly known in the art as an adapter insert, such as the adapter insert with Electric Range Knobs under parts number PM3X84 and with Gas Ranges Knobs under parts number 3M3X88 by General Electric. Looking to FIG. 3 , a first end 18 d 1 of the adapter 18 a is inserted in a depression 18 c (shown in FIG. 4 ) in the rear face 18 b of the dial 18 , and a second end 18 d 2 of the adapter 18 a is attached to the control knob stem 9 . Looking to FIG. 3 , the depression 18 c is sized to hold the adapter 18 a . The adapter 18 a may have an adapter diameter AD between ½ to ¾ inches, but generally ⅝ inches, and may have an adapter height AH between ¼ to ¾ inches high, but generally ⅜ inches, with generally ⅛ inches of the adapter extending out of the rear face 18 b of the dial 18 . The dial 18 is turned using the hand ridge 18 e . The dial 18 may be generally of a configuration and composition similar to the range knobs is the art, such as the electric range knobs sold with the adapter inserts by General Electric under parts number PM3X84, except the dial 18 of the one embodiment of the invention has the arm 12 . The arm 12 is configured to contact the at least one stop 16 when the dial 18 is mounted on the control knob stem 9 . The arm 12 may have arm length AL sufficient to extend beyond the at least one stop 16 as shown in FIG. 5 , and an arm width AW that may be between 0.18 to 0.25 inches, but could be greater. There are usually four or five such control knob stems 9 on the appliance 11 but for purposes of understanding the invention, it is only necessary to focus on one such control knob stem 9 .
[0033] Looking to FIG. 6 , where a set of original temperature markings 20 is located on an original knob 18 h , the rear plate 15 may be used. The set of original temperature markings 20 a will be compatible with the set of temperature marking 20 shown in FIGS. 1 and 2 . Referring to FIG. 1 , the alignment means 13 is between the adapter 18 a and the rear plate 15 when the rear plate 15 mounted to the face 11 a of the appliance 11 along a longitudinal axis 9 a of the control knob stem 9 in the one embodiment. Looking to FIG. 5 , at least the one stop 16 may be adjustable about the arc 53 . Increasing temperatures may be achieved by turning (i.e., rotating) the dial 18 and the arm 12 in a clockwise direction 53 c , the alignment means 13 may be turned along an arc 53 in a counter clockwise direction 53 cc relative to the rear plate 15 and the face 11 a of the appliance 11 to align the at least one stop 16 to the predetermined maximum temperature, such as third temperature 23 . Alternatively, where the increasing temperatures are achieved by turning (i.e., rotating) the dial 18 and the arm 12 in a counterclockwise direction 53 cc , the alignment means may be turned in a clockwise direction 53 c to align the alternate stop 16 a . Looking again to FIG. 1 , the rear plate 15 may be affixed to the face 11 a of the appliance 11 by doubled sided tape (not shown), a rear plate screw (not shown), or an adhesive 42 , such as glue.
[0034] Continuing to look at FIG. 1 , by having the adjusting means 17 , such as at least the first slot 17 a in the alignment means 13 , the position of the alignment means 13 may be held relative to the face 11 a of the appliance 11 by a fixing means, such as a first screw 3 , passing along a first threaded axis 50 a through the first slot 17 a of the alignment means 13 and the first rear slot 17 aa of the rear plate 15 , and into a threaded aperture, such as a threaded aperture 35 a , which is within the face 11 a of the appliance 11 . A second fixing means, such as a second screw 3 , may be inserted along a second threaded axis 50 a through the second slot 17 b of the alignment means and a second rear slot 17 bb of the rear plate 15 and into a second threaded aperture 35 a , to more securely hold the alignment means 13 in position. The first slot 17 a and the second slot 17 b are equivalent and may positioned to fit over the first and second threaded apertures 35 a that may be found on the face 11 a of the appliance 11 . The position of the alignment means 13 to the rear plate 15 and the face 11 a of the appliance 11 is fixed by tightening at least the first screw 3 into the first threaded aperture 35 a on the face 11 a of the appliance 11 so that a head underside 3 a of the first screw 3 presses against an inner face 36 around the first slot 17 a of the disc portion 13 a . In a like manner the second screw 3 may be tightened around the second slot 17 b . The inner face 36 may be somewhat recessed with respect to the outer face 37 of the disc portion 13 a to allow the first screw 3 to not rise above the outer face 37 once the first screw 3 is tightened in the first threaded aperture 35 a . The disk portion 13 a is generally disposed perpendicular to the longitudinal axis 9 a of the control knob stem 9 .
[0035] Looking to FIG. 5 , the set of temperature markings 20 assist in fixing the position of the at least the first stop 16 relative to the rear plate 15 at various locations on the rear plate 15 so that the temperature may be controlled in accordance with the one embodiment described herein.
[0036] Looking again to FIG. 1 , the dial 18 is functionally connected to the control knob stem 9 so that the turning of the dial 18 turns the control knob stem 9 . The control knob stem 9 is part of the existing appliance and is in contact with and functionally connects to the power of the appliance 11 so that as the dial 18 is turned the control knob stem 9 is turned thereby controlling the maximum temperature of the appliance 11 .
[0037] Looking again to FIG. 5 , the arm 12 will move around an arc 53 as the dial 18 turns the gas or power on in response to pressure from an user's hand. As the dial 18 is turned, at least one stop 16 arrest an arm 12 of a dial by at least the arm 12 contacting at least the one stop 16 . At least the one stop 16 may be fixed in one location or it may be adjustable to several locations, such as the first temperature 21 , the second temperature 22 , the third temperature 23 and the fourth temperature 24 . When placed on the rear plate 15 , the set of temperature markings 20 will be compatible with the set of temperature markings 20 shown in FIG. 2 on the face 11 a of the appliance or the set of original temperature markings 20 a an the original knob 18 h as shown in FIG. 6 .
[0038] Looking again to FIG. 5 , the dial 18 may be turned until the arm 12 contacts the at least one stop 16 . The at least one stop 16 in this embodiment is at the third temperature 23 . As an example, assuming the first maximum temperature corresponds to the third temperature 23 is between 300 and 410 degrees in order to prevent hot oil or grease from burning and in order to keep the temperature below the temperature at which hot oil or grease would burn, then the first maximum temperature corresponding to the third temperature 23 also corresponds to an approximate predetermined maximum temperature considered appropriate for the control knob stem 9 , meaning the high temperature control knob 10 should prevent the appliance 11 from exceeding the third temperature 23 when at least the one stop 16 is the set at the third temperature 23 .
[0039] In another embodiment of the invention, a plate-less high temperature control knob 110 is shown in FIG. 7 . The set of temperature markings, such as the first temperature 21 , the second temperature 22 , the third temperature 23 , and the fourth temperature 24 , are observable on the face 11 a of the appliance 11 . The plate-less high temperature control knob 110 has all the elements of the high temperature control shown in FIG. 1 but the deletes the rear plate 15 .
[0040] Looking to FIG. 8 , in yet another embodiment of the invention, an alignment high temperature control knob 210 comprises only the alignment means 13 of the high temperature control knob shown in FIG. 1 . The dial 18 with the arm 12 are originally a part of the appliance, and the set of temperature markings such as the first temperature 21 , the second temperature 22 , the third temperature 23 , and the fourth temperature 24 , are observable on the appliance 11 deleting the requirement for the rear plate 15 . Thus, the alignment high temperature control knob 210 would comprise only the alignment means 13 of the high temperature control knob shown in FIG. 1 .
[0041] Referring to FIGS. 9 and 10 , a modified alignment high temperature control knob 310 may consist of an alternate alignment means 113 . The alignment means 13 shown in FIGS. 1, 2, 3, 7, and 8 may be replaced by an alternate alignment means 113 . The first slot 17 a and the second slot 17 b of the alignment means 13 shown in FIG. 1 may be replaced by a plurality of hold slots, such as a hold aperture 117 c , as show in FIGS. 9 and 10 , and the center slot 13 c shown in FIG. 1 may be replaced by a stem aperture 117 d shown in FIGS. 9 and 10 . Referring to FIG. 9 , the hold aperture 117 c has a hold aperture diameter 117 cd somewhat larger than the threaded aperture diameter 35 ad . The alternate alignment means 113 comprises an alternate disc portion 113 a and the raised portion 13 b of FIG. 1 . The alternate disc portion 113 a comprises: an alternate inner face 136 with the plurality of hold slots, such as the hold aperture 117 c ; the same outer face 37 as shown in FIG. 1 ; and the stem aperture 117 d . The plurality of hold slots is disposed circularly centered on the stem aperture 117 d . The stem aperture 117 d has a stem aperture diameter 117 dd somewhat larger than the control knob stem 9 , allowing the control knob stem 9 to be disposed through (i.e., inserted) the stem aperture 117 d of the modified alternate alignment means 113 . The alternate inner face 136 is recessed in the alternate disc portion 113 a to allow the first screw 3 to remain below the outer face 37 when the first screw 3 is tightened in the first threaded aperture 35 a . The plurality of hold slots, such as hold aperture 117 c may replace the first slot 17 a and the second slot 17 b of the alignment means 13 shown in FIGS. 1, 2, 3, 7, and 8 . The alternate alignment means 113 may be rotated about the control knob stem 9 along the arc 53 until the one stop 16 or the alternate stop 16 a is at the desired location, the predetermined maximum temperature, such as any one of the first temperature 21 , the second temperature 22 , the third temperature 23 and the fourth temperature 24 . The alternate alignment means 113 is then fixed by inserting the fixing means, such as the first screw 3 of FIG. 1 , through least one of the plurality of hold slots, such as the hold aperture 117 c , and into the first threaded aperture 35 a.
[0042] Looking to FIG. 3 and specifically to the second slot 17 b , the adjusting means 17 , such as the second slot 17 b , will have an adjusting means radius of curvature 17 r equal to a distance from the longitudinal axis 9 a to the adjusting means centerline 17 c L, depicted by a dashed line. The adjusting means centerline 17 c L is everywhere the adjusting means radius of curvature 17 r (shown in FIG. 1 ) from the longitudinal axis 9 a . The adjusting means radius of curvature 17 r is equal to a threaded aperture radius of curvature 35 r shown in FIG. 2 . The threaded aperture radius of curvature 35 r is the distance from the longitudinal axis 9 a to the first threaded axis 50 a . Looking to FIG. 3 , the adjusting means 17 , such second slot 17 b , will have a adjusting means diameter 17 w somewhat larger than the threaded aperture diameter 35 ad (shown in FIG. 9 ) and the adjusting means diameter 17 w will be centered along the adjusting means centerline 17 c L The fixing means head diameter 3 w shown in FIG. 1 will be somewhat larger that the adjusting means diameter 17 w shown in FIG. 3 , allowing the head underside 3 a in FIG. 1 to be press against the inner face 36 . The adjusting means 17 , such as at least the first slot 17 a , or the equivalent second slot 17 b , may be viewed as the plurality of hold slots 117 , such as the hold apertures 117 c shown in FIG. 10 , positioned along the adjusting means centerline 17 c L shown in FIG. 3 , and merged into each other forming a single slot, such as the second slot 17 b.
[0043] In terms of a process the steps may be described as:
1) Selecting a predetermined maximum temperature, such as the third temperature 23 and removing the dial 18 from the control knob stem 9 ; 2) Loosening the fixing means, such as the first screw 3 , on the alignment means 13 and rotating the alignment means 13 so that the at least one stop 16 is aligned with the predetermined maximum temperature; 3) Tightening the fixing means to fix the at least one stop 16 ; 4) Placing the dial 18 back on the control knob stem 9 ; and 5) Turning the dial 18 to a desired temperature that does not exceed the predetermined maximum temperature aligned with the one stop 16 .
[0049] Because many varying and different embodiments may be made within the scope of the inventive concept herein taught and because many modifications may be made in the embodiment(s) herein detailed in accordance with the descriptive requirements of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense.
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The invention is a high temperature control knob that is installed on the power control knob stem of an existing appliance to prevent a material being heated from reaching a predetermined maximum temperature (e.g., the burning point temperature for oil), and thereby preventing an undesired event (e.g., a fire). The high temperature control knob comprises an alignment means having at least one stop that is adjustable about a set of temperature markings containing the predetermined maximum temperature, and may further comprise a dial with an arm that mounts of the power control knob stem. The at least one stop may be aligned to the predetermined maximum temperature by rotating the alignment means about the power control knob stem and tightening a fixing means to hold the alignment means in place. The arm of the dial contacts the at least one stop preventing the appliance from exceeding the predetermined maximum temperature.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This invention relates generally to decorative lighting of the “icicle” type used during the Christmas holiday season to decorate homes, buildings, and other structures. More particularly, this invention relates to a device used for controlling, displaying, storing, and otherwise organizing these lights and the wires associated therewith.
[0005] 2. Description of the Prior Art
[0006] Icicle lighting is well known and popularly used to provide ornamental lighting on buildings or other appropriate structures. An example of such icicle lighting is described in U.S. Pat. No. 5,975,717. This form of ornamental lighting is quite attractive but presents a problem with the numerous electrical wires which course the edge of the building and dangle therefrom. A decorator would typically attach the horizontal portion of the icicle lighting along a roof line and let the vertical wires and lights thereon freely hang down. Outside lighting of this type is naturally subjected to extreme whether conditions, and strong winds often cause these lights to tangle or flip-up onto the roof, thereby altering their well placed ornamental appearance. And at the end of the season, neat, untangled storage of the icicle lighting is virtually impossible.
[0007] Previously, the only disclosed device which offered to provide any degree of control to icicle lighting is an ornamental version described in U.S. Design Pat. No. 386,445, entitled “STRAIGHT WIRE FRAME ICICLE DISPLAY”. However, this device would only provide limited assistance in the organization, control, and storage of the icicle lighting: The wire frame does not easily attach to or detach from the lighting, there is no anchor to keep the lighting neatly in place, and due to its limited flexibility, it is difficult to store during the off-season.
SUMMARY OF THE INVENTION
[0008] Accordingly, it is the principal object of the present invention to provide the long needed display, control and organization for icicle lighting. This is accomplished by a light organizing and display device consisting essentially of a plurality of interconnected stiff members (such as rods) arranged in a series. Each rod member has located thereon a plurality of fasteners for attaching the vertically hanging portions of the icicle lighting to the rod members. Connected to the lower extremities of selected rod members, there are provided anchor lines having clips thereon for attachment to the structure being decorated. In a further feature, the fasteners provided on the rod members are releasable and consist of interlocking straps attached to the rod member. These straps have a protrusion on one end and an opening on the other end for interlocking receipt of the protrusion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] [0009]FIG. 1 is a perspective view depicting icicle lighting attached to a house and showing the light organizing and display device of the present invention installed therewith.
[0010] [0010]FIG. 2 is a plan view of the light organizing and display device of the present invention, shown without the icicle lighting attached.
[0011] [0011]FIG. 3 is a cross sectional view of one of the rod members of the light organizing and display device of FIG. 2, showing a releasable attachment strap.
[0012] [0012]FIG. 4 shows the flexible interlocking attachment strap of FIG. 3 in its closed interlocked position.
[0013] [0013]FIG. 5 is shows the light organizing and display device of FIG. 2 having the icicle lighting positioned thereon and partially attached.
[0014] [0014]FIG. 5 a shows the attachment of the lights to the light organizing and display device in more detail.
[0015] While the invention will be described in connection with a preferred embodiment, it will be understood that it is not the intent to limit the invention to that embodiment. On the contrary, it is the intent to cover all alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] Turning first to FIG. 1 there is shown a structure 10 , such as a house, on which decorative lighting in the nature of icicle lights, including the light organizing and display device of the present invention, has been applied along the roof edge. Particularly, this icicle lighting consists of light bulbs 12 , numerous segments of vertically hanging clusters of wires 14 , and a power cord 16 . The horizontal portions of the icicle lighting are shown attached to the gutter 18 of the house, but may be attached to, or along, any other desired feature on the structure. This attachment is accomplished by use of clips or hooks or other means known to the art. When so attached, the icicle lights typically present multiple segments of vertically hanging clusters of wires 14 of varying length, distributed in series along the length of the decorative lighting, as shown in FIG. 1.
[0017] The light organizing and display device of the present invention (see FIG. 2) consists of a plurality of spaced elongated organizing members 20 , arranged in series, for holding the respective vertical segments of the clusters of strings of wires 14 of the icicle lights. In the preferred embodiment, these organizing members are stiff in nature, such as rods, and have attachment means 22 thereon for fastening and holding the segments of wires 14 of the icicle lights to these organizing members.
[0018] The attachment means 22 preferably comprises flexible releasable interlocking strap members 30 (see FIG. 3). These strap members 30 are affixed to the organizing members 20 and wrap around the segments of wire strings 14 to secure them to the organizing members, as depicted most clearly in FIG. 5 a . In order to interlock the extremities of these strap members, they are each arranged with a protrusion 32 on one extremity thereof and an opening 34 on the opposite extremity for receipt of the protrusion 32 , as shown most clearly in FIG. 4. Additionally, this protrusion presents a wide outer extremity 36 and narrows at its point of attachment 38 to the strap, and the opening 34 is elastic in nature and is smaller in its un-stretched size than the wide outer extremity 36 of the protrusion 32 . Consequently, when the protrusion is forced through the opening 34 , the opening first stretches and then retracts to securely hold the protrusion 32 in place.
[0019] In a further feature of the preferred embodiment, the spaced organizing members 20 are interconnected by a flexible line 40 . This line helps maintain the desired positioning of the lighting, assists in anchoring the lighting, and facilitates the storage of the icicle lights during non-use, as more fully described below. This line 40 is shown attached to the lower extremity of the organizer members 20 , but it may be attached at any other available location on the organizing members that will accomplish a similar result. Moreover, this line 40 may equivalently consist of multiple line segments connected between the individual organizing members. When so interconnected, the organizing members 20 with attached lighting easily withstand the wind and elements and will more effectively remain in place as positioned on the structure by the decorator. At the end of the season, the short flexible segments of the line 40 located between each of the organizer members now allows the device to be rolled, folded or gathered (accordion style) for quick, easy, and untangled storage.
[0020] In yet a further feature of the preferred embodiment there is provided anchor means 42 and 44 extending from the lower extremities of certain organizing members 20 for securing them to the structure. In the preferred embodiment, this anchor means is affixed to selected organizer members and preferably to each of those positioned at the outer extremity of the series thereof, as shown in FIG. 2, to thereby anchor the vertically hanging portions of the organizing and display device (and the attached lighting) to the structure. This anchor means works in cooperation with the interconnection line 40 to maintain the organizer members in position. FIG. 1 shows the anchor 42 (left side of the drawing) attached 43 to the house structure, and the anchor 44 on the right side of the drawing is unattached.
[0021] This anchor means 42 and 44 comprises, in the preferred embodiment, clip means 46 a and 46 b affixed to the free extremity of flexible anchor lines 47 a and 47 b for quick and easy attachment to any chosen point on the structure. Such clip means, for facilitating the attachment of the anchor lines, may include a hook or clip member or any other equivalent attachment device known to the art for affixing the anchor line to an anchor point on the structure or elsewhere.
[0022] When used with pre-existing icicle lighting, the organizing and display device of the present invention is preferably attached to the icicle lighting using the releasable fastener means described above. This attachment may be accomplished before the lighting is put in place on the structure or afterwards, and is therefore easy to apply to pre-installed lighting. Moreover, the organizing and display device of the present invention may be included as part of the manufactured icicle lighting product itself, with the organizing and display device incorporated into or made integral with the lighting system. With either embodiment, upon removal of the lighting from the structure at the end of the season, the icicle lighting is designed to be left attached to the organizing and display device to assist in its storage, as described above.
[0023] From the foregoing description, it will be apparent that modifications can be made to the apparatus and method for using same without departing from the teachings of the present invention. Accordingly, the scope of the invention is only to be limited as necessitated by the accompanying claims.
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An organizing and display device for attachment to (or incorporation into) decorative icicle lighting consists of a series of interconnected rod members, where each rod member has located thereon a plurality of fasteners for attaching the hanging portions of the icicle lighting thereto. The fasteners for attaching the lighting each consist of a releasable interlocking strap member. Attached to one (or more) of the rod members, there is provided an anchor line having a clip for attachment to the structure being decorated.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 294,813, filed Aug. 20, 1981, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to an improved method for treating subterranean formations with particulate material. The improved particulate material of this invention has utility, including but not limited to, use as a proppant in hydraulic fracturing use as a fluid loss agent in hydraulic facturing and as a screening material in gravel packing. The invention also relates to a method for producing improved particulate material for use in the production of shell molds and shell cores in the foundry industry.
In the completion and operation of oil wells, gas wells, water wells, and similar boreholes, it frequently is desirable to alter the producing characteristic of the formation by treating the well. Many such treatments involve the use of particulate material. For example, in hydraulic fracturing, particles (propping agents) are used to maintain the fracture in a propped condition. Smaller size particles (70 to 140 mesh) are used to control fluid loss during fracturing. Also in sand control techniques, particulate matter is placed in the well to prevent the influx or encroachment of formation sand or particles.
Although particulate material is used in the treatment of formations for a variety of reasons, there is one problem common among such treatments, the problem of particle stability. This problem can best be appreciated when considered in connection with specific treating techniques.
In hydraulic fracturing, propping agent particles under high closure stress tend to fragment and disintegrate. At closure stresses above about 5,000 p.s.i., silica sand, the most common proppant, is not normally employed due to its propensity to disintegrate. The resulting fines from this disintegration migrate and plug the interstitial flow passages in the propped interval. These migratory fines drastically reduce the permeability of the propped fracture.
Other propping agents have been used to increase well productivity. Organic materials, such as the shells of walnuts, coconuts and pecans have been used with some success. These organic materials are deformed rather than crushed when the fracture closes under the overburden load. Aluminum propping agents are another type of propping agent which deforms rather than fails under loading. While propping agents such as these avoid the problem of creating fines, they suffer the infirmity of allowing the propped fracture width to close as the propant is squeezed flatter and flatter with time. In addition, as these particles are squeezed flatter and flatter the spaces between the particles grow smaller. This combination of decreased fracture width and decreased space between the particles results in reduced flow capacity.
An improved proppant over the materials mentioned above is spherical pellets of high strength glass. These high strength glass proppants are vitreous, rigid, and have a high compressive strength which allows them to withstand overburden pressures of moderate magnitude. In addition, their uniform spherical shape aids in placing the particles and providing maximum flow through the fracture. While these beads have a high strength when employed in monolayers, they are less satisfactory in multilayer packs. In brine at 250° F., the high strength glass beads have a tendency to disintegrate at stress levels between 5000 and 6000 p.s.i. with a resultant permeability which is no better, if not worse, than sand under comparable conditions.
Resin coated particles have been used in efforts to improve the stability of proppants at high closure stresses. Sand or other substrates have been coated with an infusible resin such as an epoxy or phenolic resin. These materials are superior to sand at intermediate stress levels. However, at high temperature and high stress levels, the resin coated particles still show a decrease in permeability to about the same degree as silica sand.
In gravel pack completions, particularly sized aggregate is placed in the well adjacent to the formation to form a filter bed through which produced fluids must flow. In one type of gravel packed completion, e.g. a linerless gravel pack, the aggregate material is injected through the well casing perforations to provide a filter outside the casing for each perforation. This type of completion frequently fails because of the inability of the aggregate to bridge across the perforation, with the result of the aggregate and formation sand entering the well bore.
Another type of gravel packed completion frequently used for sand control purposes is the liner gravel pack. This type of completion employs a well liner or screen packed in aggregate. Because of settling or migration of the aggregate it is frequently difficult to maintain the gravel in surrounding relation to the liner. Also, failure of the liner caused by corrosion or collapse results in the loss of the filter bed surrounding the liner, at least in the vicinity of the liner failure.
Obviously, a desirable characteristic of well completions involving the use of particulate material is one of particle stability. Efforts to provide such stability, particularly in gravel packed completions, include the use of organic resins or resinous materials.
U.S. Pat. No. 3,857,444 to Copeland discloses a method for forming a permeably consolidated gravel pack in a well bore. The slurry containing a particulate material coated with an uncured epoxy resin and a curing agent in a solvent is slurried in liquid hydrocarbon and introduced into place in the formation. The well is shut in until the resin coated particulate mass cures to form a permeable consolidated sand or gravel pack.
U.S. Pat. No. 3,929,191 to Graham et al discloses a method for producing coated particles for use in treating subterranean formations. The particles in this method are coated with a resin dissolved in a solvent which is then evaporated. This patent also discloses that the coating may be produced by mixing the particles with a melted resin and subsequently cooling the mixture, forming a coating of resin on the particles.
The Graham patent also discloses that the addition of coupling agents to the system improves the bonding of the resin to the particles. This improved bonding strength between the resin and particles increases the strength of the mass formed when the resin coated particles are fused and cured into a porous mass. This increased strength is important due to the high stresses the material may be subjected to in use such as when used as a proppant in hydraulic fracturing.
SUMMARY OF THE INVENTION
The present invention provides an improved method for treating a subterranean formation comprised of placing in or adjacent a formation a quantity of free-flowing, heat curable particles comprised of high strength centers, a coupling agent chemically bound to the centers and a heat curable resin coated over the centers; and causing the free flowing heat curable particles to cure and form a coherent mass in or adjacent to the formation.
The present invention also provides an improved method for producing a heat curable resin coated particles. The final product is a composite material consisting of high strength centers encapsulated with a coating of a heat curable solid resin. The material is free flowing and requires no special handling or storage conditions. The particles when cured have even greater compressive and tensile strength than those known in the prior art. The material produced by the invention is thus more useful than the materials of the prior art when used in high stress environments. For example, the method of the present invention may be used in hydraulic fracturing in situations where the material of the prior art would fail under the high closure stress of the formation. The method also yields superior gravel packs to that obtainable with the prior art. In addition the improved bonding of the resin to the centers yields a cured material with increased tensile strength. This allows shell molds and cores in the foundry industry to be made from material with a higher particle to resin ratio than heretofore possible.
These improved curable resin coated particles are produced by first coating the centers with a coupling agent. The treated centers are then heated to drive off any solvent employed with the coupling agent and to react the coupling agent with the centers. This heating also serves to raise the temperature of the centers above the melting point of the resin. The solid resin, into which a coupling agent was incorporated into during its manufacture, is then added in either flake or powdered form to the heated centers. The centers and resin are mixed until the resin forms an even coating on the surface of the centers. The mixture is then quenched with water which serves to harden the coating on the centers and to prevent further reaction of the resin.
Improved results have also been obtained using a coupling agent only in the resin. It is also possible to obtain beneficial results by using only the pretreatment of the centers. However, coating the center with a coupling agent as described above and incorporating a coupling agent in the resin has produced the best results and accordingly is the preferred method.
DESCRIPTION OF THE INVENTION
Particle Substrate
The present invention can be carried out with any suitable high strength, substrate as the particle centers. Choice of the particle substrate is governed by the properties required of the cured mass.
For example in the oil and gas industry extremely high strength proppants are needed to hold open formation fractures created by hydraulic fracturing. In such an application, the present invention may use spherical glass beads as the center. Such beads are available commercially in a variety of mesh sizes. For example Union Carbide Corporation supplies vitreous, rigid, inert, substantially spherical pellets under the trade name UCAR Props. Such beads, while of extremely high compressive strength when employed in monolayers are less satisfactory when placed in multilayer packs. These beads when resin coated by the process of this invention and then cured in place yield a permeable mass of higher compressive strength than either the beads alone or of resin coated beads of the prior art. Beads from about 6 to about 200 mesh are generally used. In extreme environments where stresses are very high sintered bauxite, aluminum oxide, ceramics such as zirconium oxide and other mineral particles may be coated. Particles from 6 to 200 mesh are generally used. (All reference to mesh size in the claims and specification are to the U.S. Standard Sieve Series.)
In less severe conditions conventional frac sand is the preferred particle substrate of the invention. An advantage of the present invention is, that due to the increased strength obtained by the coating process, it allows the lower cost frac sand to be used under more severe conditions than possible with the materials of the prior art. Silica sand of about 6 to about 200 mesh (U.S. Standard Sieve) is generally used.
In other applications such as shell and core mold manufacture in the foundry industry, the siliceous materials common to that industry may be employed.
Resin
The resins suitable for use in forming the coating include true thermosetting phenolic resins of the resole type and phenolic novolac resins which may be rendered heat reactive through the addition of catalysts. The resins must form a solid nontacky coating at ambient temperatures. This is required so that the coated particles remain free flowing and so that they do not agglomerate under normal storage conditions. Resins with softening points of 185°-240° F. (Ball and Ring Method) are acceptable.
Regardless of which type of resin is employed a coupling agent as subsequently described is preferably incorporated into the resin during its manufacture. The coupling agent, which has a functional group reactive in the phenol-formaldehyde system of the resin is added in an amount ranging from about 0.1 to 10 percent by weight of the resin. The preferred range is from about 0.1 to 3.0 percent by weight of the resin. The coupling agent is incorporated into the resin under the normal reaction conditions used for the formation of phenol-formaldehyde resins. The coupling agent is added to the resin reactants prior to the beginning of the phenol-formaldehyde reaction. This incorporation of the coupling agent in the resin is partly responsible for the increased resin-center bond strength provided by the invention.
The preferred resin to be used with the method of the present invention is a phenolic novolac resin. When such a resin is used it is necessary to add to the mixture a cross-linking agent to effect the subsequent curing of the resin. Hexamethylenetetramine is the preferred material for this function as it serves as both a catalyst and a source of formaldehyde.
It is also advantageous to add an organic acid salt such as calcium stearate to the resin-center mixture to act as a lubricant. Such an addition imparts a degree of water repellency to the finished product and aids in preventing sintering of the product during storage. The organic acid salt may be added to the resin or more conveniently may be simply added as a powder at the time the resin is added to the heated centers.
Problems associated with sintering of the product during storage can be further minimized by increasing the "stickpoint" of the resin. Raising of the stickpoint avoids problems of sintering and lumping of the resin coated particle when stored at high temperatures (100° F.-120° F.).
Stickpoint is measured by applying the resin coated particles to a square metal rod heated at one end. The rod has a uniform temperature gradation from its heated end to its unheated end. After one minute the particles are dusted from the rod. The temperature of the point along the rod at which the particles adhere to the rod is measured and is the stickpoint.
To increase the stickpoint a small amount of dry hexamethylemetetramine is added to the flake novolak resin before it is charged to the muller. The blending of the hexamethylenetetramine with the resin during the initial phase of the hot coating process allows for some polymerization of the resin to occur before cooling. This polymerization results in an increase in the resin stickpoint.
The amount of hexamethylenetetramine added in this manner is dependent upon the final stickpoint desired. Generally about 1 to about 10% dry hexamethylenetetramine based on the weight of the flake resin is added. For example the addition of 2.8% hexamethylenetetramine to the resin in the manner just described elevated the stickpoint of the finished product from 210° F. to 238° F. This increase in stickpoint is sufficient to remedy the storage problems of sintering and lumping.
Another problem encountered in the use of the product of the instant invention is the creation of dust during handling operations in the field. The resin coating on the particles is brittle and abrasive action between the particles during high velocity transport generates fine particles of free resin. This dust is objectionable to observe and its elimination is desireable.
The incorporation of a small amount of polyvinyl acetal resin into the resin coating has been found to increase the resin strength and thereby reduce its brittleness. This results in the virtual elimination of the dusting problem.
The preferred polyvinyl acetal for this application is polyvinyl butyral although other resins such as polyvinyl formals may be used.
Specifically a polyvinyl butyral, BUTVAR B-76, manufactured by Monsanto Co. has proven to be effective in strengthening the resin coating and eliminating the dust problem.
Coupling Agent
The coupling agent to be employed is chosen based on the resin to be used. For phenolic resins, the preferred coupling agents are organo functional silanes such as aminoalkylsilanes. Gamma-aminopropyltriethoxysilane has given excellent results when used with phenolic resins. Preferably the coupling agent is both incorporated into the resin structure and reacted with the center surface prior to the resin coating step. This unique dual treatment with the coupling agent results in a higher resincenter bond strength and the concomitant increase in the strength of the cured mass. The same coupling agent may be used in the resin and the center treatment or two different coupling agents may be employed. It is also possible to obtain some improvement in the strength of the cured mass by only pretreating the center surfaces.
Coating Process Parameters
The centers to be coated are weighed and then transferred to a heated rotating drum. During the transfer, the centers are sprayed with a solution containing the coupling agent. A solution is used to insure adequate wetting of the center surface with the coupling agent. The preferred solvent is water.
A sufficient quantity of water must be used to insure adequate dispersion of the coupling agent over the surface of the centers. It is also important not to use too much water as excessive time and heat are then needed to drive off the water during the evaporation step. The amount needed is of course dependent upon the size of the centers. For example for 20/40 mesh sand, it has been found that 0.1 to 3 gallon per 1000 lb of sand gives adequate coverage.
The concentration of coupling agent in the water depends on the surface area of the centers, the amount of water to be used and the nature of the coupling agent. The concentration is generally between 0.1% and 10.0% by volume. The preferred range is generally between 0.5% and 3.0%.
After the coupling agent sprayed centers have entered the heater drum, the mixture is agitated without heat for a period of time ranging from 5 seconds to 1 minute to insure proper dispersion of the coupling agent over the surface of the centers.
The heater is then fired and the centers are heated by a hot air blast to approximately 250°-350° F. During this heating period the water is evaporated and the coupling agent reacted with the surface of the centers. In addition, the hot air blast can be utilized to remove fines from the centers which can lower the permeability of the cured particle mass.
The heated centers are then discharged into a mixer. The flake resin into which a coupling agent has been incorporated is then added. The ratio of resin to the centers varies with the strength required and the size of the centers. Typically the resin coating constitutes between about 1 and about 8 percent by weight of the particles. Dry hexamethylenetetramine may also be added at this time to elevate the stickpoint as previously described.
A lubricant such as calcium stearate is added to the centers with the resin. The amount of lubricant is generally in the range of 0.1 to 10 percent based on the weight of the resin. The preferred amount is in the range of about 0.5 to 5.0 percent. Also a polyvinyl acetal may be added at this time to improve the resin strength and eliminate the creation of dust during handling.
The mixture of heated centers and resin is then agitated for a period of about 30 seconds to 5 minutes. This time must be sufficient to insure complete coverage of the centers.
An aqueous solution of hexamethylenetetramine is then added to the resin-center mixture. This solution serves as a vehicle for the addition of the hexamethylenetetramine and as a quench. The amount of hexamethylenetetramine is generally between about 10 and 20 percent based on the weight of the resin. The preferred range is between about 13 and about 17 percent. The amount of water should be sufficient to cool the mixture sufficiently to prevent reaction of the hexamethylenetetramine and to harden the resin. The amount of water needed ranges generally from about 1 to 5 gallons per 1000 lb of particles. It is of course understood that if a resole type resin is used no hexamethylenetetramine is needed. In such a case the quench is still necessary to prevent further reaction of the resin and to begin the hardening process.
After the quench solution is added, the agitation of the mixture is continued and the coated particles are further cooled by blowing air through them.
The hardened particles are then discharged to conveyors which carry the coated particles to screening and bagging operations.
TYPICAL COATING CYCLE
One thousand pounds of 20/40 frac sand is weighed in a weigh hopper. As the sand is discharged from the weigh hopper to a heater drum it is sprayed with six quarts of a water solution containing 0.89 percent by volume of Silane A-1100 (an aminoalkylsilane purchased from Union Carbide Corporation). The sprayed sand is then rotated in the heater drum for 15 seconds prior to ignition of the heater in order to insure a thorough wetting of the sand by the silane water solution.
The heater fire is ignited and the sand is heated to approximate 270° F. by the hot air blast in approximately three minutes. During this period the water is evaporated and the coupling agent reacts with the sand surface. In addition the force of the hot air blast carries away any fines from the sand.
The heated sand is then discharged into a muller where 35 pounds of the novolac resin which contains 0.5% gamma-aminopropyl-triethoxysilane along with one-half pound of calcium stearate powder is added. This mixture is mulled for 60 seconds during which time the resin melts and forms an even coating on the particles of sand. At the conclusion of the mull cycle an aqueous solution of hexamethylenetetramine is added to the mixture as a quench. The amount of hexamethylenetetramine is equal to 15% of the resin by weight. The quench water cools the resin coating to harden it and also prevents reaction of the novolac with the hexamethylenetetramine. After addition of the quench water solution, agitation is continued for approximately another minute as cool air is blown through the mixture to further cool the coated particles.
The coated sand is then discharged to a screw conveyor where it is then transported to screening equipment and shakers and ultimately bagged. The product thus produced is free flowing and may be handled with ordinary particle handling machinery typical to the oil and gas and foundry industries.
Comparative Strength Data
Table 1 shows comparative tensile strengths for cured specimens of coated sand. In each case sand (American Foundry Society #95) was coated with 3% (based on the weight of the sand) of a novolac resin. The coated sand was then cured and the hot and cold tensile strengths measured. Sample A was prepared with a standard commercial novolac (Reichold 24-713) commonly used for coating foundry sand. Sample B was prepared according to the preferred method of the invention.
TABLE 1______________________________________ Sample A Sample B (no coupling agent; (coupling agent Reichold 24-713 in resin and on resin) substrate)______________________________________Hot Tensile 283 psi 390 psiStrength (450° F.) (Average of 3 tests) (Average of 6 tests)Cold Tensile 628 psi 978 psiStrength (75° F.) (Average of 6 tests) (Average of 12 tests)______________________________________
MICROSCOPIC OBSERVATIONS OF COATED PARTICLES
Particles produced by the method of the present invention were subjected to microscopic examination in both the cured (in brine) and uncured state. Examination of uncured particles prepared without a coupling agent in either the resin or on the substrate reveals an uneven, nonuniform coating. Examination of the same particles after curing in brine show that the resin coating has pulled away from the center. Such "peel back" of the resin from the center leads to failure of the cured mass when used downhole in the oil and gas industry.
Another group of particles was coated using a coupling agent in the resin, but with no pretreatment of the centers with coupling agent. Microscopic examination of these particles show that the coating is more uniform than the coated particle without any coupling agent. However, the coating is still uneven and the uneveness is more pronounced after curing in brine. This uneveness results in lower strength in the cured mass.
A third group of particles was coated by the preferred method of the present invention. Coupling agent was incorporated in the resin and used to pretreat the centers. Examination of the uncured particles shows a uniform, even coating. This is a desireable property as it allows closer and more uniform packing of the particles with resulting higher strength. Examination of the cured particles reveal that they maintain the smooth uniform coatings after curing in brine, completely and evenly encapsulating the center.
The strength of cured multi-layer packs prepared from the three preparations of resin coated particles just discussed was measured. In the first, prepared without any coupling agent, very little consolidation was obtained in a multi-layer pack. In the second, prepared with coupling agent in the resin only, a consolidated core having low to medium strength was obtained. Finally, using coated particles prepared by the method of the invention, consolidated cores of high strength were produced.
FORMATION TREATMENT
The free-flowing, heat curable particles as produced by the above method may be used as proppants or fluid loss agents in hydraulic fracturing, as aggregate in gravel packs and in other subterranean formation treatments requiring particulate material.
In carrying out a hydraulic fracturing operation a fracture is first generated by injecting a viscous fluid into the formation at a sufficient rate and pressure to cause the formation to fail in tension. Injection of the fluid is continued until a fracture of the desired geometry is obtained. A carrier fluid having the proppant suspended therein is then pumped into the fracture. The temperature of the carrier fluid during pumping operations will be low so as to prevent premature curing of the resin. The carrier fluid bleeds off into the formation and deposits the propping agent in the fracture. This process is controlled by fluid loss agents which are small aggregate particles which temporarily slow the fluid loss to the formation.
After the proppant is placed, the well is shut in with pressure maintained on the formation. As the pressure within the fracture approaches the normal formation pressure, the fracture walls close in on the proppant and apply an overburden stress thereto. At the same time ambient formation temperature heats the resin. Initially, the resin fuses and unites at contact areas between contiguous particles or with the formation walls. As the temperature increases the polymerization reaction proceeds until the resin is cured into an insoluble and infusable cross-linked state. The pendular regions between adjacent particles bond the packed particles into a permeable network having considerable compressive strength.
In carrying out linerless gravel pack completions the particles, suspended in a carrier fluid, are injected into the well and forced through the well casing perforations. During the particle placement, the carrier fluid bleeds off into the formation and deposits the free-flowing heat curable particles in the cavity previously formed. Following placement of the particles, the well is shut in permitting the temperature to equalize in the well. Increase in the temperature in the packed interval softens or melts the resin coating and then cures the resin into an infusible cross-linked state. The permeable network resulting from this treatment provides a self-sustaining, consolidated interval which prevents the aggregate from flowing through the perforations and entering the well bore.
A more detailed description of the standard industry practices for the use of such heat curable particles in hydraulic fracturing and gravel pack completion is disclosed in U.S. Pat. No. 3,929,191 which is hereby incorporated by reference.
Further modifications and alternate embodiments of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be considered as illustrative only and for the purpose of teaching those skilled in the art the manner of carrying out the invention. Various modifications may be made in the method. It is intended that all such modifications, alterations, and variations which fall within the spirit and scope of the appended claims be embraced thereby.
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A method for treating a subterranean formation comprised of placing in or adjacent the formation a quantity of free-flowing, heat curable particles comprised of a high strength center, a coupling agent chemically bound to the center, a heat curable resin coated over the center; and causing said free flowing particles in or adjacent the formation to form a cohesive mass.
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FIELD OF THE INVENTION
The present invention relates to an apparatus to dress and hold hair and, more particularly, to gather all or sections of the hair in any number of desired positions.
BACKGROUND OF THE INVENTION
During hairdressing and preparation for activities, a variety of implements are employed for the purpose of maintaining the style and appearance of a person's hair. It is often desired to group strands of hair together so as to achieve a particular style. For example, ponytails are popular not only for the ease in which they may be cared for, but also for the comfort that they afford in keeping the hair away from the face. There are various other hairstyles in which several strands of hair join together for the purpose of fashion.
Heretofore, numerous devices have been developed for use in connection with the creation and maintenance of various hairstyles. One of the most commonly known prior devices is referred to as a snap clip. In their most basic sense, snap clips are typically formed of metal having a single, elongated, flat, narrow strip on the bottom for scooping under the desired gathered hair and a curved, top portion that can be concaved in a snap-like fashion to close over the gathered portion of hair.
While prior known hairstyling devices have known relative commercial success, none are without associated drawbacks or inherent limitations. For example, many prior devices are subject to inadvertent opening or difficulty in closing. This problem is particularly prevalent when it is necessary to grasp and secure large quantities of hair.
Another known shortcoming of current devices is their limitation in types of hair that they will hold. For example, only very small amounts of thick hair will work using current devices. Unfortunately, this eliminates most adult uses for this type of device and it has been limited to children's hair designs and markets.
It is therefore an object of the invention to provide a device to quickly and easily gather hair into any desired position on a person's head.
It is another object of the invention to bend a curved, open end of the top portion of a device into a concaved position, securing all types of hair gathered into place.
It is another object of the invention to create a device that has many more design options than what is currently available with the existing modes.
It is another object of the invention to create a device that holds all hair types in place.
SUMMARY OF THE INVENTION
Thus, the present invention is directed toward overcoming the disadvantages associated with previously known hairstyling devices, including but not limited to those discussed above. The inventive apparatus incorporates a novel combination of a snap clip closure mechanism and a plurality of elongated teeth for gathering and holding hair in fashionable and useful ways. The bottom portion of plural teeth and top portion of flexible material curves outward from the bottom portion and concaves into a closed position over the plural teeth holding the gathered hair in place.
BRIEF DESCRIPTION OF THE DRAWINGS
A complete understanding of the present invention may be obtained by reference to the accompanying drawings, when considered in conjunction with the subsequent, detailed description, in which:
FIG. 1 is a perspective view of a clip in accordance with the invention, illustrated in the closed position;
FIG. 2 is a perspective view of a clip in accordance with the invention, illustrated in the open position;
FIG. 3 is a perspective view of an alternate embodiment of an open hair clip, illustrating two widely spaced, comb-like teeth on the bottom portion;
FIG. 4 is a perspective view of the clip shown in FIG. 3 in a closed position,
FIG. 5 is a side view of an open clip;
FIG. 6 is a perspective bottom view of an open clip;
FIG. 7 is a perspective view of an open clip applied to the hair of a woman's head; and
FIG. 8 is a perspective view of the clip shown in FIG. 7 , in a closed position, holding the hair in place.
For purposes of clarity and brevity, like elements and components will bear the same designations and numbering throughout the FIGURES.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is an improved snap clip for use with a person's hair. The clip permits quick and easy gathering of both thin and thick hair.
FIG. 1 is a perspective view of the improved snap clip of the present invention, shown generally at reference numeral 18 . The lower portion 12 of the clip 18 has a plurality of comb-like, spaced apart teeth. In the preferred embodiment, a first tooth 15 , second tooth 16 and third tooth 17 are provided, as shown, but any number of teeth, greater than one, can be used in the snap clip 18 . Each tooth 15 , 16 , 17 has a free end that remains free at all times. Moreover, the teeth need not be the same length. A flexible upper portion 10 is the same length as the lower portion 12 when the clip 18 is in the closed position, as shown in FIG. 1 . Connecting the upper portion 10 and the lower portion 12 of the clip 18 is a living hinge 9 , well known in the art. The upper portion 10 is concave.
FIG. 2 is a perspective view of the clip 18 in its open position, the upper portion 10 being separated from the lower portion 12 by means of a hinge 9 .
FIG. 3 is a perspective view of an alternate embodiment of the clip 18 in its open position. An upper tooth 13 and lower tooth 14 form a comb on the bottom portion 12 . The lower portion 12 is substantially longer than the concave upper portion 10 when in a closed position. An aperture 11 is provided.
FIG. 4 is a perspective view of the clip 18 in its closed position 21 .
FIG. 5 is a side view of an open clip 18 illustrating the upper portion 10 and lower portion 12 revealing interior teeth 22 on the bottom surface of the upper portion 10 . Interior teeth 22 are used to help retain hair, not shown, in its desired position relative to the upper portion 10 and lower portion 12 of the clip 18 .
FIG. 6 is a perspective bottom view of the clip 18 in its open position. In this embodiment, the bottom surface of the upper portion 10 has interior teeth 22 spaced evenly along the bottom surface of the upper portion 10 , surrounding the aperture 11 . It should be understood, however, that the upper portion 10 can be of any shape, with or without an aperture, and that the interior teeth 22 need not be uniformly spaced as shown in FIG. 6 .
FIG. 7 illustrates a woman 19 with an open clip 18 , as shown in FIGS. 3-6 , illustrating how to gather the hair 24 into the desired style.
FIG. 8 illustrates the woman 19 wearing a closed clip 18 , illustrating how it looks in one possible style, the hair 24 being drawn back away from the face.
Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered limited to the example chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of the invention.
Having thus described the invention, what is desired to be protected by Letters Patent is presented in the subsequently appended claims.
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The present invention is directed toward overcoming the disadvantages associated with previously known hairstyling devices, including but not limited to flexible snap clips. The apparatus incorporates a combination of a snap clip closure mechanism and a comb-like bottom with elongated teeth for gathering and holding hair.
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BACKGROUND OF THE INVENTION
[0001] This invention relates generally to control systems for gas turbine engines, and, more particularly, to methods and apparatus for estimating governor dynamics.
[0002] Gas turbine engines typically include a governing sub-system that maintains the gas turbine engine at a pre-determined operational speed. For example, in a helicopter including a main rotor, the governing sub-system facilitates improving handling qualities of the helicopter. More specifically, the governing sub-system attempts to maintain the helicopter main rotor speed, NR, at a reference value, NR_REF, despite being subjected to external disturbances such as actions from pedal and cyclic, air speeds, and wind gust. FIG. 1 illustrates the overall helicopter engine control with a Full Authority Digital Engine Control (FADEC). The helicopter can change the load in the rotor system by collective pitch (CLP), cyclic, and pedals. When load is increased the rotor speed decreases, the governing system in FADEC can react to the changes in the main rotor speed, NR based on measured engine parameters and rotor speed and increase fuel flow (WF).
[0003] To improve operational handling qualities, feed forward anticipation signals may be used by the governing system to anticipate and correct for transients. If feed forward anticipation signals are not active for some maneuvers, the main rotor speed is maintained by an isochronous gas turbine Np governor, and the helicopter system responsiveness and disturbance rejection capability are reliant upon only the governor dynamics within the governing sub-system.
[0004] Known governing sub-systems use relatively simple lead-lag compensation to attenuate the main rotor response to facilitate a stable system. In addition, notch filters, centered at main rotor resonance, are often included to permit higher system frequency crossover and improved phase margin for the governing sub-system. However, these methods do not directly address system disturbance rejection capability. Furthermore, the simple structure of the governor dynamics may yield a low bandwidth system, thus limiting an overall system performance.
BRIEF SUMMARY OF THE INVENTION
[0005] In one aspect of the invention, a method for estimating gas turbine engine governor dynamics within a system is provided. The gas turbine engine includes a plurality of sensors responsive to engine operations. The method comprises identifying a first set of parameters utilized in the governing system, identifying a second set of parameters utilized in the governing system, and generating governor dynamics estimates utilizing the first and second sets of parameters to solve multiple objective optimization algorithms.
[0006] In another aspect, an apparatus for estimating governor dynamics for a gas turbine engine used in a system is provided. The apparatus is programmed to obtain a first set of parameters from a governing sub-system coupled to the system, obtain a second set of parameters from the governing sub-system, and generate governor dynamics estimates utilizing the first and second sets of parameters to solve multiple objective optimization algorithms.
[0007] In a further aspect of the invention, a governor dynamics estimation process for a system including a gas turbine engine is provided. A governor is coupled to the engine, and the design process utilizes a processor. The processor is configured to receive a first set of parameter outputs indicative of system responsiveness, receive a second set of parameter outputs indicative of system stability robustness, and generate governor estimates utilizing the first and second sets of parameters to solve multiple objective optimization algorithms.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 is a schematic illustration of a known overall helicopter engine control including a Full Authority Digital Engine Control;
[0009] [0009]FIG. 2 is a block diagram of a known general governing system for a gas turbine engine;
[0010] [0010]FIG. 3 is a flow diagram of a process of estimating governor dynamics for a gas turbine engine;
[0011] [0011]FIG. 4 is a block diagram of a general feedback system framework used with the process shown in FIG. 3;
[0012] [0012]FIG. 5 is an exemplary Bode plot illustrating open loop dynamics for coupled and uncoupled plants; and
[0013] [0013]FIG. 6 is an exemplary Bode plot illustrating open loop transfer functions for coupled and uncoupled plants.
DETAILED DESCRIPTION OF THE INVENTION
[0014] [0014]FIG. 1 is a schematic illustration of a known helicopter engine control 10 including a Full Authority Digital Engine Control (FADEC) 12 and for use with a gas turbine engine 14 , such as a CT7-8, commercially available from General Electric Aircraft Engines, Lynn, Mass. FADEC 12 receives a plurality of measured engine parameters 16 , relating to, but not limited to, temperatures T45, T1, operating rotational speeds such as turbine speed NP, shaft torque TRQ, and operating pressures PO. FADEC 12 facilitates improving handling qualities of a helicopter 18 . More specifically, engine control 10 attempts to maintain the helicopter main rotor speed, NR, at a reference value, NR_REF, despite being subjected to external disturbances including, but not limited to such as actions from pedal and cyclic, air speeds, and wind gust. Additionally, helicopter 18 can change the load in the rotor system by collective CLP, cyclic, and pedals. When load is increased, the rotor speed decreases, engine control 10 and FADEC 12 react to the changes in main rotor speed, NR based on measured engine parameters 16 to adjust rotor speed by fuel flow WF.
[0015] [0015]FIG. 2 is a block diagram 20 of an engine control system 21 including a general governing system 22 for use with a gas turbine engine 14 . More specifically, governing system 22 is used to facilitate a helicopter main rotor (not shown) being maintained at a reference speed. Governing system 22 is implemented in a processor-based engine control system. The term processor, as used herein, refers to microprocessors, application specific integrated circuits (ASIC), logic circuits, and any other circuit or processor capable of executing governing system 22 as described herein. In one embodiment, gas turbine engine 14 is a T700 engine commercially available from General Electric Aircraft Engines, Lynn, Mass., and governing system 22 is coupled to an engine control system known as a full authority digital electronic control (FADEC) available from General Electric Aircraft Engines, Lynn, Mass.
[0016] Governing system 22 includes an NP governor 24 which is used to maintain rotor speed through governor dynamics Knp. In the exemplary embodiment, the governor is an isochronous gas turbine Np governor used to maintain rotor speed. Governing system 22 also includes a comparator 30 that receives a first signal 32 and a second signal 34 . First signal 32 represents a power turbine reference speed Np_ref in rpm, and second signal 34 represents a power turbine actual speed Np in rpm. Comparator 30 compares signals 32 and 34 and transmits a signal 36 to governor 24 that represents a difference Np_err, between first signal 32 and second signal 34 in rpm.
[0017] Governor system 22 receives signal 34 and determines a fuel flow rate Wfd in pph/sec for engine 14 to operate the main rotor at the desired reference speed. A signal 38 representing fuel flow rate Wfd is then transmitted to an integrator 40 which integrates signal 38 and transmits a signal 42 to engine components (not shown), which respond to supply a desired fuel flow Wf in pph to engine 14 .
[0018] Engine 14 receives fuel at desired fuel flow Wf to operate at a power level to produce power turbine actual speed Np. More specifically, engine 14 operates in response to fuel flow Wf supplied to engine 14 to generate an amount of torque Q supplied to helicopter rotor system 46 .
[0019] Helicopter rotor system 46 operates in response to torque Q generated by engine 14 . Operation of helicopter rotor system is also affected by torque disturbances Qdmr induced to the main rotor and measured in ft-lbs., and other external disturbances. Sensors detect a power turbine (helicopter main rotor) speed Np (Nmr) and transmit a signal 50 representing the main rotor speed Np (Nmr) to the helicopter control system. An additional signal 34 representing a power turbine actual speed Np Is transmitted to comparator 30 . Based on speed error signal Np_err 36 , Np governor 24 attenuates the main rotor response and other external disturbance to maintain desired or reference speed Np ref 32 .
[0020] [0020]FIG. 3 is a flow diagram illustrating a process used to estimate governor dynamics Knp for a gas turbine engine governor (not shown) installed within a helicopter (not shown). FIG. 4 is a block diagram 102 illustrating a general feedback system framework 104 . A first step of the process used in estimating governor dynamics Knp is to identify 108 the system input signals and output signals of governing system 22 (shown in FIG. 2) for gas turbine engine 14 (shown in FIG. 2). After the governing system parameters are identified 108 , governing system 22 is transformed 110 into general feedback system framework 104 .
[0021] Specifically, commands u, measurements y, regulated signals z, and disturbances w, are identified 108 within governing system 22 . In the exemplary embodiment, signal u represents a fuel flow rate Wfd measured in pph/sec, and signal y represents a difference between a power turbine reference speed Np_ref, measured in rpm, and a power turbine actual speed Np, measured in rpm. Furthermore, regulated signal z represents power turbine speed Np, measured in rpm, and disturbances w include power turbine reference speed Np_ref, measured in rpm, and torque disturbances Qmdr induced to the helicopter main rotor and measured in ft-lbs. General feedback system framework 108 uses either open-loop or closed-loop operations to obtain transfer functions and time responses as functions of governor dynamics Knp.
[0022] The process used in estimating governor dynamics Knp then specifies 120 system performance requirements and stability robustness constraints, specifies 122 a structure of governor dynamics Knp, and characterizes 124 constraints of governor dynamics Knp. Specifically, system performance requirements are characterized 124 by the open loop transfer functions, closed-loop transfer functions, time responses, or other dynamic restraints. For example, the main rotor torque disturbance rejection level is characterized 124 by a closed-loop transfer function, or its step response, from Qdmr to Np, and the system bandwidth is specified by the closed-loop transfer function from Np ref to Np_.
[0023] Stability constraints are characterized 124 by open-loop transfer functions. For example, the open-loop transfer function from Np_err to Np describes system gain margin and phase margin constraints. Furthermore, governor dynamics, Knp, are characterized 124 with a series of general second-order systems. More specifically, the governor dynamics can be specified 122 such that governor constraints are characterized 124 by natural frequencies and damping factors.
[0024] A multiple objective optimization problem for the governor dynamics Knp is then formulated 130 and solved 132 . Specifically, the optimization problem, as a function of the governor dynamics Knp, is formulated 130 based on the performance requirements, stability constraints, governor structure selection, and governor structure. Then multiple objective optimization algorithms are used to solve 132 the problem, and governor dynamics Knp are obtained.
[0025] One advantage of this invention is that the method facilitates obtaining stabilizing governor dynamics for multiple plants with different characteristics. For example, this method can be used to obtain a governor that can ensure the stability of helicopter engine control system during the transition from a coupled plant to a decoupled plant or vice-versa. A coupled plant refers to the plant when the helicopter rotor is clutched to the engine. A decoupled plant refers to the plant when the helicopter rotor is declutched from the engine, such as during autorotation maneuvers. The dynamics of these two plants have totally different characteristics.
[0026] In an exemplary embodiment, a normalized linear model for a specific turboshaft engine and a specific helicopter rotor system and other important dynamics is identified 108 and transformed 110 into general feedback system by
w=[Np 13 ref Qdmr], u=Wfd, z=Np, and y=Np 13 ref−Np.
[0027] defining:
[0028] Step 1: Select the structure of the governing dynamics Np.
[0029] Step 2: Specify the system performance requirements and stability constraints.
[0030] Step 3: Solve the multiple objective optimization problem for the governor dynamics Knp.
[0031] From FIGS. 2 and 4, the set of achievable stable closed loop
{ G cl ( K np )= G zw +G zu K np ( I−G yu K np ) −1 G yw |stabilizing K np }
[0032] transfer functions is given by the following:
[0033] For example, the Np governor structure may be chosen as a fourth general 2 nd -order
Knp ( s ) = gn * ∏ i = 1 4 { ( s wn i ) 2 + 2 * zn i wn i + 1 ( s wd i ) 2 + 2 * zd i wd i s + 1 }
[0034] system in series as:
[0035] Wherein, gn represents the governor gain, wn and wd are natural frequencies, and zd and zn are damping factors. Those parameters will be obtained by solving the optimization problem. The optimization problem then can be defined by the performance, stability requirements, and constraints on governor dynamics Knp itself. Performance and disturbance rejection capability may be characterized using the above-defined set of the closed loop transfer functions, or through a closed loop step or ramp response in time domain. The stability margins may be characterized by the open loop transfer functions. For example, the stability margins may be characterized by the open loop transfer function from Np_err to Np. The governor natural frequencies and damping factors can also be formulated as constraints. For example, a multiple objective governor design may be formulated from open loop transfer functions, closed loop transfer functions, or directly from governor structure:
[0036] open loop gain margin>6.0 dB
[0037] open loop phase margin>50.0 deg
[0038] open loop gain at main rotor frequency<−9.0 dB
[0039] open loop gain at tail rotor frequency<−9.0 dB
[0040] governor damping factor zd>0.60
[0041] The optimization objective function is chosen to maximize the load disturbance rejection capability, which may be formulated to minimize the step response of the closed loop transfer function from main rotor torque Qdmr to Np.
[0042] [0042]FIG. 5 is an exemplary Bode plot illustrating open loop dynamics for coupled and uncoupled plants. FIG. 6 is an exemplary Bode plot illustrating open loop transfer functions for coupled and uncoupled plants. To further illustrate the design method, consider an exemplary governor design problem for a helicopter rotor and engine transitioning between coupling and decoupling situations. The two drastically different open loop dynamics from Np_err to Np, the coupled plant and the decoupled plant, are illustrated in FIG. 5.
[0043] The governor design problem is formulated as the following multiple objective optimization problem:
[0044] Max: Bandwidth of open loop transfer function from Np_ref to Np for both Coupled and decoupled systems
[0045] Subject to:
[0046] open loop gain margins>6.0 dB for both coupled and decoupled plants
[0047] open loop phase margin>50.0 deg for both coupled and decoupled plants
[0048] open loop gain at main rotor frequency<−15.0 dB for the coupled plant
[0049] open loop gain at tail rotor frequency<−15.0 dB for the coupled plant
[0050] governor damping factor zd>0.60
[0051] After solving this optimization problem with any available optimization solver, the governor dynamics Knp can be obtained. The resulting open loop transfer functions are illustrated in FIG. 6.
[0052] The above described process for estimating Np governor dynamics utilizes both the system responsiveness and the system stability robustness in determining the governor dynamics. As a result, the process facilitates generating a more accurate definition of the governor dynamics than other known design processes. Furthermore, because the process characterizes system responsiveness and the system stability robustness in open loop and closed-loop transfer functions in frequency-domain and in time-domain, the estimate process is applicable with substantially all flight conditions. In addition, because multiple optimization algorithms are solvable, the process is applicable to a plurality of governor designs or servo-loop designs. As a result, the design process accounts for system performance and robustness to provide governor dynamics estimates that facilitate improved governor design.
[0053] While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.
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An apparatus estimates governor dynamics for a gas turbine engine used in a system. The apparatus is programmed to obtain a first set of parameters from a governing sub-system coupled to the system, obtain a second set of parameters from the governing sub-system, and generate governor dynamics estimates by utilizing the first and second sets of parameter outputs to solve a multiple objective optimization algorithm problem.
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TECHNICAL FIELD
[0001] The disclosure relates to a valve device. More specifically, the disclosure relates to a valve device provided with a back-flow prevention mechanism.
BACKGROUND ART
[0002] Patent Literature 1 discloses a valve device (1) including a valve body (30) for opening and closing outflow holes (13a, 13b) for fluid.
CITATION LIST
Patent Literature
[0003] [Patent Literature 1] Japanese Patent Laid-Open No. 2007-144468
SUMMARY OF THE DISCLOSURE
Technical Problem
[0004] A valve device has been generally known in which a valve body such as a slide valve is provided at an outflow hole for fluid and a flow passage is closed and opened by displacing the valve body. When a gap space is existed between contact faces of the valve body with the outflow hole, fluid may be leaked from the gap space. Therefore, in a case that the flow passage is closed, the valve body is required to closely contacted with the outflow hole over its entire periphery. As a method for closely contacting a valve body with an outflow hole, it is conceivable that a valve body is urged to the outflow hole side by an elastic member such as a plate spring or a coiled spring. In this case, when the elastic member presses the valve body more than required, an opening and closing operation of the valve body may be obstructed and thus an urging force of the elastic member is set so that the valve body is not floated from the contact face.
[0005] On the other hand, in a case that the fluid flowed out from the valve device is flowed backward by some cause, when a pressure of the fluid flowed backward is larger than an urging force of the elastic member, the valve body is pressed together with the elastic member and a gap space is generated between the contact faces of the valve body with the outflow hole. The fluid flowed backward is entered into the inside of the valve device through the gap space and, in addition, the fluid is flowed out through the inflow hole to the outside of the valve device. Further, in a case that the elastic member is bent beyond the yield point by being pressed by the fluid flowed backward, it may be occurred that the elastic member is damaged or plastically deformed, and a flow amount of the valve device may be unable to be controlled.
[0006] In view of the problem described above, the disclosure provides a valve device capable of reducing an entering amount of fluid which is flowed backward into an inside of the valve device and reducing a flowing-out amount through the inflow hole even when back-flow of the fluid is generated by some cause and, in addition, preventing damage of an elastic member configured to urge a valve body.
Means to Solve the Problems
[0007] To solve the above-mentioned problem, the disclosure provides a valve device including a drive source, a base having a valve seat face formed with an inflow hole and an outflow hole for fluid, a case body which is placed on a valve seat face side of the base to section a valve chamber together with the base, a first valve body configured to open and close the outflow hole, and a second valve body configured to open and close the inflow hole. An output part of the drive source, the first valve body and the second valve body are accommodated in the valve chamber, and the first valve body is a substantially columnar-shaped member whose one end face slides on a peripheral edge part of the outflow hole of the valve seat face. In addition, the first valve body is turned by driving force of the drive source to be switched between a state that the outflow hole is closed and a state that the whole or a part of the outflow hole is opened.
[0008] According to this structure, the first valve body is provided for an outflow hole and, in addition, the second valve body is provided for an inflow hole. Therefore, even in a case that fluid flowed backward pushes up the first valve body and enters into a valve chamber, the fluid flowed backward is kept in the valve chamber by closing the inflow hole by the second valve body and the fluid can be prevented from being flowed backward to the outside of the valve device through the inflow hole.
[0009] Further, it may be structured that the valve chamber further accommodates an elastic member which urges the first valve body, and the first valve body is urged to an outflow hole side by the elastic member and is pressed against the peripheral edge part of the outflow hole.
[0010] In a case that the first valve body is urged and pressed by an elastic member to the outflow hole side, the first valve body is closely contacted with the outflow hole and adjustment accuracy of a flow amount by the valve device is improved. Further, a fluid amount itself which can be flowed backward to the valve chamber is restricted by closing the inflow hole by the second valve body and thus influence on the elastic member due to the first valve body being pushed up is also reduced.
[0011] Further, it may be structured that the second valve body is a substantially columnar-shaped member whose one end face slides on a peripheral edge part of the inflow hole of the valve seat face, and the second valve body is turned by driving force of the drive source to be switched between a state that the inflow hole is closed and a state that the whole or a part of the inflow hole is opened.
[0012] In this case, it is desirably structured that the drive source is a stepping motor, an output part of the drive source is a rotor and a rotor pinion of the stepping motor, the first valve body and the second valve body are structured of common components, outer peripheral faces of the first valve body and the second valve body are formed with teeth parts engaged with the rotor pinion and, when the rotor pinion is rotated, the first valve body and the second valve body are turned in the same direction.
[0013] In a case that the second valve body using a common component to the first valve body is provided on the inflow hole side and its driving method is common, an opening and closing mechanism of the inflow hole and the outflow hole is simplified and efficiency of component management can be attained. In addition, flow amount control for the inflow hole can be performed with the same degree of accuracy as the flow amount control for the outflow hole and thus backflow prevention performance of the valve device is improved.
[0014] Further, it may be structured that combinations of opening and closing states of the inflow hole and the outflow hole by the first valve body and the second valve body includes a combination of a closed state of the inflow hole and an open state of the outflow hole simultaneously.
[0015] In a case that the first valve body is intentionally set in an open state when fluid is flowed backward, the elastic member can be prevented from being plastically deformed due to the first valve body being pushed up by the fluid which is flowed backward. However, this structure is effective only when a timing of back-flow is recognized in advance.
[0016] Further, it may be structured that the valve device is disposed inside a housing of a refrigerator, and the fluid is refrigerant of the refrigerator.
[0017] Even when pressure of refrigerant on the outlet side becomes high by some cause due to a variation of the pressure caused by liquefaction and vaporization of the refrigerant circulating through the refrigerator, the back-flow of the refrigerant is prevented by the refrigerant valve in accordance with the disclosure.
Effects of the Disclosure
[0018] According to the valve device in accordance with the disclosure, the valve device can be provided which is capable of reducing an entering amount of fluid flowed backward into an inside of the valve device and a flowing-out amount through the inflow hole even when back-flow of the fluid is generated and, in addition, preventing damage of an elastic member configured to urge a valve body.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIGS. 1( a ) and 1( b ) are perspective views showing a refrigerant valve device in accordance with an embodiment of the disclosure.
[0020] FIG. 2 is a bottom view showing a refrigerant valve device.
[0021] FIG. 3 is the “X-X” line cross-sectional view showing a refrigerant valve device in FIG. 2 .
[0022] FIG. 4 is a perspective view showing a valve body drive mechanism.
[0023] FIGS. 5( a ) and 5( b ) are exploded perspective views showing valve body drive mechanisms which are viewed from an upper side and a lower side.
[0024] FIG. 6 is a cross-sectional view showing a flow passage communicating state of a valve body.
[0025] FIGS. 7( a ) and 7( b ) are cross-sectional views showing a refrigerant flow passage in a refrigerant valve device.
[0026] FIG. 8 is a cross-sectional view showing another combination of opening and closing states of valve bodies.
DESCRIPTION OF EMBODIMENTS
(Entire Structure)
[0027] A refrigerant valve device which is an embodiment of a valve device in accordance with the disclosure will be described in detail below with reference to the accompanying drawings. FIGS. 1( a ) and 1( b ) are perspective views showing a refrigerant valve device 1 in accordance with an embodiment of the disclosure. A refrigerant valve device 1 is disposed between a compressor and a cooler in a refrigerant flow passage in an inside of a refrigerator, and a supply amount of refrigerant for cooling the inside of the refrigerator is regulated.
[0028] The refrigerant valve device 1 includes a valve main body 2 , an inflow pipe 3 through which refrigerant that is fluid is flowed into the valve main body 2 , an outflow pipe 4 through which the refrigerant is flowed out from the valve main body 2 , a connector 5 configured to secure an electric connection with an external control device, and an attaching plate 6 configured to attach the refrigerant valve device 1 to an inside of the refrigerator. In the following descriptions, for convenience, extending directions of the inflow pipe 3 and the outflow pipe 4 are referred to as an upper and lower direction, the valve main body 2 is disposed on an upper side and the inflow pipe 3 and the outflow pipe 4 are disposed on a lower side.
[0029] FIG. 2 is a view showing the refrigerant valve device 1 which is viewed from a side of the inflow pipe 3 and the outflow pipe 4 . An under face of a base 10 in a disk shape is exposed in a bottom face of the valve main body 2 . A valve seat 15 a and a valve seat 15 b are fitted to the base 10 . The outflow pipe 4 is connected with a refrigerant outlet port 22 of the valve seat 15 a and the inflow pipe 3 is connected with a refrigerant inlet port 12 of the valve seat 15 b respectively.
[0030] FIG. 3 is a cross-sectional view showing the refrigerant valve device 1 which is cut by the “X-X” line in FIG. 2 . As shown in FIG. 3 , the valve main body 2 includes the base 10 and a sealing cover 11 which is a cup-shaped case body and is placed so as to cover the base 10 from an upper side with its opening facing a lower side. The sealing cover 11 is, from an upper side to a lower side, provided with a circular bottom part 31 , a small diameter tube part 32 which is extended from an outer circumferential edge of the bottom part 31 to a lower side, a large diameter tube part 33 having a diameter larger than the small diameter tube part 32 , and a case side flange 34 which is enlarged from a lower end edge (opening edge) of the large diameter tube part 33 toward an outer peripheral side. A ring-shaped part 35 which is extended in a direction intersecting the center axial line “L 0 ” of the base 10 is provided between the small diameter tube part 32 and the large diameter tube part 33 so as to connect the small diameter tube part 32 with the large diameter tube part 33 . An outer circumferential edge of the base 10 is formed with a ring-shaped base side flange 16 whose plate thickness is made thin by lowering its upper face. The sealing cover 11 is fixed to the base 10 in a state that an upper side portion of the base 10 is inserted into an inner side of a lower end opening edge of the large diameter tube part 33 and the case side flange 34 is abutted with the base side flange 16 from an upper side. The base 10 is covered by the sealing cover 11 to section a valve chamber 36 together with the base 10 .
[0031] The valve main body 2 is structured with a stepping motor 60 as a drive source by utilizing an inside and an outside of the sealing cover 11 . A rotor 61 and a rotor pinion 50 which are output parts of the stepping motor 60 are disposed inside the valve chamber 36 . The rotor 61 is rotatably supported by a rotor support shaft 62 whose upper end is fixed to the bottom part 31 of the sealing cover 11 and its lower end is fixed to a center of the base 10 . An axial line of the rotor support shaft 62 is coincided with the center axial line “L 0 ” of the base 10 and is extended in parallel with a support shaft 25 a and a support shaft 25 b which are attached to a valve seat 15 a and a valve seat 15 b. A ring-shaped drive magnet 63 is mounted on the rotor 61 .
[0032] A stator 64 of the stepping motor 60 is placed on the ring-shaped part 35 of the sealing cover 11 and is disposed on an outer peripheral side of the sealing cover 11 . The stator 64 is mounted with drive coils 65 . The drive coils 65 face the drive magnet 63 of the rotor 61 through the small diameter tube part 32 of the sealing cover 11 . The drive coil 65 is electrically connected with the connector 5 and the stepping motor 60 is driven and controlled by an external control device which is connected through the connector 5 . The stator 64 and the connector 5 are accommodated on an inner side of an outer case 46 .
[0033] (Valve Body Drive Mechanism)
[0034] FIG. 4 is a perspective view showing a valve body drive mechanism. FIG. 5( a ) is an exploded perspective view showing a principal part of the valve body drive mechanism which is viewed from an upper side, and FIG. 5( b ) is its exploded perspective view which is viewed from a lower side. As shown in FIG. 4 and FIGS. 5( a ) and 5( b ) , the valve body drive mechanism of the refrigerant valve device 1 in this embodiment includes a rotor 61 of the stepping motor 60 which is a drive source, a first valve body 20 a provided on its outer peripheral face with a teeth part 59 a which is engaged with a rotor pinion 50 provided in a pinion structure member 54 of the rotor 61 , a valve seat 15 a which is located on a lower side of the first valve body 20 a and is provided with a valve seat face 24 a on which a bottom face of the first valve body 20 a is slid, a second valve body 20 b which is provided with a teeth part 59 b engaged with the rotor pinion 50 on its outer peripheral face, and a valve seat 15 b which is located on a lower side of the second valve body 20 b and is provided with a valve seat face 24 b on which a bottom face of the second valve body 20 b is slid.
[0035] The first valve body 20 a and the valve seat 15 a, and the second valve body 20 b and the valve seat 15 b are structured by using common components and the stepping motor 60 which is a drive source is also used in common. As a result, in comparison with a case that another valve body having a different structure is prepared as the second valve body 20 b, an opening and closing mechanism of the refrigerant inlet port 12 and the refrigerant outlet port 22 is simplified and efficiency of the component management can be enhanced. Further, structures of the first valve body 20 a and the valve seat 15 a in the following descriptions are also naturally provided in the structures of the second valve body 20 b and the valve seat 15 b.
[0036] The base 10 is formed with a valve seat attaching hole 14 a to which the valve seat 15 a is fitted and a valve seat attaching hole 14 b to which the valve seat 15 b is fitted. Planar shapes of the valve seat 15 a and the valve seat 15 b are circular when viewed in axial line directions and their upper faces are formed to be the valve seat faces 24 a and 24 b which are flat. The refrigerant outlet port 22 which is an outflow hole of the refrigerant is formed at a position displaced from the center axial line “L 1 ” of the valve seat 15 a, and the refrigerant inlet port 12 which is an inflow hole of the refrigerant is formed in the valve seat 15 b at a position substantially symmetric to the refrigerant outlet port 22 with the center axial line “L 0 ” as a center. The valve seat faces 24 a and 24 b structure a part of an upper face of the base 10 .
[0037] The first valve body 20 a is a substantially columnar-shaped member whose one end face slides on a peripheral edge part of the refrigerant outlet port 22 of the valve seat face 24 a. When the first valve body 20 a is turned by driving force of the stepping motor 60 , a state that the refrigerant outlet port 22 is closed and a state that the whole or a part of the refrigerant outlet port 22 is opened are switched from each other. The first valve body 20 a is formed of a gear part 51 a which is a turning member provided with a teeth part 59 a, and a valve part 27 a which is located on a lower side of the gear part 51 a and is fixed to the gear part 51 a in a state that its end face and the end face of the gear part 51 a in the axial line direction are contacted with each other, and is integrally turned with the gear part 51 a.
[0038] A bottom face of the valve part 27 a and the valve seat face 24 a are polished to be flat faces and can be closely contacted with each other without a gap space, and the refrigerant is prevented from leaking from a gap space between the sliding faces.
[0039] As shown in FIGS. 5( a ) and 5( b ) , a projecting part 511 a is provided which protrudes to an outer side in a radial direction at one position in a circumferential direction of the gear part 51 a. The projecting part 511 a is abutted with an abutted part 55 of the pinion structure member 54 from one side or the other side around the axial line “L 1 ” when the gear part 51 a is turned and reached to a predetermined angular position to restrict a turnable range of the gear part 51 a.
[0040] An opposed face of the gear part 51 a to the valve part 27 a is formed with protruded parts 61 a, 62 a and 63 a protruded to the valve part 27 a side at equal intervals in the circumferential direction, and an opposed face of the valve part 27 a to the gear part 51 a is formed with recessed parts 70 a, 71 a and 72 a to which the protruded parts 61 a, 62 a and 63 a are fitted. The recessed part 72 a is a through-hole penetrated to a cut-out part 79 a and the protruded part 63 a fitted to the recessed part 72 a is caulked on the cut-out part 79 a side. When the protruded part 63 a is caulked, the gear part 51 a is fixed to the valve part 27 a without looseness and thus turning of the valve part 27 a can be controlled by the stepping motor 60 with a high degree of accuracy. Further, calking work is performed on the protruded part 63 a which is fitted to the recessed part 72 a provided in the cut-out part 79 a and thus scratches and deformation of the polished bottom face of the valve part 27 a are prevented.
[0041] The cut-out part 79 a and the cut-out part 79 b in this embodiment are, similarly to the forming positions of the refrigerant outlet port 22 and the refrigerant inlet port 12 , disposed at substantially symmetrical positions with the center axial line “L 0 ” as a center. Therefore, when the stepping motor 60 is rotated, the refrigerant outlet port 22 and the refrigerant inlet port 12 are simultaneously opened and closed.
[0042] A support plate 17 which is a plate-shaped member whose upper face is substantially circular is disposed to an upper side of the first valve body 20 a and the second valve body 20 b. Two arm parts 171 and 172 which are elastic members are formed at symmetrical positions in a circumferential direction of the support plate 17 by cutting-out work. The arm parts 171 and 172 are extended along the circumferential direction of the support plate 17 , and portions except their base end parts are separated from the support plate 17 to be elastically deformable in the upper and lower direction. Tip end parts of the arm parts 171 and 172 are formed in a little bulged circular shape. The support shafts 25 a and 25 b are respectively inserted into holes provided in their tip end parts and fix the positions of the support shafts 25 a and 25 b together with the valve seats 15 a and 15 b. In addition, the tip end parts are abutted with and urge upper faces of the first valve body 20 a and the second valve body 20 b and, as a result, the first valve body 20 a is pressed against a peripheral edge part of the refrigerant outlet port 22 and the second valve body 20 b is pressed against a peripheral edge part of the refrigerant inlet port 12 .
[0043] FIG. 6 is a cross-sectional view showing a state that the refrigerant outlet port 22 is opened by overlapping the cut-out part 79 a of the valve part 27 a with the refrigerant outlet port 22 in the axial line “L 1 ” direction, and a state that the refrigerant inlet port 12 is opened by overlapping the cut-out part 79 b of the valve part 27 b with the refrigerant inlet port 12 in the axial line “L 1 ” direction.
(Opening and Closing Operations of Valve Body)
[0044] As described above, the first valve body 20 a and the second valve body 20 b are structured of common components and the drive source is also used in common. Therefore, when the rotor 61 and the rotor pinion 50 are rotated by a certain amount, the first valve body 20 a and the second valve body 20 b are turned by the same angle in the same direction. In this embodiment, the first valve body 20 a and the second valve body 20 b are structured of common components and thus their turning angles are the same. However, when the number of teeth of the gear part 51 a or the gear part 51 b structuring the valve body is changed, the turning angles of the valve bodies with respect to a rotation amount of the rotor pinion 50 can be made different from each other.
[0045] As shown in FIG. 7( a ) , when a flow passage of the refrigerant is to be communicated with each other, the stepping motor 60 is rotated to an angle at which both the first valve body 20 a and the second valve body 20 b are set in open states. As a result, the refrigerant moves upward through the inflow pipe 3 , flows from the refrigerant inlet port 12 into the valve chamber 36 , spreads out inside the valve chamber 36 in a horizontal direction, flows out from the refrigerant outlet port 22 , and moves downward through the outflow pipe 4 .
[0046] On the other hand, when the flow passage of the refrigerant is to be closed, as shown in FIG. 7( b ) , the stepping motor 60 is rotated to an angle at which both the first valve body 20 a and the second valve body 20 b are set in closed states. In this case, even when the refrigerant flows backward (moves upward through the outflow pipe 4 ) due to a variation of pressure and the like caused by liquefaction and vaporization of the refrigerant circulating through the refrigerator and the refrigerant flowed backward pushes up the first valve body 20 a and enters the valve chamber 36 from the refrigerant outlet port 22 , the refrigerant inlet port 12 is closed by the second valve body 20 b. Therefore, the refrigerant entered into the valve chamber 36 is prevented from being flowed out through the refrigerant inlet port 12 to the outside of the refrigerant valve device 1 .
[0047] Further, the refrigerant inlet port 12 is closed by the second valve body 20 b which is structured of the same member as the first valve body 20 a used in the refrigerant outlet port 22 . Therefore, entering of the refrigerant to the refrigerant inlet port 12 can be prevented with the same degree of closed accuracy as a normal flow control.
[0048] In addition, the refrigerant inlet port 12 is closed and thus the valve chamber 36 becomes a sealed space. Therefore, an amount of the refrigerant which is capable of flowing into the valve chamber 36 is small. Accordingly, a resiliently bent amount of the arm part 171 caused by the first valve body 20 a moved upward is restrained and possibility of damage and plastic deformation of the arm part 171 is reduced.
[0049] Combinations of opening and closing states of the refrigerant inlet port 12 and the refrigerant outlet port 22 in this embodiment are only two of both open states and both closed states because the cut-out parts 79 a and 79 b of the first valve body 20 a and the second valve body 20 b are located at substantially symmetrical positions with the center axial line “L 0 ” as a center. However, as shown in FIG. 8 , a combination of an open state of the first valve body 20 a and a closed state of the second valve body 20 b can be attained by changing a disposing angle of the valve part 27 a or the valve part 27 b, or by changing the number of teeth of the gear part 51 a or the gear part 51 b as described above to make a difference between turning angles of the first valve body 20 a and the second valve body 20 b with respect to a rotation amount of the rotor pinion 50 .
[0050] In a case that a timing when the refrigerant is flowed backward is recognized in advance, it may be structured that the first valve body 20 a is intentionally opened according to the back-flow. In this case, when the opening and closing states are set as described above, the first valve body 20 a is prevented from being pushed upward by the refrigerant flowed backward and thus damage and plastic deformation of the arm part 171 can be prevented beforehand.
[0051] Although the disclosure has been shown and described with reference to a specific embodiment, the disclosure is not limited to the embodiment described above and various changes and modifications will be apparent to those skilled in the art from the teachings herein.
REFERENCE SIGNS LIST
[0052] 1 refrigerant valve device
[0053] 2 valve main body
[0054] 3 inflow pipe
[0055] 4 outflow pipe
[0056] 5 connector
[0057] 6 attaching plate
[0058] 10 base
[0059] 11 sealing cover
[0060] 12 refrigerant inlet port
[0061] 22 refrigerant outlet port
[0062] 60 stepping motor
[0063] 61 rotor
[0064] 50 rotor pinion
[0065] 36 valve chamber
[0066] 20 a first valve body
[0067] 20 b second valve body
[0068] 51 a, 51 b gear part
[0069] 27 a, 27 b valve part
[0070] 15 a, 15 b valve seat
[0071] 24 a, 24 b valve seat face
[0072] 17 support plate
[0073] 171 , 172 arm part
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A valve device including: a drive source; a base having a valve seat surface in which a fluid inflow hole and outflow hole are formed; a case body covering the valve seat surface-side of the base, and a valve chamber together with the base; a first valve body for opening and closing the outflow hole; and a second valve body for opening and closing the inflow hole is provided. The output part of the drive source, the first and second valve bodies are housed in the valve chamber. The first valve body is a substantially cylindrical member, one end surface of which is in sliding contact with the peripheral edge of the outflow hole in the valve seat surface, receives the driving force of the drive source and pivots such that the outflow hole is switched between a closed state and a fully or partially opened state.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to and the benefit of, and incorporates herein by reference in its entirety, U.S. Provisional Patent Application No. 61/376,811, which was filed on Aug. 25, 2010.
FIELD OF THE INVENTION
[0002] This invention relates generally to preventing the formation of hydrates in oil and gas pipelines. More particularly, in certain embodiments, the invention relates to articles and methods for reducing the adhesive strength between a hydrate and the interior surface of a deep sea pipeline or portions thereof.
BACKGROUND OF THE INVENTION
[0003] The most recent world energy outlook predicts that energy demand in 2035 will be 36% higher than in 2008. The oil and gas industry is looking at ultra deep-sea exploration as a next frontier for meeting these increasing global energy needs. However, many challenges need to be overcome before drilling and production at greater depths becomes economical. One pressing challenge is the formation of natural gas hydrates in oil and gas pipelines.
[0004] Hydrates are crystalline structures consisting of a lattice of cages of water molecules that entrap hydrocarbon molecules at elevated pressures and low temperatures. Hydrates can plug oil lines, forcing operations to stop until they are removed, and in some extreme events, can pose safety issues by forming a projectile within the line if subjected to large differential pressures. Recently, hydrates were a key reason for the failure of the containment box approach to oil recovery after the 2010 Gulf spill as they clogged the opening of the box near the sea floor and prevented oil from being siphoned to boats on the surface.
[0005] Current methods for hydrate mitigation focus on using chemicals to shift the equilibrium hydrate formation curve to higher pressures and lower temperatures, using kinetic inhibitors to slow the growth of hydrates, and insulating or heating the pipeline walls. The costs associated with these methods and with lost oil and gas production due to hydrate plugging can run into billions of dollars (more than $200 M USD is spent annually on hydrate inhibiting chemicals alone). Furthermore, these currently employed methods are energy intensive and environmentally unfriendly, and alternative approaches to reduce hydrate adhesion are of great interest.
[0006] There is a need for articles and methods that prevent the formation and accumulation of hydrates in oil and gas pipelines.
SUMMARY OF THE INVENTION
[0007] The articles, devices, and methods presented herein provide effective methods of gas hydrate mitigation in deep-sea drilling applications. In certain embodiments, hydrate-phobic surfaces are provided that ensure passive enhancement of flow assurance and prevention of catastrophic failures in deep-sea oil and gas operations.
[0008] In one aspect, the invention relates to an article for use in a deep sea oil and/or gas recovery operation, the article comprising a surface having receding contact angle of water, θ rec , of no less than 70°. In certain embodiments, the article is an underwater pipeline. In certain embodiments, the surface comprises a fluoropolymer, for example, a silsesquioxane such as fluorodecyl polyhedral oligomeric silsesquioxane. In certain embodiments, the fluoropolymer is tetrafluoroethylene (ETFE), fluorinated ethylene-propylene copolymer (FEP), polyvinylidene fluoride (PVDF), perfluoroalkoxy-tetrafluoroethylene copolymer (PFA), polytetrafluoroethylene (PTFE), tetrafluoroethylene, perfluoromethylvinylether copolymer (MFA), ethylene-chlorotrifluoroethylene copolymer (ECTFE), ethylene-tetrafluoroethylene copolymer (ETFE), perfluoropolyether, or Tecnoflon.
[0009] In preferred embodiments, the surface has receding contact angle of water, θ rec , of no less than 90°. In further preferred embodiments, the surface has receding contact angle of water, θ rec , of no less than 100°, or no less than 110°.
[0010] In another aspect, the invention relates to an article for use in a deep sea oil and/or gas recovery operation, the article having a surface comprising fluorodecyl polyhedral oligomeric silsesquioxane.
[0011] In certain embodiments, the surface is a coating. In certain embodiments, the surface is a hydrate-phobic surface that inhibits hydrate adhesion thereupon. The hydrate-phobic surface may be advantageously located on an interior wall of a pipeline extending a distance from a valve in a direction of flow through the pipeline. For example, the hydrate-phobic surface may extend at least three meters from a valve in the direction of flow. The valve may be located at a Christmas tree of an offshore system.
[0012] In certain embodiments, the hydrate-phobic surface is located on an interior wall of a pipeline: (i) extending a first distance along and/or beyond a restriction in a direction of flow through the pipeline; (ii) extending along a fuel gas line in a direction of flow through the pipeline; (iii) extending along an instrument gas line in a direction of flow through the pipeline; (iv) extending a second distance along and/or beyond a valve within a fuel gas line in a direction of flow; (v) a third distance along and/or beyond a valve within an instrument gas line in a direction of flow; (vi) extending a fourth distance along and/or beyond a location of flow-line water accumulation in a direction of flow through the pipeline; (vii) extending a fifth distance along and/or beyond a flow-line low spot in a direction of flow through the pipeline; (viii) extending a sixth distance along and/or beyond a riser in a direction of flow through the pipeline; (ix) extending a seventh distance along and/or beyond a bend in the pipeline in a direction of flow through the pipeline; and/or (x) extending an eighth distance along and/or beyond a change in topography of ocean flow traversed by the pipeline. In certain embodiments, one or more of the first through eighth distance is at least three meters. In certain embodiments, one or more of the first through eighth distances is at least five meters.
[0013] In certain embodiments, the hydrate-phobic surface is located on or about a manifold of an offshore system. In certain embodiments, the hydrate-phobic surface is located on or about a sensor embedded in a pipeline of an offshore system.
[0014] In another aspect, the invention relates to an article for use in a deep sea oil and/or gas recovery operation, the article comprising a surface having a lattice parameter within a range from 2 Å to 2.24 Å, from 3 Å to 3.36 Å, from 4 Å to 4.48 Å, or from 6 Å to 6.72 Å, thereby promoting a lattice mismatch with a clathrate hydrate layer growing thereupon and inhibiting adhesion of the clathrate hydrate to the surface. In certain embodiments, the article is an underwater pipeline.
[0015] In certain embodiments, the surface has a lattice parameter within a range from 2 Å to 2.24 Å and comprises a member selected from the group consisting of beryllium and Br 2 Ni.
[0016] In certain embodiments, the surface has a lattice parameter within a range from 3 Å to 3.36 Å and comprises a member selected from the group consisting of Cronstedtite, Silicon carbide (SiC), Iowaite, Brucite, Fe(OH) 2 (“white-rust”), Zaccagnaite, Moissanite (SiC), CaIrO 3 , Dyscrasite, Zincite, Potarite, Tungsten, Pyrochroite, Co(OD) 2 , CaPtO 3 , B2Mo, Palladinite, Scandium, Lithium, Ni 7 S 6 , Molybdenite, Theophrastite, Ag 0.6 NbS 2 , cesium, silicon, TaS 2 , CoH 2 O 2 , Koenenite, Hafnium, Magnesium, Scandium, Zirconium, Molybdenum, Nobium, Tantalum, titanium, vanadium, phosphorus, manganese-delta, AlN, GaN, NbN, TaN, TiS, VP, VS, MoB, WB, Ti 2 CS, TaP, Li 2 O 2 , Amakinite, Antimony, CuO 2 Rh, Ti 3 SiC 2 , CaFe 3 O 5 , CaFe 4 O 6 , CaFe 5 O 7 , LiFeSnO 4 , Li 0.7 Fe 0.375 Sn 0.54 O 2 , Tungstenite, Jamborite (NiOH), N, Nb 2 , Theophrastite (NiO), and Montroseite (FeVOHO 2 ).
[0017] In certain embodiments, the surface has a lattice parameter within a range from 4 Å to 4.48 Å and comprises a member selected from the group consisting of Periclase (MgO), Heazlewoodite (NiS), Stishovite (SiO), Stibarsen, vulcanite, Magnesite, Diaspore, Magnesiowustite (MgFeO), SiO 2 , GeO 2 , and FeB.
[0018] In certain embodiments, the surface has a lattice parameter within a range from 6Å to 6.72 Å.
[0019] In certain preferred embodiments, the surface has a lattice parameter within a range from 2 Å to 2.12 Å, from 3 Å to 3.18 Å, from 4 Å to 4.24 Å, or from 6 Å to 6.36 Å.
[0020] In another aspect, the invention relates to an article for use in a deep sea oil and/or gas recovery operation, the article comprising a surface having a lattice mismatch E greater than zero and ≦0.15, wherein ε=(n*a s −a h )/a h , where a s is substrate (surface) lattice parameter, a h is hydrate lattice parameter, and n is a multiple of the lattice parameter of the substrate closest to that of the hydrate. In certain preferred embodiments, 0<ε≦0.05. In still more preferred embodiments, 0<ε≦0.005.
[0021] In certain embodiments, the surface comprises a member selected from the group consisting of beryllium, Br 2 Ni, Cronstedtite, Silicon carbide (SiC), Iowaite, Brucite, Fe(OH) 2 (“white-rust”), Zaccagnaite, Moissanite (SiC), CaIrO 3 , Dyscrasite, Zincite, Potarite, Tungsten, Pyrochroite, Co(OD) 2 , CaPtO 3 , B2Mo, Palladinite, Scandium, Lithium, Ni 7 S 6 , Molybdenite, Theophrastite, Ag 0.6 NbS 2 , cesium, silicon, TaS 2 , CoH 2 O 2 , Koenenite, Hafnium, Magnesium, Scandium, Zirconium, Molybdenum, Nobium, Tantalum, titanium, vanadium, phosphorus, manganese-delta, AlN, GaN, NbN, TaN, TiS, VP, VS, MoB, WB, Ti 2 CS, TaP, Li 2 O 2 , Amakinite, Antimony, CuO 2 Rh, Ti 3 SiC 2 , CaFe 3 O 5 , CaFe 4 O 6 , CaFe 5 O 7 , LiFeSnO 4 , Li 0.7 Fe 0.375 Sn 0.54 O 2 , Tungstenite, Jamborite (NiOH), N Nb 2 , Theophrastite (NiO), Montroseite (FeVOHO 2 ), Periclase (MgO), Heazlewoodite (NiS), Stishovite (SiO), Stibarsen, vulcanite, Magnesite, Diaspore, Magnesiowustite (MgFeO), SiO 2 , GeO 2 , FeB, Clausthalite, Altaite, Gudmundite, Celestine, Hafnon, Wadeite, Fe 2 C 9 O 9 , Xifengite, Cubanite, Galena, Jagowerite, Tolovkite, Qandilite, Florenskyite, Marshite, La 2 O 3 , Ce 2 O 3 , Pr 2 O 3 , ZrO 2 , rare earth stabilized zirconia, TiN, and CrN.
[0022] In certain preferred embodiments, one or more of the following holds: (i) 0<ε≦0.005, (ii) a s is from 4 Å to 4.02 Å, and/or (iii) the surface comprises a member selected from the group consisting of Krupkaite, Periclase (MgO), Paarite, Griceite, NdOBr, Moncheite (KMg 0.5 Cu 0.5 F 3 ), ZrO 2 , Cuprostibite, Moncheite, NdOCl, PuOCl, Mn 2 PrSi 2 , Litharge, BiOI, AgI, and Ba 0.156 Bi 0.844 O 1.422 .
[0023] In another aspect, the invention relates to a deep sea oil and/or gas recovery operation, the article having a surface comprising discrete nucleation sites thereupon, thereby promoting preferred hydrate nucleation at the discrete nucleation sites, a resulting defective interface at the surface, and reduced hydrate adhesion upon the surface. In certain embodiments, the surface has heterogeneous surface chemistry. For example, the surface may be patterned with discrete hydrophobic regions and discrete hydrophilic regions, with the hydrate preferentially nucleating and/or growing on either the hydrophobic regions or the hydrophilic regions. In certain embodiments, the surface is textured. In certain embodiments, the surface comprises micro-scale and/or nano-scale particles deposited thereupon (e.g., particles with average diameter less than about 50 nm, less than about 1000, or less than about 100 micrometers). In certain embodiments, the surface comprises sintered silica and/or porous anodized aluminum. In certain embodiments, the surface comprises fluorosilane.
[0024] In certain embodiments, the surface comprises micro-scale and/or nano-scale posts (e.g., posts having width less than about 100 micrometers). For example, the surface may comprise silicon posts, e.g., which have hydrophobic surfaces. In certain embodiments, the posts have walls that are hydrophobic and tops that are hydrophilic, thereby promoting preferred hydrate nucleation at the tops and resulting in air pockets between posts.
[0025] In another aspect, the invention relates to an article for use in a deep sea oil and/or gas recovery operation, the article comprising a surface having a surface energy with negative Lewis acid parameter.
[0026] In certain embodiments of any of the above aspects of the invention, the surface is a coating. In certain embodiments, the surface is a hydrate-phobic surface that inhibits hydrate adhesion thereupon. In certain embodiments, the hydrate-phobic surface is located on an interior wall of a pipeline extending a distance from a valve in a direction of flow through the pipeline. In certain embodiments, the hydrate-phobic surface extends at least three meters from a valve in the direction of flow. In certain embodiments, the valve is located at a Christmas tree of an offshore system.
[0027] In certain embodiments, the hydrate-phobic surface is located on an interior wall of a pipeline: (i) extending a first distance along and/or beyond a restriction in a direction of flow through the pipeline; (ii) extending along a fuel gas line in a direction of flow through the pipeline; (iii) extending along an instrument gas line in a direction of flow through the pipeline; (iv) extending a second distance along and/or beyond a valve within a fuel gas line in a direction of flow; (v) a third distance along and/or beyond a valve within an instrument gas line in a direction of flow; (vi) extending a fourth distance along and/or beyond a location of flow-line water accumulation in a direction of flow through the pipeline; (vii) extending a fifth distance along and/or beyond a flow-line low spot in a direction of flow through the pipeline; (viii) extending a sixth distance along and/or beyond a riser in a direction of flow through the pipeline; (ix) extending a seventh distance along and/or beyond a bend in the pipeline in a direction of flow through the pipeline; and/or (x) extending an eighth distance along and/or beyond a change in topography of ocean flow traversed by the pipeline. In certain embodiments, one or more of the first through eighth distance is at least three meters. In certain embodiments, one or more of the first through eighth distance is at least five meters.
[0028] In certain embodiments, the hydrate-phobic surface is located on or about a manifold of an offshore system. In certain embodiments, the hydrate-phobic surface is located on or about a sensor embedded in a pipeline of an offshore system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The objects and features of the invention can be better understood with reference to the drawings described below, and the claims. The drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention. In the drawings, like numerals are used to indicate like parts throughout the various views.
[0030] While the invention is particularly shown and described herein with reference to specific examples and specific embodiments, it should be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.
[0031] FIG. 1 includes a bar graph of advancing and receding contact angle measurements of DI water on various test substrates, and a bar graph of surface energies of each of the test substrates, according to an illustrative embodiment of the invention.
[0032] FIG. 2 is a plot of work of adhesion of liquid water versus the work of adhesion of ice, according to an illustrative embodiment of the invention.
[0033] FIG. 3 is a plot of hydrate adhesion strength versus the practical work of adhesion of a 19.1 wt. % THF in water solution, according to an illustrative embodiment of the invention.
[0034] FIG. 4 is a plot of hydrate adhesion strength versus the practical work of adhesion of liquid water, according to an illustrative embodiment of the invention.
[0035] FIG. 5 is a plot of measured hydrate adhesion strength for various substrates, according to an illustrative embodiment of the invention.
[0036] FIG. 6 is a schematic view of a lattice mismatch between a hydrate and a substrate, according to an illustrative embodiment of the invention.
[0037] FIG. 7 is a schematic drawing of an interface between a hydrate and a substrate, according to an illustrative embodiment of the invention.
[0038] FIG. 8 is a plot of hydrate adhesion strength versus lattice mismatch strain, according to an illustrative embodiment of the invention.
[0039] FIG. 9A is a schematic drawing of a hydrate-phobic surface (surface with inhibited hydrate adhesion thereto) with discrete preferential hydrate nucleation sites, according to an illustrative embodiment of the invention.
[0040] FIG. 9B is a schematic drawing of a hydrate-phobic surface patterned with hydrophobic and hydrophilic regions, according to an illustrative embodiment of the invention.
[0041] FIG. 9C is a schematic drawing of a hydrate-phobic surface patterned with posts deposited thereupon, the tops of which serve as preferential hydrate nucleation sites, according to an illustrative embodiment of the invention.
DETAILED DESCRIPTION
[0042] It is contemplated that compositions, mixtures, systems, devices, methods, and processes of the claimed invention encompass variations and adaptations developed using information from the embodiments described herein. Adaptation and/or modification of the compositions, mixtures, systems, devices, methods, and processes described herein may be performed by those of ordinary skill in the relevant art.
[0043] Throughout the description, where articles, devices and systems are described as having, including, or comprising specific components, or where processes and methods are described as having, including, or comprising specific steps, it is contemplated that, additionally, there are articles, devices, and systems of the present invention that consist essentially of, or consist of, the recited components, and that there are processes and methods according to the present invention that consist essentially of, or consist of, the recited processing steps.
[0044] Similarly, where articles, devices, mixtures, and compositions are described as having, including, or comprising specific compounds and/or materials, it is contemplated that, additionally, there are articles, devices, mixtures, and compositions of the present invention that consist essentially of, or consist of, the recited compounds and/or materials.
[0045] It should be understood that the order of steps or order for performing certain actions is immaterial so long as the invention remains operable. Moreover, two or more steps or actions may be conducted simultaneously.
[0046] The mention herein of any publication, for example, in the Background section, is not an admission that the publication serves as prior art with respect to any of the claims presented herein. The Background section is presented for purposes of clarity and is not meant as a description of prior art with respect to any claim.
[0047] In certain embodiments, the materials and methods described herein prevent hydrate plug formation in oil and gas pipelines by reducing hydrate adhesion strength to surfaces using functionalized coatings. Tools are provided for the design of low hydrate adhesion surfaces, i.e., “hydrate-phobic surfaces.” In one embodiment, these tools provide a pathway to develop hydrate-phobic coatings for enhanced flow assurance. With reduced hydrate adhesion forces, hydrates (e.g., clathrate hydrates) that form on pipeline walls and other pipeline components are more easily detached from the walls by hydrodynamic forces within the pipeline.
[0048] In one embodiment, the adhesion strength of a hydrate to a solid surface is reduced by lowering the surface energy of the surface. As described further herein, the adhesion strength may be quantified or predicted in terms of the work of adhesion of a probe fluid, such as water, that is in turn characterized by a receding contact angle of the probe fluid (e.g., water) on the surface. For example, surfaces with high receding contact angles of water and other probe fluids may ensure low hydrate adhesion. In another embodiment, acid-base and van der Waals interactions, described above, are tailored for lowering hydrate adhesion.
[0049] In certain embodiments, hydrate adhesion is reduced by adjusting the wettability and/or surface energy of the adjacent substrate to produce a hydrate phobic surface. With this approach, the adhesion strength between a hydrate and the surface may be reduced by more than a factor of four, compared with the hydrate on bare steel. This reduction may be achievable on surfaces characterized by low Lewis acid, Lewis base, and van der Waals interactions, such that the work of adhesion is minimized.
[0050] In certain embodiments, an article is provided for use in a deep sea oil and/or gas recovery operation. The article includes a hydrate-phobic surface or coating that provides a reduced adhesion strength with a hydrate. In one embodiment, a receding contact angle, θ rec , between a probe fluid and the surface is greater than 70°, greater than 80°, greater than 90°, greater than 100°, or greater than 110°. The probe fluid may be water and/or a hydrate. In one embodiment, the probe fluid is a liquid that has surface energy parameters that are substantially similar to (e.g., within 20% of, within 10% of, or within 5% of) the surface energy parameters for a hydrate of interest (e.g., methane hydrate). The surface energy parameters include Lifshitz van der Waals, Lewis acid, and/or Lewis base parameters. In another embodiment, the surface or coating includes a fluoropolymer, silsesquioxane, fluorodecyl polyhedral oligomeric silsesquioxane, fluorinated ethylene-propylene, and/or perfluoropolyether. The article may be an underwater pipeline.
[0051] In another embodiment, hydrate adhesion strength is correlated with the normalized practical work of adhesion of a suitable probe fluid with similar surface energy properties to those of the hydrate. The probe fluid serves as a simple and valuable tool for predicting hydrate adhesion strength and rapidly screening surface treatments or coatings for hydrate-phobicity. For example, in certain embodiments, a probe fluid is identified to predict the adhesion strengths of gas hydrates (e.g., methane hydrate) to various materials. The probe fluid may be used because a liquid with identical chemistry to a gas hydrate may be unstable, as the solubility of a hydrate-stabilizing gas in liquid water may be much lower than its concentration in the hydrate phase. Thus, the surface energies of gas hydrates, such as methane hydrate, may be measured using van Oss-Chaudhury-Good (vOCG) analysis and a liquid solution designed with commensurate surface energy properties (characterized using a “reverse vOCG” analysis). This solution can then serve as a probe fluid to predict the adhesion strengths of gas hydrates to various materials, providing a much simpler alternative to high pressure gas hydrate adhesion testing. This approach can therefore lead to rapid screening of potential hydrate-phobic surfaces, such as those with specific chemistry chosen to minimize polar and van der Waals interactions governing the work of adhesion.
[0052] For example, in certain embodiments, contact angles may be measured for a probe fluid having surface energies that are similar to those of a hydrate of interest (e.g., methane hydrate) and various substrates. The contact angles may be used to calculate the practical work of adhesion, which has been shown to be correlated to adhesion strength. By measuring contact angles and calculating the practical work of adhesion for the probe fluid on various substrates of interest, substrates that produce low hydrate adhesion strengths may be readily identified. In one embodiment, simple measurements of receding contact angles of the probe fluid on substrates are a tool for the design or identification of hydrate-phobic surfaces.
[0053] In another embodiment, further reductions in hydrate adhesion are achieved by minimizing polar and nonpolar parameters of surface energy. In addition, hydrate adhesion may be further reduced by tailoring nano- and micro-scale surface morphology and chemistry to prevent penetration of the hydrate into the texture such that the hydrate rests atop the texture features to reduce contact at the hydrate-substrate interface. Other approaches, such as designing hybrid low/high surface energy morphologies that can spatially control nucleation (e.g. promote nucleation atop surface features) could be used to reduce hydrate adhesion under conditions favorable to desublimation or condensation.
[0054] In one embodiment, the probe fluid approach to predicting adhesion strength is extended to other materials. For example, the practical work of adhesion of a material in its liquid state to a substrate may be used to estimate the adhesion strength of the same material in its solid state to a substrate. This approach to predicting adhesion strength and methods of controlling adhesion strength may benefit many industrial applications such as de-icing, welding, composite materials, thin films and coatings, and salt scaling.
[0055] There are many factors that contribute to adhesion between two solids. The most significant of these are van der Waals forces, hydrogen bonding, electrostatic effects, and the surface morphology, which affects the total contact area over which the above effects act, and the amount of physical interlocking between the surfaces. Assuming electrostatic effects are negligible, the interaction of these bodies with each other will be due to van der Waals forces and hydrogen bonding (a Lewis acid/Lewis base interaction, which is especially important when dealing with polar materials such as water, ice, or hydrates) and surface texture.
[0056] As discussed below, a series of experiments were performed to measure contact angles, surface energies, and the strength of adhesive bonds between a hydrate and various materials. For example, the adhesion strength of Tetrahydrofuran (THF) hydrate was measured on surfaces having a range of wettabilities and energetic characteristics. The results of these adhesion tests indicate that adhesion strength ranged from 422±69 kPa on steel, which has a measured advancing surface energy of 36 mJ m −2 , to 90±16 kPa on steel coated with an 80/20 PEMA/fluorodecyl POSS blend, which has a measured advancing surface energy of 9 mJ m −2 . This four-fold reduction in adhesion strength demonstrates the importance of surface chemistry to adhesion. However, to design surfaces for reduced adhesion, the key surface properties that affect adhesion must be determined. In one embodiment, adhesion strength is correlated with the work of adhesion.
[0057] The work of adhesion between two smooth bodies is known to depend strongly on van der Waals (apolar), electron acceptor (Lewis acid), and electron donor (Lewis base) interactions. The latter interactions are generally alluded to as polar interactions and arise primarily due to hydrogen bonding, and are therefore especially important when considering polar materials such as water, ice, or hydrates. The sum of these interactions can be characterized by the thermodynamic work of adhesion, W a , which is a function of the Lifshitz van der Waals, Lewis acid, and Lewis base parameters of surface energy of the adhering materials, denoted by γ LW ,γ + , and γ − respectively. The work of adhesion of a material A to a material B is given by
[0000] W AB a =2(√{square root over (γ A LW γ B LW )}+√{square root over (γ A + γ B − )}+√{square root over (γ A − γ B + )})
[0000] where the subscripts A and B denote the two adhering materials. Note that the work of adhesion of material A to itself is simply the work of cohesion of material A, W A c . Then by reducing the right side of Equation 1, with both subscripts denoting material A, we obtain,
[0000] W A c =2(γ A LW +2√{square root over (γ A + γ A − )})≡2γ A total (1)
[0000] where γ A total , is the total surface energy of material A in equilibrium with its vapor. If one of the materials in Equation 1 is a liquid that exhibits a non-zero contact angle, θ AB , then the work of adhesion is also given by the Young-Dupré equation:
[0000] W AB a =γ A total (1+cos θ AB ) (3)
[0000] If θ AB =0 then A may spread on B and W AB a >W AA c . In this fully wetted regime, W AB a ≧γ A total (1+cos θ AB )=2γ A total =W A c . Thus Equation 3 cannot be used to calculate the work of adhesion when θ AB =0.
[0058] In certain embodiments, reducing γ X LW , γ X + , and/or γ X − for one of the surfaces (e.g., a wall of a pipeline) reduces the work of adhesion and thereby reduces the adhesion strength of a hydrate. Similarly, the influence of surface texture (ranging from nano to micro scales along with hierarchical nano/micro engineered surfaces) may also lead to the same effect.
[0059] FIG. 1 includes a bar graph of measured contact angles for DI water on various substrates, and a bar graph of surface energies for each of these substrates. The surface energies were calculated using vOCG analysis of measured advancing and receding contact angles of polar and nonpolar test fluids, as described in the Experiments below.
[0060] Because it may be difficult to measure surface energy parameters of a hydrate, such as solid THF hydrate, a model or probe fluid may be used to mimic the hydrate and predict the strength of adhesion forces between the hydrate and various surfaces. For example, it may be difficult to determine the surface energy parameters of a solid THF hydrate due to the evaporation of THF from the frozen hydrate surfaces prior to contact angle measurements of the test fluids used in the vOCG analysis. Further difficulties arise in selecting test fluids that are insoluble in THF and remain liquid at temperatures below the melting temperature of THF hydrate, 4.4° C. Hence, having a probe liquid that can mimic the adhesion properties of the THF hydrate is desirable for predicting the hydrate-phobicity (i.e., the ability to reduce hydrate adhesion) of a surface. For example, in studies of ice adhesion, liquid water may be used as a probe fluid. Specifically, correlations may be made between the adhesion strength of ice on a selected substrate and the work of adhesion of liquid water on that same substrate.
[0061] To apply a similar approach to predicting hydrate adhesion, ice and water were studied as a model system to provide support for a probe fluid approach and to gain insights into the selection of an appropriate probe fluid for hydrates. As discussed previously, the adhesion strength of a material to a substrate is a function of its work of adhesion to that substrate. However, for studies of ice adhesion, the work of adhesion of liquid water on a selected substrate is correlated with the adhesion strength of ice to that same substrate. It is hypothesized that the existence of this correlation is attributable to the similarity of the surface energy parameters of ice and liquid water. For water at 25° C., √{square root over (γ LW )}=4.67 mJ 1/2 m −1 , √{square root over (γ + )}=5.05 mJ 1/2 m −1 , √{square root over (γ − )}=5.05 mJ 1/2 m −1 , γ total =72.8 mJ m −2 , and for ice at 0° C., √{square root over (γ LW )}=5.44 mJ 1/2 m −1 , √{square root over (γ + )}3.74 mJ 1/2 m −1 , √{square root over (γ − )}=5.29 mJ 1/2 m −1 , and γ total =69.2 mJ m −2 . Consequently, the work of adhesion of liquid water to most materials is approximately equal to that of ice. This near-equality is demonstrated by calculating the work of adhesion of liquid water and that of ice to the surfaces tested in this work. Using Equation 1, the work of adhesion of ice is calculated using the surface energy parameters of ice listed above and the surface energy parameters calculated for each of the substrates using vOCG analysis (see Table 1).
[0000]
TABLE 1
Surface energy parameters for various substrates.
Advancing surface energy data
Receding surface energy data
γ LW
{square root over (γ + )}
{square root over (γ − )}
γ total
γ LW
{square root over (γ + )}
{square root over (γ − )}
γ total
Substrate
[mJ/m 2 ]
[mJ 1/2 /m]
[mJ 1/2 /m]
[mJ/m 2 ]
[mJ/m 2 ]
[mJ 1/2 /m]
[mJ 1/2 /m]
[mJ/m 2 ]
1-Butanethiol
32
−0.6
1.5
30
42
−0.3
1.9
41
1H, 1H, 2H, 2H-
10
0.5
0.0
10
25
−0.3
1.4
24
Perfluorodecane-
thiol
Methyl 3-mercapto-
44
0.0
3.7
44
44
0.6
4.9
50
propionate
4-Mercapto-1-
46
0.4
6.4
52
N/A
N/A
N/A
N/A
butanol
50/50 Butanethiol/
40
−0.4
2.8
38
47
−0.2
4.3
45
Methyl 3-mercapto-
propionate
50/50 Butanethiol/4-
44
0.5
3.7
48
51
0.5
6.1
57
Mercapto-1-butanol
Trichloro(1H, 1H,
8
0.8
0.3
8
25
0.1
2.4
26
2H, 2H perfluoro-
octyl)silane
Octadecyltrichloro-
24
−0.3
0.2
24
30
−0.4
1.9
28
silane
80 wt. %/20 wt. %
9
0.1
0.3
9
13
−0.2
1.1
12
PEMA/fluorodecyl
POSS
Clean glass
41
0.7
7.8
51
N/A
N/A
N/A
N/A
Bare steel
39
−0.3
3.9
37
N/A
N/A
N/A
N/A
[0062] Referring to FIG. 2 , the resulting values are plotted against the work of adhesion for water, determined from its advancing and receding contact angles on the test substrates. The strong linear correlation (R 2 =0.98) suggests that work of adhesion measurements for liquid water are a good approximation of the work of adhesion of ice. The work of adhesion of liquid water was calculated using vOCG analysis measured advancing and receding water contact angles on each test substrate. The work of adhesion of ice was calculated using the surface energy properties of ice and the advancing and receding surface energy properties of each test substrate. The similarities between the work of adhesion of liquid water and ice explain why water is an effective probe fluid for gauging ice adhesion.
[0063] According to fracture mechanics theory, adhesion strength of ice is a function of the work of adhesion of ice. Consistent with this theory and the near-equality between the works of adhesion of water and ice, the adhesion strength of ice should therefore correlate with the work of adhesion of liquid water. That is, τ ice =f(W ice a )≅g(W water a ), where τ ice the strength of ice adhesion, W ice a is the work of adhesion of ice, and W water a is the work of adhesion of liquid water. Different values for work of adhesion can be determined depending on the contact angle (advancing, receding, static), used in Equation 3. It has been observed that ice adhesion strength correlates most strongly with the work of adhesion calculated from receding contact angle measurements, γ water (1+cos θ rec ), that is, with the practical work of adhesion for liquid water. Table 2 presents contact angles for water on various substrates. Adhesive strength of ice adhesion on these substrates is also provided.
[0000]
TABLE 2
Contact angles for water on various substrates.
Fraction of
Tests with
Average Shear
# of Ice
Completely
Strength of Ice
θ adv ,
θ rec ,
Adhesion
Adhesive
Adhesion at
Substrate
water a
water a
Tests
Failure b
−10° C. (kPa) c
Bare Steel
86.2 ± 3.3
25.8 ± 2.5
9
0.33
698 ± 112
PMMA
83.6 ± 3.6
60.7 ± 1.3
11
0.73
463 ± 65
PC
93.4 ± 1.0
73.9 ± 3.3
7
0.86
400 ± 83
PBMA
92.8 ± 2.4
74.6 ± 1.7
9
0.44
384 ± 52
PDMS
108.9 ± 1.5
91.7 ± 5.1
9
1.00
291 ± 44
(Sylgard 184)
PEMA
84.6 ± 2.4
68.0 ± 2.5
9
0.67
510 ± 101
99/1 PEMA/
97.5 ± 1.2
67.5 ± 2.2
9
0.22
475 ± 50
fluorodecyl POSS
97/3 PEMA/
105.4 ± 3.7
77.0 ± 4.7
8
1.00
367 ± 86
fluorodecyl POSS
95/5 PEMA/
122.2 ± 2.0
104.0 ± 5.3
8
1.00
278 ± 93
fluorodecyl POSS
90/10 PEMA/
122.6 ± 2.1
107.6 ± 6.9
12
0.92
247 ± 45
fluorodecyl POSS
80/20 PEMA/
123.8 ± 1.2
118.2 ± 2.4
7
1.00
165 ± 27
fluorodecyl POSS
70/30 PEMA/
124.2 ± 0.9
116.4 ± 2.9
9
1.00
166 ± 44
fluorodecyl POSS
50/50 PEMA/
125.0 ± 1.7
114.1 ± 2.4
8
1.00
185 ± 57
fluorodecyl POSS
Tecnoflon
118.3 ± 1.4
73.7 ± 2.1
17
0.76
389 ± 63
99/1 Tecnoflon/
125.7 ± 1.9
79.2 ± 3.4
13
0.92
392 ± 88
fluorodecyl POSS
97/3 Tecnoflon/
127.0 ± 1.7
87.7 ± 4.8
11
0.82
412 ± 64
fluorodecyl POSS
95/5 Tecnoflon/
126.6 ± 1.2
92.9 ± 4.3
15
1.00
328 ± 97
fluorodecyl POSS
90/10 Tecnoflon/
126.6 ± 0.8
98.0 ± 5.3
9
1.00
345 ± 104
fluorodecyl POSS
80/20 Tecnoflon/
126.0 ± 0.9
103.7 ± 4.3
11
1.00
313 ± 70
fluorodecyl POSS
70/30 Tecnoflon/
125.2 ± 0.8
110.0 ± 3.1
9
1.00
205 ± 40
fluorodecyl POSS
50/50 Tecnoflon/
128.3 ± 1.1
108.7 ± 3.4
8
1.00
265 ± 42
fluorodecyl POSS
Fluorodecyl POSS
137.6 ± 4.8
110.0 ± 3.8
15
1.00
250 ± 54
[0064] In another embodiment, a probe fluid is selected to be used in approximating the work of adhesion of solid hydrate to various substrates. For example, for the solid THF hydrate, the 19.1 wt. % THF in water solution used to form THF hydrate is a good choice. FIG. 3 is a plot of THF hydrate adhesion strength versus the normalized practical work of adhesion, 1+cos θ rec , of the 19.1 wt. % THF in water solution. A linear fit through the origin shows an excellent correlation (R 2 =0.90) consistent with the fact that hydrate adhesion strength must approach zero as the work of adhesion of a probe fluid approaches zero (supplementary materials). In comparison, referring to FIG. 4 , if DI water is used as a probe fluid, a linear correlation passing through the origin is relatively poor (R 2 =0.51).
[0065] The surface energy properties of the 19.1 wt. % THF in water solution were estimated using a “reverse vOCG analysis” of its advancing and receding contact angles on each of the test surfaces (see supplementary material). The resulting surface energy parameters are √{square root over (γ LW )}=4.3 mJ 1/2 m −1 , √{square root over (γ + )}=1.6 mJ 1/2 m −1 , √{square root over (γ − )}32 9.1 mJ 1/2 m −1 , and γ total 47 mJ m −2 . The polar terms are significantly different from the aforementioned polar surface energy parameters of water, resulting in different work of adhesion measurements on the test surfaces. The correlation in FIG. 3 exists because the polar and van der Waals surface energy properties of the 19.1 wt. % THF in water solution reflect those of THF hydrate, just as liquid water reflects the surface energy properties of ice. Thus, the practical work of adhesion of 19.1 wt. % THF in water solution can be used to estimate the adhesion strength of THF hydrate. The lowest hydrate adhesion strength was observed on the 80%/20% PEMA/fluorodecyl POSS treated steel disc, which exhibited the highest receding contact angle of the THF-water solution (90°). The positive slope and monotonic behavior of the data plotted in FIG. 3 suggest that lower hydrate adhesion could be achieved on surfaces with lower practical work of adhesion to the THF-water probe fluid. This can be accomplished by minimizing the polar and nonpolar surface energy parameters of the coating.
[0066] Referring again to FIG. 3 , the high surface energies of clean glass and steel resulted in their complete wetting by the THF-water solution (θ rec =0). For these surfaces the normalized practical work of adhesion may be greater than two (1+cos(0)). For this reason, these points were excluded from the correlation, while presented on the plot to demonstrate their much greater adhesion to hydrates compared to the treated substrates. More than four-fold reduction in adhesion strength was measured on low- surface energy coatings compared to bare steel.
[0067] FIG. 5 is a plot of measured hydrate adhesion strength for various substrates. As indicated, the adhesion strength generally decreased with decreasing surface energy of the substrates.
[0068] Referring again to Table 1 and FIG. 3 , the lowest hydrate adhesion strength was observed on the 80%/20% PEMA/fluorodecyl POSS treated steel disc, which exhibited the highest receding contact angle of the THF-water solution (90°). The positive slope and monotonic behavior of the data plotted in FIG. 3 suggest that lower hydrate adhesion could be achieved on surfaces with lower practical work of adhesion, compared to the 19.1 wt. % THF in water solution. A lower practical work of adhesion may be accomplished by tailoring the surface chemistry to minimize the polar and van der Waals interactions that govern Equation 1. Although the PEMA/POSS blend has extremely low van der Waals and polar parameters of surface energy, it is possible for the Lewis acid parameter of the surface energy, √{square root over (γ B + )}, to be negative, as is the case for some of the surfaces in Table 1. The significance of this result is that the acidic character in a surface leads to a negative contribution to its surface energy (since γ B total =γ B LW +2√{square root over (γ B + )}√{square root over (γ B − )}) and a negative (repulsive) contribution to its work of adhesion with other polar materials (2√{square root over (γ B + )}√{square root over (γ B − )}<0). Thus, in one embodiment, further reductions in adhesion strength are possible with a negative Lewis acid parameter of the surface energy.
[0069] Negative values of √{square root over (γ + )} have been observed on the surfaces of thiols and silanes that terminate in hydrocarbon chains (1-Butanethiol, 50/50 Butanethiol/Methyl 3-mercaptopropionate, Octadecyltrichlorosilane, in Table 1). When negative values of √{square root over (γ + )} for the solid surface are multiplied by positive values of √{square root over (γ − )} of the hydrate (or hydrate-mimicking probe fluid), they lend a negative contribution to the work of adhesion (see Equation 1). If √{square root over (γ − )} of the substrate is low enough, there can be an overall “non-van der Waals” repulsion captured in the Lewis-acid and Lewis-base terms of the work of adhesion. Such negative values of √{square root over (γ + )} (and consequent repulsive forces with other materials such as a hydrate) may, for example, exist on a surface made up of an array of positive dipoles oriented outward from the surface. In one embodiment, this is consistent with the observation that surfaces terminating in hydrocarbon chains have negative √{square root over (γ + )}. The positive dipoles on the hydrogen in the hydrocarbon chains have an electrostatic repulsion with the positive dipoles of water that may be stronger than their attraction to the negative dipoles of water. A similar effect may be observed in other materials that have a permanent positive charge, or that can be given a temporary or permanent positive. In one embodiment, pyroelectric materials are utilized, which can provide a positive surface charge upon heating or cooling.
[0070] In another embodiment, the adhesion strength of a hydrate is reduced by engineering a lattice mismatch between the hydrate and the surface. Specifically, referring to FIG. 6 , the lattice constant of the surface material 600 is engineered or selected to be different from the lattice constant of the hydrate material 602 . As depicted, the lattice mismatch results in a dangling bond 604 at an interface between the materials 600 , 602 . By increasing the lattice mismatch (i.e., the mismatch between the lattice constants of the two materials 600 , 602 ), defects may be created at the hydrate-surface interface, thereby reducing the strength of the adhesive bond. FIG. 7 is a schematic drawing of a hydrate-surface interface 700 showing defects or cracks 702 at the interface.
[0071] In one embodiment, the influence of the temperature and the guest molecule (e.g., methane) on the lattice parameter is small. Lattice structure, however, is important (e.g., SI, SII, SH). Methane hydrate is an SI (space group Pm3n) type hydrate, and its lattice parameter was measured at a=11.77 Å at 100K. At higher temperatures, the lattice parameter of the methane hydrate has not been measured. However, because lattice parameters of hydrates have very little dependence on the guest molecule, the lattice parameter of ethylene oxide hydrate, another SI hydrate, may be used to estimate the lattice parameter of methane hydrate. The lattice parameter of ethylene oxide is 12.03 Å at −25° C. Thus, surfaces may be designed based on the lattice parameter of methane hydrate being around 12 Å in deep sea pipelines.
[0072] In certain embodiments, the lattice spacing to be considered is
[0000] ε=( n*a — s−a — h )/ a — h (4)
[0000] where ε is the lattice mismatch, a_s is the substrate lattice parameter, a_h is the hydrate lattice parameter, and n is the multiple of the lattice parameter of the substrate that is closest to that of the methane hydrate. For a lattice parameter of methane hydrate around 12 Å, materials with lattice parameters around 2, 3, 4, 6, or 12 are of interest. For reference, while methane hydrate is cubic, with only 1 lattice parameter (12 Å), the substrate may have more than one lattice parameter. The hydrate will undergo nucleation and grow on exposed crystal planes of the substrate having the least mismatch with the hydrate.
[0073] In certain embodiments, the lattice mismatch results in a tensile lattice strain of between 0.001 (˜0) and 0.12. In one embodiment, the lattice parameter for the substrate is from about 2 to about 2.24, from 3 to about 3.36, from 4 to about 4.48, or from 6 to about 6.72. In another embodiment, the desired lattice mismatch with methane hydrate is achieved using a substrate that includes one or more of the following materials: Br 2 Ni, Cronstedtite, Silicon carbide (SiC), Iowaite, Brucite, Fe(OH) 2 (“white-rust”), Zaccagnaite, Moissanite (SiC), CaIrO 3 , Dyscrasite, Zincite, Potarite, Thungsten, Pyrochroite, Co(OD), CaPtO 3 , B 2 Mo, Palladinite, Scandium, Lithium, Ni 7 —S 6 , Molybdenite, Theophrastite, Ag0.6NbS 2 , cesium, silicon, TaS 2 , Co H 2 O 2 , Koenenite, Hafnium, Magnesium, Scandium, Zirconium, Molybdenum, Nobium, Tantalum, titanium, vanadium, phosphorus, manganese-delta, AlN, GaN, NbN, TaN, TiS, VP, VS, MoB, WB, Ti 2 CS, TaP, Li 2 O 2 , Amakinite, Antimony, CuO 2 Rh, Ti 3 SiC 2 , CaFe 3 O 5 , CaFe 4 O 6 , CaFe 5 O 7 , LiFeSnO 4 Li0.7Fe0.375Sn0.54O 2 , Tungstenite, Jamborite (NiOH), Nb 2 , Theophrastite (NiO), Montroseite (FeVOHO 2 ), Periclase (MgO), Heazlewoodite (NiS), Stishovite (SiO), Stibarsen, vulcanite, Magnesite, Diaspore, Magnesiowustite (MgFeO), SiO 2 , GeO 2 , and FeB.
[0074] FIG. 8 is a plot of measured hydrate adhesion strength versus mismatch strain (i.e., strain caused by lattice mismatch), on various substrates. The TiNx substrate was prepared via reactive sputtering of titanium and nitrogen, onto VWR glass slides. The boron nitride (BN) substrate was prepared from high purity hexagonal BN (available from McMaster-Carr of Atlanta, Ga.). A 1 mm thick BN sheet was polished using 1500 grit silicon carbide polishing paper. The GeO 2 and Er 2 O 3 substrates were produced by sputtering onto VWR glass slides. The TiO 2 surface was fabricated by sputtering titanium, which oxidizes in ambient air to form TiO 2 . Alumina was formed by the oxidation of polished aluminum in ambient air. The gold substrate was an evaporated gold-coated glass slides having 100 nm of gold with a 5 nm adhesion layer of titanium (available from Evaporated Metal Films of Ithaca, N.Y.).
[0075] When water-wet gas expands rapidly through a valve, orifice or other restriction, hydrates may form due to rapid gas cooling caused by adiabatic (joule-thomson) expansion. This commonly occurs in fuel gas lines or instrument gas lines. In certain embodiments, to prevent the accumulation of hydrates in a pipeline, the pipeline includes a hydrate-phobic surface or coating. For example, the surface may be located just beyond a restriction, such as a vale or a choke valve. In one embodiment, the surface is located within the first three meters after a valve. The surfaces may also be located at one or more of the following locations: in orifices or other restrictions; within fuel gas lines or instrument gas lines (e.g., after valves within fuel gas lines or valves within instrument gas lines); downstream of flow-line water accumulations, such as a flow-line low spot or at a riser, or where there is a change in flow geometry (e.g., a bend or pipeline dip along an ocean floor depression); at a nucleation site (e.g., weld slag, or pipe flanges); in the manifold; and on sensors embedded within the pipeline.
EXPERIMENTAL EXAMPLES (INCLUDING CONSTRUCTIVE EXAMPLES)
[0076] For the hydrate adhesion strength measurements, tetrahydrofuran (THF) hydrate was used as a model system because THF is completely miscible in water and forms hydrate at atmospheric pressure and temperatures below 4.4° C. for a solution of 19.1% THF (by weight) in water. THF hydrate adhesion was tested using a custom-built adhesion testing apparatus housed in a glove box containing a nitrogen environment. A solution of 19.1 wt. % THF in DI water was poured into glass cuvettes and frozen to the test substrates. The liquid columns were frozen for 2 hours at −15° C. to yield an array of hydrate columns encased in cuvettes and adhered to the test substrates. The substrate temperature was monitored using a thermocouple attached to the top of one of the substrates. To minimize frost formation on the test substrates and apparatus, the relative humidity was kept below 5%.
[0077] The force required to detach each hydrate column from its test substrate was measured by driving a 12 mm wide wedge-shaped probe head of a force transducer (model ZP-44, available from Amada, Inc. of Northbrook, Ill.) into contact with the side of the hydrate-filled cuvette at a constant velocity of 1 mm s −1 and continuing to drive the probe forward until the hydrate broke free from the substrate. Hydrate adhesion strength was obtained by dividing the measured maximum force by the cross-sectional area (1 cm 2 ) of the hydrate-substrate interface established by the cuvette size. Fracture was observed to be predominantly adhesive, that is, no hydrate shards remained on the surfaces after adhesion testing.
[0078] The mechanism of hydrate formation was observed as the THF-water solution was subcooled during the hydrate freezing process. Results indicate that the hydrate formed on the solid surface (e.g., the cuvette surface), which was at the lowest temperature, and grew into the solution, confirming that heterogeneous nucleation occurred on the surface. The hydrate continued to grow until the columns of solution were completely solidified.
[0079] A library of test surfaces with varying chemistries was established in order to elucidate the influence of surface properties, such as wettability and surface energy, on adhesion strength. These surfaces, ranging from hydrophilic to hydrophobic, include thiolated gold, silane-treated glass, and a blend of 80 wt. %/wt.20% poly(ethyl methacrylate) (PEMA)/fluorodecyl polyhedral oligomeric silsesquioxane (fluorodecyl POSS) spin coated onto steel. Surface energies of each of the test substrates were calculated using van Oss-Chaudhury-Good (vOCG) analysis from measured advancing and receding contact angles of up to five test fluids. Advancing and receding contact angles of DI water and surface energies calculated from advancing and receding contact angles of the test fluids are provided in FIG. 1 , above, for each of the surfaces tested.
[0080] Referring to FIG. 1 , advancing contact angles range from 35° to 125° and receding contact angles range from 5° to 115°. Advancing surface energies range from 8 mJ m −2 to 50 mJ m −2 and receding surface energies range from 12 mJ m −2 to 57 mJ m −2 . Receding contact angles of several of the test fluids on 4-Mercapto-1-butanol were zero, thus its receding surface energy could not be determined precisely, and the plotted value represents its minimum receding surface energy.
[0081] Contact angles of four polar fluids: DI water (18 MΩ-cm, Millipore), ethylene glycol (Alfa Aesar), formamide (Alfa Aesar), and a 19.1 wt. % mixture of THF (Alfa Aesar) in DI water, and two nonpolar fluids: 1-bromonaphthalene (Alfa Aesar) and diiodomethane (Alfa Aesar), were measured on the test surfaces using a Ramé-Hart Model 500 Advanced Goniometer/Tensiometer. Advancing (θ adv ) and receding (θ rec ) angles were taken as an average of at least 8 measurements. 5 μl droplets were deposited at a volume addition/subtraction rate of 0.2 μl s −1 , yielding contact line velocities less than 1 mm min −1 . The resulting capillary numbers (Ca=μV/γ) were less than 10 −5 for all fluids tested, ensuring that the measured dynamic contact angles were essentially the same as contact angles obtained immediately after the contact line comes to a stop. Advancing and receding surface energies were computed using vOCG analysis of the gathered advancing and receding contact angle data.
[0082] The Lifshitz-van der Waals, Lewis acid, and Lewis base contributions, as well as the total solid phase surface energy (γ LW , √{square root over (γ + )}, √{square root over (γ − )}, and γ total respectively) are provided in Table 1, above. Different values are obtained depending on whether advancing or receding values of test fluids are used in the vOCG analysis. Some receding surface energies could not be determined because non-zero receding contact angles of at least one nonpolar and two polar probe fluids were not always attained. For example, receding surface energies of steel, glass, and 4-mercapto-1-butanol could not be determined because non-zero receding contact angles of at least one nonpolar and two polar test fluids were not attained on these surfaces. The error in these surface energy data is on the order of 15%. The surface energy parameters in Table 1 were calculated from advancing and receding contact angles of DI water, ethylene glycol, formamide, 1-bromonaphthalene, and diiodomethane using vOCG analysis, where γ total =γ LW +2√{square root over (γ + )}√{square root over (γ − )}.
[0083] The surface tension, and therefore the contact angle, of the THF-water solution varied with time due to evaporation of THF from the solution. The variation of surface tension with time was measured using the pendant drop method. Based on these measurements, care was taken to measure advancing and receding contact angles of the THF-water solution before significant evaporation of THF from the solution could occur.
[0084] Surface texture plays an important role in adhesion and can often result in interlocking of the adhering materials, increasing adhesion strength. This has been demonstrated in studies of ice adhesion, in which a linear increase in adhesion strength may be observed with the Wenzel roughness, that is, the total surface area divided by the occluded area. For the purpose of these experiments, the goal was to investigate the effects of surface chemistry alone, and therefore efforts were focused on smooth surfaces. Surface profilometry was conducted to verify the smoothness of the test surfaces. A Tencor P-12 profilometer with a 2 μm radius stylus and a Zygo interferometer were used to measure the roughness of the steel discs and the 80%/20% PEMA/fluorodecyl POSS coated steel discs. Atomic force microscopy (AFM) was carried out on glass, gold, and some representative silanes and thiols using a VeecoDimension 3100 scanning probe microscope operating in the tapping mode. The Wenzel roughness was r<1.06 for all surfaces tested.
[0000] Reduction of Hydrate Adhesion to a Surface Disposed with Preferred Nucleation Sites.
[0085] Without wishing to be bound by a particular theory, it is believed that the rate of heterogeneous nucleation on a smooth surface is a function of substrate temperature, pressure, and the surface energies of the interfaces between the hydrate, vapor, and solid phases. This nucleation rate decreases with the surface energy of the substrate, and with increasing substrate temperature. The result of these dependencies is that for a given substrate surface energy, a certain degree of subcooling, or overpressure, beyond the hydrate dissociation temperature and pressure is required before any macroscopically detectable nucleation occurs. Thus for a surface comprised of two surface energies, any observable nucleation (e.g. of hydrate, frost, or condensate) will occur exclusively, or at least preferentially, on the high surface energy patches. This can effectively control the preferred nucleation sites of water in condensation experiments. Similarly, high surface energy sub-micron particles (e.g. metals, ceramics, and cermets) may be deposited onto a surface of lower surface energy (e.g. using solution deposition methods, followed by sintering, figure., or inkjet printing). These dispersed particles, or dispersed piles of particles, may then act as high surface energy nucleation sites for the hydrate.
[0086] Hydrate nucleation can similarly be inhibited on low surface energy materials. To demonstrate this, we measured the temperature at which nucleation of THF hydrate is macroscopically detectable, T_crit, on a fluorosilane treated glass slide (low surface energy/hydrophobic) and a clean glass (high surface energy/hydrophilic) slide filled two glass cuvettes with a mixture of THF-water, and flipped them over onto substrates of different surface energies using the protocol previously described. A 19.1 wt. % solution of THF in DI water was poured into glass cuvettes, and flipped over onto the glass and fluorosilane treated glass substrates, resulting in contact of the THF-water solution with the substrate. These substrates were then placed on a Peltier plate, and frozen at a rate of 2° C. per minute. The temperature was monitored using a thermocouple that had been frozen to the surface of a glass substrate mounted next to the test substrates. A high definition camera was used to record the hydrate formation in each of cuvettes, and temperature at which incipient hydrate formation was detected, T_crit, was recorded for each substrate. For glass hydrate formation was observed at −1.2° C., whereas on fluorosilane hydrate formation was observed at −8° C. high surface energy materials.
[0087] Without wishing to be bound by any particular theory, it is believed that adhesion will be reduced on surface comprising discrete nucleation sites (e.g., high surface energy sites or high-surface energy nanoparticles sites) because hydrate crystals grow outward from the discrete nucleation points. These hydrate freezing fronts collide, creating a defective interface between the bulk hydrate and the substrate. Furthermore, the adhesion strength per unit area is significantly higher for hydrate that grows directly from a surface than for hydrate that is brought into contact with a surface. Thus, a hydrate will only have high adhesion strength at the high surface energy points on which it nucleated, which may comprise a small fraction of the total surface area. Whereas on a smooth surface, hydrate can grow from any point on the surface, resulting in greater adhesion strength. To demonstrate this effect, hydrate adhesion strength was measured for a hydrate that had grown directly from a surface and compared to a hydrate that grew from high surface energy particles within the solution. We demonstrate a 50% reduction in adhesion when a hydrate grows from particles to a substrate rather than directly on a substrate.
[0088] Two surfaces were treated with fluorosilane in separate cuvettes. One cuvette was filled with a mixture of 19.1 wt. % THF in water solution mixed with silica particles of 30 nm diameter, such that the suspended silica made up 10% of the total solution weight. The solution was then sonicated to break up any silica that may have agglomerated. The other cuvette did not contain nanoparticles. It was found that hydrate adhesion was reduced by 50% due to the presence of the nanoparticles within the solution. It is believed that this is because nucleation preferentially occurs on the nanoparticles rather than the substrate, and the resulting hydrate adhesion on the surface is lower due to capillary bridging.
[0089] FIG. 9A is a schematic drawing 900 of a substrate 902 with hydrate-phobic surface (surface with inhibited hydrate adhesion thereto) with discrete preferential hydrate nucleation sites 904 . Hydrate 906 preferentially nucleates and grows at the discrete nucleation sites, resulting in reduced hydrate adhesion to the surface.
[0090] FIG. 9B is a schematic drawing 908 of the substrate 902 with a hydrate-phobic surface patterned with hydrophobic regions ( 912 ) and hydrophilic regions ( 910 ). Hydrate 914 preferentially nucleates and grows on the hydrophilic regions, resulting in reduced hydrate adhesion to the surface.
[0091] FIG. 9C is a schematic drawing 916 of the substrate 902 with a hydrate-phobic surface patterned with posts 920 , the tops of which serve as preferential hydrate nucleation sites. Hydrate 922 preferentially nucleates and grows from the tops of the posts 920 , forming air pockets 924 between the posts 920 , resulting in reduced hydrate adhesion to the surface.
Equivalents
[0092] While the invention has been particularly shown and described with reference to specific preferred embodiments, it should be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
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This invention relates generally to articles, devices, and methods for gas hydrate mitigation in deep-sea drilling applications. In certain embodiments, hydrate-phobic surfaces are provided that ensure passive enhancement of flow assurance and prevention of catastrophic failures in deep-sea oil and gas operations.
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TECHNICAL FIELD
The field is slip agents for protecting glass sheets from scratching.
TECHNICAL BACKGROUND
The shipment of display glass has employed surface protection of both substrate sides using a combination of laminated films with paper interleaf or more recently, a very clean single layer paper-only interleaf material. Referring to FIG. 1 (Prior art) in the former process, three sheets were used between adjacent glass sheets 10 , 12 and 12 , 14 . Two outer layers of polymer film 16 , 18 were coated onto facing surfaces 20 , 22 of the glass, which sandwiched a sheet of paper 24 between them. The laminated film protection method requires a polymer film coater, films and a film peeler. This three layer interleaf adds extra process steps and sheets of material and increases manufacturing costs. It is highly desirable to use a single layer interleaf material to pack glass sheets at the bottom of the draw (BOD) in a fusion draw process, and to pack finished goods.
At the bottom of the draw the glass is unfinished and has sharp edges that chip easily during subsequent handling and finishing operations. This leads to an increased level of glass chips and other particles on the glass that can cause scratching of the glass during subsequent handling, finishing and shipping of the glass. The surface of the glass may also be scratched by the handling and finishing equipment itself, or by dirt and glass particles on or from the handling and finishing equipment and from other sources. It is desirable to protect the surface of the glass from scratching during handling, finishing and shipping operations downstream of the BOD.
TECHNICAL SUMMARY
In general, a method of protecting glass sheets from scratching comprises applying slip agent to a surface of a glass sheet before finishing and/or shipping operations. The slip agent can be present on the glass sheet in an amount ranging from 1 to 10,000 nanograms per centimeter 2 . Scratching of the glass sheet is inhibited during the finishing and/or shipping operations using the slip agent. The slip agent can be formed as a discontinuous layer on the glass sheet. Application of the slip agent to the surface of the glass sheet can form surface roughness on the glass sheet comprising the slip agent. Part of the slip agent can be transferred onto particles present on the glass sheet, thereby protecting the surface of the glass sheet from scratching. Alternatively rolling or sliding of particles on the slip agent, rather than directly on the glass sheet, can prevent scratching of the glass sheet. The glass surface is cleaned to remove the slip agent and any particles on the glass sheet. The slip agent may be applied to the glass by any means, such as transfer using paper or film, spraying or dipping. Spraying or dipping may apply a thicker coating of slip agent on the glass sheet than transfer using paper or film.
Another aspect of this disclosure is a method of protecting glass sheets from scratching comprising applying a slip agent to a surface of a glass sheet before a finishing operation. The slip agent may form a discontinuous layer on the glass. The glass sheet has no lamination of slip agent containing material on it (e.g., no Visqueen film is laminated onto the glass during finishing). The slip agent comprises a long chain fatty ester or long chain fatty amide. Scratching of the glass sheet during the finishing and handling operations is inhibited using the discontinuous layer of slip agent.
Modification of an interleaf paper or polymer film with slip agent, followed by transfer of slip agent to the surface of glass sheets stacked in a temporary shipment package with the modified interleaf paper or polymer film between each glass sheet, provides the surface of the glass with a thin layer of slip agent that protects the glass surfaces from scratches during crate packing, in-plant handling and processing directly on horizontal finishing lines after the paper is removed for finishing. The slip agent transferred to the glass prevents scratches on a glass surface from bottom of the draw (BOD) to finishing (e.g. during shipment between glass forming plants), currently a problem for large sized (generation 8 and 10) glass, as well as shipment and handling to customers of the glass manufacturer. It is believed that the slip agent on the glass forms a micro surface roughness forming discontinuous layer on the surface of the glass. This disclosure refers to paper or film that is applied to the glass sheet for transfer of the slip agent to the glass sheet, and to interleaf paper or film that is disposed between sheets of glass, which may or may not transfer the slip agent to the glass sheet.
This disclosure features use of a carrier membrane, for example, a paper or polymer film that includes a slip agent that can transfer to the surface of the glass. Once the paper or film is pressed against the glass sheet, this will leave slip agent on the surface of the glass that can prevent or reduce glass surface scratches from other surfaces or particles during finishing (e.g., edge grinding), handling and shipping operations, thereby improving the yield of glass during finishing as well as during shipment between glass forming plants and customers. The slip agent remaining on the glass surface can be washed off easily in subsequent washing processes. The paper or film can have the slip agent imbibed within the paper or coated on it as a surface coating. Although the term “imbibe” is used to generally describe the presence of slip agent in the paper as by submerging in slip agent liquid, and “coating” for application of slip agent to the outside of the paper, the terms may be used interchangeably in this disclosure.
The specific slip agent can be a long chain fatty ester or a long chain fatty amide, for example, erucamide. The slip agent composition imbibed within or coated on the paper may include any other chemical agent that can be incorporated into paper to prevent scratches from inorganic particles while leaving residuals on the glass surfaces that also prevent scratching when present in very small amounts. The slip agent residuals are easily removed using standard glass washing processes and equipment
This disclosure features methods of applying a slip agent onto the surface of a glass sheet, and the glass sheet itself that contains this slip agent on its surface. Various techniques can be used to apply the slip agent to the glass, such as compressing interleaf paper or polymer film containing the slip agent between adjacent glass sheets in a stack of glass sheets. Another technique to apply the slip agent to the glass sheet is to compress a paper or polymer film including the slip agent between pressure rollers and the glass on one or both sides of a glass sheet. Yet another way to apply the slip agent to the glass sheet is to laminate a slip agent containing polymer film to the glass sheet (e.g., Visqueen film) and then to strip the laminated film from the glass sheet before the finishing process. When the slip agent is applied to the glass sheets using the pressure roll process, laminated film process, or stacked glass with interleaf compression process, a first form of scratch protection to the glass sheets is provided. The slip agent that remains on the glass sheets offers the glass sheet first scratch protection along the finishing line where the glass sheet undergoes edge grinding and washing operations. When the slip agent imbibed or coated interleaf paper or polymer film is inserted between glass sheets in a stack, the slip agent offers a second form of protection against scratches from particles present between the glass sheets of the stack. The terms, first form of scratch protection and second form of scratch protection, are arbitrary terms used to differentiate between (a) preventing scratching of glass sheets in a stack using interleaf paper or film that is coated or imbibed with slip agent (second scratch protection) from (b) preventing scratching by leaving a slip agent on the glass surface, such as by transfer of slip agent from the paper or film and removal of the paper or film from the glass surface (first scratch protection).
In general, the method of protecting glass sheets from scratching can comprise positioning slip agent containing paper or polymer film on one of the glass sheets. The slip agent can be a long chain fatty ester or long chain fatty amide slip agent. The slip agent is present on at least the surface of the paper or film in contact with the glass sheet. The paper or film is pressed against or between the glass sheets and a small portion of the slip agent on the paper or film is transferred onto the glass sheets. The paper or film is then removed from the glass sheet, leaving the transferred slip agent on the glass providing the first scratch protection. The transfer of a portion of the slip agent onto the glass sheet can form surface roughness on the glass sheet comprising the slip agent. The first scratch protection provides protection against scratches during subsequent finishing and handling operations, such as along the finishing line, where scratching may be caused by rolls or rollers, steel cut tables, steel bars of glass separation devices associated with the cut tables, and other equipment. This scratching is resisted by moving particles (e.g., glass and other particles) against the slip agent rather than directly against the bare glass. The second scratch protection is provided when the paper or film is inserted between glass sheets within a stack, whereby scratching from glass particles or other particles is resisted by moving the particles against the slip agent on the paper rather than against the bare glass.
In applying the slip agent to the glass sheet via compression in a stack of glass, an additional glass sheet is placed against the paper (now referred to as interleaf paper as it is sandwiched between adjacent glass sheets) such that the slip agent is presented from the interleaf paper in contact with the additional glass sheet. The steps of positioning the interleaf paper against a glass sheet and applying another glass sheet on top of the interleaf paper are repeated until a stack of glass sheets is arranged with a sheet of interleaf paper between each pair of adjacent glass sheets. The steps of pressing the interleaf paper against the glass sheet and transferring the slip agent to the glass sheet occur when the interleaf paper located between the glass sheets is compressed as a result of a weight of the glass sheets in the stack. In the second form of scratch protection, scratching from glass or other particles between the glass sheets is resisted by moving (rolling or sliding) the particles against the slip agent on the interleaf paper while the interleaf paper is within the stack, rather than moving the particles on the glass. Alternatively, scratching may be prevented by keeping particles on the glass stationary and rolling or sliding the slip agent on the glass and particles. The first scratch protection can be achieved by slip agent that remains on the surface of the glass after separating the glass sheets of the stack and removing the interleaf paper. Therefore, the compression technique of applying slip agent to the glass sheet provides both the first and second forms of scratch protection.
Regarding details of the method, the interleaf paper or polymer film can comprise one interleaf sheet including slip agent protruding from (e.g. imbibed in or coated on) both sides of the interleaf sheet. Alternatively, the interleaf paper or film can comprise two interleaf sheets, each imbibed or coated on only one side with the slip agent and arranged such that the slip agent faces outwardly away from the other interleaf sheet. Now, scratching is avoided (second scratch protection) by the slip agent contacting the particles between the interleaf paper or film and the glass. Also, a portion of the slip agent is transferred to the glass sheet (first scratch protection). In both cases, scratching of the glass sheet is minimized by the slip agent.
Regarding further details of the method, the interleaf paper can be subjected to a super calendar operation, or not. The paper or film can comprise erucamide as the long chain fatty amide and an alkyl or alkenyl ketene sizing agent. The slip agent can be present on the glass sheet in an amount ranging from 1 to 10,000 nanograms per centimeter, more particularly, in an amount ranging from 1 to 3000 nanograms per centimeter 2 , even more specifically, in an amount ranging from 1 to 500 nanograms per centimeter 2 .
In a process of applying the slip agent from slip agent imbibed or coated paper or polymer film using rolls, the method includes providing on one or both sides of a glass sheet the paper or polymer film wound on a feed roll, with the paper or film extending from the feed roll to a take-up roll. Next, as the paper or film advances from the feed roll onto the take-up roll, the paper or film and the glass sheet are compressed between rollers on either side of the glass sheets, thereby pressing the paper or film against the surface of the glass sheet and transferring a portion of the slip agent to the surface of the glass. The paper or film is removed from contact with the glass sheet once the glass sheet passes through the rollers traveling to the take-up roll.
In another process of applying the slip agent to the glass sheet, a slip agent containing polymer film is applied as a laminate on the glass sheet and then the laminate film is stripped from the glass sheet to result in the transfer of slip agent to the glass sheet.
Another embodiment of this disclosure is a sheet of glass itself. The glass sheet comprises a slip agent distributed across a major surface of the glass by any means. The slip agent comprises a long chain fatty ester or a long chain fatty amide. The slip agent is distributed on the glass sheet in an amount ranging from 1 to 10,000 nanograms per centimeter 2 , more particularly, in an amount ranging from 1 to 3000 nanograms per centimeter 2 , even more specifically, in an amount ranging from 1 to 500 nanograms per centimeter 2 . The slip agent can be formed as a discontinuous layer on the glass sheet. The slip agent can be discontinuously distributed across the major surface(s) of the glass sheet as a surface roughness comprising the slip agent. The long chain fatty amide can comprise erucamide. Compounded into the paper or polymer film material, the slip agent acts as an internal lubricant that transfers to the surface where it is presented against the glass. In this disclosure, the lubrication is provided to surfaces of glass sheet onto which the slip agent is applied or otherwise transferred by the paper or polymer film material or by other means.
On the other hand, the interleaf paper or film can comprise two interleaf sheets, each coated or imbibed on only one side with the slip agent and arranged such that the slip agent coated side faces inwardly toward the other interleaf sheet. This enables the adjacent glass sheets of the stack to slip relative to each other as the slip agent of the two interleaf sheets between the adjacent glass sheets slide relative to each other, but the uncoated surfaces of the interleaf sheets do not slide relative to the glass sheets, thereby achieving the second scratch protection. In this case, the particles between the interleaf sheets and the glass do not move upon movement of the sheets, but rather movement occurs between the adjacent interleaf sheets away from the glass surfaces. However, when using this inwardly facing, single-side coated interleaf paper or film, slip agent would need to be separately applied to the glass sheets in order to achieve the first scratch protection, because the facing interleaf sheets would not transfer any slip agent to the glass sheets. When the slip agent coated or imbibed sides of the interleaf sheets face each other, this can be used for transfer between glass forming plants and temporary storage of glass within the same plant, not for use on the finishing line.
Prevention of scratches during handling and shipment using the slip agent at the surface of the interleaf provides the following advantages. It will yield improvement through scratch reduction. There will be a cost reduction through process simplification and film coating elimination. Scratching can be avoided using the paper or film at the bottom of the draw on difficult to protect unfinished glass having particle chips from unground edges and other sources. It is an inexpensive approach versus other alternatives. No additional surface washing techniques are needed to make the glass surface less active and remove particles that could scratch in subsequent washing and handling.
Many additional features, advantages and a fuller understanding of the invention will be had from the accompanying drawings and the detailed description that follows. It should be understood that the above Technical Summary provides a description in broad terms while the following Detailed Description provides a more narrow description and presents embodiments that should not be construed as necessary limitations of the broad invention as defined in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view showing the prior art use of Visqueen film lamination on glass with a sheet of paper between the film (a three layer system);
FIG. 2 is a view of a single interleaf paper or film between glass sheets;
FIG. 3 is a view showing use of a double sided coated interleaf paper or film before application to the glass sheets;
FIG. 4 shows a compressed stack of glass sheets and second scratch protection provided by the slip agent between the interleaf and the glass sheet;
FIG. 5 shows separated glass sheets and first scratch protection provided on the glass sheets in the form of a slip agent surface roughness discontinuous layer;
FIG. 6 is a view showing use of single side coated interleaf paper or film before application to the glass sheets in which one slip agent coating faces away from the coating of the other interleaf;
FIG. 7 shows a compressed stack of glass sheets and second scratch protection provided by the slip agent between each interleaf and the glass sheet;
FIG. 8 shows separated glass sheets and first scratch protection provided on the glass sheets in the form of a slip agent surface roughness discontinuous layer;
FIG. 9 is a view showing use of single side coated interleaf paper or film before application to the glass sheets in which one slip agent coating faces toward the coating of the other interleaf;
FIG. 10 shows a compressed stack of glass sheets and slippage between the interleaf sheets providing scratch protection;
FIG. 11 shows the separated glass sheets and no slip agent surface roughness protection provided on the glass sheets;
FIG. 12 shows a method of applying a slip agent surface roughness discontinuous layer to a glass sheet using rollers;
FIG. 13 compares the defects and yields of glass sheets subjected to a Visqueen peeled film, untreated paper, erucamide coated paper, and single layer polymer film;
FIG. 14 shows the contact angle on glass treated with a Visqueen peeled film, untreated paper, erucamide and stearamide imbibed paper under different papermaking conditions, and single layer polymer film; and
FIG. 15 shows the effect of temperature on the contact angle on glass treated with erucamide imbibed paper and single layer polymer film.
DETAILED DESCRIPTION
Referring to FIG. 2 , a slip agent can be applied to a glass sheet in one technique through compression when preparing a stack of glass sheets for shipment (hereinafter to be referred to as the “compression method”). As illustrated, a carrier membrane, for example, a single sheet of the interleaf paper or polymer film containing slip agent 26 is positioned between adjacent glass sheets 28 , 30 and 30 , 32 in a stack 34 of glass sheets ( FIG. 4 ). A stack of glass sheets can include 100 or more sheets, for example. Referring to FIG. 3 , slip agent protrudes from both sides 37 , 39 of interleaf sheet 40 facing opposing surfaces 42 , 44 of the glass sheets. When the interleaf sheet(s) 40 are compressed between the glass sheets 28 , 30 due to the weight of the glass sheets in the stack ( FIG. 4 ), a small portion of the slip agent is transferred to the surfaces 42 , 44 of the glass. Upon unstacking of the glass sheets 28 , 30 and separation of the interleaf paper or film from the glass sheets, the transferred portion of the slip agent remains on the glass sheets ( FIG. 5 ) providing the first scratch protection for the glass. When the glass sheets are stacked with the interleaf sheet(s) 40 between the glass sheets 28 , 30 , the slip agent provides the second scratch protection for the glass sheets against any particles 46 located between the glass sheets during handling and storage of the stack of glass sheets.
Although the mechanics of the first and second scratch protection are not fully understood, it is believed particles such as glass chips may roll or slide upon the slip agent rather than on the bare glass, thereby preventing scratches on the glass. The slip agent may roll between the glass sheet and the interleaf paper or film, or it may coat particles that roll between the interleaf paper or film, or both.
While the slip agent protruding from the interleaf sheet or film and transferred onto the glass sheet is depicted in the figures, it will be appreciated that the slip agent, interleaf, and glass sheets are not to scale. Only nanogram amounts per centimeter 2 of the slip agent is transferred to the glass sheet. The slip agent may not actually resemble what is shown in the drawings. The slip agent molecules may be polar, which could help to align the molecules on the interleaf paper and film, and on the glass sheet. This may produce a glass sheet with surface roughness on one or both sides thereof. Interior glass sheets of the stack may include a discontinuous layer of slip agent that forms surface roughness layer on both sides of the glass sheet.
Another approach is to use the compression method to apply the slip agent when coated on only one side of an interleaf sheet. Two such single-sided interleaf sheets 50 , 52 would be used. The interleaf sheets 50 , 52 can be placed between two glass sheets with their slip agent coated sides facing outwardly away from each other, as shown in FIG. 6 . Upon compression of the interleaf sheets between the two glass sheets 28 , 30 due to the weight of the stack of glass sheets ( FIG. 7 ), a portion of the slip agent is transferred to the glass sheets surfaces 58 , 60 and provides second scratch protection. While the glass is stacked with interleaf sheets as shown in FIG. 7 , particles such as glass chips 46 between the glass sheets can roll or slide on the slip agent 36 on the interleaf sheets 50 , 52 instead of on the bare glass surfaces 58 , 60 , or the particle movement could be inhibited by the slip agent contact between the paper or film sheet and the glass sheet. The facing surfaces 64 , 66 of the interleaf sheets may provide some slip in the stack, but the primary slip would be along the plane between the slip agent coated interleaf surfaces 54 , 56 and the glass surfaces 58 , 60 . A portion of the slip agent is then transferred onto the inwardly opposing surfaces 58 , 60 of adjacent glass sheets as shown in FIG. 8 , providing the first scratch protection for the glass in which the particles roll or slide on the slip agent 48 remaining on the glass after the interleaf sheets 50 , 52 have been removed from the glass sheets.
The compression method for applying the slip agent to the glass sheets via interleaf sheets placed between the sheets of glass in a stack of glass sheets offers second scratch protection to the glass sheets within the stack. That is, any glass particles from the cut edge (or other particles) that are located between the glass sheets will move against the slip agent on the interleaf sheets rather than against the bare glass, which prevents scratching of the glass when the glass sheets of the stack move relative each other. On the other hand, slip agent may be located between the glass sheet and the particles. Moreover, once the glass sheets of the stack are separated, the interleaf sheets are removed and the glass sheets are ready to be placed on the finishing line; the glass sheets contain the slip agent (first scratch protection). At this point, no interleaf sheets remain on the glass sheets during the finishing run. The glass sheets are solely protected by the slip agent on the surface of the glass. The interleaf paper that performed better than others as described in the examples below is one which was imbibed with or coated with erucamide as the long chain fatty amide as well as a sizing agent such as alkyl ketene dimer.
Another technique for applying slip agent to glass sheets disclosed herein is coating (laminating) a polymer film containing the slip agent to the glass sheet (e.g., Visqueen polymer film that includes erucamide slip agent) and then stripping the film from the glass sheet. After the film is stripped from the glass, some of the slip agent remains on the glass sheet. This provides the first form of scratch protection of the glass along the finishing line after the film has been removed.
In a process of applying the slip agent from the paper or polymer film to the glass sheets using rolls, the method includes providing on both sides of a glass sheet the paper or polymer film 80 wound on a feed roll 84 , the paper or film extending from the feed roll to a take-up roll 82 . Next, as the paper or film 80 advances onto the take-up rolls, the paper or film and the glass sheet 86 are compressed between rollers 88 on either side of the glass sheet (in a direction shown by arrows 90 ). The glass sheet moves in a direction 92 . The glass sheet may also move in the opposite direction, opposite to the traveling direction of the paper or film. This presses the slip agent 36 protruding from the paper or film 80 onto the glass sheet 86 and transfers some slip agent 36 from the paper or film onto the glass sheet. The paper or polymer film is removed from the glass sheet once the sheet passes through the rollers and then it travels to the take-up roll where it is wound up. The paper or film may still contain a sufficient quantity of slip agent after contacting the glass sheet for enabling reuse of the paper or film to apply slip agent to additional glass sheets or it might only be used one time.
Two single-sided interleaf sheets 68 , 70 between adjacent glass sheets in a stack of glass sheets, wherein the coated sides 72 , 74 of two interleaf sheets are inwardly facing relative to each other ( FIG. 9 ), may be employed to achieve the second scratch protection only for the glass sheets. The interleaf sheets have outer surfaces 76 , 78 without slip agent facing the inner surfaces 58 , 60 of the adjacent glass sheets. In this way, the friction where the two interleaf sheets' uncoated sides contact the sheets of glass is greater than the friction where the two interleaf sheets' coated sides contact each other. Upon compression of the interleaf sheets between the glass sheets as shown in FIG. 10 any particles 46 on the bare glass are prevented from scratching the glass because the principal movement between adjacent glass sheets is via slip agent 36 along the plane between the interleaf sheet surfaces 72 , 74 (e.g. where friction is the lowest), thereby providing the second scratch protection of the glass. Once the glass sheets are separated no slip agent transfers to the opposing surfaces 58 , 60 of the glass sheets ( FIG. 11 ). If first scratch protection of the glass is desired for the finishing line after the interleaf sheets have been removed from the glass, then the slip agent would need to be applied to the surface of the glass sheets through another means.
The paper used in this disclosure is made using a Fourdrinier paper making machine and can be purchased from the Thilmany Pulp & Paper Company. An overview of a Fourdrinier machine is described in U.S. Pat. No. 7,189,308, which is incorporated herein by reference. The optional alkyl ketene dimer sizing agent is added at the wet end of the process. In addition, the slip agent can be added at the size press such as passing the paper through a bath including the sizing agent. Then, the paper passes through drier cans at a temperature exceeding a melting point of the erucamide. Next, at the dampener where water is added to obtain a proper curl of the paper, this is another location at which the slip agent can alternatively be added. At the dampener the slip agent can be coated onto one side of the paper. Then, the paper passes to the supercalendar, which squeezes the paper between opposing denim covered stainless steel rolls and stainless steel rolls. At this location fibers are locked down in the paper. The paper of this disclosure can be calendared or uncalendared. Then the paper travels to a rewinder. The slip agent can alternatively be coated onto the paper by spraying at the supercalendar or the rewinder. Suitable paper is described in publication WO 2008/002584, which is incorporated herein by reference.
The slip agent can be added to the paper as a dispersion (e.g., a wax dispersion) or an emulsion. The slip agent may be added as a solid to the polymer resin that forms the polymer film. Stable aqueous wax dispersions are disclosed in U.S. Pat. Nos. 5,743,949 and 4,481,038, which are incorporated herein by reference in their entireties. The supplier of the emulsion can also provide defoamer and surfactant in the slip agent emulsion or dispersion to facilitate application of the slip agent to the paper. A suitable defoamer is ethylene his distearamide.
Compounds that might be suitable as slip agents include at least one long chain fatty acid ester or fatty acid amide. The long chain fatty acid esters and fatty acid amides of this disclosure are derivatives of saturated and unsaturated normal fatty acids ranging from fourteen to thirty-six carbon atoms. Representative fatty acids are, for example, tetradecanoic, pentadecanoic, hexadecanoic, heptadecanoic, octadecanoic, nonadecanoic, eicosanoic, hencosanoic, decosanoic, tetracosanoic, pentacosanoic, tricosanoic, hexacosanoic, triacontanoic, dotriacontanoic, tetratriacontanoic, hentriacontanoic, pentatriacontanoic, hexatriacontanoic acids, myristic, palmitic, stearic, arachidic, behenic and hexatrieisocontanoic (C 36 ) acids, oleic, palmitoleic, linolenic and cetoleic, and the like.
Long chain fatty amides are preferred as slip agents, suitable slip agent might include one or more of the following: unsaturated fatty acid monoamide (e.g., oleamide, erucamide, recinoleamide); saturated fatty acid monoamide (preferably, lauramide, palmitamide, arachidamide, behenamide, stearamide, 12 hydroxy stearamide); N-substituted fatty acid amide (e.g., N-stearyl stearamide, N-behenyl behenamide, N-stearyl behenamide, N-behenyl stearamide, N-oleyl oleamide, N-oleyl stearamide, N-stearyl oleamide, N-stearyl erucamide, erucyl erucamide, erucyl stearamide, stearyl erucamide, N-oleyl palmitamide); methylol amide (e.g., methylol stearamide, methylol behenamide); unsaturated fatty acid bis-amide (e.g., ethylene bis-oleamide, hexamethylene bis-oleamide, N,N′-dioleyl adipamide, ethylene bis oleamide, N,N′-dioleyl sebacamide); saturated or unsaturated fatty acid tetra amide; and saturated fatty acid bis-amide (e.g., methylene bis-stearamide, ethylene bis-stearamide, ethylene bis-isostearamide, ethylene bis-hydroxystearamide, ethylene bis stearamide, ethylene bis-behenamide, hexamethylene bis-stearamide, hexamethylene bis-behenamide, hexamethylene bis-hydroxystearamide, N,N′-distearyl adipamide, N,N′-distearyl sebacamide).
Specific long chain fatty amides that may be suitable are erucamide, stearamide, oleamide and behenamide. Fatty amides are commercially available from Humko Chemical Company and include, for example Kemamide S (stearamide), Kemamide U (oleamide), Kemamide E (erucamide). In addition, fatty amides are commercially available from Croda Universal Ltd., and include, for example, Crodamide OR (oleamide), Crodamide ER (erucamide), Crodamide SR (stereamide), Crodamide BR (behenamide).
The sizing agent used herein is known as an alkyl ketene dimer (AKD); these types of sizing agents are described in U.S. Pat. No. 6,576,049, which is incorporated herein by reference in its entirety. Specific examples of AKD sizing agents that may be suitable in the present invention include but are not limited to octyl ketene dimer, dodecyl ketene dimer, tetradecyl ketene dimer, decyl ketene dimer, hexadecyl ketene dimer, eicosyl ketene dimer, docosyl ketene dimer, octadecyl ketene dimer, tetracosyl ketene dimer. Also included are those prepared from organic acids and mixtures of fatty acids such as those found in palmitoleic acid, rincinoleic acid, oleic acid, linoleic acid, linolenic acid, olive oil, coconut oil, palm oil, and peanut oil. Mixtures of any of such acids may also be used. AKD sizing agents can include but are not limited to those comprising at least one alkyl group comprising from about 8 to about 36 carbon atoms.
The slip agent can be washed off the glass at the finishing line using known washing processes and equipment, including brushes, ultrasound, water jet spraying, and detergent (e.g., potassium hydroxide detergent) at a pH of 10-12. The washing fluids will not dissolve the erucamide surface roughness, but it is nevertheless removed from the glass sheets by the mechanical action cleaning processes and devices of the finishing line.
This disclosure will now provide a description by way of the following examples, which are for the purpose of illustration and should not be interpreted to limit the invention as defined in the claims.
Example 1
The following conditions were evaluated: 2-sided erucamide imbibed paper in which the erucamide was applied at the size press (Condition 1); 1-sided erucamide imbibed paper in which the erucamide was applied at the size press (Condition 2); 2-sided erucamide imbibed paper in which the erucamide was applied at the size press, the paper including alkyl ketene dimer (AKD) (Condition 4); 2-sided stearamide imbibed paper in which the stearamide was applied at the size press, the paper including AKD (Condition 6); erucamide coated paper in which the erucamide was applied at the dampener (Condition 7); and stearamide coated paper in which the stearamide was applied at the dampener (Condition 8). The supercalendaring conditions were as indicated in the following Table 1. The number of nips in the supercalendar conditions refer to the number of rollers through which the paper passed and these rollers were either heated or cold as indicated. The erucamide and stearamide were applied to the paper as aqueous dispersions, wherein the 10% value indicates the concentration of the erucamide or stearamide in the dispersions.
TABLE 1
Roll
Roll
Roll
Coating Condition
Supercalender
Lot Serial
Width
Weight
Length
#
Conditions
Conditions
Number
(Gen)
(kg)
(m)
8
stearamide (10%) @
5 nip cold stack
N2423275
lab size
dampener
N2423276
Gen 5
311
3,658
N2423608
Gen 8
468
2,713
7
erucamide (10%) @
6 nip cold stack
N2423279
lab size
dampener
N2423280
Gen 5
172
1,981
N2423281
Gen 8
311
1,829
1
coated 2 side (C2S)
full hot stack
N2423266
lab size
erucamide (10%) @ size
N2423265
Gen 5
336
3,975
press
N2423252
Gen 8
476
2,900
non-supercalendered
N2423269
lab size
N2423268
Gen 5
325
3,975
N2423256
Gen 8
462
2,900
2
coated 1 side (C1S)
full hot stack
N2423261
lab size
erucamide (10%) @ size
N2423262
Gen 5
321
3,975
press
N2423258
Gen 8
468
2,900
4
coated 2 side erucamide
5 nip hot stack
N2423272
lab size
(10%) @ size press; with
N2423271
Gen 5
180
2,134
internal AKD
N2423610
Gen 8
468
2,896
6
coated 2 side stearamide
5 nip hot stack
N2423202
lab size
(10%) @ size press; with
N2423283
Gen 8
251
1,554
internal AKD
6
coated 2 side stearamide
non-supercalendered
N2423255
lab size
(10%) @ size press; with
N2423254
Gen 8
288
1,783
internal AKD
The initial testing of the papers from the paper mill included coefficient of friction testing as shown below.
TABLE 2
Coefficient of Friction of Papers
Sheet
Sheffield
COF to steel
COF
Condition
Side
Smoothness
Test # 1
Test # 2
average
WR-
Control
felt
327
0.27
0.31
0.29
139
wire
347
0.29
0.31
0.30
1
2 sided Eruc
felt
127
0.25
0.27
0.26
SC
wire
152
0.29
0.29
0.29
1b
2 sided Eruc
felt
297
0.28
0.30
0.29
NC
wire
321
0.27
0.23
0.25
2
1 sided Eruc
felt
100
0.27
0.27
0.27
SC
wire
115
0.24
0.29
0.27
2b
One sided Eruc
felt
332
0.23
0.30
0.27
NC
wire
335
0.26
0.27
0.27
3b
One sided Eruc
felt
338
0.29
0.31
0.30
NC w/AKD
wire
346
0.31
0.27
0.29
4
2 sided Eruc
felt
96
0.29
0.27
0.28
w/AKD SC
wire
122
0.29
0.22
0.26
4b
2 sided Eruc
felt
344
0.25
0.23
0.24
w/AKD NC
wire
352
0.28
0.27
0.28
6
2 sided Stear-
felt
109
0.28
0.31
0.30
SC 5 nips
wire
150
0.30
0.25
0.28
6b
2 sided
felt
342
0.26
0.23
0.25
Stearamide
wire
362
0.30
0.28
0.29
w/AKD NC
7
Eruc @
felt
166
0.21
0.15
0.18
dampener SC
wire
172
0.27
0.29
0.28
7b
Eruc @
felt
322
0.16
0.15
0.16
dampener NC
wire
327
0.30
0.26
0.28
8
Stear @
felt
143
0.26
0.27
0.27
dampener SC
wire
158
0.24
0.26
0.25
8b
Stearamide @
felt
327
0.26
0.27
0.27
dampener NC
wire
341
0.26
0.24
0.25
*b samples are non-supercalendered
The coefficient of friction (COF) data support the understanding that the mechanism of action of the slip agent is not primarily by lowering the coefficient of friction. In Table 2, COF to steel means rubbing a steel plate across the paper to ascertain the COF. The above data shows that most papers have similar COF values. This includes un-coated paper. The only significantly lower COF results were obtained from the single sided dampener trial results (e.g. the slip agent was applied to the paper at the dampener), for both calendared and uncalendared papers. Therefore, COF alone is not responsible for the scratch protection differences to be shown later in this disclosure, produced by Condition 1 (2-sided erucamide imbibed paper in which the erucamide was applied at the size press) using supercalendared paper. This was supported by earlier testing using solid slip agents on glass versus the liquid slip agent, glycerol, in which the solid slip agents outperformed the liquid slip agents. Here the solid particles were better in scratch prevention, although both provided low COF. In addition, the supercalendar differences indicate that the calendared paper may not be driving the slip agent towards or away from the surfaces. Finally, from contact angle data discussed below, it was inferred that the dampener process results in the most slip agent on the felt-side paper surfaces, and that it does not migrate to the papers wire-side upon rolling.
Example 2
Testing of Coated Papers and Selection of 2-Sided Erucamide Coated Paper from the Supercalendar Process for Scale Up
The paper-conditions that were deemed acceptable from the mill trial were Condition 1 (2-sided erucamide imbibed paper applied at the size press) and Condition 6 (2-sided stearamide imbibed paper applied at the size press and including AKD), with calendared and uncalendared paper available from each. Other conditions became useful primarily for later testing since there were line issues with foaming, coating pumping, coating concentration variations, and roll alignment during other conditions. Although the dampener trials were satisfactory, the 1-sided coatings were not used for scale-up, since at this time two sheets of coated paper per substrate had a high cost. Best results were obtained under Condition 4 (2-sided erucamide imbibed paper in which the erucamide was applied at the size press, the paper including AKD).
Stain testing was conducted using washed glass (e.g., 2% Semiclean KG solution at 45° C. for 15 minutes) having a low particle count, stacked for 16 hours at 50° C. and 85% relative humidity under a packing weight (e.g., 4.4 kg). Particle density of the glass sheets was measured after washing using ETHAN (or MDM2) inspection system.
A scratch test was developed to evaluate motion of the materials rubbed across the glass surface. As in stain testing, the glass sheets were 5×5 inches. The glass was washed and had a low particle count. This test used a simple flat-bottomed container with the material attached to the base to ride across the glass, not including glass chips, in a repeatable way. Loading, speed and number of passes can be controlled. Once the test was complete the results after washing were compared using a particle density instrument.
4 materials at the top of Table 3 were evaluated to choose candidates for on-line tests. All results are listed in particles per square centimeter left on glass surfaces after testing. Results of 10 or less for stain are acceptable, while scratch numbers below 40 are generally acceptable. All slip agents in Table 3 were applied at the size press except the two noted for the dampener application. The tests showed that stearamide had higher stain results compared to erucamide, which made erucamide a more suitable slip agent.
TABLE 3
Scratch and Stain Data for New Single Layer Materials
Month 1
Month 2
Month 3
Scratch
Scratch
Scratch
Coated Paper Condition
Stain Average
Median
Stain Average
Median
Stain Average
Median
2-Sided Stearamide w/AKD, SC; C6
39.2
11.9
2-Sided Stearamide w/AKD, no SC; C6
209
8.3
50.1
2-Sided Erucamide, SC; C1
5.7
25.7
2-Sided Erucamide, no SC; C1
1.7
22.4
Control, WR-139 Uncoated paper
2.4
1
4.4
34.1
16
1-sided Erucamide, size press; C2
4.1
3.5
2-sided Erucamide, w/AKD; C4
2.6
4.1
1-sided Erucamide, dampener; C7
9.6
30.9
1-sided Stearamide, dampener; C8
3.1
11.9
ENW53B (2%) SL polymer
4.1
10
ENW53B (1.5%) SL polymer
7.6
13.9
From Table 3, the best choices were from condition 1(C1), the 2-sided erucamide imbibed materials. Super-calendared (SC) and uncalendared versions of C1 were evaluated further. All scratch analysis results (Table 3) are shown to be in an acceptable range.
Stearamide with AKD, condition 6 (C6) stained the glass more than the erucamide. Later data (Table 5) will show stearamide was in higher concentration at the glass surface, before washing, compared to erucamide. The alkyl ketene dimer (AKD) used in C6 is a common sizing agent used in the paper industry. Addition of this less expensive material (AKD) was intended to bind to the paper interior and allow more slip agent to migrate to or remain at the surface. For erucamide imbibed in the paper at the size press, Condition 4 (C4), there was a higher amount of material found on glass surfaces after contact with AKD versus without AKD.
The Month 3 result listed in Table 3 for condition C1 was high (50.1), as was the control result (16) since these samples were aged for 2 weeks at 50° C. in a humidity chamber with dense pack loading (23 g/cm 2 ) and 50% relative humidity. This temperature effect has been observed by several techniques to bring more erucamide slip agent to the paper surface.
Also shown are limited results for the polymer single layer (SL) interleaf. Those results were based on 3 replicates per test, due to sample availability. Usually stain is based on 15 replicates, and scratch on at least 5 replicates. The sample was a single layer polymer film (“SL polymer film”; i.e., no other separate independent layers) that included three sublayers, one being a central medium density polyethylene core. The core was made of a foam of medium density polyethylene. Two outer skin layers of low density polyethylene sandwiched the core. The total film thickness ranged from about 70 to 120 microns.
Example 3
On Line Testing of 2-Sided Erucamide Coated Paper and Single Layer Polymer Paper
Glass surfaces contacting one paper imbibed with erucamide (“Coated paper”) and one single layer polymer film imbibed with erucamide (“SL polymer film”) were compared along with glass surfaces contacting un-coated paper and glass surfaces with Visqueen film residue after peeling (“Manually peeled Visqueen film”). Generation 8 lots of 100 for each interleaf type were packed in separate crates then loaded onto the finishing line. The order of run may be relevant. The Visqueen peeled surfaces were run first while the uncoated paper was run second to be followed by the Coated paper and SL polymer film test materials. The Visqueen stripping left the most slip agent at the surface, while the uncoated paper left no slip agent protection. The expectation was that slip agent residue from Visqueen deposited on machine parts would be removed prior to testing the new materials by the glass packed in un-coated paper. Testing was carried out over two days with about a week of separation between tests, due to line availability. Results are listed in Table 4 below.
SIS is a known optical method for identifying defects in which defects are measured by strobing light onto the glass and locating the defects using a scanning camera. IPC is a similar known optical defect measurement technique. Controllable yield was the number of glass sheets that included a critical defect that would have required scrapping or recutting of the glass sheet divided by the total number of glass sheets tested.
TABLE 4
Input
Controllable
SIS Defect
Sample
Sheets
Yield
Counts
IPC
1)
Peeled
49
100%
150-190
Visqueen Film
Uncoated
99
84%
1000-1400
Paper
Coated Paper
100
97%
120-170
SL Polymer
30
90%
30-450
Film
2)
Peeled
50
100%
100-130
0.006
Visqueen Film
Uncoated
100
67%
1000-1200
0.012
Paper
SL Polymer
74
90%
120-180
0.017
Film
A useful representation of this data is shown in FIG. 13 . This figure shows results from BOD through Finishing Testing of Materials. Note that SIS defect counts while not including rejectable defects are a measure of surface cleanliness of the substrates, and therefore an indicator of performance beyond yield criteria. FIG. 13 shows that the lowest number of defects and best yields were achieved using manually peeled Visqueen film (data labeled A), the Coated paper (data labeled C), and the SL polymer film (data labeled D), whereas the worst yields were from the uncoated paper (data labeled B).
Example 4
Contact Angle Measurements
When the contact angle measured for a treated sheet of glass is higher, it means there is more of the treatment material on the glass. FIG. 14 first shows the anticipated range of contact angles expected from the surface of glass after peeling off Visqueen film, which included erucamide. The aged BOD surface is the contact angle that resulted from many months of aging BOD sourced glass in a crate before peeling (indicated as Vpa in FIG. 14 ), while other contact angle data was obtained by using washed glass with laminated Visqueen film which was immediately stripped (indicated as Vpf in FIG. 14 ). This table verifies that aging deposits more erucamide on the surface of the glass Vpa, raising the contact angle relative to the glass with the stripped laminated Visqueen film Vpf. In FIG. 13 the 100% yields are observed for the aged Visqueen film peeled surfaces. The next small bar P of FIG. 14 represents the glass samples held overnight with only the dense pack uncoated paper; this had almost no effect, and low contact angle indicates no transfer of coating material to the glass. The next set of bars C1, C1unc, C2, C4, C6 and C6unc show the various conditions from the slip agent coated paper trials, with the unc in C1unc and C6unc indicating uncalendared paper, with the remaining bars being calendared paper. D1 and D2 were dampener trials of paper having 10% solids, erucamide loading. The last bar at the end Pf was for the single layer polymer film run in FIG. 13 . The higher contact angle of C1 versus the polymer film concurs with the yield of 97% versus 90% observed in FIG. 13 .
All conditions were further lab-tested for stain and scratch as Table 1 shows, and Condition C4, showed favorable results. Condition C4 with alkyl ketene dimer (AKD) showed a higher contact angle ( FIG. 14 ) than other conditions of coated paper. For this reason, the next trial used paper made by C4.
Example 5
The glass was placed in contact with the coated paper and held overnight in a clean room. This simulates the transfer of slip agent due to compression of the glass sheets in a stack. The glass surfaces after paper contact were examined to confirm the transfer of slip between paper and glass surfaces. Many analytical techniques were attempted but were unable to determine this transfer due to the presence of very small particles of erucamide not uniformly spread on the surface of glass with low coverage. The mass ESI (Electrospray ionization)-MS-MS, mass spectrometry results did show both the identity and amount, using a solvent wash of the surface. Table 5 shows ESI MS-MS results for several trial paper coating conditions.
TABLE 5
Erucamide Transfer to Glass from Paper
Stearamide
Erucamide
(ng/6.4 cm2) at
(ng/6.4 cm2)
Paper Type for Contact
glass surface
at glass surface
Dampener, 10% solids, Stearamide
1120
Detected
5453
Detected
2-Sided Stearamide w/AKD
1696
Detected
Uncalendered
1303
Detected
2-Sided Stearamide w/AKD
2206
Detected
2071
Detected
2-Sided Erucamide w/AKD
262
163
1-Sided Erucamide
55
Visqueen, peeled
240
134
Uncoated Paper
Not Detected
Not Detected
Not Detected
Not Detected
Each test was done in duplicate. Stearamide coatings were shown to be contaminated with erucamide, which shows that the stearimide samples were not pure. Erucamide with AKD showed transfer to the glass surface in the range of peeled Visqueen film, with 1-sided Erucamide coating transferring less to glass, although the COF of the 1-sided (Table 2) was lower. The uncoated paper showed no slip agents. The high amounts of stearamide transferred were not easily washed off the surfaces as shown in Table 3. The highest amount of stearamide transferred was without AKD but at the dampener, where a higher surface concentration is likely since the paper is near the end of the papermaking process, and completely formed, and denser versus at the size press.
Example 6
To enhance the amount of erucamide transferred from interleaf paper or polymer film interleaf, the materials were tested at elevated temperatures. There were higher contact angles with increased temperatures for the two sided erucamide coated paper, Pc, but the effect for the film, Pf, was much less significant than for the paper. There is a possibility that transfer of glass at higher than usual temperatures in the shipment container with paper contact, or temperature rises in warehouses could enhance the surface protection of coated papers. FIG. 15 shows this result. The base temperature of 19.4 degrees C. was the clean room temperature.
Many modifications and variations of the invention will be apparent to those of ordinary skill in the art in light of the foregoing disclosure. Therefore, it is to be understood that, within the scope of the appended claims, the invention can be practiced otherwise than has been specifically shown and described.
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This disclosure features use of a paper or polymer film that includes a slip agent that can transfer to its surfaces. Once the paper or film is pressed against a glass sheet, this will leave a thin surface roughness of slip agent that can prevent or reduce glass surface scratches from other surfaces or particles during shipping or finishing (e.g., cutting to size, conveyance of glass), thereby improving the yield of glass shipments between glass forming plants and customers. The thin discontinuous layer of slip agent remaining on the glass surface can be washed off easily in subsequent washing processes. The paper or film can have the slip agent imbibed within the paper or coated on it as a surface member.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a non-provisional application claiming priority from Chinese Patent Application No. CN201110452621.X, filed Dec. 30, 2011, and incorporated herein by reference in its entirety.
FIELD OF THE DISCLOSURE
[0002] The present invention relates to an electric tool for weeding the lawn in a garden, and more particularly to an electric weeder.
BACKGROUND OF RELATED ART
[0003] In the prior art, the traditional methods for weeding the lawn include manual weeding and spraying herbicide by a chemical method. In order to alleviate work intensity of manual weeding and enhance the efficiency of weeding, some digging tools are designed for weeding, which contain manual machine and hand-held electric weeder. However, these digging tools almost have some disadvantages, for example, the weeds cannot be eradicated, or some large pits may be remained in the ground after weeding, so that the initial greensward and then the lawn are damaged.
[0004] The prior electric weeder commonly includes a diving device, a transmission device, an operating handle, a connecting device, a removing device, and a working head. This weeder has a relatively long and incompact overall structure, and the removing structure is too complex for the user to operate conveniently; moreover, the handle structure of the machine is not designed according to the characteristic of the weeding operation, that is, it is not designed by cooperating the weeding operation with the ergonomics application, resulting in that the user may get tired easily when operating the machine and it is time and labor consuming.
SUMMARY
[0005] The object of the present invention is to provide an electric weeder which can exactly weed the lawn with little damage, and it includes a simple weeds-removing mechanism and can enhance the efficiency of weeds-removing. In addition, the present invention provides an operating method for weeding, and also provides an optimal size range of the external appearance which incorporates with the external shape of the machine, with such size range, the weeder enables the force direction of the hand of the operator approximately pass through the working head of the machine during the operation so as to obtain an object of labor saving.
[0006] In order to resolve the above technical problem, the present invention provides an electric weeder, including a driving device, a transmission shaft, a working head, a sleeve, a removable handle, and a removing plate. The driving device is disposed in the housing, a transmission shaft is rotatively driven by the driving device, the working head is connected to and rotated along with the transmission shaft. The sleeve is mounted around the transmission shaft and connected to the housing; the removable handle is configured to move along the transmission shaft, and one end of the removable handle is disposed around the sleeve; the removing plate is disposed on the other end of the removable handle and configured to move along with the removable handle, and the removing plate is provided with a through portion allowing the working head to pass through.
[0007] The invention also provides an electric weeder, including a housing, a driving device, a working head, and a removable handle. The driving device is disposed in a housing, and including an axis line. The working head is connected to the axis line and driven by the driving device; the removable handle moves relative to the working head and the housing, and wherein on end of the removing handle is movably connected to the housing, the other end includes a removing plate, and the removing plate includes a through portion being passed through by the working head.
[0008] The beneficial effects of the present invention are as follows:
[0009] The electric weeder of the present invention can exactly weed the lawn with little damage, and the weeds-removing mechanism is simple and practical. The removable handle is directly cooperated with the weeds-removing mechanism in the axial direction such that the weeds and soils can be pushed out by the removable handle without any connections that are usually arranged between the conventional operating handle and the weeds-removing mechanism, which makes the overall structure of the machine more simple and effectively reduces the overall length of the machine; the removable handle can remove the weeds automatically so as to lower the work intensity of the operator and increase the efficiency of weeding. Contrary to the conventional machine, the design for the external structure of the present invention advantageously cooperates with the ergonomics. As a result, the operator can operate the machine with labor and time saving, and it is not easy to feel tired upon holding the machine, thus the work efficiency can be enhanced greatly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a structural view of an electric weeder according to one embodiment of the present invention;
[0011] FIG. 2 is a structural view of the electric weeder of FIG. 1 during removing the weeds;
[0012] FIG. 3 is a structural view of an electric weeder according to another embodiment of the present invention;
[0013] FIG. 4 is a structural view of the electric weeder of FIG. 3 during removing the weeds; and
[0014] FIG. 5 is a structural view of the external structure of the electric weeder according to the present invention.
DETAILED DESCRIPTION
[0015] Next, the present invention will be described with reference to the drawings. The following embodiments are only used to explain the technical solutions of the present invention more clearly, and cannot be used to restrict the protection scope of the present invention.
The First Embodiment
[0016] As shown in FIGS. 1 and 2 , the electric weeder includes a power portion, a transmission portion, and a weeds-removing mechanism. A driving device (not shown) is disposed in a main housing 7 and used to drive a transmission shaft 2 to rotate. A sleeve 8 which is mounted around the transmission shaft 2 is connected to the lower end of the main housing 7 , and in other embodiments, the sleeve 8 may be integrated with the main housing 7 . One end of the sleeve 8 is connected to the main housing 7 , and the other end is a flange 81 protruding from the body of the sleeve. Generally, the working head of the machine includes several rods 1 arranged on the same circumference, wherein the ends of the rods are all connected to the transmission shaft 2 . The driving device may be similar to that of an electric drilling machine, an electric screwdriver, or other electric driving devices.
[0017] A removable handle 5 is disposed around the periphery of the transmission shaft 2 and can slide along the transmission shaft 2 . The removable handle 5 is configured as cylinder shape, wherein one end thereof is a hook 52 which is slidably mounted around the outer wall of the sleeve 8 and limited by the flange 81 on the lower end of the sleeve 8 so as to slide without disengaging from the outer wall of the sleeve 8 , and the other end thereof is closed by a removing plate 3 . The removing plate 3 is provided with several through portions for allowing several rods 1 to pass through, respectively. In addition, a circular limiting plate 51 is connected to the inner wall of the removable handle 5 , and the distance between the limiting plate 51 and the hood 52 is larger than the height of the sleeve 8 , so that the flange 81 on the sleeve 8 is always located between the limiting plate 51 and the hook 52 . The circular structure formed in the limiting plate 51 will not interfere with the movement of the transmission shaft 2 , and the transmission shaft 2 can freely rotate or shuttle axially therein.
[0018] The weeds-removing mechanism further includes a reset element which is generally a reset spring 4 mounted around the transmission shaft 2 . The transmission shaft 2 is provided with a shoulder 21 , thus, one end of the reset spring 4 may be abutted against a limiting plate 51 in the removable handle 5 , and the other end of the reset spring 4 may be abutted against the shoulder 21 on the transmission shaft 2 , so that the reset spring 4 is held by the limiting plate 51 and the shoulder 21 .
[0019] When using the electric weeder to weed the lawn, as shown in FIG. 1 , the center of the circumference surrounded by the rods 1 should be aligned with the roots of the weeds and the machine should be inserted into the ground with an appropriate depth. Subsequently, the switch 6 is activated to control the start of the driving device in the main housing 7 , and then the transmission shaft 2 is driven by the driving device and rotated to bring the rods 1 to rotate, such that the roots of the weeds and the soil can be wrapped on the rods 1 under the action of the rotation of the rods 1 . At this time, the operator may turn off the switch 6 and pull the rods 1 together with the weeds and soil out of the ground. In this way, only a very small pit may be remained on the ground which was occupied by the weeds.
[0020] When removing the weeds, the operator may push the removable handle 5 downwards, and the removable handle 5 may force the removing plate 3 to move downwards, as shown in FIG. 2 . With the guidance of the through portions on the removing plate, the removing plate 3 may move downwards along the rods 1 to remove out the soil wrapped on the rods 1 and the weeds in the soil. Since the reset spring 4 abuts against the shoulder on the transmission shaft 2 at one end and keeps static relative to the transmission shaft 2 , the limiting plate 51 in the removable handle 5 will compress the reset spring 4 when the removable handle 5 moves downwards in the axial direction of the sleeve 8 . During the movement of the removable handle 5 , the extreme position thereof is limited by locking the hook 52 at one end of the removable handle 5 on the flange 81 of the sleeve 8 .
[0021] When the soil wrapped on the rods 1 and the weeds in the soil have been removed out by pushing the removable handle 5 downwards, if the operator releases the removable handle 5 , the weeds-removing mechanism will restore to its initial position automatically under the action of the reset force of the reset spring 4 .
The Second Embodiment
[0022] As shown in FIGS. 3 and 4 , the present embodiment is improved on the basis of the first embodiment.
[0023] In the present embodiment, the removing plate 3 is moveably connected to the removable handle 5 . The removing plate 3 is provided with a circle of protruding flange 31 at the outer periphery, and the end of the removable handle 5 is correspondingly provided with a circle of groove 53 for accommodating the protruding flange 31 of the removing plate 3 , so that the removing plate 3 can be freely rotated in the removable handle 5 . With such configuration, when the removable handle 5 is pushed to slide up and down in the axial direction, the removing plate 3 can also be forced to slide. Moreover, the structure of the sleeve 8 in the first embodiment is changed in the present embodiment. Specifically, a sleeve 9 which is mounted around the transmission shaft 2 is connected to the lower end of the main housing 7 , and in other embodiments, the sleeve 9 may be integrated with the main housing 7 . One end of the sleeve 9 is connected to the main housing 7 , and the other end is connected with a protruding spring limiting block 10 . In addition, a circular limiting plate 51 is connected to the inner wall of the removable handle 5 , wherein the distance between the limiting plate 51 and the hook 52 is smaller than the height of the sleeve 9 , and the spring limiting block 10 connected to the sleeve 9 can stop the downward movement of the limiting plate 51 so as to restrict the removable handle 5 to slide in a certain range.
[0024] The reset spring 4 is mounted around the sleeve 9 and the two ends of the reset spring 4 respectively abuts against the hook 52 of the removable handle 5 and the spring limiting block 10 so that it can be held by the hook 52 of the removable handle 5 and the spring limiting block 10 .
[0025] Other structures are similar to those in the first embodiment.
[0026] When weeding the lawn, the driving device is turned on by the switch 6 to drive the transmission shaft 2 to be rotated, and the rods 1 can be rotated along with the transmission shaft 2 to force the removing plate 3 mounted around the rods 1 to be rotated. Since the removing plate 3 is movably connected with the removable handle 5 , the removable handle 5 would not rotate when the removing plate 3 is rotated with the rods 1 . Moreover, the reset spring 4 is mounted around the sleeve 9 , so that the reset spring 4 , the sleeve 9 , and the spring limiting block 10 would not rotate with the transmission shaft 2 when the transmission 2 is rotated. In this way, it can prevent the removable handle 5 , the reset spring 4 , the sleeve 9 and other elements rotating as the rotation of the transmission shaft 2 , thereby reducing the output power of the driving device.
The Third Embodiment
[0027] In the first embodiment, as shown in FIGS. 1 and 2 , during the normal state (i.e. the electric weeder is not operated); the removable handle 5 is located at a position near to the top portion under the action of the reset spring 4 . Every time the machine is operated, it is necessary to overcome the elastic force of the reset spring to manually push the removable handle 5 downwards to a position near to the bottom portion so as to force the removing plate 3 to remove the weeds.
[0028] In the present embodiment, the position of the reset spring 4 in the first embodiment is changed, that is, the reset spring is mounted around the transmission shaft and held by the limiting plate 51 and the flange 81 .
[0029] During the natural state (i.e. the electric weeder is not operated), the removable handle 5 is located at a position near to the bottom portion under the action of the reset spring, namely, a position shown in FIG. 2 . When the operator uses the machine to remove the weeds, the center of the circumference surrounded by the rods 1 should be aligned with the roots of the weeds and the machine should be inserted into the ground with an appropriate depth, the removing plate 3 will be pushed to move upwards due to the resistance of the soil, and then the insertion force can overcome the elastic force of the reset spring. As a result, as shown in FIG. 1 , the removable handle 5 is pushed to a position near to the top portion (in other embodiments, the removable handle can also be lifted upwards by hand firstly), and the reset spring is compressed. As such, if the operator activates the switch 6 , the rods 1 will rotate along with the transmission shaft 2 , so that the roots of the weeds and the soil can be wrapped on the rods 1 under the action of the rotation of the rods 1 . At this time, the operator may pull the rods 1 together with the weeds and soil out of the ground, and the removable handle can be automatically restored to remove the weeds under the action of the reset force of the reset spring. That is to say, it is not necessary to manually push the removable handle 5 and can obtain the automatic weeds-removing.
The Fourth Embodiment
[0030] In the second embodiment, as shown in FIGS. 3 and 4 , during the natural state (i.e. the electric weeder is not operated), the removable handle 5 is located at a position near to the top portion under the action of the reset spring 4 . Every time the machine is operated, it is necessary to overcome the elastic force of the reset spring to manually push the removable handle 5 downwards to a position near to the bottom portion so as to force the removing plate 3 to remove the weeds.
[0031] In the present embodiment, the position of the reset spring 4 in the second embodiment is changed, that is, the reset spring 4 is mounted around the sleeve 9 which is located at the outside of the removable handle, and the reset spring 4 is held by the hook 52 of the removable handle 5 and the shoulder formed at the joint between the housing and the sleeve.
[0032] During the natural state (i.e. the electric weeder is not operated), the removable handle 5 is located at a position near to the bottom portion under the action of the reset spring, namely, a position shown in FIG. 4 . When the operator uses the machine to remove the weeds, the center of the circumference surrounded by the rods 1 should be aligned with the roots of the weeds and the machine should be inserted into the ground with an appropriate depth, the removing plate 3 will be pushed to move upwards due to the resistance of the soil, and then the insertion force can overcome the elastic force of the reset spring. As a result, as shown in FIG. 3 , the removable handle 5 is pushed to a position near to the top portion (in other embodiments, the removable handle can also be lifted upwards by hand firstly), and the reset spring is compressed. As such, if the operator activates the switch 6 , the rods 1 will rotate along with the transmission shaft 2 , so that the roots of the weeds and the soil can be wrapped on the rods 1 under the action of the rotation of the rods 1 . At this time, the operator may pull the rods 1 together with the weeds and soil out of the ground, and the removable handle can be automatically restored to remove the weeds under the action of the reset force of the reset spring. That is to say, it is can obtain the automatic weeds-removing without manually pushing the removable handle 5 .
The Fifth Embodiment
[0033] As shown in FIG. 5 , the external dimensions of the electric weeder in the above embodiments are optimally designed.
[0034] The optimal lengths of the electric weeder are as follows:
[0035] 1. The length L 1 of the hand-held portion of the main housing 7 of the electric weeder is 50<L 1 ≦170 mm, so that a space for receiving the fingers is provided when the operator holds the handle;
[0036] 2. The length L 2 of the removable handle 5 is 60<L 2 ≦200 mm, so that a space for operating with fingers is provided when the operator holds the removable handle to remove the weeds;
[0037] 3. The width L 3 for holding on the main housing 7 is 30<L 3 ≦60 mm, so that the main housing is adapted to be hand-held by the operator and a space for operating with fingers is provided;
[0038] 4. The overall length of the machine is L 0 =L 1 +L 2 +L 3 /2>50+60+15=125 mm, L 0 =L 1 +L 2 +L 3 /2≦170+200+30=400 mm, and thus 125<L 0 ≦400 mm;
[0039] 5. The effective working length of the pin is 20<L 4 ≦50 mm, and L 4 /L 0 =0.05˜0.4.
[0040] The optimal diameter ratios of the electric weeder are as follows:
[0041] 1. The diameter Φa of the circumference along which the rods 1 are arranged is Φ8 mm≦Φa≦Φ20 mm. With this range, the pit remained on the ground after weeding has a suitable diameter, and the resistance during the rotation of the pin is also suitable since the larger the diameter is, the greater the resistance is.
[0042] 2. The diameter Φb of the end of the removable handle 5 is Φ12≦Φb≦Φ30 mm. With this range, the operator can easily observe the roots of the weeds, and the end of the removable handle would not obstruct the vision of the operator.
[0043] 3. The diameter Φc of the hand-held portion of the handle is Φ25≦Φc≦Φ45 mm. With this range, the handle is suitable to be held by hand.
[0044] 4. In order to make the operator observe that the working head is exactly located at the roots of the weeds during the operation, the ratio of the working portion is Φa /Φb=0.5˜1.
[0045] The above contents are the preferred embodiments of the present invention. It should be noted that without departing the technical principle of the present invention, the person skilled in the art may make some modifications and changes to the present invention, which may be considered as a part of the protection scope of the present invention.
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The invention provides an electric weeder, including a housing, a driving device, a working head, and a removable handle. The driving device is disposed in a housing, and including an axis line. The working head is connected to the axis line and driven by the driving device; the removable handle moves relative to the working head and the housing, and wherein on end of the removing handle is movably connected to the housing, the other end includes a removing plate, and the removing plate includes a through portion being passed through by the working head. The electric weeder of the present invention can exactly weed the lawn with little damage, the overall structure of the machine is more simple to effectively reduce the overall length of the machine; the removable handle can remove the weeds automatically to lower the work intensity and increase the weeding efficiency.
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BACKGROUND OF THE INVENTION
This invention relates to a seat having means for adjusting the support for the back of a user and it refers particularly, but not exclusively, to an automobile seat having means for adjusting the support for the lumbar region of a user's back.
Different means have been proposed for adjusting the back rests of seats, such as automotive seats, so as to provide greater or lesser support for the lumbar region of the back but the means proposed have been rather complex in construction and do not provide a desirable fineness of adjustment.
SUMMARY OF THE INVENTION
Accordingly, it is an object of this invention to provide a seat having back rest adjusting means which will be of simple construction, easy to operate, and which will enable the support for the lumbar region of the back to be adjusted to suit the requirements of the person occupying the seat.
Another object is to provide a seat, such as a motorcar seat, having a variable contour support for the back which may be adjusted to maximise comfort and minimise fatigue.
According to the invention devised with these and other objects in view there is provided a seat having a base or seat, a back rest supported in desirable fixed or adjustable relationship to the base or seat, and means for adjusting the lumbar region of the back rest so as to cause it to project forwardly relative to the seat to a greater or a lesser extent, characterised in that the lumbar region adjusting means include a strap extending across the back rest and means for decreasing or increasing the effective length of the strap where it extends across the back rest so as to cause the said portion of the back rest to project forwardly a greater or lesser extent.
There may be provided a cushion of resilient material between the strap and the back of the seat--such as a cushion of foam plastics or foam rubber, and the means for adjusting the effective length of the strap may be at least one hand-operable adjusting screw means by which the length of the strap, from an anchorage point adjacent one side of the seat back to a strap guide adjacent the other side of the seat back, may be adjusted as required. There may be one or two of said adjusting screw means for one length of strap.
If desired there may be provided more than one adjusting strap at spaced locations in the height of the seat back rest, so that the adjustment may be effected over a greater length of lumbar region, with appropriate adjusting means for each said strap.
The accompanying drawings illustrate one practical embodiment of an adjustable back support for a seat constructed in accordance with the present invention. The drawings show only such parts of a seat necessary to illustrate the application of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional plan view of a seat back rest at the lumbar region showing one embodiment of an adjustable screw means for decreasing or increasing the length of a strap extending across the back rest;
FIG. 2 is a detail plan view in section of the adjustable screw means shown in FIG. 1;
FIG. 3 is a plan view of the adjustable screw means shown in FIG. 1;
FIG. 4 is a view in elevation of the adjustable screw means; and
FIG. 5 is an end view of the adjustable screw means shown in FIGS. 3 and 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The seat back rest 6, as illustrated in FIG. 1 has a base frame 7 for supporting the back rest 6 and that base frame may be adjustable relative to the base or seat (not shown) so that the angle of inclination of the back rest may be adjusted, as is customary. Forwardly of the base frame 7 is the material 8 covering the back rest. Behind that material is a padding 9 of suitable material and in the lower part of the back rest--corresponding in location to the lumbar region of the back of a person using the seat--is a strap 10 extending transversely across the back. As shown, one end of the strap 10 is attached at 11 to a side frame member 12 and supported at the other side by a guide 13 on a mounting frame 14 which is secured to the other side frame member 12a of the base frame. Said guide 13 is attached to and forms part of the frame 14 which has an integral boss 15 which boss 15 and guide 13 extend through a hole 16 in the side member 12a of base frame 7. The other end of the tensioning strap 10 passes over guide 13 and over a strap carrier 17 which forms part of a nut 18 engaging the threaded end 19 of shaft 20 rotatably supported in boss 15. The strap 10 then passes to the rear of mounting frame 14 where it is secured by fixing plate 21 and appropriate fixing screws 22 which may also secure the mounting frame 14 in position relative to said side member 12a. The outer end of the shaft 20 is flattened or squared at 23 to engage a corresponding recess in the hub of a knob or finger wheel 24. The inner end of hub of the knob 24 and the abutting end of boss 15 are formed with snap fit engaging formations to permit the knob to be rotated but to prevent axial movement thereof. The shaft 20 is formed with a medial collar arranged to provide a snap fit in a recess in the inner end of the boss 15, the arrangement being such as to provide for rotation of the shaft but to prevent axial movement thereof.
The strap carrier 17 forming part of nut 18 is in the form of a foot to engage the strap 10 and has at its outer side margins T formations 25 to engage correspondingly shaped guide grooves 26 in side arms 27 of the mounting frame 14 (see FIG. 5).
Rotation of the knob 24 will cause rotation of the adjustment screw 19 to thereby cause the nut 18 and strap carrier 17 to move either inwardly or outwardly, the formations 25 and grooves 26 preventing rotation of the nut and ensuring axial movement only of the nut 18. The strap carrier 17 engages with the tensioning strap 10 to cause the effective length of said strap between its end 11 and the guide 13 to be reduced or increased as the nut 18 is caused to travel inwardly or outwardly relative to the adjustment screw 19 by turning of the knob 24.
It is apparent that as that effective length is reduced the back rest, at the lumbar region, will be caused to project forwardly and when the length is increased it will be permitted to retract.
In the case of a bucket-type seat there may be two of the adjustment means, one at each side and the end 11 of the strap 10 will be passed through the second adjustment means, to be anchored by a second strap carrier 17 and fastener 21. If two such adjustment means are provided it may be of advantage to have the screw on one a right-hand thread and on the other a left hand thread, so that the adjustment may be effected by simultaneous operation in the same direction in relation to the seat.
Naturally, the details of construction of the seat itself do not form part of this invention. Thus, the design and construction of the back rest may be modified to suit particular requirements, as may the mode of attachment of the tensioning strap to the seat. The seat back rest may be provided with additional spring members or padding, and the foam cushion or other padding behind the covering material may be covered with any suitable material to provide for ease of travel of the tensioning strap across the back of the back rest.
If desired there may be two of said tensioning straps across the back of the back rest and they may be adjusted either by individual adjusting means or by the operation of a single adjusting means operable to effect adjustment on both straps simultaneously.
The strap (or straps) may be made of any suitable material, such as nylon webbing, and may be covered with suitable protective material--which may be resilient (such as foam).
If desired the mounting frame need not be secured to the side frame member 12a as the tension of the strap will tend to hold it in position. However, it is believed one or more screw fasteners may be used to ensure a firm connection therewith when no pressure is applied to the back rest.
It is believed this invention may be applied to seats other than automotive seats, e.g. seats in an aircraft, and, indeed, to other articles for the support of the body.
While the invention has been particularly shown and described with reference to a 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.
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This invention relates to a seat having a strap and a tension device therefore for adjusting the support for the back of a user. The adjusting device including a strap or straps extending across the back rest of a seat and being manually adjustable for decreasing or increasing the effective length of the strap or straps where extending across the back rest so as to cause portion of the back rest to project forwardly a greater or lesser extent.
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BACKGROUND OF THE INVENTION
This invention relates to a method and apparatus for creation of moire fabric. Traditional moire fabrics are defined as a wavy or watered effect on textile fabric, especially a corded fabric of silk, rayon, or one of the manufactured fibers. An excellent example of a corded fabric would be a faille. Failles are generally defined as having fine, bright, continuous filament warps and coarse spun filling and a plain weave. This creates a noticeable ribbed effect in the filling direction. Other fabrics can be utilized with typically lesser results, however, a visible ribbed effect should be present in the fabric's filling.
Moire fabric falls into one of two categories. The first is an uncontrolled moire when the filling ribs of one layer of fabric are intentionally skewed with respect to the second layer of fabric prior to applying pressure to both layers of fabric. This will result in a significant increase in the number of filling ribs that cross with the associated increase in vertical moire lines. This is very undesirable since the appearance of the moire fabric will never be consistent and will vary from batch to batch. Traditionally, controlled moire fabric is formed by selectively distorting or skewing small portions of the filling ribs so that the filling ribs only cross in selective areas. The most common method is the Francais bar method in which ribbed woven fabric is dragged over a stationary bar which has a series of knobs which are spaced at desired intervals. This is done at very high tension. The knobs distort the filling into a bow wherever they touch the fabric. When two pieces of this fabric are subjected to pressure, a traditional controlled moire will result that is typically found in upholstery, drapery, apparel, and other end uses. Problems with this type of moire patterning include the fact that the pattern is repeatedly fixed and dragging under high tension can damage and/or destroy the fabric.
Another traditional method utilized in creating controlled moire fabric is the "scratch" method. This is accomplished by means of a resilient roll having the desired designs embossed thereon. These designs may include flowers, geometrics, and so forth. While the fabric is in contact with this embossed roll, it is "scratched" with a series of steel blades which distort the filling yarns of the fabric according to the pattern that is embossed on the roll. Upon applying pressure to two pieces of this treated fabric, a moire pattern is produced. Again, there is the problem of the destruction or damage to the yarns by the steel blades and a fixedly repeatable pattern. This "scratch" method produces very poor results with a large quantity of broken filaments. The blades actually only contact the warp yarns thus producing a large amount of broken filaments with only minimal movement of the filling yarn. It is the movement of the filling yarn that is the desired result. Furthermore, by examination of faille fabric, the filling is virtually covered by warp yarns and thus it is very difficult to move the filling by mechanical means. Also, this "scratch" method creates fuzz on the surface of the fabric that results in less shine and poor moire patterns.
Yet another traditional method of producing a controlled moire is by that found in U.S. Pat. No. 2,448,145, which discloses the selective application of water to fabric with a noticeable ribbed effect in the filling direction. The fabric is then placed under high tension and then dried. This will distort the filling yarns in the wet areas differently than the filling yarns in the dry areas. Again, upon applying pressure to two pieces of this treated fabric, a moire pattern is produced. A severe problem with this technology is that it would be very difficult to wet yarns selectively while leaving adjacent yarns dry for a very precise pattern. Furthermore, stretching under high tension can severely weaken or even destroy filling yarns. Furthermore, this method is deficient in that it only works on fibers that absorb large amounts of water such as cotton, silk and so forth. Each pattern requires a specific patterning roll or screen which only changes the pick count slightly in the areas treated with water. While this may produce some beating when the fabrics are sandwiched and calendered, it does not produce true moire because the filling is not distorted with bow or skew.
The present invention solves these problems in a manner not disclosed in the known prior art.
SUMMARY OF THE INVENTION
An apparatus and method for creation of moire fabric by directing at least one stream of pressurized heated gas at the surface of said first piece of overfed fabric to provide lateral yarn displacement and selectively interrupting and re-establishing contact between said stream and said surface in accordance with pattern information in order to pattern said first piece of fabric. This is followed by combining said patterned first piece of fabric with an unpatterned second piece of fabric in overlapping relationship and applying pressure by means of calender rolls having smooth surfaces to said combination of said first piece of patterned fabric and said second piece of unpatterned fabric. By using high pressure heated gas and shrinking some of the thermoplastic yarns, there is movement of the filling yarns in the fabric.
An advantage of this invention is to have moire patterns of any length or, in other words, patterns that do not necessarily repeat.
Still another advantage of this invention is the means of patterning is relatively nondestructive with overfed fabric.
Another advantage of this invention is extremely precise since the amount of shrinking of thermoplastic fibers can be exactly controlled.
A further advantage of this invention is that patterning can be extremely complex with the only limits being those of the human imagination.
Another advantage of this invention is that patterning can be altered while the machine is processing and downloaded in real time with the only limit being that of the complexity of the available computer system utilized in the storage and retrieval of moire patterns.
Yet another advantage of this invention is that the fill yarns can be shifted up to five-eighths of an inch.
In another advantage of this invention is that a perfect fill yarn shift sine wave can be created by contrasting treated portions of textile fabric with untreated portions of textile fabric.
These and other advantages will be in part apparent and in part pointed out below.
BRIEF DESCRIPTION OF THE DRAWINGS
The above as well as other objects of the invention will become more apparent from the following detailed description of the preferred embodiments of the invention when taken together with the accompanying drawings, in which:
FIG. 1 is a schematic side elevation view of apparatus for heated pressurized fluid stream treatment of a moving textile fabric to impart a surface pattern or change in the surface appearance thereof, and incorporating novel features of the present invention;
FIG. 2 is an enlarged partial sectional elevation view of the fluid distributing manifold assembly of the apparatus of FIG. 1;
FIG. 3 is an enlarged broken away sectional view of the fluid stream distributing manifold housing of the manifold assembly as illustrated in FIG. 2;
FIG. 4 is an enlarged broken away sectional view of an end portion of the fluid stream distributing manifold housing;
FIG. 5 is a graph comparing percentage of shrinkage as a function of temperature for a number of fiber types;
FIG. 6 is a diagrammatic side view of two supply rolls, two calendering rolls and two take-up rolls;
FIG. 7 is a photomicrograph (1.1×) of the face of the untreated textile fabric of Example 1;
FIG. 8 is a photomicrograph (1.1×) of the face of the textile fabric of Example 1 after the step of selectively patterning the fabric by means of high pressure streams of heated gas;
FIG. 9 is a photomicrograph (1.1×) of the face of the textile fabric of Example 1 after the step of selectively patterning the fabric by means of high pressure streams of heated gas and the step of calendering under one ton of pressure per linear inch with a second layer of the untreated fabric of FIG. 7;
FIG. 10 is a photomicrograph (1.1×) of the face of the untreated textile fabric of Example 2;
FIG. 11 is a photomicrograph (1.1×) of the face of the textile fabric of Example 2 after the step of selectively patterning the fabric by means of high pressure streams of heated gas;
FIG. 12 is a photomicrograph (1.1×) of the face of the textile fabric of Example 2 after the step of selectively patterning the fabric by means of high pressure streams of heated gas and the step of calendering under one ton of pressure per linear inch with a second layer of the untreated fabric of FIG. 10;
FIG. 13 is a schematic side elevation view of apparatus for laser beam treatment of a moving textile fabric to impart a surface pattern or change in the surface appearance thereof, and incorporating novel features of the present invention; and
FIG. 14 is a diagrammatic side view of a preferred chase-calendering system having a supply roll, two calendering rolls and a take-up roll in which treated fabric is pressed against untreated fabric by the calendering rolls.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the accompanying drawings, and initially to FIG. 1, which shows, diagrammatically, an overall side elevational view of apparatus for heated pressurized gas stream treatment of a textile fabric to impart lateral yarn displacement. As seen, the apparatus includes a main support frame including end frame support members, one of which 10 is illustrated in FIG. 1. Suitably rotatably mounted on the end support members of the frame are a plurality of textile fabric guide rolls which direct an indefinite length of textile fabric 12, from a fabric supply roll 18, past a pressurized heated gas treating unit, generally indicated at 16. After treatment, the textile fabric is collected in a continuous manner on a take-up roll 14. As shown, textile fabric 12 from supply roll 18 passes over an idler roll 36 and is fed by a pair of driven rolls 34, 32 to a main driven textile fabric support roll 26 with the textile fabric 12 between drive roll 32 and textile fabric support roll 26 being overfed and slack in a range of between two and twenty percent with a preferred range of between two and twelve percent. The amount of overfeed depends on the construction, weave tightness, fiber type, and other factors related to the textile fabric 12. The overfeed must stop before the point at which puckering of the textile fabric 12 occurs. The surface of the textile fabric passes closely adjacent to the heated fluid discharge outlet of an elongate fluid distributing manifold assembly 30 of treating unit 16. The treated textile fabric 12 thereafter passes over a series of driven guide rolls 22, 24 and an idler roll 20 to take-up roll 14 for collection.
As illustrated in FIG. 1, fluid treating unit 16 includes a source of compressed gas, such as an air compressor 38, which supplies pressurized air to an elongate air header pipe 40. Header pipe 40 communicates by a series of air lines 42 spaced uniformly along its length with a bank of individual electrical heaters indicated generally at 44. The heaters 44 are arranged in parallel along the length of heated fluid distributing manifold assembly 30 and supply heated pressurized air thereto through short, individual air supply lines, indicated at 46, which communicate with assembly 30 uniformly along its full length. Air supplied to the heated fluid distributing manifold assembly 30 is controlled by a master control valve 48, pressure regulator valve 49, and individual precision control valves, such as needle valves 50, located in each heater air supply line 42. The heaters 44 are controlled in suitable manner, as by temperature sensing means located in the outlet lines 46 of each heater, with regulation of air flow and electrical power to each of the heaters to maintain the heated fluid at a uniform temperature and pressure as it passes into the manifold assembly along its full length.
Typically, for patterning textile fabrics, such as pile fabrics containing thermoplastic yarns, the heaters are employed to heat air exiting the heaters and entering the manifold assembly to a uniform temperature of about 700° F.-750° F. However, the range of temperature for fabric treated with this apparatus may be between about 500° F. to about 1200° F. or more. The preferred operating temperature for any given textile fabric depends upon: the components of the textile fabric, the construction of the textile fabric, the desired effect, the speed of transport of the textile fabric, the pressure of the heated pressurized gas, the tension of the textile fabric, the proximity of the textile fabric to the treating manifold, and others.
The heated fluid distributing manifold assembly 30 is disposed across the full width of the path of movement of the textile fabric and closely adjacent the surface thereof to be treated. Although the length of the manifold assembly may vary, typically in the treatment of textile fabric materials, the length of the manifold assembly may be 76 inches or more to accommodate textile fabrics of up to about 72 inches in width.
Details of the heated fluid distributing manifold assembly 30 may be best described by reference to FIGS. 2-3 of the Drawings. As seen in FIG. 2, which is a partial sectional elevation view through the assembly, there is a first large elongate manifold housing 54 and a second smaller elongate manifold housing 56 secured in fluid tight relationship therewith by a plurality of spaced clamping means, one of which is generally indicated at 58. The manifold housings 54, 56 extend across the full width of the textile fabric 12 adjacent its path of movement.
As best seen in FIG. 2, first elongate manifold housing 54 is of generally rectangular cross-sectional shape, and includes a first elongate gas receiving compartment 81, the ends of which are sealed by end wall plates suitably bolted thereto. Communicating with bottom wall plate through fluid inlet openings, one of which, 83, is shown in FIG. 2, and spaced approximately uniformly therealong are the air supply lines 46 from each of the electrical heaters 44.
The manifold housings 54, 56 are constructed and arranged so that the flow path of gas through the first housing 54 is generally at a right angle to the discharge axes of the gas stream outlets of the second manifold housing 56.
As best seen in FIGS. 2 and 3, manifold housing 54 is provided with a plurality of gas flow passageways 86 which are disposed in uniformly spaced relation along the plate in two rows to connect the first gas receiving compartment 81 with a central elongate channel 88.
Baffle plate 92 serves to define a gas receiving chamber in the compartment 81 having side openings or slots 94 to direct the incoming heated air from the bank of heaters in a generally reversing path of flow through compartment 81. Disposed above channel-shaped baffle plate 92 is compartment 81 between the fluid inlet openings 83 and fluid outlet passageways 86 is an elongate filter member 100 which is a generally J-shaped plate with a filter screen disposed thereabout.
As seen in FIGS. 2, 3 and 4, a second smaller manifold housing 56 comprises first and second opposed elongate wall members, each of which has an elongate recess or channel 108 therein. Wall members are disposed in spaced, coextensive parallel relation with their recesses 108 in facing relation to form upper and lower wall portions of a second gas receiving compartment 110, in the second manifold housing 56. The gas then passes through a third gas receiving compartment 112 in the lower wall member of manifold housing 56 which is defined by small elongate islands 111 approximately uniformly spaced along the length of the member, as shown in FIG. 4. A continuous slit directs heated pressurized air from the third gas receiving compartment 112 in a continuous sheet across the width of the fabric at a substantially right angle onto the surface of the moving textile fabric 12. Typically, in the treatment of textile fabrics such as pile fabrics containing thermoplastic pile yarn or fiber components with a flat woven textile fabric containing thermoplastic or fiber yarn, the continuous slit 115 of manifold 56 may be 0.015 to about 0.030 of an inch in thickness. For precise control of the heated air streams striking the fabric, the continuous slit is preferably maintained between about 0.070 to 0.080 of an inch from the fabric surface being treated. However, this distance from the face of the fabric can be as much as 0.100 of an inch and still produce good pattern definition. The deflecting air tubes are spaced 20 to the inch over the 72 inch air distributing manifold, although apparatus has been constructed as coarse as 10 to the inch and as fine as 44 to the inch.
Second manifold housing 56 is provided with a plurality of spaced gas inlet openings 118 (FIGS. 2 and 3) which communicate with the elongate channel 88 of the first manifold housing 54 along its length to receive pressurized heated air from the first manifold housing 54 into the second gas receiving compartment 110.
The continuous slit 115 of the second manifold housing 56 which directs a stream of air into the surface of textile fabric 12 is provided with tubes 126 which communicate at a right angle to the discharge axis of continuous slit 115 to introduce pressurized cool air, i.e., air having a temperature substantially below that of the heated air in third gas receiving compartment 112, at the heated gas discharge outlet 116 to deflect selectively the flow of heated air through the continuous slit 115 in accordance with pattern control information. Air passing through the tubes 126 may be cooled by a water jacket which is provided with cooling water from a suitable source, not shown, although such cooling is not required.
As seen in FIG. 1, pressurized unheated air is supplied to each of the tubes 126 from compressor 38 by way of a master control valve 128, pressure regulator valve 129, air line 130, and unheated air header pipe 132 which is connected by a plurality of individual air supply lines 134 to the individual tubes 126. Each of the individual cool air supply lines 134 is provided with an individual control valve located in a valve box 136. These individual control valves are operated to open or close in response to signals from a pattern control device, such as a computer 138, to deflect the flow of hot air through continuous slit 115 during movement of the fabric and thereby produce a desired pattern in the fabric. Detailed patterning information for individual patterns may be stored and accessed by means of any known data storage medium suitable for use with electronic computers, such as magnetic tape, EPROMs, etc. The foregoing details of the construction and operation of the manifold assembly 30 of the gas treating apparatus are the subject matter of commonly assigned U.S. Pat. No. 4,471,514 entitled "Apparatus for Imparting Visual Surface Effects to Relatively Moving Materials" and issued on Sep. 18, 1984. The disclosure thereof is included herein by reference for full description and clear understanding of the improved features of the present invention.
Each cool air fluid tube 126 is positioned at approximately a right angle to the plane defined by slit 115 to deflect heated pressurized air away from the surface of the moving fabric 12 (FIG. 3) as the textile fabric approaches continuous slit 115. This deflection is generally at about a 45 degree angle from the path defined by continuous slit 115, and serves to direct the deflected heated air toward the oncoming textile fabric 12. Thus, a strong blast of mixed hot and cold air strikes the surface of the textile fabric prior to its being subjected to the action of the heated air issuing from continuous slit 115.
This configuration of tubes 126 provides sufficient volume of air in combination with that from the continuous slit 115 to preheat textile fabric 12 to a temperature preferably short of permanent thermal modification.
It should be noted that, due to the insulation 8 generally surrounding manifold 54, preheating is not believed to be the result of heat radiation from the manifold, but is rather the result of the exposure of textile fabric 12 to the heated air issuing from continuous slit 115, as that air is diverted by the relatively cool air issuing from tubes 126. The heated air used for this purpose is air that has been diverted, in accordance with patterning instructions, after issuing from continuous slit 115, i.e., this air would be diverted whether or not pre-heating was desired. Therefore, preheating of the textile fabric is achieved as an integral part of, and is inseparable from, the patterning process, and requires no additional or separate heated air source. By so doing, not only is a separate preheating step and its attendant complexity unnecessary, but it is believed a separate preheating step would be incapable of imparting heat of sufficient intensity and directivity to maintain the textile fabric 12 at an effective preheated temperature at the instant the heated patterning air issuing from continuous slit 115 contacts the textile fabric, as shown in FIG. 4.
This preheating may cause additional thermal modification during the patterning step. As can be seen in connection with FIG. 5, the amount of shrinkage is a function of the type of fiber involved and the temperature to which it is subjected. The temperature of the hot air is adjusted to accommodate a particular fiber so that the amount of shrinkage can be controlled regardless of the fabric.
Additional information relating to the operation of such a pressurized heated gas apparatus, including more detailed description of patterning and control functions, can be found in coassigned U.S. Pat. No. 5,035,031, that issued on Jul. 30, 1991, which is incorporated by reference as if fully set forth herein and coassigned U.S. Pat. No. 5,148,583, that issued on Sep. 22, 1992, which is incorporated by reference as if fully set forth herein and coassigned U.S. Pat. No. 4,393,562, that issued on Jul. 19, 1983, which is incorporated by reference as if fully set forth herein and coassigned U.S. Pat. No. 4,364,156, that issued on Dec. 21, 1982, which is incorporated by reference as if fully set forth herein and coassigned U.S. Pat. No. 4,418,451, that issued on Dec. 6, 1982, which is incorporated by reference as if fully set forth herein.
In the alternative, another means of achieving lateral yarn displacement, although not the preferred means, is to subject textile fabric to the heat of a laser. Referring now to FIG. 13, which shows, diagrammatically, an overall side elevational view of apparatus for laser treatment of a textile fabric to impart lateral yarn displacement. There is a plurality of textile fabric guide rolls which direct an indefinite length of textile fabric 304, from a fabric supply roll 302, past a laser unit, which is indicated by numeral 320. After treatment, the textile fabric 304 is collected in a continuous manner on a take-up roll 316. As shown, textile fabric 304 from supply roll 302 passes over an idler roll 306 to a main driven textile fabric support roll 308. The surface of the textile fabric 304 is hit by the laser beam from laser unit 320 between idler roll 306 and driven textile fabric support roll 308. The treated textile fabric 304 thereafter passes over a series of driven guide rolls 312, 314 and to take-up roll 316 for collection.
Laser unit 320 is preferable a 10.6 micron wavelength, eighty watt, carbon dioxide laser, although any of a wide variety of lasers will suffice. One typical laser of this type is manufactured by Laser Machining, Inc. that is located at 500 Laser Drive, MS 628, Industrial Park, Somerset, Wis. 54025. Although not specifically limited thereto, the preferred range of moving the textile fabric 304 is a speed of one hundred to two hundred inches per minute.
Referring now to FIG. 6, the next step in the process is to take the patterned textile fabric 216 and have this patterned fabric processed by a calender mechanism that is generally indicated by numeral 201. The patterned textile fabric 216 is placed on supply roll 220 and an unpatterned textile fabric 226 is placed on supply roll 210. Both the patterned textile fabric 216 and unpatterned textile fabric 226 are fed into an upper calendering roll 230 and lower calendering roll 232. For good patterning, both the patterned textile fabric 216 and unpatterned textile fabric 226 should be ribbed since the surface of the upper calendering roll 230 is smooth as well as the surface of lower calendering roll 232. The moire pattern is made by placing these two layers of ribbed textile fabric 216 and 226 on top of each other so that the ribs of the upper unpatterned textile fabric 226 are slightly off-grain in relation to the lower patterned textile fabric 216. These true moire patterns are produced when the upper unpatterned textile fabric 226 is sandwiched with the lower patterned textile fabric 216 and passed through the calender rolls 230 and 232 at high pressure so that wherever the filling yarns cross, a moire pattern is produced. The unpatterned textile fabric 226 may be the lower fabric with the patterned textile fabric 216 being the upper textile fabric with no consequential difference. A pressure of 300 to 10,000 pounds per linear inch of fabric between the upper calendering roll 230 and lower calendering roll 232 on the textile fabrics 216 and 226 causes the ribbed pattern of the patterned textile fabric 216 to be pressed into the unpatterned textile fabric 226 and visa-versa. Pressure requirements for producing moire depend on the speed of traverse, temperature, moisture, and types of calender rolls utilized. A typical range for temperature would be between 100 and 450 degrees Fahrenheit. A typical range for moisture would be between 30 and 100 percent relative humidity for natural fibers. Artificial fibers are typically unaffected by relative humidity. The speed of traverse is typically between 10 and 100 feet per minute.
Flattened areas in the ribs reflect more light and create a contrast to unflattened areas. The patterned textile fabric 216 and unpatterned textile fabric 226 are then received by take-up rolls 250 and 240, respectively. The crushed and uncrushed portions of either textile fabric 216 or fabric 226 causes a difference in light reflectance. This creates a wavy or watery effect in both textile fabrics 216 and 226, respectively. In this case, both textile fabrics 26 and 226 will have the same moire pattern but they will be mirror images. This technique is especially useful when geometric or floral patterns are used. If both textile fabrics 216, 226 are patterned, they would be very difficult to keep in register. The method of treating textile fabric 12 with pressurized heated gas can result in a shift in the fill yarn of up to five-eighths of an inch depending on the fabric fiber, construction, weave, and so forth.
Beat repeat patterns may be introduced by having the pick count different in the two layers of textile fabric 216 and 226 that are sandwiched together. This may be accomplished by weaving two different pick counts. Another way to accomplish this is to place tension on one of the layers which will reduce the pick count slightly to produce a beating. "Beating" is defined as the pattern developed due to superimposed waves of different frequencies.
Textile fabric 226 does not have to be unpatterned and may also be patterned with a different pattern than patterned textile fabric 216. Also, either textile fabric 216 or 226 may have a different pick count to produce a beating pattern. With this embodiment, the preferred material for the upper calendering roll 230 is a metal such as steel and the preferred material for the lower calendering roll 232 is a composite fiber.
The preferred means of calendering is to utilize a chase-type calendering system such as that disclosed in FIG. 14 as opposed to that disclosed in FIG. 6. There is a plurality of textile fabric guide rolls which direct an indefinite length of textile fabric 404, from a fabric supply roll 402, over a series of driven guide rolls 412, 414 and then through calender roll 432. Calender roll 432 is equivalent to calender roll 232 disclosed in FIG. 6. The textile fabric 404 is then fed by a series of driven rolls 442, 4444, and 446 to a main driven textile fabric support roll 448. The surface of the textile fabric passes closely adjacent to the treating unit 450 which may be either a hot gas unit designated in FIG. 1 by numeral 16 or a laser unit designated in FIG. 13 by numeral 320. After treatment, the textile fabric 404 goes around idler roll 460 and then through upper calendering roll 430, which is equivalent to upper calendering roll 230 found in FIG. 6. The moire patterns are produced when the upper treated textile fabric 404 is sandwiched with same lower untreated textile fabric 404 and passed through the calender rolls 430 and 432 at high pressure so that wherever the filling yarns cross, a moire pattern is produced. A pressure of 300 to 10,000 pounds per linear inch of fabric between the upper calendering roll 430 and lower calendering roll 432 on the textile fabric 404 causes a ribbed pattern to be created. A pattern does not appear on the untreated textile fabric 404 due to the fact that the lower calender roll 432 is air cooled so the temperature does not typically exceed 120 degrees Fahrenheit. The speed of traverse is typically between 10 and 100 feet per minute. The textile fabric 404 is then collected in a continuous manner on a take-up roll 462. With this preferred embodiment, the preferred material for the upper calendering roll 230 is a metal such as steel and the preferred material for the lower calendering roll 232 is a lightweight polymer, such as nylon. A typical calendar of this type is manufactured by Ramtsch Kleinewefers Kalander GmbH in 1975 located at 415 Krefeld, Postfach 2350, Germany.
Other methods of applying pressure include high pressure rotary presses and platen presses. Some very beautiful textile fabrics are produced by creating the moire fabric and then printing the textile fabric with a colorant such as a dye or pigment. The fabric may, also, be printed first and then patterned by pressurized heated gas and then calendered under pressure to produce a different effect. It may also be patterned by pressurized gas, printed and then calendered to produce a novel textile fabric. Any type of textile fabric printing may be used including but not limited to rotary screen, flat bed, air brush or engraved roll.
Most fiber types will work with this invention including, but not limited to, polyester, polyamide, acetate, rayon, cotton, and so forth. This invention is not restricted to plain weaves but most woven fabrics will work including, but not limited to, dobby and jacquard woven fabrics. Woven fabrics have warp yarns extending in the warp direction and fill yarns extending in the fill direction. For best results, the fill yarns should have a ribbed effect. Furthermore, this invention is not restricted to woven fabrics since a moire pattern can be applied to warp knit fabrics. Warp knit fabrics have wales which are a column of loops lying lengthwise in the fabric and correspond to the warp in woven fabrics. Also, warp knit fabrics have courses which are a row of loops or stitches running across a knit fabric corresponding to filing in woven fabrics.
If approximately fifty percent of the textile fabric is treated by pressurized heated gas and fifty percent of the textile fabric is not treated by pressurized heated gas, then a shift in the fill yarn will be in the form of a sine wave.
The following examples demonstrate, without intending to be limiting in any way, the method by which fabrics of the present invention have been generated.
EXAMPLE 1
An apparatus similar to that schematically depicted in FIGS. 1-4 and 6 was used, in accordance with the following specifications.
Fabric: a faille fabric having a warp comprised of 132 ends/inch of 73.23 denier bright polyester continuous filament and a fill comprised of 7.95 denier spun polyester and a pick count of 33. The faille fabric has been woven, prepared, dyed and heat-set and has a weight of 5.16 ounces per square yard. A photomicrograph of this fabric is shown by FIG. 7 at 1.1 magnification.
This fabric was then patterned with vertical bands utilizing a continuous slit hot air nozzle.
Fluid: hot air, at a pressure of 3.2 p.s.i.g.
Pattern gauge: 20 lines per inch.
Source of pattern data: Floppy disk, with appropriate associated electronics of conventional design.
Roll: solid, smooth stainless steel, rotating at a circumference speed of 9 yards per minute in the same direction as warp yarns in fabric.
In this Example, the entire fabric surface was treated in a series of vertical bands. The yarns have been thermally modified by shrinkage where the streams have impacted the fabric. A photomicrograph of this treated fabric is shown by FIG. 8 at 1.1 magnification.
This patterned fabric was then sandwiched with an unpatterned piece of the same fabric and run through a BRIEM® calender at eight yards a minute with a temperature of three-hundred and eighty degrees Fahrenheit on the steel roll with a pressure of one ton per linear inch. The upper roll is made of steel and the lower roll is made of a composite fiber with heat transferred between both rolls. BRIEM® calenders were formerly manufactured by Ernest L. Frank Associates, Inc., 515 Madison Avenue, New York, N.Y. 10022, who is no longer in existence. Both pieces of fabric display the moire pattern shown by the photomicrograph of FIG. 9 at 1.1 magnification.
EXAMPLE 2
An apparatus similar to that schematically depicted in FIGS. 1-4 and 6 was used, in accordance with the following specifications.
Fabric: a faille fabric having a warp comprised of 106 ends/inch of 152.36 denier bright polyester continuous filament and a fill comprised of 13.24 denier spun polyester and a pick count of 31. The faille fabric has been woven, prepared, dyed and heat-set and has a weight of 5.88 ounces per square yard. A photomicrograph of this fabric is shown by FIG. 10 at 1.1 magnification.
This fabric was then patterned with vertical bands with a continuous slit hot air nozzle.
Fluid: hot air, at a pressure of 3.2 p.s.i.g.
Pattern gauge: 20 lines per inch.
Source of pattern data: Floppy disk, with appropriate associated electronics of conventional design.
Roll: solid, smooth stainless steel, rotating at a circumference speed of 9 yards per minute in the same direction as warp yarns in fabric.
In this Example, the entire fabric surface was treated in a series of vertical bands. The yarns have been thermally modified by shrinkage where the streams have impacted the fabric. A photomicrograph of this treated fabric is shown by FIG. 11 at 1.1 magnification. This patterned fabric was then sandwiched with an unpatterned piece of the same fabric and run through a BRIEM® calender at eight yards a minute with a temperature of three-hundred and eighty degrees Fahrenheit on the steel roll with a pressure of one ton per linear inch. The upper roll is made of steel and the lower roll is made of a composite fiber with heat transferred between both rolls. Both pieces of fabric display the moire pattern shown by the photomicrograph of FIG. 12 at 1.1 magnification.
As this invention may be embodied in several forms without departing from the spirit or essential character thereof, the embodiments presented herein are intended to be illustrative and not descriptive. The scope of the invention is intended to be defined by the following appended claims, rather than any descriptive matter hereinabove, and all embodiments of the invention which fall within the meaning and range of equivalency of such claims are, therefore, intended to be embraced by such claims.
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An apparatus and method for creation of moire textile fabric. This can be achieved by directing at least one stream of pressurized heated gas at the surface of said first piece of overfed fabric to provide lateral yarn displacement and selectively interrupting and re-establishing contact between said stream and said surface in accordance with pattern information in order to pattern said first piece of fabric. This is followed by combining said patterned first piece of fabric with an unpatterned second piece of fabric in overlapping relationship and applying pressure by means of calender rolls having smooth surfaces to said combination of said first piece of patterned fabric and said second piece of unpatterned fabric. By using high pressure heated gas and shrinking some of the thermoplastic yarns, there is movement of the filling yarns in the fabric.
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PRIOR RELATED APPLICATIONS
[0001] This invention claims priority to U.S. 61/644,252, filed on May 8, 2012 and incorporated by reference in its entirety herein.
FEDERALLY SPONSORED RESEARCH STATEMENT
[0002] Not applicable.
FIELD OF THE DISCLOSURE
[0003] The disclosure generally relates to novel formulations of nitrofurans, and more particularly to novel formulations including nifurtimox with enhanced activity with lower toxicity.
BACKGROUND OF THE DISCLOSURE
[0004] Nifurtimox (3-methyl-4-(5′-nitrofurfurylidene-amino)-tetrahydro-4H-1,4-thiazine-1,1-dioxide), shown below as formula (1), is used to treat Chagas disease and has the potential of treating various types of cancers. Chagas disease is caused by the protozoan parasite Trypanosoma cruzi , which is widely distributed throughout the Americas, particularly in poor, rural areas of Mexico, Central America, and South America.
[0000]
[0005] Marketed by Bayer as Lampit® tablets, Nifurtimox is administered three times a day with the duration of treatment ranging from 90 days (acute infection) to 120 days (chronic infection). This treatment is associated with significant toxicities, and patient compliance is also challenging. The pharmacological activities of Nifurtimox are related to its blood level; the active compound has a relatively short time to peak (1-2 h) and a short half-life (2.95±1.19 h), and the toxicities are likely related to the peak effects. Currently available Lampit® tablet (Nifurtimox) dosing regimen is T.I.D. The objective of this invention is to develop a multi-particulate sustained release (SR) capsule formulation with optimal absorption over the dosing interval with a daily frequency of dosing of QD or possibly BID. To do so, we employ an extrusion and spheronization process.
[0006] Nifurtimox is also believed to have the potency to treat cancers. Non-limiting examples of cancers treatable by Nifurtimox include: neuroblastoma, medulloblastoma, peripheral malignant nerve sheath tumor, ependymoma, chraniopharyngioma, astrocytoma, meningioma, germinoma, glioma, mixed glioma, choroid plexus tumor, oligodendroglioma, peripheral neuroectodennal tumor, primitive neuroectodermal tumor (PNET), CNS lymphoma, pituitary adenoma, Schwannoma, basal cell carcinoma, biliary tract cancer, bladder cancer, bone cancer, brain and CNS cancer, breast cancer, cervical cancer, choriocarcinoma, colon and rectum cancer, connective tissue cancer, cancer of the digestive system, endometrial cancer, esophageal cancer, eye cancer, fibroma, cancer of the head and neck, gastric cancer, intra-epithelial neoplasm, kidney cancer, larynx cancer, leukemia including acute myeloid leukemia, acute lymphoid leukemia, chronic myeloid leukemia, chronic lymphoid leukemia, liver cancer, small cell lung cancer, non-small cell lung cancer, lymphoma including Hodgkin's and Non-Hodgkin's lymphoma, melanoma, oral cavity cancer, ovarian cancer, pancreatic cancer, prostate cancer, retinoblastoma, rhabdomyosarcoma, rectal cancer, renal cancer, cancer of the respiratory system, sarcoma, skin cancer, stomach cancer, testicular cancer, thyroid cancer, uterine cancer, cancer of the urinary system, carcinomas or sarcomas.
[0007] Multi-particulate dosage forms have several advantages in comparison to single-unit dosage forms like tablets. In a multi-particulate form, the dosage of the drug substance is divided into sub-units consisting of thousands of spherical particles. Although the manufacture and design of these particles is more complex than that of tablets, multi-particulate dosage forms offer options and advantages to provide unique product characteristics, such as specific drug release patterns. Unlike non-disintegrating, monolithic, single-unit forms, which retain their structure in the digestive tract, multi-particulate preparations consist of numerous sub-units that disperse after administration. Because each sub-unit acts as an individual modified release entity, the multiple-unit approach offers certain advantages for a modified release dosage form, namely, a stable plasma profile, little risk of local side effects, reduced dependency on the nutrition state, reduced risk of dose dumping, and low intra- and inter-individual variability. An optimized pharmacokinetic profile with good patient compliance can be achieved with multi-particulate dosage forms.
[0008] The current Nifurtimox dosage regimen, toxicity, pharmacokinetic parameters (short time to peak and short half life) and the advantages of multi-particulate dosage forms (reduced risk of toxicity, good patient compliance, and stable plasma profile) make Nifurtimox a potential candidate for development of a Sustained Release multi-particulate dosage form.
SUMMARY OF THE DISCLOSURE
[0009] The present invention relates to a novel multi-particulate dosage form for sustained-released Nifurtimox formulations. With different compositions of the formulation, the water-insoluble Nifurtimox can be continuously released for 24 hours or longer, thus improving patient's compliance with once-a-day regimen instead of T.I.D.
[0010] The sustained-released formulation of Nifurtimox comprises a therapeutically effective amount of Nifurtimox, a water-swellable hydrophilic polymer, and a binder, such that the formulation can continuously release Nifurtimox for up to 24 hours.
[0011] As used herein, “binder” means a compound that holds particulate ingredients that may be included in a tablet and/or particulates and the other ingredients in a tablet together. Binders are classified according to their application: solution binders are dissolved in a solvent (for example water or alcohol can be used in wet granulation processes). Examples of solution binders include gelatin, cellulose, cellulose derivatives, polyvinylpyrrolidone, starch, sucrose and polyethylene glycol. Dry binders are added to the powder blend, either after a wet granulation step, or as part of a direct powder compression (DC) formula. Examples include cellulose, methylcellulose, polyvinylpyrrolidone and polyethylene glycol. Binders are well known in the art of preparing pharmaceuticals, and additional non-limiting examples include acacia, alginic acid, carboxymethylcellulose sodium, microcrystalline cellulose, citric acid, dextrin, ethylcellulose, glucose, guar gum, hydroxypropyl methylcellulose, polyethylene oxide, povidone, pregelatinised starch, syrup, lactose, polyvinylpyrrolidone/vinyl acetate copolymer, and the like. Microcrystalline cellulose is the preferred binder. Microcrystalline cellulose is commercially available as Avicel® PH (pharmaceutical grade) from FMC Corporation, Philadelphia, Pa., particularly Avicel® PH 101, PH 102, PH 103, PH 112, PH 200, PH 301, PH 302 and Ceolus. In some cases, pressure-responsive excipient may be used in the formulation.
[0012] As used herein, “water-swellable hydrophilic polymer” refers to polymers that increase its volume upon contacting water due to crosslinking, thereby altering the drug release profile inside the GI tract. Suitable examples of water-swellable hydrophilic polymers include celluloses, such as carboxymethyl cellulose sodium, carboxymethyl cellulose, hydroxypropyl methylcellulose or hypromellose (“HPMC”), methylcellulose, hydroxymethylcellulose, hydroxyethylcellulose, hydroxy propyl cellulose (HPC), polyvinyl pyrrolidones, high-molecular weight polyvinylalcohols, and copolymers thereof; gums, such as natural gum, agar, agrose, sodium alginate, carrageenan, fucoidan, furcellaran, laminaran, hypnea, eucheums, gum Arabic, gum ghatti, gum karaya, gum tragacanth and locust bean gum; hydrophilic colloids, such as alginates, carbopols and polyacrylamides; other substances, such as arbinoglactan, pectin, amylopectin, gelatin, N-vinyl lactams and polysaccharides.
[0013] Hydroxypropyl methylcellulose or “HPMC” or “hypromellose” is partly O-methylated and 0-(2-hydroxypropylated) cellulose. It is available in various grades, such as K4M, K15M, K35M, K100M, K200M, K100LV, E3, E5, E6, E15 and E50 varying in viscosity and extent of substitution. In oral solid dosage forms, it is primarily used as a tablet binder, film-former, and as a matrix for use in extended-release tablet formulations.
[0014] As used herein, “enteric polymer” means a polymer, whose solubility is dependent on the pH in such a manner that it generally prevents the release of the drug in the stomach, but permits the release of the drug in the gastrointestinal tract at some stage after the particles have passed from the stomach.
[0015] As used herein, “pharmaceutically acceptable” means that the modified noun is appropriate for use in a pharmaceutical product; that is the pharmaceutically acceptable material is relatively safe and/or non-toxic, though not necessarily providing a separable therapeutic benefit by itself.
[0016] As used herein, “pharmaceutically effective amount” means an amount of a pharmaceutical active compound, or a combination of compounds, when administered alone or in combination, to treat, prevent, or reduce the risk of a disease state or condition. The term also refers to an amount of a pharmaceutical composition containing an active compound or combination of compounds. For example, a pharmaceutically effective amount refers to an amount of the pharmaceutical active present in a pharmaceutical composition or formulation of the present invention or on a medical device containing a composition or formulation of the present invention given to a recipient patient or subject sufficient to elicit biological activity, for example, activity against a known disease.
[0017] The use of the word “a” or “an” when used in conjunction with the term “comprising” in the claims or the specification means one or more than one, unless the context dictates otherwise.
[0018] The term “about” means the stated value plus or minus the margin of error of measurement or plus or minus 10% if no method of measurement is indicated.
[0019] The use of the term “or” in the claims is used to mean “and/or” unless explicitly indicated to refer to alternatives only or if the alternatives are mutually exclusive.
[0020] The terms “comprise”, “have”, “include” and “contain” (and their variants) are open-ended linking verbs and allow the addition of other elements when used in a claim.
[0021] The phrase “consisting of” is closed, and excludes all additional elements.
[0022] The phrase “consisting essentially of” excludes additional material elements, but allows the inclusions of non-material elements that do not substantially change the nature of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 shows the microscopic images of the microparticulate beads of different Nifurtimox sustained release capsule formulations of this invention.
[0024] FIG. 2 is the bead size distribution curves of different Nifurtimox sustained release formulations of this invention.
[0025] FIG. 3 shows the dissolution profiles of different Nifurtimox sustained release capsule formulations in 0.1N HCl with 5% HCl.
[0026] FIG. 4 shows the dissolution profiles of different Nifurtimox sustained release capsule formulations in 2% w/v SDS in deionized water.
DETAILED DESCRIPTION
[0027] The disclosure provides novel Nifurtimox sustained release capsule formulations that are capable of continuously releasing Nifurtimox for 24 hours or more. The formulations comprise a therapeutically effective amount of Nifurtimox, a water-swellable hydrophilic polymer, and a binder. The formulation releases less than 50% of Nifurtimox after 8 hours, and releases more than 70% of Nifurtimox after 24 hours, thus showing sustained-release characteristics.
[0028] In one aspect of this invention, a formulation for controlled release of Nifurtimox is provided, wherein the formulation comprises a therapeutically effective amount of Nifurtimox, a water-swellable hydrophilic polymer, and a binder, wherein the formulation can continuously release Nifurtimox for at least 24 hours.
[0029] In another aspect of this invention, a method for treating a patient having Chagas disease or cancer is provided. The method comprises the steps of: administering, once daily, to the patient a sustained release capsule formulation of Nifurtimox, wherein the sustained release capsule formulation of Nifurtimox comprises a therapeutically effective amount of Nifurtimox, a water-swellable hydrophilic polymer, and a binder. The sustained release capsule formulation of Nifurtimox continuously releases Nifurtimox for at least 24 hours.
[0030] In one embodiment, the formulation is in multi-particulate form enclosed in a capsule. In another embodiment, the capsule comprises enteric materials. In yet another embodiment, the particulates in the multi-particulate formulation is further coated by an enteric material.
[0031] In one embodiment, the formulation comprises 10 to 40% w/w on dry solids basis of Nifurtimox. In a preferred embodiment, the formulation comprises 15 to 35% w/w on dry solids basis of Nifurtimox, and in a more preferred embodiment the formulation comprises 20 to 30% w/w on dry solids basis of Nifurtimox.
[0032] The water-swellable hydrophilic polymers that can be used in this formulation include but not limited to celluloses, such as carboxymethyl cellulose sodium, carboxymethyl cellulose, hydroxypropyl methylcellulose or hypromellose (“HPMC”), methylcellulose, hydroxymethylcellulose, hydroxyethylcellulose, hydroxy propyl cellulose (HPC), polyvinyl pyrrolidones, high-molecular weight polyvinylalcohols, and copolymers thereof; gums, such as natural gum, agar, agrose, sodium alginate, carrageenan, fucoidan, furcellaran, laminaran, hypnea, eucheums, gum Arabic, gum ghatti, gum karaya, gum tragacanth and locust bean gum; hydrophilic colloids, such as alginates, carbopols and polyacrylamides; other substances, such as arbinoglactan, pectin, amylopectin, gelatin, N-vinyl lactams and polysaccharides. Preferred water swellable hydrophilic polymer is Eudragit®RS PO, Eudragit®RL PO manufactured by Evonik Industries, Methocel K 100 Premium LV CR by Colorcon, Inc., or combinations thereof.
[0033] In one embodiment, the formulation comprises 1 to 40% w/w on dry solids basis of water-swellable hydrophilic polymer. In another embodiment, the formulation comprises 20 to 40% w/w on dry solids basis of water-swellable hydrophilic polymer. In yet another embodiment, the formulation comprises 1 to 10% w/w on dry solids basis of water-swellable hydrophilic polymer.
[0034] The binders that can be used in this formulation include but not limited to gelatin, cellulose, cellulose derivatives, polyvinylpyrrolidone, starch, sucrose and polyethylene glycol, cellulose, methylcellulose, polyvinylpyrrolidone and polyethylene glycol, acacia, alginic acid, carboxymethylcellulose sodium, microcrystalline cellulose, citric acid, dextrin, ethylcellulose, glucose, guar gum, hydroxypropyl methylcellulose, polyethylene oxide, povidone, pregelatinised starch, syrup, lactose, polyvinylpyrrolidone/vinyl acetate copolymer, and the like. In a preferred embodiment, microcrystalline cellulose is used as the binder. In a preferred embodiment, Avicel® PH 101 or PH 102, or combinations thereof, made by FMC Corporation, Philadelphia, Pa., is used as the binder.
[0035] In one embodiment, the formulation comprises 20 to 60% w/w on dry solids basis of binder. In another embodiment, the formulation comprises 25 to 55% w/w on dry solids basis of binder. In another embodiment, the formulation comprises 30 to 50% w/w on dry solids basis of binder.
[0036] The materials that can be employed in making drug-containing particles or microparticulates are any of those commonly used in pharmaceutics and should be selected on the basis of compatibility with the active drug and the physicochemical properties of the pellets.
[0037] Acrylic polymers are widely used as tablet coatings and as retardants of drug release in sustained released formulations. The commonly used acrylic polymers are high permeable Eudragit® RL and low permeable Eudragit® RS, both of which are neutral copolymers of poly (ethylacrylate, methyl methacrylate) and trimethyl aminoethyl methacrylate chloride, and are insoluble in water and digestive juices; but they swell and are permeable, which means that drugs embedded in their matrices can be released by diffusion. Therefore, the permeability of drug through Eudragit RS and/or RL is independent of the pH of the digestive tract. The degree of permeability depends on the relative proportion of quaternary ammonium groups in Eudragit®. The proportion of functional quaternary ammonium groups in Eudragit® RL and Eudragit® RS is 10 and 5%, respectively. Eudragit® RL PO and RS PO are fine, white powders with a slight aminelike odor. They are characteristically the same polymers as Eudragit® RS and RL.
[0038] In some embodiment, the extruded and spheronized Nifurtimox beads or particulates can further be coated to achieve different release profile. For example, the beads can be coated by enteric polymers in addition to the sustained release formulation.
[0039] Enteric polymers that may be used in the oral pharmaceutical formulation include but are not limited to: hydroxypropyl methylcellulose acetate succinate (HPMCAS), hydroxypropyl methylcellulose phthalate (HPMCP), polyvinyl acetate phthalate, cellulose acetate phthalate, cellulose acetate trimellitate, shellac, zein, polymethacrylates containing carboxyl groups, amylose acetate phthalate, styrene maleic acid copolymer, and cellulose acetate succinate. Examples of commercially available enteric material are available under the trade names EUDRAGIT® L 100 (methyl methacrylate/methacrylic acid copolymers wherein the ratio of free carboxyl groups to esters is about 1:1), EUDRAGIT® S 100 (methacrylic acid/methyl methacrylate copolymer with a 1:2 ratio of MA to MMA) or EUDRAGIT® L (methacrylic acid/methyl methacrylate copolymer with a 1:1 ratio of MA to MMA). Aqueous colloidal polymer dispersions or re-dispersions can be also applied, e.g. EUDRAGIT® L 30D-55 (methacrylic acid/ethyl acrylate copolymer), EUDRAGIT® L100-55 (ethyl acrylate, methacrylic acid copolymer), EUDRAGIT® preparation 4110D (methacrylic acid/methyl acrylate/methyl methacrylate copolymers wherein the ratio of methacrylic acid, methyl acrylate and methyl methacrylate monomers is about 1:6.5:2.5); AQUATERIC® (a mixture containing 66-73% of cellulose acetate phthalate (CAP), poloxamer and acetylated monoglycerides), AQUACOAT® CPD 30 (FMC) (30% by weight aqueous dispersion containing cellulose acetate phthalate (CAP) polymer); KOLLICOAT MAE® 3OD (ethyl acrylate/methacrylic acid copolymers wherein the ratio of free carboxyl groups to esters is about 1:1) 30DP (BASF) (methacrylic acid/ethyl acrylate copolymer, 30% dispersion); and EASTACRYL® 3OD (Eastman Chemical)((30% polymeric dispersion of methacrylic acid ethyl acrylate copolymer in water). In one embodiment, the enteric polymer is hydroxypropyl methylcellulose acetate succinate (HPMCAS).
[0040] The coating composition may further include pharmaceutically acceptable excipients, such as plasticizers, opacifiers and coloring agents. Examples of plasticizers include acetylated triacetin, triethyl citrate, tributyl citrate, glycerol tributyrate, diacetylated monoglyceride, polyethylene glycols, propylene glycol, sesame oil, acetyl tributyl citrate, acetyl triethyl citrate, diethyl oxalate, diethyl phthalate, diethyl maleate, diethyl fumarate, dibutyl succinate, diethylmalonate, dioctyl phthalate, dibutyl sebacate and mixtures of these. Examples of opacifiers include titanium dioxide, talc, calcium carbonate, behenic acid and cetyl alcohol. Examples of coloring agents include ferric oxide red, ferric oxide yellow, Lake of Tartrazine, Allura red, Lake of Quinoline yellow and Lake of Erythrosine.
[0041] In one embodiment, the formulation releases less than 50% of Nifurtimox after 8 hours. In another embodiment, the formulation releases less than 45% of Nifurtimox after 8 hours. In another embodiment, the formulation releases less than 40% of Nifurtimox after 8 hours.
[0042] In one embodiment, the formulation releases more than 70% of Nifurtimox after 24 hours. In another embodiment, the formulation releases more than 80% of Nifurtimox after 24 hours. In another embodiment, the formulation releases more than 90% of Nifurtimox after 24 hours.
[0043] The following examples are intended to be illustrative only, and not unduly limit the scope of the appended claims.
Example 1
Sustained Release Capsule Formulations
[0044]
[0000]
TABLE 1
Chemicals And Materials Used In The Development Of Sustained Release
Formulations Of Nifurtimox
Chemical/material
Supplier
Avicel PH 101
FMC Corp. (Newark, DE)
Avicel PH 102
FMC Corp. (Newark, DE)
Eudragit ® NE 30D
Evonik Degussa Corp. (Piscataway, NJ)
Eudragit ® RS PO
Evonik Degussa Corp. (Piscataway, NJ)
Eudragit ® RL PO
Evonik Degussa Corp. (Piscataway, NJ)
Foremost #310 Regular
Foremost Harms (Baraboo, WI)
(Lactose Monohydrate)
Hard Gelatin Capsules
Capsugel (Peapack, NJ)
(0SF White Opaque)
Hydrochloric Acid
Mallinkrodt (St. Louis, MI)
Magnesium Stearate
Spectrum Chemicals (Gardena, CA)
Methocel K100M Premium CR
Colorcon Inc. (West Point, PA)
(IF10828)
Methocel K100 Premium LV CR (IF 10807)
Colorcon Inc. (West Point, PA)
Methocel K100 M Premium (IF 10826)
Colorcon Inc. (West Point, PA)
Nifurtimox
WuXi AppTec Co., Ltd (Shanghai, China)
Phosphate Buffer Saline
EMD Chemicals (Gibbstown, NJ)
(10X PBS)
Plasdone K29/32
ISP Corp. (Wayne, New Jersey)
Polysorbate 80 (Tween 80)
Spectrum Chemicals (Gardena, CA)
Sodium Dodecyl Sulfate (SDS)
JT Baker (Phillipsburg, NJ)
Starch 1500
Colorcon Inc. (West Point, PA)
[0000]
TABLE 2
Equipment Used In The Development of The Sustained
Released Formulation Of Nifurtimox
Equipment
Manufacturer
Model
Capsule Filling Funnel
Torpac (Fairfield, NJ)
Size 0 Capsule
Dissolution Apparatus
Vanekl Industries (Edison, NJ)
VK7000
Extruder
LCI Corporation (Charlette, NC)
MG-55
KitchenAid Mixer
KitchenAid Inc (St. Joseph, MI)
K5SS
Planetary Mixer
Glascol LLC (Terre Haute, IN)
RD-20
Marumerizer
LCI CORPORATION
QJ230T
(Spheronizer)
(CHARLOTTE, NC)
Stainless Steel Sieves
Fisher Scientific (Pittsburgh,
Fisherbrand
PA)
U.S. Standard
Tap Density Apparatus
Vankel Industries (Edison, NJ)
10705
[0045] Extrusion-spheronization was used to develop matrix based Sustained Release formulations of Nifurtimox. A sustained release matrix formulation may comprise a drug, one or more water-swellable hydrophilic polymers, excipients such as fillers or binders, a flow aid (glident) and a lubricant. Other functional ingredients, such as buffering agents, stabilizers, solubilizers and surfactants, may also be included to improve or optimize the release performance of the formulation. Various water soluble, insoluble, and water swellable polymers, such as hydroxypropyl methylcellulose (HPMC), hydroxypropylcellulose (HPC), polyethylene oxide (PEO), and methacrylic copolymers have been used in bead form to achieve desired SR profiles. The mechanism of drug release from the beads depends on the type of the polymer used and the solubility of the active drug. In the case of hydrophilic polymers, drug release for soluble drugs occurs by diffusion of the drug through the hydrated portion of the matrix and erosion of the outer hydrated polymer on the surface of the matrix; for insoluble drugs, erosion is the predominant mechanism.
[0046] Examples of lubricants and glidents include stearic acid, magnesium stearate, calcium stearate, zinc stearate, sodium stearyl fumarate, glyceryl monostearate, glyceryl palmitostearate, hydrogenated vegetable oil, mineral oil, silicon dioxide, sodium lauryl sulfate, talc, sucrose esters of fatty acid, microcrystalline wax, yellow beeswax and white beeswax.
[0047] For the invention, Methocel (HPMC based), Eudragit® RL and Eudragit® RS (methacrylic copolymer based) were used to make beads with Sustained Release properties to fill into capsules. Initially several placebo formulations with different viscosity grades of methocel, percent of polymer, and amount of granulating liquid (deionized water) to make a wet mass were used to evaluate the extrusion-spheronization process. Based on Nifurtimox's solubility, dose requirement, and drug loading per capsule, five capsule formulations were optimized to make beads with SR properties.
Example 2
Preparation of Sustained Release Beads
[0048] The total granulation batch size for each formulation listed in Table 3 was about 50 g. The dry excipients and active ingredients were blended in a Planetary Mixer (KitchenAid Inc., St. Joseph, Mich.) for ˜10 min. The blend was granulated in the same mixer using deionized water to achieve the appropriate consistency for extrusion. The granulations were extruded through a 1.0 mm×1.0 mm×22.6% (hole diameter×thickness×open area) stainless steel dome-discharge extrusion die using a lab-scale extruder (Model MG-55, LCI Corporation, Charlotte, N.C.). The extruded material was transferred to a spheronizer (Model QJ2 30T, LCI Corporation, Charlotte, N.C.) fitted with a 2.0 mm (space between grooves) crosshatched spheronizer plate (friction plate). Eudragit® polymer formulations were extruded at 30 rpm and spheronized at 1000 rpm for 30 sec. Formulations with Methocel were extruded at 30 rpm and spheronized at 1500 rpm for 3 min. The Eudragit® polymer beads were dried in a drier at 50° C. for 18 h, and the Methocel beads were dried at 50° C. for 2 h. FIG. 1 shows the Nifurtimox SR beads from different formulations.
[0000]
TABLE 3
Formula for Preparation of Different Nifurtimox Capsule
Formulations
Formulation (% w/w/ on dry solids basis)
Immediate
Formulation
Sustained Release (bead filled)
Release
Number
1
2
3
4
5
6
Ingredient
Nifurtimox
20
35
35
35
35
35
Avicel PH
45
30
30
50
47.5
55
101
Plasdone K
5
5
5
—
—
—
29/32
Eudragit ®
30
30
—
—
—
—
RS PO
Rudragit ®
—
—
30
—
—
—
RL PO
Lactose
—
—
—
10
10
10
Monohydrate
Methocel K
—
—
—
5
7.5
—
100
Premium LV
CR
Total (%)
100.0
100.0
100.0
100.0
100.0
100.0
Percent
68.0
60.0
60.0
56.0
56.0
—
Granulating
Liquid Used
(Deionized
Water)
Example 3
Characterization of Beads
[0049] Beads of each formulation were sieved for 2 min by hand using nest of standard sieves size 12, 18, and 30 (1680, 1000, and 595 microns). The beads retained on each sieve were weighed and that data (Table 4) was used to construct percent bead size distribution curves. Bead formulations with Methocel (Formulations Nos. 4 and 5) had tighter size distribution and higher product yield compared to the bead formulations with Eudragit®. The size range of 1000 to 595 microns was considered appropriate, and the weight of beads in this range was reported as the product yield. For each formulation bead product yield, bulk and tapped density were determined, and Carr's index (%) and the Hausner ratio were calculated (Table 5). All SR bead formulations showed good flow properties based on the calculated Carr's index (<15) and Hausner ratio (<1.25).
[0000]
TABLE 4
Sieve Analysis of Nifurtimox Sustained Release Bead Formulations
Bead Size (microns)
>1680
1000
595
<595
Percent beads
Percent beads
Percent beads
Percent beads
Formulation
retained on Sieve
retained on Sieve
retained on Sieve
passed through
No.
12
18
30
Sieve 30
1 (SR)
0
36.21
50.75
13.04
2 (SR)
0
60.37
33.16
6.47
3 (SR)
0
46.01
40.41
13.68
4 (SR)
0
77.80
20.47
1.73
5 (SR)
0
82.19
15.50
2.23
[0000]
TABLE 5
Physical Characteristics of Nifurtimox Sustained Release Bead
Formulations
Total
Product
Bulk
Tapped
Carr's
Formulation
Yield
yield
density
density
index
Hausner
No
(%)
(%)
(g/ml)
(g/ml)
(%)
ratio
1 (SR)
56.44
86.96
0.68
0.71
4.23
1.04
2 (SR)
50.97
93.53
0.63
0.68
7.35
1.08
3 (SR)
49.82
86.43
0.65
0.66
1.52
1.02
4 (SR)
67.65
98.27
0.72
0.78
7.69
1.08
5 (SR)
64.82
97.77
0.68
0.76
10.53
1.12
Example 4
Capsule Filling
[0050] About six capsules of each formulation were filled by hand with the help of a capsule-filling funnel (Torpac, Fairfield, N.J.) ( FIG. 6 ) for size 0 capsules. Formulation 15825-41-1 was an immediate release powder formulation; all the other formulations were Sustained Release bead formulations. The particle size range for the bead formulations was 1000 to 595 microns. For each formulation, the average capsule fill weight and average Nifurtimox per capsule were calculated (Table 6).
[0000]
TABLE 6
Average Capsule Fill Weight and Drug Per Capsule of
Nifurtimox Formulations
Capsule Size: 0
Average
Average
empty
Average filled
estimated
Formulation
capsule
capsule weight
Average fill
Nifurtimox per
No.
weight (g)
(g)
weight (g)
capsule (mg)
1 (SR)
0.095
0.596
0.501
100.11
2 (SR)
0.095
0.524
0.430
150.34
3 (SR)
0.095
0.525
0.430
150.67
4 (SR)
0.095
0.523
0.429
150.02
5 (SR)
0.096
0.524
0.428
149.95
6 (IR)
0.095
0.380
0.285
99.65
Example 5
Capsule Content Assay
[0051] A. Capsule with Bead Formulation
[0052] The content of a capsule were emptied into a 100 ml volumetric flask using a weighing paper funnel. The capsule shell was tapped several times to remove all the beads. Dimethyl sulfoxide (DMSO, 10 ml) was added to the flask by volumetric pipette and the contents were sonicated for 10 min. if a visual inspection of the flask showed that beads were still present, then the flask was subjected to an additional 10 min of sonication. Once a suspension was achieved, the flask was filled to the 100 ml mark with acetonitrile. The flask was inverted and shaken multiple times to ensure proper mixing then left to stand for 10 min. A. 1.0 ml aliquot was taken with a volumetric pipette and transferred to a 10 ml volumetric flask. The flask was filled to the 10 ml mark with acetonitrile and mixed. A 1.5 ml aliquot was taken up in a syringe (all polypropylene); filtered through a 13 mm, 0.45 μm nylon membrane filter into a HPLC vial; and analyzed by high-performance liquid chromatography (HPLC).
[0053] B. Capsule with an Amorphous Powder Formulation
[0054] The contents of a capsule were emptied into a 100 ml volumetric flask fitted with a long step funnel. The capsule shell was rinsed with 3 ml of acetonitrile directly into the flask. The funnel was rinsed with acetonitrile (15 ml) and removed from the flask. The contents were sonicated for 10 min, then the flask was filled to the 100 mL mark with acetonitrile. The flask was inverted and shaken multiple times to ensure proper mixing, then left to stand for 10 min. A 1.0 ml aliquot was taken with a volumetric pipette and transferred to a 10 ml volumetric flask. The flask was filled to the mark with acetonitrile and mixed. A 1.5 ml aliquot was taken up in a syringe (all polypropylene); filtered through a 13 mm, 0.45 μm nylon membrane filter into a HPLC vial; and analyzed by HPLC.
[0055] Two capsules of each formulation were assayed; the expected and average Nifurtimox found per capsule are listed in Table 7. All HPLC findings were within the limits expected for the amount of Nifurtimox per capsule.
[0000]
TABLE 7
Capsule Contents of Nifurtimox Formulations Analyzed by HPLC
Estimated
Average Nifurtimox
Nifurtimox
per capsule found by
Standard
Formulation No.
per capsule (mg)
HPLC (mg)
Deviation
1 (SR)
100.00
103.74
1.27
2 (SR)
150.00
150.28
2.23
3 (SR)
150.00
151.82
0.23
4 (SR)
150.00
150.69
1.59
5 (SR)
150.00
148.97
2.13
6 (IR)
100.00
101.41
0.54
Example 6
Nifurtimox Solubility Studies
[0056] Nifurtimox is poorly soluble in water. To select a buffer for the in vitro release (dissolution) studies, solubility of Nifurtimox in possible buffers was determined by HPLC. For each 5 ml of the prepared buffer, drug was added in excess and mixed for 2 hr on a planetary mixer. Each sample was filtered through a syringe filter (0.45 μm nylon membrane) and analyzed by HPLC. Solubility results are listed in Table 8. Among the tested buffers, 0.1N HCl with 5% SDS had the highest solubility (308.46 μg/ml).
[0000]
TABLE 8
Solubility of Nifurtimox
Formulation
Nifurtimox Found by HPLC
No.
Buffer
(μg/ml)
7
Water
19.35
8
0.1N HCl
90.61
9
0.1N HCl + 5% Tween 80
11.47
10
0.1N HCl + 5% SDS
308.46
11
1X PBS
13.06
12
1X PBS + 5% Tween 80
109.43
13
1X PBS + 5% SDS
113.59
Example 7
In Vitro Release Studies
[0057] Nifurtimox release studies for each formulation were performed in duplicate using a standard USP dissolution apparatus II (Vankel, VK7000), at 100 rpm, in a medium of 900 mL 5% sodium dodecyl sulfate (SDS) in 0.1N hydrochloric acid (pH ˜1.2) at 37°±5° C. At specified time intervals (0.5, 1, 2, 4, 8, 10, and 24 h), 2 ml of sample was collected from each basket and replaced with the same volume of buffer. Collected samples were centrifuged for 10 min; 0.5 ml of sample was collected from the supernatant and analyzed by HPLC to determine the amount of Nifurtimox released at each time point. The average percent of Nifurtimox released over time was calculated (Table 9) and plotted ( FIG. 3 ) to observe the SR achieved by each formulation.
[0000]
TABLE 9
Average Percent Nifurtimox (in 0.1 N HCl with 5% SDS) Released Over Time
Formulation
Nifurtimox
Nifurtimox
Nifurtimox
Nifurtimox
Nifurtimox
Nifurtimox
Capsule
Capsule
Capsule
Capsule
Capsule
Capsule
Formulation
Formulation
Formulation
Formulation
Formulation
Formulation
4(SR)
5(SR)
2(SR)
3(SR)
1(SR)
6(IR) a
Average
Average
Average
Average
Average
Average
Percent
SD
Percent
Percent
Percent
Percent
Percent
Time
Drug
(standard
Drug
Drug
Drug
Drug
Drug
(hr)
Released
deviation)
Released
SD
Released
SD
Released
SD
Released
SD
Released
SD
0
0
0
0
0
0
0
0
0
0
0
0
N/A
0.5
6.79
0.56
5.06
1.07
4.2
1.1
7.03
0.04
5.72
0.89
46.28
N/A
1
11.71
0.55
8.36
1.13
7.7
1.49
13.03
0.06
9.42
0.73
49.66
N/A
2
18.54
0.11
12.12
1.25
12.88
1.91
21.78
1.33
14.28
0.93
56.06
N/A
4
27.5
2.71
16.34
1.04
27.07
3.46
32.79
1.57
22.21
1.12
67.26
N/A
8
39.04
3.69
21.81
1.6
54.33
4.33
42.82
1.59
39.02
2.28
67.62
N/A
10
42.02
3.7
23.6
1.35
59.25
1.76
44.37
1.25
45.76
1.42
63.82
N/A
24
45.17
0.51
30.32
0.86
43.32
1.28
40.42
0.95
43.74
0.19
41.21
N/A
a Formulation 6 was a direct powder filled, immediate release capsule formulation, and dissolution was not performed in duplicate.
N/A = Not Applicable.
[0058] During analysis of the dissolution samples (in 0.1N HCl with 5% SDS), about 25% of Nifurtimox degradation in 24 hr was observed and was evident from the low amounts of recovery at the 24 hr time point shown in FIG. 8 . Further analysis of Nifurtimox degradation in dissolution samples is required to quantify the exact amount of Nifurtimox released over time.
[0059] Capsules formulations 2-5 contained 150 mg per capsule (size 0); capsules formulations 1 and 6 contained 100 mg of Nifurtimox per capsule. Maximum HPLC recovery observed was about 70% of the strength of the capsule; however, it was difficult to estimate the exact amount of degradation of Nifurtimox over time before the capsules were analyzed. Without considering the amount of Nifurtimox degraded over time, the percent of drug release observed in the SR formulations ranged from 23.6% to 59.25% in 10 hr, whereas IR formulation released about 63.92%.
Example 8
Nifurtimox Stability in 2% W/V SDS in Deionized Water
[0060] Due to the degradation of Nifurtimox observed in dissolution buffer (0.1 N HCl with 5% SDS), a preliminary stability study of Nifurtimox in 2% w/v SDS in deionized water was performed. To 20 ml of 2% SDS solution, an excess amount of Nifurtimox was added and the solution was stirred with a magnetic stirrer for 45 min. The solution was filtered using a 0.45 μm nylon syringe filter, and aliquots of 1 ml samples were collected in HPLC vials and stored at different temperatures (25° C. and 37° C.) for different time periods (0 to 24 hr). HPLC analysis results are presented in Table 10. Based on the amount of Nifurtimox found in initial (0 hr) and final (24 h) samples, there is no significant degradation of Nifurtimox in 2% w/v SDS (in water) at 25° C. and 37° C. for up to 24 hr.
[0000]
TABLE 10
Nifurtimox Stability in 2% W/V SDS (In Water)
Estimated
Amount of
Temp
Time
Peak Area
Nifurtimox
Sample Number
(° C.)
(hr)
(9.6 min)
(μg/ml)
1
25
0
13727.20
344.22
2
4
13558.00
339.96
3
8
13773.00
345.38
4
12
13806.00
346.21
5
16
13835.00
346.94
6
20
13755.00
344.92
7
24
13631.00
341.80
Control 1
25
0
0.00
0.00
Control 2
0.00
0.00
Control 3
0.00
0.00
Control 4
0.00
0.00
8
37
1
13511.00
338.78
9
2
13549.00
339.74
10
3
13511.00
338.78
11
24
13709.00
343.76
12
24
13542.00
339.56
Example 9
In Vitro Release Studies Using 2% W/V SDS in Deionized Water as Dissolution Buffer
[0061] As described in earlier sections, the Nifurtimox release (dissolution) studies were repeated using a dissolution buffer of 2% w/v SDS in deionized water. Dissolution of each formulation was performed in duplicate. The average percent of Nifurtimox released over time was calculated (Table 11) and plotted ( FIG. 4 ) to observe the SR achieved by each formulation.
[0000]
TABLE 11?
Average Percent Nifurtimox (in 2% WN SDS in Water) Released Over Time
Formulation
Nifurtimox
Nifurtimox
Nifurtimox
Nifurtimox
Nifurtimox
Nifurtimox
Capsule
Capsule
Capsule
Capsule
Capsule
Capsule
Formulation
Formulation
Formulation
Formulation
Formulation
Formulation
4(SR)
SD
5(SR)
2(SR)
3(SR)
1(SR)
6(IR) a
Average
(stan-
Average
Average
Average
Average
Average
Percent
dard
Percent
Percent
Percent
Percent
Percent
Time
Drug
devia-
Drug
Drug
Drug
Drug
Drug
(hr)
Released
tion)
Released
SD
Released
SD
Released
SD
Released
SD
Released
SD
0
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.5
9.05
0.50
4.37
0.58
4.65
0.49
8.48
0.53
4.95
0.45
54.56
1.51
1
20.98
2.07
8.53
0.77
8.16
0.68
25.22
1.03
8.97
0.21
65.40
0.87
2
39.69
3.46
14.73
1.40
13.12
0.53
66.05
1.66
14.64
0.35
78.00
1.17
4
61.70
1.36
24.26
0.70
20.73
1.40
90.09
0.11
22.67
0.15
89.54
2.20
8
76.12
2.73
38.93
1.42
32.18
1.08
96.56
0.96
34.35
0.88
95.68
2.50
10
79.02
3.17
44.85
1.48
37.69
1.12
97.64
0.50
39.21
0.72
96.41
2.99
24
88.90
3.84
70.75
2.94
88.62
2.19
99.71
1.16
81.78
2.90
98.90
2.83
a Formulation 6 was a direct powder filled, immediate release capsule formulation, and dissolution was not performed in duplicate.
[0062] HPLC analysis determined the maximum recovery was about 98.90% of the strength of the capsule (formulation 6) and no significant instability of Nifurtimox was observed with the dissolution performed in 2% w/v SDS in deionized water. Among the tested SR formulations, the percent Nifurtimox release observed ranged from 37.69% to 97.64% in 10 hr, whereas the IR formulation released about 96.4%. More controlled release was observed as the percentage of Methocel polymer was increased from 5% to 7.5% in the formulation (formulations 4 and 5; FIG. 4 ). Formulation 2 with Eudragit® RS PO achieved higher controlled release compared to formulation 3 with Eudragit® RL PO ( FIG. 4 ).
[0063] From the results shown above, sustained release capsule formulations of Nifurtimox were formulated by extrusion spheronization using Methocel and Eudragit® polymers. SR capsule formulations of Nifurtimox (150 mg) prepared using 5% Methocel (Formulation 4) resulted in sustained drug release of ˜79% in 10 hr and ˜89% within 24 hr and with 7.5% Methocel (Formulation 5) the sustained release observed was ˜44% in 10 hr and ˜70% within 24 hr. Nifurtimox capsule formulations (150 mg) prepared using Eudragit® RS PO (Formulation 2) achieved a sustained release of ˜37% in 10 hr and ˜88% within 24 hr compared to Eudragit® RL PO (Formulation 3) which resulted in ˜90% drug release within 4 hr.
[0064] The results demonstrated above show that the formulations of the present invention has significantly improved sustained-release profile for treating the Chagas disease and other diseases or disorders that are treatable by Nifurtimox. This not only reduces the toxicities associated with immediate-release Nifurtimox, but also improves patient compliance for less frequent administration. Therefore, it is expected that the formulations of this invention to have wide applications on different diseases that are treatable by Nifurtimox.
|
The present invention relates to a novel formulation of sustained-release Nifurtimox with enhanced activity while having low toxicity. The formulation can improve patient compliance by reducing the frequency of administering the drug.
| 0
|
CROSS REFERENCE TO RELATED APPLICATION
This application is the U.S. National Stage of International Application No. PCT/EP2004/006258, filed Jun. 9, 2004 and claims the benefit thereof. The International Application claims the benefits of German Patent application No. 103 26 426.4 DE filed Jun. 10, 2003, both of the applications are incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
The invention relates to a method for increasing the capacity of an installation used to carry out an industrial process.
BACKGROUND OF THE INVENTION
An increase of a few percentage points in the capacity of an installation for carrying out an industrial process results as a rule in a disproportionately high improvement in profits for the operator of the installation. This type of industrial process can typically be a process with production lines which run through the installation, such as lines for the manufacture of paper, textiles, plastics or metal foils. With such processes the capacity of the process is determined by the speed of the track, e.g. measured in meters per second.
When a machine part for a machine contained in the installation or a complete part of the installation is designed for such an installation, this is mostly done on the basis of similar machines or parts of the installation, taking into account a certain amount of capacity reserve. However, under the operating conditions which actually occur in the installation, the loads imposed on the machine or the parts of the installation are mostly different to those in previously known installations. It is thus not possible to say with any certainty in what way it is possible to increase the capacity of an installation without overloading one or more parts of the installation.
Previous measures for increasing the capacity in such installations, especially in complex installations such as installations for carrying out continuous processes for manufacturing of goods on a production line have also generally lacked long-term sustainability.
SUMMARY OF THE INVENTION
The object of the present invention is therefore to specify a method which allows the capacity of an installation to be increased in a sustained and economical manner.
This object is achieved in accordance with the invention by a method in accordance with the claims. Advantageous embodiments of the method are the object of the subclaim.
The invention in this case is based on the knowledge that previous measures for increasing the capacity in installations has always only been based on considering particular points in the installation and has therefore as a rule ignored long-term sustainability. The determination of the process variables relevant to the capacity of the installation envisaged by the invention and the recording of these variables under changing operating conditions guarantees that all aspects of the influencing factors restricting the capacity of the installation will be taken into consideration. Changing operating conditions here are taken to mean the operating conditions occurring during regular operation of the installation, i.e. in the case of a paper machine the operation of the machine with paper of different qualities and types for example. This avoids looking at only a few specific individual aspects of the installation such as the drive system, under a number of specific operating conditions, but not taking into account other factors and operating conditions which dictate the capacity. As a result this makes not just a short-term increase, but a sustained increase in capacity possible.
The smallest control reserve of the control loops determines the increase in capacity which can be obtained without any further measures. This guarantees that first of all the existing capacity reserves that can be secured are checked and these reserves are secured if necessary. This represents the increase in capacity that can be most easily achieved from the economic standpoint.
If the aim is to use additional measures to obtain an increase in capacity which goes beyond the existing capacity reserve, this can be done by defining a capacity increase target for the installation, determining the necessary control reserves in the control loops for the desired increase in capacity and determining the control loops with a control reserve which is too low for the desired capacity increase.
From the number of control loops with control reserves which are too low it is already evident what effort will be needed for further investigations and possibly also for the implementation of measures for increasing capacity. With a large number of control loops a decision can be taken under some circumstances to define a smaller increase in capacity, so that further investigations are only required for the correspondingly smaller number of control loops.
According to an advantageous embodiment of the invention further steps include a technical and/or technological investigation of the control loops with a control reserve which is too small and formulation of measures for producing the control reserves needed in each case by relieving the load on the relevant control loops and/or by replacing components in the relevant control loops by higher-performance components
These measures can finally be evaluated from a technical and or commercial standpoint. On the basis of this evaluation the decision process for the implementation of the improvement measures can be simplified and a solution found which is the optimum solution for the operator of the installation from the cost/benefits standpoint.
Overall the sequence of the above steps ensures that priority is given to dealing with the points for which there is the greatest potential for improvement or for which the cost effectiveness of a conversion is the greatest. At the same time this process allows available capacity reserves to be secured in the most economical way even in a highly-complex installation.
The method in accordance with the invention is especially suitable for increasing the capacity in an installation for executing a continuous process, especially a process for manufacturing goods on production lines, e.g. paper, textiles, plastic or metal foils, for which the capacity is determined by the speed of the production line.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention as well as a further advantageous embodiments of the invention in accordance with the features of the subclaims are explained in more detail below with reference to exemplary embodiments in the figures. The Figures show:
FIG. 1 a recording of process variables in an installation for manufacturing paper,
FIG. 2 a representation of an inventive process sequence depicted as a flowchart,
FIG. 3 a basic diagram for determining the process variables relevant for the capacity of an installation,
FIG. 4 a diagram of the process variables relevant for a paper machine,
FIG. 5 a machine velocity/moment diagram for determining the control reserve for a drive motor and
FIG. 6 a determination of the control reserve for the drive motor of FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows an installation 1 for manufacturing paper. The installation 1 comprises a wide diversity of installation parts which are needed for the different steps in the production process for paper, for example a material preparation system 1 a , a paper machine 1 b , a roller/calendar 1 c , roll cutter 1 d and cross cutter 1 e . The paper runs as a production line 8 through major parts of the installation 1 .
The installation 1 features a plurality of drive components 11 , automation components 12 and energy supply components 13 for driving, supplying power to and controlling the different components in the production process.
A device 2 is used to determine the control reserves in the installation 1 . The device 2 features a recording unit 3 , an evaluation unit 4 , an input unit 7 and an output unit 5 .
The recording unit 3 is used for recording process variables P 1 . . . P 10 of the paper production process on the installation 1 . This can for example involve measurement signals which are recorded using signal generators already present and/or to be provided in the installation 1 .
The process variables can originate from a wide diversity of sources of the processor and be present in any form, including different forms, e.g. analog, binary, numeric and/or as a changeable physical variable. The evaluation unit 4 is used for determining the control reserves in the control loops of the installation 1 . To this end a large number of characteristic capacity curves for a plurality of components, especially standard components occurring in the installation are stored in a memory of the evaluation unit 4 . The output unit 5 can be used to present the control reserves for display. Furthermore the device 2 features an input unit 7 for entering a desired capacity increase into the installation 1 .
In FIG. 2 the method in accordance with the invention is explained on the basis of a flowchart. The procedure is advantageously carried out by a service provider who has the appropriate know-how and technical facilities to do so.
In a first step 31 —as explained in detail in FIG. 3 and 4 —the process variables relevant for a capacity of the installation are determined. In a second step 32 these process variables are recorded under changing operating conditions of the installation, and in a third step 33 —as illustrated by the examples in FIG. 5 and 6 —a smallest control reserve of the control loops of the installation is determined on the basis of the recorded process variables. This control reserve can be used to increase the capacity of the installation without any appreciable investment outlay. In a step 33 a a check is therefore made as to whether an increase in capacity beyond this smallest control reserve is desired. If this is not required, the procedure can be ended in step 39 b , by securing the available capacity reserve.
If an increase in the capacity of the installation which exceeds the reserve is required, in a further procedural step 34 such a desired capacity increase of the installation can be defined. In a further step 35 the control reserves necessary for the desired increase in capacity are determined in the control loops of the installation and in a further step 36 the control loops with a control reserve which is too small for the desired capacity increase are determined.
For the control loops with a control reserve which is too small, technical and/or technological investigations of the control loops can be performed in a further step 37 to establish the control reserves needed in each case by relieving the load on the relevant control loops and/or through replacing components in the relevant control loops by more powerful components. In a further step 38 a technical and/or commercial evaluation of these measures can be undertaken, on the basis of which a final implementation of the measures is undertaken in step 39 a.
The process variables relevant for the capacity of an installation can be easily established in this way by applying in the more general sense the method of “cutting free” known per se from technical mechanics.
This is done in a first step by determining a process variable representing the capacity of the installation. In the case of an installation for paper production this might typically be the speed of the paper in the installation
In a next step, as basically shown in FIG. 3 , a core process 6 of the installation is defined and all interfaces 21 - 25 of the core process 6 to the ancillary processes 41 - 45 surrounding it (e.g. ancillary processes for energy, water and compressed air supply) are determined and investigated for their effect in relation to this representational process variable. This can be done by measuring the physical effects (e.g. forces, currents, fields, throughflows, pressures) at these interfaces. These physical effects of process variables can be measured by signal generators already present and/or to be provided, which if necessary must be accommodated at the interfaces.
If there is a effect relationship with the representational process variable at an interface, a process variable which is relevant to the capacity of the installation is present at this interface and a more precise technical investigation is undertaken for the components of the ancillary process to determine the control reserve. The interfaces which do not have an effect relationship are not considered any further and instead the interfaces the interfaces are drawn closer to the core process or moved to within the core process and an investigation is conducted at these new interfaces for an effect relationship with the representational process variable. In this case too interfaces with an effect relationship to the representational process variable are identified as relevant process variables for which in further steps more precise technical investigations for determining the control reserves are to be performed.
Such a systematic, step-by-step “drawing closer” of the interfaces of the ancillary process into the core process ensures that all of the process variables relevant for determining the capacity of the installation are determined, not only in the area of the core process but also in the area of the ancillary processes.
In the case of an installation for paper production the subprocess running on the paper machine can be defined as the core process for example. Interfaces to ancillary processes with effect relationships to the speed of the paper passing through the installation are then to be found in the area of material and energy flows, for example for feeding energy, steam, water, fibers, chemicals and additives as well as for removal of water, condensate and waste heat. The relevant process variables in the area of the ancillary processes are thus in this case—as shown in FIG. 4 —the supply of energy 51 (e.g. measured as power P), the supply of steam 52 (measured as volume per unit of time), the supply of water 53 (measured as volume per unit of time) the supply of fibers 54 (measured as mass per unit of time), the supply of chemicals 55 (measured as mass per unit of time) the removal of water 56 (measured as volume per unit of time), the removal of condensate 57 (measured as volume per unit of time) and the removal of waste heat 58 (measured as power P). These relevant process variables can only be recorded under changing operating conditions of the installation, e.g. for different qualities and types of paper, and—as explained below—the control reserves in the control loops of the installation for paper production determined.
An advantageous procedure for determining the control reserve for an electric motor for driving a paper machine of installation 1 in accordance with FIG. 1 will be explained with the aid of FIG. 5 and FIG. 6 . The procedure is basically also applicable to other control loops of the installation (e.g. steam, vacuum, coating).
At a defined velocity v of the paper in the paper machine a defined load (moment) M is present at the electric motor. This operating point defines a specific class K in the speed/load plane v/M shown in FIG. 4 . For each class K the time (duration) T is counted in which the motor is operated in this class and shown in a plane perpendicular to the v/M plane. The classes K with the longest times can thus be determined. These can subsequently be approximately described by a linear relationship between moment M and machine velocity v described and represented by a straight line gradient G. Basically the relationship between moment M and machine velocity v can naturally also be described through complex functions.
The diagram in FIG. 6 shows the moment M of the motor over the velocity v of the machine, with these two parameters being approximated by a linear relationship in accordance with FIG. 4 represented by the straight line gradient G. With a speed-regulated drive the maximum power of a motor or a converter (depending on which is the smaller) is a hyperbolic curve HK in the velocity/moment plane v/M. The distance RV of this hyperbolic curve HK to the straight line gradient G is a measure for the control reserve and thereby for the maximum possible increase in speed.
In the case of determination of the control reserve for example with regard to the positioning of a vacuum or steam control valve, velocity and load of an ancillary drive, of fluid streams etc. the machine velocity can also be plotted by the position of the valve, the speed of the ancillary drive or the fluid stream instead of via the load, the duration determined and the approximately linear or complex relationship with the velocity v determined.
The processes to be considered in the case of an installation with a continuous production process, e.g. an installation for paper production, are as a rule not very dynamic. The dynamic components in the process variables are not even of primary interest for the determination of the control reserves. Of greater interest instead is the average long-term behavior of the process variables. The process variables are therefore preferably filtered (appr. 2 s) and only sampled appr. every 5 s.
Preferably an online evaluation of the recorded data with subsequent data compression is undertaken for a subsequent offline evaluation of the recorded data.
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The invention relates to a method for increasing the capacity of an installation used to carry out an industrial process in an economical and sustainable manner. Said method consists of the following steps: process variables relevant to the capacity of the installation are determined; said process variables are monitored during variable operating conditions of the installation; and a very small control reserve of the control loops of the installation is established on the basis of the monitored process variables.
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TECHNICAL FIELD
[0001] The present invention relates to a vehicle travel control system which includes adaptive cruise control, pre-crash control, or the like.
BACKGROUND ART
[0002] Recently, interest in a safety technique for an automobile has increased greatly. Thus, various preventive safety systems have been put to practical use mainly by an automobile related company and the like. Among these preventive safety systems, a system which uses Adaptive Cruise Control (hereinafter, referred to as “ACC”) or pre-crash control is widely known.
[0003] The ACC controls a vehicle traveling speed to a pre-set vehicle speed without an operation intervention by a driver or controls a distance between an own vehicle and a vehicle traveling ahead thereof to a predetermined distance (see, e.g., PTL 1).
[0004] Also, the pre-crash control is control to reduce impact of a collision by activating a brake or to reduce impact of a collision on an occupant by appropriately tightening a seat belt when it is not possible to avoid a collision with a target getting closer to an own vehicle from the front, side, or behind thereof (see, e.g., PTL 2).
[0005] Generally, control algorithm such as what has been described above is incorporated into a microcontroller or the like. A vehicle travel control system is realized by the following system configuration. That is, by calculating a control command such as acceleration, which is requested to the vehicle according to each kind of control algorithm, and by transmitting a command to a brake actuator, breaking of a vehicle is performed and by transmitting a command to a throttle actuator, driving of the vehicle is performed.
[0006] Here, a plurality of kinds of control algorithm is often incorporated into the microcontroller or the like. Thus, it is important to determine a control command from which control algorithm is employed to control a vehicle according to a condition.
[0007] For example, in a vehicle in which two kinds of control algorithm, which are the ACC and the pre-crash control, are mounted, when pre-crash control is started during the execution of the ACC, it is considered that a priority is given to a command of the pre-crash control having higher urgency.
[0008] However, when the above described condition is a case where a vehicle-to-vehicle distance suddenly becomes short due to sudden breaking of a preceding vehicle during preceding vehicle follow-up traveling control by the ACC, it can be assumed that acceleration is controlled in a deceleration direction by the ACC before determination to start the pre-crash control is made. In this case, when a control command is simply switched to a value calculated by the pre-crash control along with the determination to start the pre-crash control, it may be considered that breaking force is rather weakened depending on setting for calculating a control command in each kind of control algorithm.
[0009] As a method to solve such a problem, PTL 3 discloses a vehicle control system including: a distance detection unit configured to detect a distance between an own vehicle and a forward obstacle, which includes a preceding vehicle, in a predetermined range forward in a traveling direction of the own vehicle; a relative speed detection unit configured to detect a relative speed between the own vehicle and the obstacle; a first target acceleration calculation unit configured to calculate first target acceleration for keeping a set vehicle-to-vehicle distance based on a distance and a relative speed with the preceding vehicle in such a manner that follow-up traveling is performed with the set vehicle-to-vehicle distance away from the preceding vehicle traveling a traveling lane of the own vehicle; a second target acceleration calculation unit configured to calculate second target acceleration for decelerating the own vehicle when it is determined that the own vehicle may collides with the forward obstacle based on a distance and a relative speed with the forward obstacle; a third target acceleration calculation unit configured to calculate third target acceleration which is at least equal to or smaller than smaller one of the first and second target acceleration based on the first target acceleration and the second target acceleration when the second target acceleration is calculated by the second target acceleration calculation unit while the first target acceleration is calculated by the first target acceleration calculation unit; and a control unit configured to control a speed adjustment member including a brake system provided to the own vehicle in such a manner that acceleration of the own vehicle matches the third target acceleration when the third target acceleration is calculated by the third target acceleration calculation unit.
[0010] Also, other than these, a system to control a vehicle safely and comfortably similarly to a skilled driver by controlling a target longitudinal acceleration/deceleration control command according to a lateral jerk generated in response to a driver operation has been proposed (see, e.g., PTL 1 and PTL 2).
CITATION LIST
Patent Literatures
[0000]
PTL 1: JP 11-39586 A
PTL 2: JP 2000-95130 A
PTL 3: JP 2008-296887 A
Non-Patent Literature
[0000]
NPL 1: M. Yamakado, et al., An experimentally confirmed driver longitudinal acceleration control model combined with vehicle lateral motion, Vehicle System Dynamics, Vol. 46, Supplement, pp. 129-149, Taylor & Francis, 2008
NPL 2: J. Takahashi, et al., An hybrid stability-control system: combining direct-yaw-moment control and G-Vectoring Control, Vehicle System Dynamics, pp. 1-13, iFirst, Taylor & Francis, 2012
SUMMARY OF INVENTION
Technical Problem
[0016] However, in the described method, only strength of a target longitudinal acceleration/deceleration control command of a vehicle is considered and a condition in which a lateral motion of a vehicle is generated by curved road traveling, a lane change, avoidance behavior by a steering operation of a driver, or the like is not considered. Thus, vehicle behavior may be destabilized by applying a control command and it is difficult to say that reliability or safety as a system is secured adequately.
[0017] To solve the described problem, a purpose of the present invention is to provide a vehicle travel control system which is capable of controlling a vehicle while keeping vehicle behavior stable by calculating a suitable command from control commands, which are calculated by a plurality of kinds of control algorithm, while considering a lateral motion of an own vehicle and not making a driver feel discomfort.
Solution to Problem
[0018] To solve the described problem, a vehicle travel control system according to the present invention includes: a first unit configured to calculate a target longitudinal acceleration/deceleration control command of an own vehicle based on input information; a second unit configured to calculate a target longitudinal acceleration/deceleration control command according to a lateral jerk which acts on the own vehicle; and an arbitration unit configured to perform, based on the target longitudinal acceleration/deceleration control command calculated by the second unit, arbitration of the target longitudinal acceleration/deceleration control command calculated by the first unit, wherein output from the arbitration unit is set as a command to control the target longitudinal acceleration/deceleration control command of the own vehicle.
[0019] The input information is a distance or a relative speed between the own vehicle and a forward obstacle, traveling route information from a vehicle navigation system or a Global Positioning System, or a vehicle speed set by a driver of the own vehicle and the first unit is configured to calculate a target longitudinal acceleration/deceleration control command with the vehicle speed as a target speed in such a manner that the vehicle speed is kept.
[0020] Also, the arbitration unit is configured to calculate an acceleration period, a deceleration period, or a steady period based on the target longitudinal acceleration/deceleration control command calculated by the second unit and to perform arbitration according to the period.
[0021] Furthermore, a unit configured to switch a control gain which is for the target longitudinal acceleration/deceleration control command calculation by the second unit is included.
Advantageous Effects of Invention
[0022] According to the present invention, it is possible to provide a vehicle travel control system which is capable of performing control while keeping vehicle behavior stable by calculating a suitable command from control commands, which are calculated by a plurality of kinds of control algorithm, while considering a lateral motion of an own vehicle and not making a driver feel discomfort.
BRIEF DESCRIPTION OF DRAWINGS
[0023] FIG. 1 is a view illustrating a schematic block configuration of a vehicle travel control system according to a first embodiment which is an embodiment of the present invention.
[0024] FIG. 2 is a flowchart of a routine which is executed by a traveling control ECU 113 of the vehicle travel control system according to the first embodiment and is repeated in predetermined time intervals.
[0025] FIG. 3 is a view illustrating an example of an outline of an operation by processing for calculating an acceleration/steady/deceleration period based on G-Vectoring control in step 203 in the routine executed by the traveling control ECU 113 of the first embodiment.
[0026] FIG. 4 is a view illustrating a flow of a routine executed in step 204 of the routine executed by the traveling control ECU 113 of the first embodiment.
[0027] FIG. 5 is a schematic view illustrating a traveling road of an own vehicle, in which the vehicle travel control system according to the first embodiment is mounted, from entering a curve until getting out of the curve.
[0028] FIG. 6 is a view illustrating a time series waveform of each of an ACC command, a GVC command, vehicle state status, an acceleration control command, and a deceleration control command of when the own vehicle travels according to a traveling scenario in FIG. 5 .
DESCRIPTION OF EMBODIMENTS
[0029] In the following, a vehicle travel control system according to an embodiment of the present invention will be described with reference to FIG. 1 to FIG. 6 . Note that in the drawings and the following description, the same reference numbers or the same reference signs are used to the same ones.
First Embodiment
Block Configuration
[0030] FIG. 1 is a view illustrating a schematic block configuration of a vehicle travel control system of a first embodiment which is an embodiment of the present invention. In FIG. 1 , the vehicle travel control system includes an environment recognition sensor unit 110 , a vehicle state recognition sensor unit 111 , a control state switching unit 112 , a traveling control Electronic Control Unit (ECU) 113 , a breaking unit 114 , and a driving unit 115 .
[0031] The environment recognition sensor unit 110 detects a distance, a relative speed, an angle, or the like to a preceding vehicle, a person, an object, or the like which mainly exists ahead of an own vehicle (not illustrated) and transmits the result to the traveling control ECU 113 . Specifically, the environment recognition sensor unit 110 is, for example, a stereo camera, a monocular camera, a millimeter-wave radar, or a laser radar.
[0032] The vehicle state recognition sensor unit 111 includes a function to collect behavior information of a vehicle such as a speed of an own vehicle, a yaw rate, a target longitudinal acceleration/deceleration control command, or vehicle lateral acceleration and operation information of a driver such as an accelerator opening, a depressed amount of a brake, or a steering angle and to transmit the information to the traveling control ECU 113 .
[0033] Note that information transmitted to the traveling control ECU 113 from the environment recognition sensor unit 110 and the vehicle state recognition sensor unit 111 only needs to be minimum information necessary for each kind of vehicle control algorithm described later. Thus, according to information necessary to be collected, a configuration such as a sensor can be added or deleted.
[0034] The control state switching unit 112 includes a function to switch a control gain (Cxy) in G-Vectoring control described later. As a specific example, by a dial switching type switch, it is made possible for a user to select a control mode such as a Normal mode or a Safety mode. A control gain set in the Safety mode is larger than a control gain set in the Normal mode.
[0035] The traveling control ECU 113 includes, for example, a ROM to store programs of a plurality of kinds of vehicle control algorithm described later, a CPU to execute various kinds of calculation processing, and a RAM to store a calculation result.
[0036] The breaking unit 114 includes a function to put a brake on a vehicle according to a braking command on the vehicle as a result of the calculation in the traveling control ECU 113 . For example, a mechanism such as a pump to discharge a high-pressure brake fluid and an electromagnetic valve to supply the brake fluid to a wheel cylinder of each wheel while adjusting a pressure of the brake fluid is suitable.
[0037] The driving unit 115 drives a vehicle according to a driving instruction on the vehicle as a result of the calculation in the traveling control ECU 113 . Specifically, an engine system, an electric motor system, or the like which can vary driving force of a vehicle according to a command is suitable.
[0038] Note that in the first embodiment, it is assumed that a generally used controller area network (CAN) is used as an in-vehicle network for transmission of information which network connects the environment recognition sensor unit 110 , the vehicle state recognition sensor unit 111 , the traveling control ECU 113 , the breaking unit 114 , and the driving unit 115 . However, the communication unit is not the main point in the present invention and a different communication unit may be used.
[0039] <Processing Flow>
[0040] Next, specific processing in the traveling control ECU 113 included in the vehicle travel control system according to the first embodiment of the present invention will be described with reference to FIG. 2 . FIG. 2 is a flowchart of a routine which is executed by the traveling control ECU 113 and is repeated in predetermined time intervals.
[0041] In the following, a case in which control algorithm mounted in the traveling control ECU 113 is the ACC and the G-Vectoring control will be described.
[0042] When the routine is activated, first, input processing in step 200 is executed. Information measured by the environment recognition sensor unit 110 , the vehicle state recognition sensor unit 111 , and the control state switching unit 112 is received through the CAN and is converted into a data format used in a step described later. Specifically, calculation of a new physical quantity or the like is performed by physical unit conversion processing, time differentiation processing, or calculation by an already-known physical equation on an input signal.
[0043] Next, ACC processing in step 201 is executed. When a preceding vehicle is not caught or when a preceding vehicle is not within an ACC control range although the preceding vehicle is caught, an ACC command for driving in a vehicle speed set by a driver is calculated. Also, when a preceding vehicle is caught within the ACC control range, an ACC command for controlling a vehicle-to-vehicle distance (inter-vehicle time) to what is set by a driver is calculated.
[0044] Next, G-Vectoring control processing in step 202 is executed and a GVC command (Gx_GVC) is calculated by an Mathematical Formula 1.
[0000]
Gx_GVC
=
-
sgn
(
Gy
·
G
y
.
)
C
xy
1
+
Ts
G
.
y
[
Mathematical
Formula
1
]
[0000] Here, Gx_GVC: a GVC command, Gy: vehicle lateral acceleration, Ġy: vehicle lateral jerk, Cxy: a control gain, t: a temporary lag time constant, and s: a Laplace operator.
[0045] Note that in the first embodiment, as vehicle lateral acceleration and vehicle lateral jerk used in Mathematical Formula 1, it is assumed that information input from the vehicle state recognition sensor unit 111 is used. However, information estimated, by a publicly-known vehicle model, from a steering angle and a speed of an own vehicle may be used.
[0046] Note that order of execution of step 201 and step 202 is not limited to this order and can be changed.
[0047] Next, processing for calculating an acceleration/steady/deceleration period based on the G-Vectoring control in step 203 is executed and vehicle state status (T_state) is calculated. According to the GVC command (Gx_GVC) calculated in step 202 and a vehicle state status previous value (T_state_Z 1 ), this vehicle state status is determined by a logic illustrated in Table 1. As actual processing defined in a format such as what is illustrated in Table 1, in respect to input data described in an entry field, it is determined whether a condition is satisfied serially from the top and when the data matches the condition, processing described in an output field is executed and determination of the condition thereafter is not executed.
[0000]
TABLE 1
Logic table for calculation of vehicle state status
Input data
Vehicle state
Output data
status previous
GVC command
Vehicle state
value (T_state_Z1)
(Gx_GVC)
status (T_state)
—
≦Gx_th4
Deceleration zone
(T_deccel)
Deceleration zone
≦Gx_th3
Deceleration zone
(T_deccel)
(T_deccel)
—
Gx_th1≦
Acceleration zone
(T_accrl)
Acceleration zone
Gx_th2≦
Acceleration zone
(T_accrl)
(T_accrl)
Deceleration zone
Gx_th3 < and <
Steady zone
(T_deccel) or
Gx_th1
(T_steady)
steady zone
(T_steady)
Other than what is above
Normal zone
(T_normal)
[0048] Here, T_state: vehicle state status, Gx_GVC: a GVC command, Gx_th 1 : a threshold with which an acceleration zone is determined, Gx_th 2 : a threshold with which an acceleration zone is determined in light of hysteresis when a previous zone is an acceleration zone, Gx_th 3 : a threshold with which a deceleration zone is determined in light of hysteresis when a previous zone is a deceleration zone, and Gx_th 4 : a threshold to determine a deceleration zone. Note that a place “-” in the table indicates that the place is not used for determination of a condition. That is, here, it means that the vehicle state status previous value may be any zone.
[0049] FIG. 3 is a view illustrating an example of an operation outline in respect to the processing for calculating an acceleration/steady/deceleration period based on the G-Vectoring control in step 203 described above. In an upper view in FIG. 3 , a horizontal axis indicates time and a vertical axis indicates a GVC command (Gx_GVC). A case in which a unit of the GVC command (Gx_GVC) is expressed in acceleration of gravity “G” is exemplified. In a case of a positive value, an acceleration control command is expressed and in a case of a negative value, a deceleration control command is expressed.
[0050] Also, in a lower view in FIG. 3 , a horizontal axis indicates time and a vertical axis indicates vehicle state status. In the following, how vehicle state status is determined corresponding to the time change in the upper view in FIG. 3 will be described.
[0051] First, when the GVC command gradually decreases in a negative direction from a vicinity of zero (that is, deceleration becomes larger) and becomes smaller than the threshold with which a deceleration zone is determined (Gx_th 4 ), it is determined that the vehicle state status has entered a deceleration period (T_deccecl). Also, it is determined that in a zone therebefore, the vehicle state status is a normal zone (T_normal).
[0052] Next, when the GVC command gradually increases in a positive direction and becomes larger than the threshold with which a deceleration zone is determined in light of hysteresis when a previous zone is a deceleration zone (Gx_th 3 ), it is determined that the vehicle state status has become a steady zone (T_steady). Here, by setting determination thresholds of the deceleration zone and the steady zone separately, it is possible to prevent the vehicle state status from switching positions alternately (performing hunting) when the GVC command transitions in a vicinity of the determination threshold.
[0053] Next, when the GVC command exceeds the vicinity of zero and becomes a positive value from a negative value (that is, deceleration control command changes to acceleration control command) and further increases gradually in the positive direction and becomes larger than the threshold with which an acceleration zone is determined (Gx_th 1 ), it is determined that the vehicle state status has entered an acceleration period (T_accecl).
[0054] Next, when the GVC command gradually decreases and becomes smaller than the threshold with which an acceleration zone is determined in light of hysteresis when a previous zone is an acceleration zone (Gx_th 2 ), it is determined that the vehicle state status has returned to the normal zone (T_normal). Here, a purpose of providing the determination thresholds of the acceleration zone and the normal zone separately is to prevent the vehicle state status from switching places alternately (performing hunting), similarly to what has been described above.
[0055] Note that in the vehicle state status, it is possible to adjust a period in each state by giving a predetermined period of moratorium since each condition is satisfied.
[0056] Next, output arbitration processing in step 204 will be described with reference to FIG. 4 . FIG. 4 is a flowchart of a routine executed in the output arbitration processing in step 204 .
[0057] As described, a case in which a unit of a control command from each application is expressed in the acceleration of gravity “G” is exemplified. In a case of a positive value, an acceleration control command is expressed, and in a case of a negative value, a deceleration control command is expressed. In the following description, the control command from each application may be conveniently called an acceleration control command in a case of a positive value and called a deceleration control command in a case of a negative value.
[0058] Also, when each control command calculated in the ACC processing in step 201 or the G-Vectoring control processing in step 202 is actually used in step 401 and step 402 , processing is performed with a deceleration control command as zero in a case where the control command is a positive value and conversely, processing is performed with an acceleration control command as zero in a case where the control command is a negative value.
[0059] First, deceleration control command calculation processing corresponding to the vehicle state status in step 401 is executed. According to the vehicle state status calculated in the processing for calculating an acceleration/steady/deceleration period based on the G-Vectoring control in step 203 , processing such as what is illustrated in Table 2 is executed.
[0060] As described, in the first embodiment, a case where mounted applications are the ACC and the G-Vectoring control is descried. Thus, select low of a deceleration control command of each application described in Table 2 is processing to select smaller value between an ACC deceleration control command calculated in the ACC processing in step 201 and a GVC deceleration control command calculated in the G-Vectoring control processing in step 202 .
[0061] Also, in a case where processing with no deceleration control command is selected, even when there is a deceleration control command from any application, the deceleration control command is not performed and is set as zero, literally. The deceleration control command calculated in such a manner is transmitted to a breaking unit.
[0062] Note that here, when an acceleration/deceleration control command is applied to a vehicle in a case where the vehicle state status is the steady zone (T_steady), vehicle behavior may be destabilized. Thus, it is possible to select processing with no deceleration control command, which is one characteristic of the first embodiment.
[0000]
TABLE 2
Logic table for deceleration control command calculation
processing corresponding to vehicle state status
Input
Output
Vehicle state status (T_state)
Deceleration control command
Normal zone (T_normal)
Select low of deceleration
control command of each
application
Deceleration zone (T_deccel)
Select low of deceleration
control command of each
application
Acceleration zone (T_accrl)
Select low of deceleration
control command of each
application
Steady zone (T_steady)
No deceleration control
command
[0063] Next, acceleration control command calculation processing corresponding to the vehicle state status in step 402 is executed. According to the vehicle state status calculated in the processing for calculating an acceleration/steady/deceleration period based on the G-Vectoring control in step 203 and the deceleration control command calculated in the deceleration control command calculation processing corresponding to the vehicle state status in step 401 , processing such as what is illustrated in Table 3 is executed.
[0064] Select high of an acceleration control command of each application described in Table 3 is processing to select a larger value between an ACC acceleration control command calculated in the ACC processing in step 201 and a GVC acceleration control command calculated in the G-Vectoring control processing in step 202 .
[0065] Here, when select high processing is executed according to the vehicle state status and the deceleration control command calculated in step 401 , it is possible to further add limit processing to the GVC acceleration control command calculated in the G-Vectoring control processing in step 202 . In this case, it is possible to control an acceleration control command which is needlessly large in respect to a condition of a lateral motion of a vehicle and to execute acceleration processing while stabilizing behavior.
[0066] Also, in a case where processing with no acceleration control command is selected, even when there is an acceleration control command from any application, the acceleration control command is not performed and is set as zero, literally. The acceleration control command calculated in such a manner is transmitted to a driving unit.
[0000]
TABLE 3
Logic Table for acceleration control command calculation
processing corresponding to vehicle state status
Input
Output
Vehicle state
Deceleration
Acceleration
status (T_state)
control command
control command
Normal zone
Present
No acceleration
(T_normal)
control command
Absent (zero)
Select high of
acceleration
control command of
each application
Deceleration zone
Present
No acceleration
(T_deccel)
control command
Absent (zero)
No acceleration
control command
Acceleration zone
Present
No acceleration
(T_accrl)
control command
Absent (zero)
Select high of
acceleration
control command of
each application
Steady zone
Present
No acceleration
(T_steady)
control command
Absent (zero)
No acceleration
control command
[0067] <Example of Specific Traveling Scene>
[0068] FIG. 5 is a schematic view illustrating a traveling road of an own vehicle, in which the vehicle travel control system according to the first embodiment is mounted, from entering a curve until getting out of the curve. In FIG. 5 , it is assumed that the traveling road includes a straight zone (N 1 to N 2 ), a transient zone (N 2 to N 3 ) including a relaxation curve, a steady turning zone (N 3 to N 4 ), a transient zone (N 4 to N 5 ) including a relaxation curve, and a straight zone (N 5 to N 6 ).
[0069] Also, in FIG. 5 , the following scene is assumed. That is, in the straight zone (N 1 to N 2 ), after an own vehicle 500 traveling at a set vehicle speed by the ACC catches up with a preceding vehicle 501 traveling at a speed lower than the set vehicle speed and performs follow-up traveling for a certain period of time, the preceding vehicle deviates from an own lane due to a lane change or the like and the own vehicle 500 accelerates to the set vehicle speed again. A traveling scenario in which the own vehicle 500 keeps traveling and enters a curved road (N 2 to N 5 ), and then, travels a straight road (N 5 to N 6 ) again will be described as an example.
[0070] Next, FIG. 6 is a view illustrating a time series waveform of each of the ACC command, the GVC command, the vehicle state status, the acceleration control command, and the deceleration control command of when traveling is performed according to the described traveling scenario.
[0071] First, in the straight zone (N 1 to N 2 ), a driver keeps a steering angle constant in order to make the own vehicle travel straight. Thus, vehicle lateral acceleration which acts on the own vehicle becomes constant in the vicinity of zero, and thus, the GVC command becomes zero. Also, as described, in this zone, since the own vehicle 500 driving at the set vehicle speed by the ACC catches up with the preceding vehicle 501 traveling at a speed lower than the set vehicle speed and enters an ACC control range, a negative ACC command is calculated to perform control to a vehicle-to-vehicle distance or an inter-vehicle time set by the driver in advance. When the preceding vehicle deviates from an own lane due to a lane change or the like after the follow-up traveling in this state is performed for a certain period of time, a positive ACC command is calculated for acceleration to the set vehicle speed.
[0072] On the other hand, since it is determined that the vehicle state status in this zone is a normal zone, as the deceleration control command, select low of a command of each application is output and as the acceleration control command, select high of a command of each application is output in a case of no deceleration control command. Here, as described, the GVC command is zero. Thus, as a result, the ACC command is output as it is.
[0073] Next, when the own vehicle enters the transient zone (N 2 to N 3 ), the driver starts a steering operation gradually and starts increasing the steering. In response to this driver operation, vehicle lateral acceleration which acts on the own vehicle also increases gradually. Thus, since a lateral jerk increases, a command in the deceleration direction is calculated as the GVC command. Here, as the ACC command, to compensate the speed of the own vehicle decelerated by the GVC command, a command in the acceleration direction is gradually calculated. On the other hand, since the vehicle state status in this zone becomes the deceleration zone, the acceleration control command becomes absent (zero) and as the deceleration control command, select low of a command of each application is output. In the vehicle behavior here, while a load moves to front wheels due to the deceleration and cornering stiffness of the front wheels is improved, a load on rear wheels is decreased and cornering stiffness of the rear wheels is decreased. According to these effects, maneuverability can be improved. This is a characteristic effect of entry into a corner by the G-Vectoring control, but a similar effect can be acquired even when a plurality of kinds of control algorithm is combined.
[0074] Subsequently, when the own vehicle enters a steady zone (N 3 to N 4 ), the driver stops increasing the steering and keeps the steering angle constant. Here, since the vehicle lateral acceleration which acts on the own vehicle becomes constant, the GVC command becomes zero. Here, as the ACC command, to compensate the speed of the own vehicle decelerated by the GVC command, the command in the acceleration direction is continuously calculated.
[0075] On the other hand, since the vehicle state status in this zone becomes the steady zone, the acceleration control command and the deceleration control command become absent (zero). In the vehicle behavior here, as described, since the driver keeps steering in such a manner that the steering angle becomes constant and makes the vehicle balance in such a manner as to trace a target route, the vehicle may be destabilized when an acceleration or deceleration control command by the control algorithm is applied. Thus, in this steady zone in the first embodiment, both of the acceleration and deceleration are not performed.
[0076] Subsequently, when the own vehicle enters the transient zone (N 4 to N 5 ), the driver starts returning the steering. In response to this driver operation, the vehicle lateral acceleration which acts on the own vehicle 500 gradually decreases. Here, as the GVC command, a command in the acceleration direction is calculated. Here, as the ACC command, to compensate the speed of the own vehicle decelerated by the GVC command, the command in the acceleration direction is continuously calculated.
[0077] On the other hand, since the vehicle state status in this zone becomes the acceleration zone, as the deceleration control command, select low of a command of each application is output and as the acceleration control command, select high of a command of each application is output since the deceleration control command becomes absent. In respect to the vehicle behavior here, a load moves to the rear wheels due to the acceleration and the cornering stiffness of the rear wheels is increased, and thus, the vehicle behavior is stabilized.
[0078] Note that here, especially when the acceleration control command is output with a command of each application being select high, acceleration may be performed suddenly and a driver may feel discomfort. Thus, it is preferable to add processing to moderate the sudden change of a command, which processing is, for example, general low-pass filter processing or making a command increase in a certain ratio.
[0079] Then, when the own vehicle 500 enters the straight zone (N 5 to N 6 ), the driver stops the steering operation and keeps a steering angle constant to keep the vehicle travel straight. Thus, the vehicle lateral acceleration which acts on the own vehicle 500 becomes constant, and thus, the GVC command returns to zero again. Here, as the ACC command, an acceleration control command is calculated to perform traveling at a pre-set vehicle speed.
[0080] On the other hand, since the vehicle state status in this zone becomes the normal zone, as the deceleration control command, select low of a command of each application is output and as the acceleration control command, select high of a command of each application is output since the deceleration control command becomes absent. Here, as described, the GVC command is zero. Thus, as a result, the ACC command is output as it is.
[0081] In the first embodiment, arbitration of the deceleration or acceleration control command of each application is performed in such a manner described above.
[0082] In the above, the arbitration in a case of the ACC and the G-Vectoring control has been described. However, in respect to control algorithm to be an object, a similar effect can also be acquired by adding or replacing with control algorithm, which gives an acceleration/deceleration control command in a longitudinal direction, such as pre-crash control.
Second Embodiment
[0083] A vehicle travel control system of a second embodiment according to the present invention will be described. Since there are many similar points between the second embodiment and the described first embodiment, deceleration control command calculation processing corresponding to vehicle state status in step 401 which is a main difference will be described in the following.
[0084] In the second embodiment, in the deceleration control command calculation processing corresponding to vehicle state status in step 401 , processing illustrated in Table 4 is executed according to vehicle state status calculated in the processing for calculating an acceleration/steady/deceleration period based on the G-Vectoring control in step 203 . A specific difference with Table 2 in the first embodiment is a point that processing in a steady zone is select low of a deceleration control command of each application. In the steady zone, both acceleration and deceleration are not preferably performed on a vehicle. However, actually, since a command from control algorithm, which has high urgency, such as pre-crash may be executed, a method to employ the strongest deceleration control command is employed.
[0085] In the second embodiment, arbitration of the deceleration or acceleration control command of each application is performed in such a manner described above.
[0000]
TABLE 4
Logic table for deceleration control command calculation
processing corresponding to vehicle state status
Input
Output
Vehicle state status (T_state)
Deceleration control command
Normal zone (T_normal)
Select low of deceleration
control command of each
application
Deceleration zone (T_deccel)
Select low of deceleration
control command of each
application
Acceleration zone (T_accrl)
Select low of deceleration
control command of each
application
Steady zone (T_steady)
Select low of deceleration
control command of each
application
Third Embodiment
[0086] A vehicle travel control system of a third embodiment according to the present invention will be described. Since there are many similar points between the third embodiment and the described first embodiment, acceleration control command calculation processing corresponding to vehicle state status in step 402 which is a main difference will be described in the following.
[0087] In the third embodiment, in the acceleration control command calculation processing corresponding to vehicle state status in step 402 , processing illustrated in Table 5 is executed according to vehicle state status calculated in the processing for calculating an acceleration/steady/deceleration period based on the G-Vectoring control in step 203 and a deceleration control command calculated in the deceleration control command calculation processing in step 401 .
[0088] A specific difference is a point that processing in an acceleration zone is select low of an acceleration control command of each application. In the acceleration zone, it is preferable to execute acceleration requested by each application as soon as possible. However, when sudden acceleration is performed by select high, vehicle behavior may be destabilized. Thus, select low is selected to prevent the destabilization.
[0089] In the third embodiment, arbitration of the deceleration or acceleration control command of each application is performed in such a manner described above.
[0000]
TABLE 5
Logic table for acceleration control command calculation
processing corresponding to vehicle state status
Input
Output
Vehicle state
Deceleration
Acceleration
status (T_state)
control command
control command
Normal zone
Present
No acceleration
(T_normal)
control command
Absent (zero)
Select high of
acceleration
control command of
each application
Deceleration zone
Present
No acceleration
(T_deccel)
control command
Absent (zero)
No acceleration
control command
Acceleration zone
Present
No acceleration
(T_accrl)
control command
Absent (zero)
Select low of
acceleration
control command of
each application
Steady zone
Present
No acceleration
(T_steady)
control command
Absent (zero)
No acceleration
control command
REFERENCE SIGNS LIST
[0000]
100 vehicle travel control system
110 environment recognition sensor unit
111 vehicle state recognition sensor unit
112 control state switching unit
113 traveling control ECU
114 breaking unit
115 driving unit
500 own vehicle
501 preceding vehicle
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A vehicle travel control system includes a first unit configured to calculate a target longitudinal acceleration/deceleration control command of the own vehicle based on a distance or a relative speed between the own vehicle and a forward obstacle, traveling route information from a vehicle navigation system or a Global Positioning System, and input information such as a vehicle speed set by a driver; a second unit configured to calculate a target longitudinal acceleration/deceleration control command according to a lateral jerk that acts on the own vehicle; and an arbitration unit configured to perform, based on the target longitudinal acceleration/deceleration control command calculated by the second unit, arbitration of the target longitudinal acceleration/deceleration control command calculated by the first unit, wherein output from the arbitration unit is set as a command to control the target longitudinal acceleration/deceleration control command of the own vehicle.
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PRIOR ART
The invention is based on a device for potential-free transmission of data in bus networks with bit-by-bit arbitration operating in response to dominant and recessive bit levels. This is a matter of providing a failure-tolerant bus coupling circuit with galvanic separation or decoupling, for a local multi-master network with the bit-by-bit arbitration.
A very effective method of bus allocation in local multi-master networks is bit-by-bit arbitration (e.g. CAN, ICC, DDB).
Multi-master networks with bit-by-bit arbitration operate with the logical bit levels which are physically represented on the bus by `dominant` and `recessive` states. The recessive bit level on the bus can be overwritten at any time by means of transmitting the dominant bit level. The bus content is decided in that the transmitter bus of a recessive bit during the simultaneous sensing of a dominant bit gives up the contest and becomes the receiver bus.
With this concept, the DC component of the signals is included in the transmission via the line.
Examples of these physical representations of logical bit levels on the bus are:
______________________________________`dominant` bit level `recessive` bit level______________________________________low-impedance high-impedancelight on light offvoltage on no voltagepower on no power______________________________________
In the prior art networks with bit-by-bit bus arbitration, optoelectronic components must be used for galvanic decoupling or separation of the individual substations at least on the transmitting side, since these optoelectronic components can include the DC component in the transmission:
opto-coupler for coupling at a bus with electrical line;
optical transmitter and receiver at a light wave-guide bus with star coupler.
Opto-couplers are components with relatively high failure rates which can not be used at extreme temperatures or at rapid changes in temperature.
Because of the required `dominant` and `recessive` bit levels, only opto-couplers with open collector outputs are taken into consideration for the target network. During breakdown of this output transistor the `dominant` bit level is generated, and the entire network is blocked.
Optical transmitters and receivers at the light waveguide with star coupler are too expensive and too unreliable for use in motor vehicle networks.
The limitations in the use of light guides and optical plug-in contacts do not at present allow use under extreme conditions (e.g. in motor vehicles).
If light (`dominant` bit level) is continuously produced during the failure of a driver of the transmitting element, the entire network is blocked. During failure of the star coupler the network is likewise blocked.
It is the object of the invention to provide a device for potential-free transmission of data which does not block the transmission path during the failure of a station and is reliable and inexpensive with respect to its use in large quantities, particularly in motor vehicles.
ADVANTAGES OF THE INVENTION
An electrical potential separation between the input and output of the device of this invention is achieved so that network stations equipped with the device can also be operated when the individual stations are at different potentials or when strong inphase interferences occur on the busline.
Differential interferences which are imported into the respective station via the busline are decoupled (positive differential interference) or limited (negative differential interference), respectively, at the demodulator. The circuit blocks located after the demodulator as seen from the busline, are accordingly protected from destruction.
During failure or short circuiting of a block of the coupling circuit prior to the separating device, e.g. of a driver or interface block, the bus traffic on the busline between the remaining station is not impaired, since the bus is decoupled by means of the separating device and demodulator.
The device is very reliable and inexpensive, so that it can be used e.g. in motor vehicles.
BRIEF DESCRIPTION OF THE DRAWING
Embodiment examples of the invention are shown in the drawing and are explained in more detail in the following description.
FIG. 1 shows a block diagram of the device of the invention in connection with the overall bus system of a global or main network, e.g. in a motor vehicle;
FIG. 2 shows a time-dependent diagram for the operation of the device;
FIG. 3 shows two embodiments of a modulation encoder for the device;
FIG. 4 shows example of a driver circuit for the device;
FIG. 5 shows an example of a local network;
FIG. 6 shows examples of the galvanic separation circuit;
FIG. 7 shows circuit arrangement for the demodulation;
FIG. 8 shows a circuit arrangement for a bus coupling network;
FIGS. 9 and 10 show embodiment of the device of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
a) Bus System
FIG. 1 shows the block diagram of the overall bus system of a main network for use in a power supply system of a motor vehicle.
It comprises master bus stations 1, 2, 3 in connection with a global or main network 4. The master bus stations 1, 2, 3 are connected to the main network 4 via the bus lines 41, 42, 43. Every master bus station comprises modulation encoder 10, driver 20, local network 30, galvanic separation circuit 40, demodulator 50 and bus coupling network 60. The signal to be transmitted is generated by an interface block 7 and is available at bus line 101. The interface block 7 also processes the received signal which is present at line 71, possibly modified by means of additional blocks.
b) Description of a Master Bus Station (using bus station 1 by way of example)
The digital signal to be transmitted from the interface block 7 is applied via the lines 101 to the modulation encoder 10. The latter produces two intermediate code signals without DC component (FIGS. 2c and 2d) from the input signal with DC component (FIG. 2b). The outputs of the modulation encoder 10 are connected via lines 201 to the inputs of the driver 20. The outputs of the driver 20 are connected to the inputs of the local network 30 via lines 301. This network 30 can comprise additional inputs 302, 303 etc. in order to couple with one another interface blocks and application circuits of additional substations each having a corresponding modulation encoder and driver. The outputs of the local network 30 are connected via lines 401 to the inputs of the galvanic separation circuit 40. The outputs of the galvanic separation circuit 40 are applied to the inputs of the demodulator 50 via lines 501. A signal with DC component is generated again in the demodulator from the galvanically decoupled or separated intermediate code signals without DC component. The outputs of the demodulator 50 are connected to the inputs of the bus coupling network 60 via lines 601. The outputs of the bus coupling network 60 are connected to the inputs of the main network 4 via the bus lines 41; moreover, a signal received at the output of the network 60 is fed from this location via lines 71, possibly via additional (non-illustrated) blocks, to the interface block 7. This interface block 7 assembles the read bits of the fed back signal and transmits the resulting data via line 6 to the application circuit 5. Many participating master bus stations can be interconnected by the main network 4 over a greater distance.
The local network 30 can also be dispensed with. The outputs 301 of the driver 20 are then connected directly to the inputs 401 of the galvanic separation circuit 40.
Modulation encoder 10 and driver 20 can also be integrated in the interface block in an inexpensive manner. For this reason, the modulation encoder and driver are directly connected with the interface block.
An example of the manner of operation of the transmission device of the invention is shown in FIG. 2 with the aid of the time-dependent diagram. FIG. 2a shows the clock signal having a frequency at which the processing of the arriving data to be transmitted is effected in the modulation encoder 10. The signal to be transmitted is shown in FIG. 2b. Changes in the bit level are possible in each instance only in synchronism with the clock pulses. The signal to be transmitted is converted by means of the modulation encoder 10 into two intermediate code signals shown in FIG. 2c and FIG. 2d, which serve to control a galvanic separating element. These intermediate code signals, according to FIG. 2c and FIG. 2d, are both at logical `0` during the transmission of a recessive bit, but are alternately at logical `0` and logical `1` when transmitting a dominant bit. In other words, time intervals of the dominant single bit levels of one intermediate code signal (FIG. 2c) coincide with time intervals of the recessive single bit levels of the other intermediate code signal (FIG. 2d), and time intervals of the dominant single bit levels of the other intermediate code signal coincide with time intervals of the recessive single bit levels of the one intermediate code signal. FIG. 2e shows the `modulated` intermediate output signal after the galvanic separation. In this instance, there is a positive voltage +4 during each dominant bit of the intermediate code signal of FIG. 2c and a negative voltage 4 during each dominant bit of the other intermediate code signal (FIG. 2d), but zero voltage during coincidence of a recessive bit in both intermediate code signals. After the demodulation of the `modulated` output signal, the original signal configuration, as shown in FIG. 2f, is obtained again. The result is a potential-separated transmission of a signal which corresponds with respect to its configuration to the original transmitted signal according to FIG. 2b.
Embodiment examples of the individual component blocks of the device of the invention incorporated in the bus stations of the system, according to FIG. 1, are described in more detail in the following.
c) Modulation Encoder
FIGS. 3a and 3b show two embodiment examples for the modulation encoder 10.
The modulation encoder 10 has the object of preparing the signal to be transmitted for the connection to a galvanic separating element. The transmitted signal (FIG. 2b) is acted upon by the clock signal (FIG. 2a) which acts as a modulation code carrier for this purpose. The latter can advisably have the same frequency as the bit clock of the transmitted signal or can have a higher frequency.
It is possible to let the modulation encoder run freely or to synchronize it, e.g. to start the modulation encoders of all bus substations in the same manner at the start of each transmission. A synchronization ensures that the intermediate code signals of all bus substations are in the same phase. This is necessary if the intermediate code signals of a plurality of substations are coupled in the local network 30.
FIG. 3a shows an embodiment example of an unsynchronized modulation encoder.
The transmitted signal is applied to the input line 1011 and is applied to the D-input of a D-flip-flop 102 and to the T-input of a toggle flip-flop 103. The clock signal reaches the clock inputs of the two flip-flops 102 and 103 via the input line 1012. The Q-output of the D-flip-flop 102 is applied to one input of the logical AND gates 104 and 105 in each instance and also leads to the output line 2011. The Q-output of the toggle flip-flop 103 is applied to the second input of the AND gate 104, the Q-inverted output is applied to the second input of the AND gate 105. The outputs of the AND gates 104 and 105 form the output lines 2012 and 2013. Operation:
The D-flip-flop 102 and the toggle flip-flop 103 are clocked with the clock signal; the transmitted signal is applied to the D- and T-inputs, respectively, of the two flip-flops. In this case, the `dominant` level is a logical `1` and the `recessive` level is a logical `0`. The D-flip-flop 102 synchronizes the transmitted signal according to the clock signal. The toggle flip-flop 103 changes state at a `dominant` transmitted signal with every clock pulse edge, so that its Q- and Q-inverted outputs change polarity with every clock pulse. By means of the AND gating relation of the Q- and Q-inverted outputs of the toggle flip-flop with the synchronized transmitted signal, it is achieved that the output lines 2012 and 2013 are both at logical `0` during the transmission of a `recessive` bit, but when transmitting a `dominant` bit are alternately at logical `0` and logical `1` in the time intervals of the clock signal.
FIG. 3b shows an embodiment example of a synchronized modulation encoder.
In contrast to the unsynchronized modulation encoder according to FIG. 3a, the toggle flip-flop in this instance is reset by means of a synchronization signal. For this purpose, the synchronization signal is applied to the `reset` input of the toggle flip-flop 106 via the line 1013. The synchronization signal can be e.g. a short pulse at the start of a new communication.
The outputs of this modulation encoder behave logically in the same way as in the unsynchronized modulation encoder; the phase relation of the modulation encoder outputs 2012 and 2013 in this instance is additionally defined with respect to all other modulator encoder outputs, also synchronized outputs, and are connected to the local network 30.
d) Driver
FIGS. 4a and 4b show respectively embodiment examples for an open collector driver and for a push-pull driver. Such a push-pull driver is obtainable e.g. under the designation SN74126 from the company TEXAS INSTRUMENTS.
The type of driver utilized depends on the manner in which the galvanic separation circuit is carried out. When a transformer with a center tap on the primary side is used, e.g. an open collector driver is used; a push-pull driver is used in a transformer without center tap on the primary side.
FIG. 4a shows an embodiment example of an open collector driver.
The input intermediate code signals FIGS. 2c and 2d coming via lines 2012 and 2013 from the modulation encoder 10 are guided to the base terminals of the n-p-n transistors 204 and 205 via the resistors 202 and 203. The emitter terminals of the transistor 204 and 205 are applied to ground potential. The collector terminals are connected with the output lines 3011 and 3012. The amplified signal can be taken off at the latter.
FIG. 4b shows an embodiment example of a push-pull driver.
In this instance the input signals coming via lines 2012 and 2013 from the modulation encoder 10 are applied to the signal inputs of two push-pull drivers 206 and 207. The drivers are tri-state drivers which can be switched to high impedance via the line 2011 to which the transmitted signal, which is synchronized with the modulator clock signal, is applied. The outputs of the two push-pull drivers 206 and 207 are connected to the output lines 3011 and 3012.
e) Local Network
FIG. 5 shows an embodiment example for a passive local network 30.
The driver outputs (3011, 3012), (3021, 3022), respectively, and (3031, 3032) of the individual local substations are connected via resistors 306 . . . 311 to the local buslines 304 and 305 in the same direction. The outputs 4011 and 4012 are likewise connected to the buslines 304 and 305 via the resistors 312 and 313. The resistors 306 . . . 311 and 312, 313, respectively, can be dispensed with if desired.
f) Galvanic separation circuit
FIGS. 6a to 6c show some embodiment examples for the galanic separation circuit 40.
FIGS. 6a and 6b show two constructions of galvanic separation by means of transformers, while FIG. 6c shows a galvanic separation by means of capacitors.
FIG. 6a shows a transformer 402 with single primary and secondary windings for galvanic separation. The input intermediate code signals are applied via lines 4011 and 4012 respectively to the primary winding of the transformer, while the secondary winding is connected with the output lines 5011 and 5012 delivering the `modulated` output signal of FIG. 2e.
FIG. 6b shows a transformer 403 with center tap on the primary and secondary windings for galvanic separation. The input lines 4011 and 4012 are applied to the outer connections of the primary winding, the input line 4013 is applied to its center tap. The outer connections of the secondary winding are connected with the ouptut lines 5011 and 5012, the center tap is connected with the output line 5013.
In the galvanic separation circuits according to FIGS. 6a and 6b, inphase interferences which can occur on the busline are blocked by the transformer. They can not reach the primary side of the transformer.
Two capacitors 404, 405 are used in the four terminal capacitor circuit of FIG. 6c for galvanic separation. The input lines 4011 and 4012 are connected with the output lines 5011 and 5012 via the two capacitors 404 and 405.
g) Demodulator
FIGS. 7a and 7b show two embodiment examples for the demodulator 50.
FIG. 7a shows a Graetz or bridge rectification. The input terminals of the bridge 502 are connected via lines 5011 and 5012 to the outputs of the galvanic separation 40. The demodulated signal (FIG. 2f) is available at the outputs 6011 and 6012 of the Graetz rectifier 502.
FIG. 7b shows a demodulator which is preferably connected to the output of a transformer (FIG. 6b) with a center tap on the secondary side. In this instance, the lines 5011 and 5012, are connected with the output line 6011 of the demodulator via the rectifying diodes 503 and 504. The center tap line 5013 arrives directly at the output line 6012.
h) Bus Coupling Network
FIG. 8 shows an embodiment example for the bus coupling network 60.
The input lines 6011 and 6012 are applied to the output lines 411 and 412 via the resistors 602 and 603. A Zener diode 604 can be connected between the output lines 411 and 412.
This diode prevents extreme bus levels from occurring outside the wanted signal range. Differential bus interferences are accordingly clipped off; moreover, reflections on the busline which can occur due to faulty terminations are dampened.
FIG. 9 and 10 show two embodiment examples of a bus station incorporating the device of the invention. The blocks 7, 10 and 20 are integrated in an interface module 8 (e.g. CAN-controller module). Thus, only a few external component elements are necessary, which enables an inexpensive realization.
FIG. 9 shows an embodiment example of a bus system or station with galvanic decoupling circuit 40 using a transformer according to FIG. 6a and subsequent demodulator 50 using Graetz rectification according to FIG. 7a. The interface 7, the modulation encorder 10 according to FIG. 3a and the driver 20 according to FIG. 4b are integrated in the interface module 8.
ADVANTAGES OF THE ARRANGEMENT ACCORDING TO FIG. 9
Inphase interferences on the busline can not cause any differential signal on the secondary side of the transformer, i.e. its effects can not reach the primary side of the transformer and the interface module 8.
Positive differential interferences on the busline have no effect on the transmitting side, since all diodes of the rectifier are in blocking condition.
Negative differential interferences do not cause any differential signal at the transformer, since all diodes of the Graetz rectifier are conductive and accordingly the two connections of the secondary winding are at the same potential.
During failure of one or both drivers or when there is a shorted coil of the transformer at the primary or secondary side, the remaining bus traffic on the busline is not impaired, since the bus is decoupled by means of the rectifier.
FIG. 10 shows an embodiment example of a bus system or station with galvanic decoupling using a transformer having center taps on the primary and secondary sides according to FIG. 6b and subsequent full-wave rectification according to FIG. 7b. The modulation encorder according to FIG. 3a and the driver according to FIG. 4a are integrated in an interface module 8. The block 9, which contains blocks equivalent to 5 and 8, is added as an embodiment example for a local network or substation.
ADVANTAGES OF THE ARRANGEMENT ACCORDING TO FIG. 10
Inphase interferences on the busline can not cause any differential signal on the secondary side of the transformer, i.e. its effects can not reach the primary side of the transformer.
Positive differential interferences on the busline have no effect on the transmitting side, since all diodes of the rectifier block.
Negative differential interferences do not cause any differential signal at the transformer, since two currents of the same magnitude flow in opposite directions in the secondary winding.
During failure of one or both drivers or when there is a shorted coil of the transformer at the primary or secondary side, the remaining bus traffic on the busline is not impaired, since the bus is decoupled by means of the rectifier.
When there are a plurality of local substations the separating device and the demodulator are needed only once, which enables a particularly inexpensive solution.
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A device for potential-free transmission of dominant and recessive data bits in a bus system operating with bit-by-bit arbitration includes a series connection of a modulator, a galvanic separation circuit, and a demodulator. Data bits to be transmitted are scanned in the modulator at equidistant time intervals and are divided into two intermediate trains of data bits wherein the dominant bits alternate with the recessive bits. The two intermediate trains are applied to two input terminals of a galvanic separating device, and a demodulation is effected on the output side of the separating device.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a national phase entry of International Application No. PCT/US2012/041386, filed Jun. 7, 2012, which claims the benefit of the filing date of U.S. Provisional Application No. 61/532,327, filed on Sep. 8, 2011, the contents of each are herein incorporated by reference.
TECHNICAL FIELD
The subject matter described herein relates to techniques, methods, systems and articles for removing low frequency signal components from physiological signals such as electrocardiogram signals.
BACKGROUND
An electrocardiogram (ECG) is a test that records the electrical activity of the heart as recorded by electrodes attached to the outer surface of the skin. Impedance variation between the recording electrode and the skin due to respiration or other body movement can cause baseline variations (also referred to as low frequency wander) in the ECG signal. Baseline variation is one type of noise in electrocardiogram signals. FIG. 1 is a plot 100 showing an example ECG signal containing baseline variation. QRS complexes 110 can be identified by sharp spikes in the signal.
There are a variety of methods for baseline removal from the ECG, including high-pass filtering, adaptive filtering, wavelet transform, time-frequency analysis, curve fitting, etc. One approach, which is a special type of curve fitting, is the cubic spline method. A cubic spline is fitted on isoelectric reference points to estimate the baseline. The cubic spline method can be prone to error in the calculation of the isoelectric reference points, especially in the presence of noise.
ECG baseline variation can comprise a low frequency signal within a range of 0 to 0.8 Hz. According to the American Health Association (AHA), the frequency in the ECG signal is typically above 0.05 Hz. Since the frequency band of the baseline noise overlaps with the ECG signal of interest, a simple high-pass filter is not sufficient for removing the baseline.
Another approach to baseline removal is to use a high-pass filter. However, since the baseline is a type of in-band noise, a cut-off frequency cannot be set that would completely separate the ECG signal from the baseline. An approach adapting the cutoff frequency of the baseline filter to the heart rate was introduced by L. Lundstrom in 1995. According to Fourier theory, the frequency spectrum of a periodic signal is non-zero only on the base frequency and harmonics. This means that if the period is T, the lowest frequency is 1/T. An ideal ECG, which has constant heart rate and identical morphology for each heart beat, can be treated as a periodic signal, such that the lowest frequency is HeartRate/60 (Hz). If the cutoff frequency is set to this value, the low frequency noise can be removed. However, when the heart rate is low, this approach can not remove the baseline variation completely.
SUMMARY
In one aspect, a system includes a low pass-filter and a Savitzky-Golay filter. The low-pass filter receives and processes a first electrocardiogram signal. The filter removes at least the high frequency components of the first electrocardiogram signal. The Savitzky-Golay filter estimates a baseline variation of the first electrocardiogram signal from the filtered first electrocardiogram signal.
In another aspect, a first electrocardiogram signal is received. The first electrocardiogram signal is processed in a filter to remove at least high frequency components of the first electrocardiogram signal. The filtered first electrocardiogram signal is processed in a Savitzky-Golay filter to estimate a baseline variation of the first electrocardiogram signal. The estimate of the baseline variation is provided.
One or more of the following features can be included. For example, a delay module and a combination module can be included. The delay module can time shift the first electrocardiogram signal and the combination module can combine the time shifted first electrocardiogram signal and the baseline variation estimate to produce a second electrocardiogram signal with the baseline variation removed. A down-sampler and an up-sampler can be included. The down-sampler can reduce the sampling rate of the filtered first electrocardiogram signal and the up-sampler can increase the sampling rate of the baseline variation estimate.
The low-pass filter can have a cutoff frequency of about 0.8 hertz. The first electrocardiogram signal can be sampled at a rate of about 500 hertz. The polynomial order or degree can be 2 or greater. The polynomial degree of the Savitzky-Golay filter can be between about 2 and about 10. The window size of the Savitzky-Golay filter can be less than about 750. The down-sampler can reduce the sample rate of the filtered first electrocardiogram signal by a factor of about 40 and the up-sampler can increase the sample rate of the baseline variation estimate by a factor of about 40. The up-sampler can perform linear interpolation. Providing the estimate of the baseline variation can include providing for further processing, storage, transmission, or display.
Articles of manufacture are also described that comprise computer executable instructions permanently stored (e.g., non-transitorily stored, etc.) on computer readable media, which, when executed by a computer, causes the computer to perform operations herein. Similarly, computer systems are also described that may include a processor and a memory coupled to the processor. The memory may temporarily or permanently store one or more programs that cause the processor to perform one or more of the operations described herein. In addition, methods can be implemented by one or more data processors either within a single computing system or distributed among two or more computing systems.
The subject matter described herein provides many advantages. For example, knowledge of heart rate is not required to perform baseline variation removal. Additionally, distortion can be reduced by using filters with linear phase and the baseline variation can be completely removed even when there is spectral overlap between the baseline and the ECG signal. Further, information about the isoelectric points of the ECG signal may not be required and the delay introduced by processing can be minimal. The current subject matter can be insensitive to noise, easier to implement and suited to implementation on ECG monitoring systems.
The details of one or more variations of the subject matter described herein are set forth in the accompanying drawings and the description below. Other features and advantages of the subject matter described herein will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
FIG. 1 is a plot showing an example ECG signal containing baseline variation;
FIG. 2 is a system diagram of an ECG baseline variation removal system;
FIG. 3 is a system diagram of an ECG baseline variation removal system with down and up samplers;
FIG. 4 is a plot of a time series illustrating a window used for a Savitzky-Golay polynomial fit;
FIG. 5 is a plot illustrating an example ECG, and signals measured from the output of different components of a system in accordance with the current subject matter;
FIG. 6 is a plot showing a comparison of an input ECG and an output ECG of a system in accordance with the current subject matter;
FIG. 7 is a plot illustrating the limited distortion introduced by the current subject matter;
FIG. 8 is a plot showing a performance comparison between the current subject matter, a high-pass filter method and a cubic spline method; and
FIG. 9 is a process flow diagram illustrating a method a removing baseline variation from an ECG.
Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
FIG. 2 is a system diagram 200 of an ECG baseline variation removal system. An input ECG 210 is passed to a low-pass filter 220 to produce a filtered signal which has the high frequency components of the signal removed. The filtered signal is then passed to a Savitzky-Golay (SG) filter 230 which creates an estimate of the baseline variation of the input ECG 210 . The SG filter is a filter that performs a local polynomial regression (of degree k) on a series of values (of at least k+1 points) to determine a smoothed value for each point. One advantage of this approach is that it preserves features of the distribution such as relative maxima, minima and width, which are usually ‘flattened’ by other adjacent averaging techniques (like moving averages, for example). The ECG 210 can also be passed to a delay module 240 to be delayed in time (e.g., time shifted). The delay can compensate for any delays introduced by the low-pass filter 220 and SG filter 230 processing so that the input ECG 210 can, in a combination module 250 , be combined with the estimated baseline variation produced by the SG filter 230 to produce an output ECG with the baseline variation removed 260 .
The low-pass filter can be, for example, a symmetric finite impulse response (FIR) filter with 100 taps and a cutoff frequency of 0.8 Hz. The low-pass FIR filter can remove the sharp QRS spikes (e.g., label 110 in FIG. 1 ) to improve the estimation of the baseline by the SG filter. The properties of the SG filter are determined by a window length and polynomial order or degree. The polynomial order or degree can be 2 or greater. For example, the polynomial order or degree can be specified to be between about 2 and about 10 and when the input ECG is sampled at 500 Hertz, the window size can be about 750 samples or less. The window size can depend on the input ECG sample rate and be adjusted accordingly. The longer the window and the lower the polynomial order, the lower the cutoff frequency. For example, if the ECG signal is sampled at 500 Hz, a window size of 2*250+1 and a polynomial order of 2 is specified, then the SG filter will introduce about 500 milliseconds of delay and the computational load will be equivalent to a FIR filter with 650 taps.
Referring now to FIG. 5 with further reference to FIG. 2 . FIG. 5 is a plot illustrating an example input ECG 510 , a corresponding filtered signal 520 generated by the low-pass filter 220 , a corresponding baseline variation 530 generated by the SG filter 230 , and an output ECG 540 produced by the combination module 250 . The duration of each signal shown is four seconds, and the average R-wave peak amplitude is 0.9 mV. The example input ECG was collected from a patient and the baseline variation caused by respiration is evident. The QRS complexes have been removed from the filtered signal 520 ; however P and Q waves have not been removed. The baseline variation estimate 530 is a smooth signal that approximates the baseline variation evident in the example ECG input 510 . The output ECG 540 is the example input ECG 510 with the baseline variation estimate 530 removed.
FIG. 6 is a plot showing forty-nine beats of the example input ECG 510 and output ECG 540 that have been divided into one-heart-beat segments and time shifted to align their R-wave peaks. At 610 , each segment of the example ECG has been superimposed and a high variation between heart beat segments is evident. At 620 , each segment of the output signal has been superimposed and a low variation between heart beat segments is evident. At 630 and 640 , the average of the segments is shown for the example input ECG and output ECG respectively. Since the baseline variation noise is not synchronized to the heart rate, the average of the example input ECG segments can be considered baseline free (i.e., the variation averages to zero). At 650 , the difference between 630 and 640 is shown. The difference is close or almost zero (i.e. a straight line), showing that the baseline variation has been successfully removed.
FIG. 7 is a plot illustrating the limited distortion introduced by the current subject matter. To further characterize performance, an ECG without any baseline variation is used as input. FIG. 7 shows an ECG without baseline variation and the ECG after baseline variation removal. Both have been divided into multiple one-heart-beat segments and time shifted to align their R-wave peaks. At 710 each segment of the input ECG is superimposed and 730 shows their average. At 720 , each segment of the output ECG is superimposed and 740 shows their average. 750 is the difference between 730 and 740 . The difference is near zero and therefore indicates that the distortion provided by the current subject matter is minimal.
FIG. 8 is a plot comparing the performance between the current subject matter, a high-pass filter method and a cubic spline method. An input ECG containing baseline variation which has been divided into one-heart-beat segments and time shifted to align their R-wave peaks and superimposed is presented at 810 . A similar presentation is provided for ECGs that have been processed by a high-pass method 820 , a cubic spline 830 , and the current subject matter 840 . It is evident from FIG. 8 that 840 presents an output ECG with the least variability and therefore is an improvement over the high-pass method, cubic spline method, or no processing at all. Additional tests were performed using an input ECG containing motion artifacts and an artificial 0.8 Hz sinusoid and similar results were found.
FIG. 3 is a system diagram 300 of an ECG baseline variation removal system. The input ECG 210 is passed to an anti-aliasing low-pass filter 220 . The anti-aliasing filter low-pass filter can be an infinite impulse response (IIR) filter. The filtered ECG is down-sampled by down-sampler 310 and passed to SG filter 330 . The SG filter creates an estimate of the baseline variation of the input ECG 210 . The estimate is up-sampled by up-sampler 320 . The up-sampling can be, for example, a linear interpolation. The ECG signal 210 can also be delayed by delay module 240 . The delay can compensate for any delays introduced by the anti-aliasing low-pass filter 220 , down-sampler 310 , SG filter 230 , and up-sampler 320 processing so that the input ECG 210 can, in combination module 250 , be combined with the estimated baseline variation produced by the SG filter 230 to produce an output ECG with the baseline variation removed 340 .
If the input ECG 210 has a sampling rate of 500 Hz, is down-sampled by a factor of 40 to a 12.5 Hz rate, and assuming the SG filter window size is 2*6+1 and the polynomial order is 2, then the delay will be 540 milliseconds and the computational load will be equivalent to a FIR filter with 17 taps. The baseline variation estimate can be up-sampled by a factor of 40 to combine the input ECG.
FIG. 9 is a process flow diagram 900 illustrating a method a removing baseline variation from an ECG. At 910 , the ECG is received. The ECG can have a sample rate of about 500 Hz. At 920 , at least the high frequency components of the ECG are removed. The high frequency components can be frequencies above about 0.8 Hz. Optionally, at 930 , the processed ECG can be down-sampled. At 940 , a baseline variation of the ECG can be estimated using a SG filter. The window length and polynomial degree of the SG filter can be selected based on the sample rate and baseline variation frequency. Optionally, at 950 , the estimate can be up-sampled. Optionally, at 960 , the estimate can be combined with a delayed ECG to produce an ECG with the baseline variation removed. Additionally, the baseline variation estimate can be provided for further processing, transmission, storage or display.
The SG filter determines a smoothed value for each data point in a series by performing a local polynomial fit in a window of predetermined length. The polynomial function can be defined as:
p ( n )= a 0 n 0 +a 1 n 1 +a 2 n 2 + . . . +a M n M
M is the polynomial order, n is a independent variable, and a 0 , a 1 , . . . , a M are polynomial coefficients. FIG. 4 is a plot 400 of a time series 410 . x(i) represents the time series 410 at any arbitrary sample i. The window length can be 2*N+1, and then a least squares polynomial fit centered at the ith sample can be expressed as a matrix equation BA=X, namely,
[
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A least-squares solution can be expressed as A=(B T B) −1 B T X and the smoothed value of the ith sample, denoted as y(i), can then be calculated as
y ( i )= a 0 n 0 +a 1 n 1 +a 2 n 2 + . . . +a M n M | n=0 =a 0 .
From the above-mentioned equation, the smoothed value is determined by a 0 only. a 0 is the inner product between the first row in (B T B) −1 B T and X. The matrix B is determined by the window size, 2*N+1, and the polynomial order, M. Therefore, (B T B) −1 B T can be known once the window size and the polynomial order are known. Let the first row in (B T B) −1 B T be [h(−N) . . . h(−1) h(0) h(1) . . . h(N)], then y(i) can be written as
y
(
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=
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As the first row in (B T B) −1 B T is symmetric with respect to the central point, n=0, y(i) can be written as
y
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The right hand side of the above equation is the convolution between h(n) and x(n). Therefore, the output of the SG filter can be expressed as the input filtered by a FIR filter that is determined by the window size and the polynomial order. Further, the SG filter has a linear phase response and a delay of half the window size.
Various implementations of the subject matter described herein may be realized in digital electronic circuitry, integrated circuitry, specially designed ASICs (application specific integrated circuits), computer hardware, firmware, software, and/or combinations thereof. These various implementations may include implementation in one or more computer programs that are executable and/or interpretable on a programmable system including at least one programmable processor, which may be special or general purpose, coupled to receive data and instructions from, and to transmit data and instructions to, a storage system, at least one input device, and at least one output device.
These computer programs (also known as programs, software, software applications or code) include machine instructions for a programmable processor, and may be implemented in a high-level procedural and/or object-oriented programming language, and/or in assembly/machine language. As used herein, the term “machine-readable medium” refers to any computer program product, apparatus and/or device (e.g., magnetic discs, optical disks, memory, Programmable Logic Devices (PLDs)) used to provide machine instructions and/or data to a programmable processor, including a machine-readable medium that receives machine instructions as a machine-readable signal. The term “machine-readable signal” refers to any signal used to provide machine instructions and/or data to a programmable processor.
Although a few variations have been described in detail above, other modifications are possible. For example, the logic flow depicted in the accompanying figures and described herein do not require the particular order shown, or sequential order, to achieve desirable results. Other embodiments may be within the scope of the following claims.
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A system includes a low pass-filter and a Savitzky-Golay filter. The low-pass filter receives and processes a first electrocardiogram signal. The filter removes at least the high frequency components of the first electrocardiogram signal. The Savitzky-Golay filter estimates a baseline variation of the first electrocardiogram signal from the filtered first electrocardiogram signal. Related apparatus, systems, techniques and articles are also described.
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BACKGROUND
The invention relates to radio frequency detection, and more particularly to signaling to a user the presence of radio frequency output of a mobile station, among other wireless transmitters.
U.S. Pat. No. 6,190,227 describes, “An incoming call reporting toy that visually or au rally reports a call arrival state of a portable terminal to a person around the toy in an amusing fashion. An electromagnetic wave emitted when a portable terminal receives an incoming call is used to activate an incoming call reporting circuit incorporated in the toy body. A signal outputted from a signal controller configuring the incoming call reporting circuit drives a motor to allow the toy body to perform a predetermined operation while emitting a sound and/or light, thereby notifying a person around the toy of the arrival of the call at the portable terminal.”
A product brochure for a Plantronics M1000 Headset states, “We've used our 40 years of headset experience to engineer and design the ultimate Bluetooth headset. Using a second-generation Bluetooth chipset, the M1000 Wireless Headset offers superior sound quality, longer talk time, superb comfort and stability, weighing less than an ounce . . . Key Features . . . In-use indicator light.”
Lenses have been used in many different forms for centuries. A lens may have refractive qualities that provide correction for poor vision. A lens includes such transparent devices as windshields of motorcycle helmets, transparent glass or plastic of diving masks, and goggles worn to keep out dust, debris and other particles.
When a mobile station is set to silent or vibrate mode, frequently the only way to be aware of an incoming call is to observe changes on the display of the mobile station. A mobile station that is stowed away, or otherwise out of sight will have no way to communicate, under these circumstances, that a call has arrived. Sometimes this serves a valid purpose, i.e. avoiding disturbing others nearby who are concentrating on other things. Sometimes, though, it is acceptable to take the call, but not acceptable for disturbing rings and other audible stimuli to occur. Thus, it would be helpful to improve awareness of mobile station status in a highly visible or other way, preferably without the need to be tethered to the mobile station.
SUMMARY
A wireless communication reporter embodiment may receive a wireless signal and by way of a radio frequency detection circuit, provide a signal. The signal may be passed to a light emitter or other indicator which is supported by the head mount. Thus the combined apparatus may be worn on the head of a user.
An advantage of the embodiment is that it may detect signals transmitted by a mobile station for relatively private awareness and sensing by the user.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is further described in the detailed description which follows in reference to the noted plurality of drawings by way of non-limiting examples of preferred embodiments of the present invention in which like reference numerals represent similar parts throughout the several views of the drawings and wherein:
FIG. 1 is a view of a wireless communication reporter embodiment having a light emitter; and
FIG. 2 is an edge-wise view of a lens portion of an embodiment.
DETAILED DESCRIPTION
A head mount may be any head worn or supported device that is not, under normal circumstances, sufficiently transparent for images to pass through and be discernable by a human being having good or poor eyesight. A head mount may be adapted to receive a lens. A lens may be a sufficiently transparent material suitable for images to pass through and be discernable by a human being having good or poor eyesight, wherein such lens is sufficiently small to be supported on a person's head by, e.g. a head mount. A head mount may be head worn or supported in the most broad sense that the head includes all human body parts above the neck, and that support may be of a temporary nature of a few minutes or a more permanent nature, lasting for months.
One such head mount is a frame for eyeglasses. One such lens may be a plastic, glass or other translucent material that is ground, polished and shaped to fit in the frame. A head mount may have many parts, for example a typical eyeglass frame comprises a first arm, a first hinge, a lens carrier, a second hinge and a second arm. A head mount may have few parts, for example laboratory safety goggles may be comprised of a semi-rigid facemask and an elastic band used to encircle the head.
One or more lenses may be supported by multiple head mounts. For example, a first arm may be affixed to a first lens. The first lens may be affixed to a bridge. The bridge may be affixed to a second lens. The second lens may be affixed to a second arm. In this situation, the first arm, bridge and second arm are all head mounts.
A lens must, in its head-worn configuration, be predominantly unobstructed by opaque foreign objects supported by the head mount, including parts of the head mount, while being worn.
FIG. 1 shows a head mount 101 , with a left lens 103 and a right lens 105 according to an wireless communication reporter embodiment. A source of stimulus or indicator, such as a light emitter 107 , may occupy a minute fraction of the visible area of the left lens 103 . The light emitter 107 is coupled to a radio frequency detection circuit 109 (RFDC). As an option, RFDC 109 may include a photocell, which may provide a reading of ambient light levels and adjust current to the light emitter 107 to provide higher intensity light when ambient light is high, and lower intensity light when ambient light is low. Light emitter 107 may flash, e.g. on a duty cycle long enough not to be annoying to the person wearing the device. A range for the RFDC 109 may be extended by providing an antenna 111 along an arm 109 of the head mount 101 .
FIG. 2 shows a lens 103 that provides a diffuser 211 which may enhance visibility of the light emitter 107 .
Because the indicator is so close to a user's eyes, ears and skin, only a very low level stimulus may be required for people of ordinary sensory abilities to sense that the indicator is operating. By the same token, a higher level of stimulus may be required in situations where there is ambient noise or light that might otherwise drown out such stimulus. Disease, injury, age, intoxication and other awareness factors may impact the ability of a user to be aware of a stimulus, however a reasonable level of stimulus for most situations may be that which most people who use prescription glasses can see under normal daylight circumstances.
FIG. 1 shows the light source or light emitter 107 coupled to the indicator output 106 and operative based on the indicator output 106 , the light source having an anisotropic output directed along at least one ray or principal ray, wherein the at least one ray points in a direction of the user. The light or light emitter may be any combination of radiating means combined with reflectors, shades and focussing lenses as are known in the art. A suitable light emitter may be a light emitting diode. The light or light emitter may initially transmit light in several directions, however, after any intervening reflectors, shades or lenses, very little or no light may pass in a direction away from a user wearing the embodiment.
Radio frequency detection circuit (RFDC) 109 may be tuned to at least one cellular frequency band, which may, preferably be an uplink channel, e.g. a signaling channel selected from frequencies in an uplink signaling band of a cellular telephone. Cellular telephones are known to respond to communications transmitted from a base station on a cellular band. The cellular telephone may respond using an uplink signaling channel which is a type of cellular band radio signal. The power level for such a radio frequency response is often set by national and international standards. Thus, the effective radiative power (ERP) of a cellular telephone transmitter in good working order, is within a known tolerance of effective radiative power set for the cellular regime in which the cellular phone operates. There is less variability between manufacturers in the radio frequency band licensed for cellular. However, for transmissions that are outside the licensed band, or that are inside the licensed band, but in a roll-off region of unintended but unavoidably transmitted frequencies, the ERP may vary over a greater range of levels, despite a common distance from transmitting cellular telephone to RFDC. Consequently, it may be difficult to select a RFDC preset level that is equally sensitive to cellular telephones of all manufacturers.
The radio waves emitted by a cellular telephone antenna may be anisotropic, i.e. they may not radiate with uniform power in all directions. Occasionally cellular telephones and supporting antennas are built with reduced radio output in a direction, such as, e.g. toward the user of the cellular telephone when held to the head. A mobile phone may be placed in an environment with a number of obstructions that block, diffract or reflect radio frequencies in the cellular bands. Nevertheless, signals emitted by a cellular telephone generally exhibit a rapid diminution in power in relation to the inverse square of the distance a receiver is from the cellular telephone antenna.
Such a diminution in signal power is predictable to some extent, and a receive threshold, or preset level, may be established for signals that arrive from a cellular telephone that is in a locus of a person. A locus of a person may be the immediate surroundings of the person including locations in and among worn items, as well as areas within the immediate reach of a person or user's hand. A locus of a person may include a volume of space of a typical office or bedroom.
A locus of a cellular telephone is similar in concept to the locus of a person. It may be the space from which a person may occupy and reach through to immediately reach and grasp the cellular telephone. The locus of a cellular telephone may be a volume of space of a typical office or bedroom. The preset level may be set to operate to detect uplink signaling signals of the cellular telephone throughout most of the locus of the cellular telephone under most circumstances. In other words, if the radio frequency detection circuit 109 is in the locus of the cellular telephone, the preset level will be low enough to detect most uplink signaling signals of the cellular telephone. A RFDC 109 that is within the locus of a cellular telephone may, nevertheless, fail to detect a uplink signaling signal in situation where, e.g. the cellular telephone is behind a metallic wall. The RFDC 109 may be in a null, created by, e.g. Raleigh fading—thus also the RFDC 109 may fail to detect a transmitting cellular telephone. Just the same, the preset level may be set to detect a presence of a uplink signaling signal, wherein the RFDC 109 is in the locus of the cellular telephone.
The RFDC 109 may detect signals within one or more cellular bands. The RFDC 109 may be tuned to detect a sub-frequency or channel of a cellular band, e.g. a uplink signaling channel.
Similarly, a RFDC 109 may detect, on rare occasions, an uplink signaling signal from a cellular telephone that the RFDC 109 is beyond the locus of the cellular telephone. Though anomalous, such an occurrence may happen if the RFDC 109 is at a constructive interference point of multiple radio paths from the cellular telephone, or multiple cellular telephones receive a call and respond with a uplink signaling channel transmittal concurrently.
Thus, during extraordinary circumstances, where the preset level may be a locus level that corresponds to a locus of a cellular telephone, the RFDC 109 may provide a false signal when outside the locus of a cellular telephone, and may fail to provide a signal when the inside the locus of a cellular telephone. Nevertheless, for ordinary use, e.g. the embodiment worn on the head, and a cellular telephone worn or temporarily placed in a dock or on a table, the RFDC may provide a stimulus when inside the locus of a transmitting cellular telephone so-placed.
A locus level may correspond to an arms-length space which may be useful in that more remote cellular telephones may not trigger the RFDC 109 . Thus, a likelihood that the cellular telephone of a neighboring user may be low. A locus level may correspond to a body-length space, which may be useful in that a cellular telephone may be placed on a table, floor or other resting place and still be capable of triggering the RFDC 109 . The arms-length space is the idealized space that, absent reflections, diffractions or blocking of radio waves, an RFDC 109 found within a radius of approximately a human's arm length of the cellular telephone, will trigger a indicating signal in the RFDC. The body-length space is the idealized space that, absent reflections, diffractions or blocking of radio waves, an RFDC found within a radius of approximately a human's body length of the cellular telephone, will trigger a indicating signal.
Although the invention has been described in the context of particular embodiments, various alternative embodiments are possible. Thus, while the invention has been particularly shown and described with respect to specific embodiments thereof, it will be understood by those skilled in the art that changes in form and configuration may be made therein without departing from the scope and spirit of the invention.
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Disclosed is a stimuli providing indicator ( 107 ) that is responsive to nearby transmitted radio signals. Fixed and mobile stations may produce such signals. In addition a cellular telephone operating at a high transmit power may be detected. Indicator ( 107 ) may be supported by a lens ( 103 ) which itself may be supported by at least one head mount ( 101 ).
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CROSS REFERENCES TO RELATED APPLICATIONS
Not applicable.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
The present invention relates to exercise equipment in general and to rocking exercise boards in particular.
Strength and flexibility of the lower body are important to everyone. Strength and flexibility in the feet, ankles, knees, thighs and hips can reduce the possibility of injury or strain from engaging in various sporting activities. On the other hand, to those who have suffered an injury to the lower extremities, a program of exercise which both strengthens and improves joint mobility can be critical in recovering full use of the extremities and in preventing recurrence of ankle, knee and joint strains and injuries.
Those involved in sporting activities, for example skiing, biking, roller blading, ice skating, etc., have long known of the benefits of warmup and other stretching exercises to reduce the possibility of injury by imparting greater strength and mobility, particularly with respect to the lower extremities of the body.
Tendons, the connective structures of the body, link together the various bones and joints within the body. Muscles provide the motive power for the joints. Muscles can be strengthened by exercise and tendons can be lengthened by repeated stretching. Greater muscular strength allows the body to resist excessive motion between bodily joints. Increased flexibility or tendon length allows a greater range of movement of the joints before damage is sustained by the body.
A full range of motion of the joints of the lower extremities is extremely important to mobility which, in turn, has a major impact on the quality of life. For those who have suffered injuries which interfere with mobility there is a very real need to recover the mobility. Such recovery of mobility can often be achieved through exercise which builds joint strength and flexibility.
One exercise device which is known for exercising the lower extremities consists of a board supported on two rockers. The exercise is performed by standing on the board while grasping a stationary object and rocking back and forth on the board. Thus, the upper portion of the body is held substantially vertical while the lower portion of the body conforms to the inclined surface produced by the board rocking back and forth. The orientation of the body with respect to the direction of rocking may be varied so the joints of the lower extremities receive a full range of motion.
Existing boards with rockers, such as shown in my U.S. Pat. No. 5,643,164, the disclosure of which is incorporated herein by reference, are designed to increase the range of motion of joints. The board shown in my prior patent illustrates a means whereby the maximum extension of the joints may be approached gradually and the joint held in that position of maximum extension for a period of time. However, an exercise board which provides a wider range of exercises is desirable.
What is needed is an exercise board which can be used to perform a wider range of exercises.
SUMMARY OF THE INVENTION
The exercise board of this invention has an upper planer support surface of roughly rectangular shape where the short sides of the rectangle have been replaced by convex arcs. Opposite the upper planer support surface, are two spaced apart parallel arcuate rockers which are perpendicular to the long sides of the rectangle and extend outwardly of the board. Each rocker has a flat portion adjacent to one long edge of the rocker board. The flat sections make an angle of approximately 45° with the planar surface of the board. Between the two rockers, on the side of the board opposite that on which a person using the board stands, a hemispherical pedestal or projection is formed. A band of rubber is also fastened to the board between the rockers. The band of rubber is arranged to accommodate a foot placed between the band of rubber and the bottom surface of the board so the front portion of the foot is retained between the band of rubber and the board. The band of rubber fastened between the rockers can be used for exercising the tibialis, extensor, peroneus and flexor longus muscles. With the foot positioned so the front portion of the foot is retained by the band of rubber the foot can be rocked to the inside and the outside, the leg can be twisted toward the inside of the step and with the heel of the foot resting on the bottom surface of the board the foot can be rocked back stretching the band of rubber.
Handles for picking up or grasping the exercise board are formed by holes which pass through the board adjacent the ends of the board formed by the convex arcs. A rubber strap is passed through one handle hole across both rockers and through the opposite handle hole, and exercises are performed using the strap by placing both feet on the board and, either while seated or standing, moving the arms and upper body against the resistance provided by the strap.
It is an object of the present invention to provide an exercise device for improving strength and mobility of the joints of the lower extremities.
It is another object of the present invention to provide a means mounted to the board for exercising the tibialis, extensor, peroneus and flexor longus muscles.
It is a further object of the present invention to provide an exercise device which can be used to perform exercises for the correction of posture.
Further objects, features and advantages of the invention will be apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded isometric view of the exercise board of this invention.
FIG. 2 is a front elevational view of the exercise board of FIG. 1 showing a first exercise.
FIG. 3 is a front elevational view of the exercise board of FIG. 1 showing a second exercise.
FIG. 4 is a rear elevational view of the exercise board of FIG. 1 showing a third exercise.
FIG. 5 is a rear elevational view of the exercise board of FIG. 1 showing a forth exercise.
FIG. 6 is a front elevational view of the exercise board of FIG. 1 showing an exercise involving a rubber strap.
FIG. 7 is a bottom plan view of the exercise board of FIG. 1 .
FIG. 8 is a top plan view of the exercise board of FIG. 1 .
FIG. 9 is a side elevational view of the exercise board of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring more particularly to FIGS. 1-9 wherein like numbers refer to similar parts, a rocker board 20 is shown in each of the figures. The board 20 is used to perform a wide variety of exercises which are particularly designed to increase the strength and flexibility of the lower body. The board is an improvement on my earlier invention shown in U.S. Pat. No. 5,643,164 which describes various exercises which can be performed using a board having features incorporated in the board 20 . The improved board 20 incorporates a band of rubber 22 or other elastic material which is fastened to a bottom surface 24 between the board rockers 26 . As shown in FIG. 2 , the band of rubber 22 accommodates the front portion 28 of the foot 30 of a person 32 using the exercise board 20 . The band or loop of rubber 22 is shown exploded away in FIG. 1 , and in plan view in FIG. 7 , and may be constructed of any elastic material, for example such as the Thera-Band® latex or latex free synthetic elastomer bands produced by the Hygienic Corporation.
The band of rubber 22 biases the foot 30 placed within the band 22 into normal flat engagement with the bottom surface 24 . Thus the muscles of the foot and lower leg may be exercised by moving the foot 30 against the elastic resistance provided by the band of rubber 22 . As shown in FIG. 2 , the foot 30 is rocked backwards so that the front portion 28 of the foot 30 engages and stretches the band of rubber 22 . Thus the elastic resistance of the band of rubber 22 strengthens the tibialis and peroneus muscles. A second exercise, illustrated in FIG. 3 , involves rotating the foot 30 to the outside which works the tibialis, extensor, and flexor hallicus longus muscles. A similar exercise is illustrated in FIG. 4 where the foot 30 is rotated to the inside of the step.
FIG. 5 illustrates an exercise performed by rotating the whole leg 34 against resistance provided by the band of rubber 22 . The foot 30 is slid the under the band 22 and the whole leg is rotated internally. During the foregoing exercises, if the board 20 has a tendency to move it can be held in place by the foot not being exercised 36 . This exercise is designed to correct problems in persons who have excessive “flares” in one or both feet.
The upper surface 38 of the board 20 has a general rectangular shape with two long straight parallel sides or edges 40 connected to by two shorter convex arcs 42 , as shown in FIG. 8 , on which the person 32 who is exercising stands as shown in FIG. 6 . Grip enhancing strips 41 are fixed to the upper surface 38 . Spaced just inside of the convex arcs 42 are convex shaped holes 44 which form hand holds. The holes 44 can also be used to perform a set of exercises by running an elastic band or tube 46 such as the Thera-Band® latex tubing produced by the Hygienic Corporation. The elastic band 46 is threaded through one handhold 44 , across both rockers 26 , and up through the other handhold 44 . The elastic band of 46 is grasped at each end with each hand 48 while standing on the board 20 , or at least putting one foot on the board 20 . The exercise is performed by raising one shoulder as high as possible, followed by lowering that shoulder and raising the opposite shoulder as high as possible as illustrated in FIG. 6 . The exercise illustrated in FIG. 6 is designed to correct an imbalance of the shoulders.
A similar exercise (not illustrated) using the elastic band 46 is performed while sitting on a chair with both feet placed on the upper surface 38 of the board 20 . The person exercising leans forward and grasps the rubber tubing 46 . The exercise is performed in three distinct stages. The first movement is to raise the neck back as far as is comfortable, then the shoulders are pulled back, while still leaning over, squeezing the shoulder blades together. Finally the spine is extended or arched backwards. These exercises are designed to correct three posture conditions simultaneously: a forward head position where the head is not centered over the shoulders, rounded shoulders, and slumped posture.
The board 20 has certain similarities to my earlier invention shown in U.S. Pat. No. 5,643,164. Opposite the upper planer support surface 38 are the two spaced apart parallel arcuate rockers 26 which are perpendicular to the long sides 40 of the upper surface 38 , the rockers extend outwardly of the bottom surface 24 of the board 20 . Each rocker has a lower profile 52 as shown in FIG. 9 for engaging the floor 54 , the lower profiles 52 of the two rockers 26 being substantially the same. The rockers 26 are covered with strips 55 of higher friction material as shown in FIG. 1 . Each of the lower profiles 52 has an arcuate portion 56 which adjoins a straight portion 58 . The arcuate portion 56 extends along more than half the lower profile 52 of the rockers 26 . Each arcuate portion is part of a curved surface which gives the board 20 a rocking motion. The straight portions 58 define an angle of about 45 degrees to the upper surface 38 , as shown in FIG. 9 , so that when the exercise board is tilted to bring the straight portions 58 of the rocker profiles 52 into engagement with the floor 54 , the upper surface is held in a static position at an angle of about 45 degrees to the floor. The straight portions 58 form part of a planer surface which intersects a plane formed by the upper surface 38 at about 45 degrees.
Similar to my earlier invention, a substantially hemispherical projection 60 extends from the lower surface 24 of the board 20 . The hemispherical projection 60 is positioned spaced between the rockers 26 as shown in FIGS. 1-7 . Sufficient space is provided between the rockers 26 for placing the foot 30 over the projection to stretch the foot without interference with the first and second rockers. The hemispherical projection 60 is offset laterally so as to be closer to one rocker 26 , and horizontally to be closer to one of the long sides 40 to provide space for the band of rubber 22 .
The board 20 can be manufactured by injection molding or rotational molding, but is preferably created as two injection molded pieces, of the material such as high impact polystyrene which are glued together along a parting line 62 . The over-molding may be used to form the hemispherical projection 60 and the grip strips 41 on the upper surface 38 and the grip strips 55 on the rockers 26 of a softer material such as an elastic compound compatible form over-molding with polystyrene. Generally the hemispherical projection 60 may benefit from being formed of a different durometer from the gripping surfaces 41 , 55 . As shown in FIG. 1 , the band of rubber 22 is held in place by a pair of cold rolled steel cleats 64 which are held by fasteners such as screws 66 into parallel pockets 68 recessed from the lower surface 24 of the board 20 . The screws are received in brass inserts (not shown) which are inserted the lower surface 24 while the molded part is still hot. The edges of the rubber band 22 pass under the cleats, and the cleats 64 fit tightly so that the band of rubber 22 is clamped between the cleats 64 by the portion of the board forming the pockets 68 .
In addition to the exercises shown in my earlier patent U.S. Pat. No. 5,643,164, and those described above, the following additional exercises have been developed for use with the exercise board 20 where the board is positioned with the straight portions 58 of the board rockers 26 flat against the floor 54 so that the upper surface 38 is positioned at an angle of 45 degrees with respect to the floor 54 . The first exercise is performed with the heels of the feet on the floor and the front portion of the foot extending up the 45 degree slope formed between the board and the floor. The feet are spread slightly apart in the pigeon-toed position. The exercise is performed by squatting as if to sit just enough to feel stretching. The position is then held for 30 to 60 seconds. A second exercise is performed with the heels positioned on the floor and the front portions of the feet extending up the 45 degree angle while the pelvis is leaned to each side for 30 seconds. A third exercise is performed with the outside edge of a single foot placed partly on the floor and partly parallel to the long side 40 . The body is leaned slightly toward the board 20 and the positioned held for 30 seconds to one minute. The fourth exercise is similar to the third exercise only the foot is flexed in the opposite direction. The exercise is performed while straddling the board 20 so the inside of the foot is placed on the edge of the board. A fifth exercise is performed by placing the toes and ball of the foot so that they extend upwardly along the slope surface of the board and stepping over the board with the other foot and bending the knee to obtain maximum stretch. This positioned is held for 30 seconds to one minute.
It should be understood that the band of rubber 22 may be a continuous loop which is attached to the underside of the board 20 or may be a strap of material as illustrated in FIG. 1 . The band of rubber may be replaced with any elastic material which tends to bias the foot against the board, thus providing elastic resistance necessary for the various exercises performed using the band of rubber.
It is understood that the invention is not limited to the particular construction and arrangement of parts herein illustrated and described, but embraces all such modified forms thereof as come within the scope of the following claims.
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A generally rectangular exercise board with curved ends has an upper planer support surface. Beneath the support surface, are two projecting spaced parallel arcuate rockers. Each rocker has a flat portion adjacent to one long edge of the rocker board. The flat sections makes an angle of approximately 45° with the planar surface of the board. A hemispherical projection is formed between the two rockers. A band of rubber is fastened to the board between the rockers which is arranged to accommodate a foot placed between the band of rubber and the bottom surface of the board so the front portion of the foot is elastically biased against the board and exercises can be performed by moving the foot away from the board to induce elastic strain in the band of rubber.
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FIELD OF THE INVENTION
[0001] This invention relates to a white balance correction apparatus and method. More particularly, the invention relates to a white balance correction apparatus and method used in a device such as a digital camera or digital video camera.
BACKGROUND OF THE INVENTION
[0002] [0002]FIG. 13 is a block diagram illustrating the structure of a single CCD type digital camera as one example of a conventional image sensing apparatus according. In FIG. 13, a solid-state image sensing device 1 such as a CCD has its surface covered by an RGB color filter of, e.g., a Bayer-type array, which enables color image sensing. The optical image of an object that impinges upon the image sensing device 1 via a lens (not shown) is converted to an electric signal by the image sensing device 1 . In order to eliminate noise from the electric signal obtained by the conversion, the signal is processed by a CDS/AGC circuit 2 , after which a conversion is made to a digital signal by an A/D converter circuit 3 pixel by pixel in successive fashion.
[0003] The digital signal that is output from the A/D converter circuit 3 has its white gain adjusted by a white balance circuit 4 , whence the resulting signal is sent to a luminance notch circuit 12 . The luminance notch circuit 12 uses a vertical low-pass filter (VLPF) to execute processing for reducing signal gain of a frequency in the vicinity of the Nyquist frequency in the vertical direction. Gain reduction processing by a horizontal low-pass filter (HLPF) is executed similarly in the horizontal direction. Such a filter shall be referred to as a “luminance notch filter” below. Next, a horizontal band-pass filter (HBPF) circuit 13 and vertical band-pass filter (VBPF) circuit 16 raise the frequency, which is slightly lower than the Nyquist frequency weakened by the notch filters.
[0004] Amplitude is adjusted subsequently by PP (aperture peak) gain circuits 14 and 17 in both the horizontal and vertical directions, and then low amplitude is cut, thereby eliminating noise, by base clipping (BC) circuits 15 and 18 . The horizontal and vertical components are subsequently added by an adder 19 , main gain is applied by an APC (Aperture Control) main gain circuit 20 , and the resultant signal is added to a baseband signal by an adder 21 . A gamma conversion circuit 22 then performs a gamma conversion and a luminance correction (YCOMP) circuit 23 executes a luminance-signal level correction based upon color.
[0005] Next, as an example of color signal processing, a color interpolation circuit 5 executes an interpolation with regard to all pixels in such a manner that all color pixel values will be present, and a color conversion matrix (MTX) circuit 6 converts each of the color signals to a luminance signal (Y) and color difference signals (Cr, Cb). Color-difference gain of low- and high-luminance regions is then suppressed by a chroma suppression (CSUP) circuit 7 , and band is limited by a chroma low-pass filter (CLPF) circuit 8 . The band-limited chroma signal is converted to an RGB signal and is simultaneously subjected to a gamma conversion by a gamma conversion circuit 9 . The RGB signal resulting from the gamma conversion is again converted to Y, Cr, Cb signals, gain is adjusted again by a chroma gain knee (CGain Knee) circuit 10 , and a linear clip matrix (LCMTX) circuit 11 makes a minor correction of hue and corrects a shift in hue caused by individual differences between image sensing devices.
[0006] Processing executed by the white balance circuit 4 in the image sensing apparatus of FIG. 13 will now be described. The image signal output from the image sensing device 1 and converted to a digital signal by the A/D converter circuit 3 is divided into a plurality (any number of) blocks of the kind shown in FIG. 14, and color evaluation values Cx, Cy, Y are calculated for each block based upon the following equations:
Cx= ( R−B )/ Y
Cy= ( R+B− 2 G )/ Y
Y= ( R+G+B )/2 (1)
[0007] The color evaluation values Cx, Cy of each block calculated in accordance with Equations (1) are compared with a previously set white detection region (described later). If the evaluation values fall within the white detection region, it is assumed that the block is white and then the summation values (SumR, SumG, SumB) of respective ones of the color pixels of the blocks assumed to be white are calculated. White balance gains kWB_R, kWB_G, kWB_B for each of the colors RGB are then calculated from the summation values using the following equations:
kWB — R= 1.0 /SumR
kWB — G= 1.0 /SumG
kWB — B= 1.0 /SumB (2)
[0008] The white balance circuit 4 performs the white balance correction using the white balance gains thus obtained.
[0009] [0009]FIGS. 15A and 15B are graphs illustrating a white detection region 101 . In order to obtain the white detection region 101 , a white object such as a standard white sheet (not shown) is sensed from high to low color temperatures using light sources at arbitrary color temperature intervals, and the color evaluation values Cx, Cy are calculated based upon Equations (1) using the signal values obtained from the image sensing device 1 . Next, Cx and Cy obtained with regard to each of the light sources are plotted along the X axis and Y axis, respectively, and the plotted points are connected by straight lines. Alternatively, plotted points are approximated using a plurality of straight lines. As a result, a white detection axis 102 from high to low color temperatures is produced. In actuality, there are slight variations in spectral diffraction even for the color white. For this reason, the white detection axis 102 is provided with some width along the direction of the Y axis. This region is defined as the white detection region 101 .
[0010] The conventional white balance detection apparatus, however, has certain drawbacks. For example, consider a case where a close-up of the human face is taken in the presence of a light source such as sunlight having a high color temperature. Though the color evaluation values of a white subject in the presence of sunlight are distributed as indicated by area 103 in FIG. 15A, the color evaluation values of the human complexion are distributed as indicated by area 105 in FIG. 15A. These values are distributed in an area substantially the same as that (the area indicated at 104 in FIG. 15A) of color evaluation values of the color white photographed in the presence of a light source such as white tungsten having a low color temperature.
[0011] Further, the color evaluation values are distributed as indicated in area 106 in FIG. 15B in a case where an area (on the order of 7000 K) in which the blue of the sky has grown pale, as at the horizon or at the boundaries of clouds, is included in a scene in, say, a scenery mode. This substantially coincides with the distribution of evaluation values (area 107 in FIG. 15B) of the color white sensed under cloudy conditions or in the shade. As a consequence, the color temperature of the scene is judged to be higher than it actually is (color temperature under clear skies is on the order of 5500 K) and the pale blue of the sky is corrected to white. This represents a judgment error.
SUMMARY OF THE INVENTION
[0012] The present invention has been made in consideration of the above situation and has as its object to reduce erroneous decisions regarding white evaluation, thereby performing a better white balance correction.
[0013] According to the present invention, the foregoing object is attained by providing a white balance correction apparatus comprising; a dividing unit adapted to divide an image into a plurality of areas; a white evaluation unit adapted to determine whether image data within every divided area is indicative of the color white according to the position of each divided area in the image; and a white balance correction unit adapted to perform a white balance correction based upon image data determined to be indicative of the color white.
[0014] According to the present invention, the foregoing object is also attained by providing a white balance correction method comprising; dividing an image into a plurality of areas; determining whether image data within every divided area is indicative of the color white according to the position of each divided area in the image; and performing a white balance correction based upon image data determined to be indicative of the color white.
[0015] Other features and advantages of the present invention will be apparent from the following description taken in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the figures thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate an embodiment of the invention and, together with the description, serve to explain the principles of the invention.
[0017] [0017]FIG. 1 is a block diagram illustrating a structure of a white balance correction apparatus according to a first embodiment of the present invention;
[0018] [0018]FIGS. 2A and 2B are diagrams illustrating white detection regions according to the first embodiment of the present invention;
[0019] [0019]FIGS. 3A and 3B are diagrams illustrating the division of a screen in the first embodiment of the present invention;
[0020] [0020]FIG. 4 is a flowchart illustrating white evaluation processing according to the first embodiment of the present invention;
[0021] [0021]FIG. 5 is a flowchart illustrating processing for determining whether or not the color of complexion is present in an automatic mode according to the first embodiment of the present invention;
[0022] [0022]FIGS. 6A and 6B are diagrams illustrating the division of a screen in a first modification of the invention;
[0023] [0023]FIGS. 7A and 7B are diagrams illustrating white detection regions according to the first modification of the present invention;
[0024] [0024]FIG. 8 is a diagram illustrating the division of a screen in a second modification of the invention;
[0025] [0025]FIGS. 9A and 9B are diagrams illustrating white detection regions according to the second modification of the present invention;
[0026] [0026]FIGS. 10A and 10B are diagrams illustrating white detection regions according to the second modification of the present invention;
[0027] [0027]FIG. 11 is a block diagram illustrating the structure of a white balance correction apparatus according to the second embodiment of the present invention;
[0028] [0028]FIGS. 12A to 12 C are diagrams illustrating the division of a screen according to the second embodiment of the present invention;
[0029] [0029]FIG. 13 is a block diagram illustrating the structure of a conventional image sensing apparatus;
[0030] [0030]FIG. 14 is a diagram illustrating division of a screen indicating units for performing white evaluation;
[0031] [0031]FIGS. 15A and 15B are diagrams illustrating a conventional white detection region; and
[0032] [0032]FIGS. 16A to 16 C are diagrams illustrating examples of detection patterns for detecting a white region on a screen conforming to brightness of an object in the first modification of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] Preferred embodiments of the present invention will be described in detail in accordance with the accompanying drawings.
[0034] [First Embodiment]
[0035] [0035]FIG. 1 is a block diagram illustrating the structure of a white balance correction apparatus according to a first embodiment of the present invention. The white balance correction apparatus according to this embodiment is capable of being used instead of the white balance circuit 4 shown in FIG. 13, by way of example. The components of the image sensing apparatus with the exception of the white balance circuit 4 will be described below with reference to FIG. 13.
[0036] As shown in FIG. 1, the white balance correction apparatus includes a mode determination unit 30 for determining the operating mode of the image sensing apparatus (modes such as an automatic mode, portrait mode for sensing a person or persons, scenery mode for sensing scenery and manual mode for allowing the user to set a white balance correction value); an evaluation block dividing unit 31 for dividing the output signal of the image sensing device 1 into a plurality of evaluation blocks of the kind shown in FIG. 14; a white detection region storage unit 32 for storing a white detection region (referred to as a “standard white correction region” below) serving as a standard; a white detection region varying unit 33 for changing the white detection region when appropriate using limit values; a pattern storage unit 34 for storing, classified by mode, patterns which are combinations of position on the screen and a white decision region that has been changed by the white detection region varying unit 33 used in order to subject the evaluation block at this position to white evaluation; a white evaluation unit 35 for determining whether each evaluation block obtained by division by the evaluation block dividing unit 31 is white or not; a WB coefficient calculation unit 36 for calculating white balance (WB) coefficients, which are used in a WB correction, from signal values of evaluation blocks judged to be white by the white evaluation unit 35 ; a WB coefficient storage unit 37 for storing WB coefficients obtained by the WB coefficient calculation unit 36 ; and a WB correction unit 38 for applying a WB correction to the output signal of the image sensing device 1 using the WB coefficients stored in the WB coefficient storage unit 37 . It should be noted that the white detection region storage unit 32 , pattern storage unit 34 and WB coefficient storage unit 37 may be implemented by a single memory or by a plurality of memories.
[0037] The reference white detection region stored in the white detection region storage unit 32 will now be described. The description will relate to a case where a primary-color filter is used as the image sensing device 1 .
[0038] In FIGS. 2A and 2B, reference numerals 201 and 202 denote a white detection region and a white detection axis, respectively. As in the example of the prior art, a white object such as a standard white sheet (not shown) is sensed from high to low color temperatures using light sources at arbitrary color temperature intervals, and the color evaluation values Cx, Cy are calculated based upon Equations (1) using the signal values obtained from the image sensing device 1 . Next, Cx and Cy obtained with regard to each of the light sources are plotted along the X axis and Y axis, respectively, and the plotted points are connected by straight lines or the plotted points are approximated by a plurality of straight lines. As a result, the white detection axis 202 from high to low color temperatures is produced. It should be noted that the X axis corresponds to the color temperature of the light source and the Y axis corresponds to the amount of correction in the green direction (that is, the color-temperature direction of luminance and the color-temperature direction of fluorescent light). In actuality, there are slight variations in spectral diffraction even for the color white. For this reason, the white detection axis is provided with some width along the direction of the Y axis. This region is defined as the white detection region 201 . The data of the white detection region thus defined is stored in the white detection region storage unit 32 when the white balance correction apparatus is manufactured or shipped.
[0039] Conventionally, the evaluation block dividing unit 31 divides the output signal of the image sensing device 1 into a plurality of evaluation blocks of the kind shown in FIG. 14, and the white evaluation unit 35 calculates the color evaluation values Cx, Cy block by block using the Equations (1) and determines that a block is white if the calculated color evaluation values Cx, Cy fall within the white detection region 201 . According to a characterizing feature of the first embodiment of the present invention, however, the size (limits along the direction of color temperature in an example shown in FIGS. 2A and 2B) of the white detection region 201 can be changed by the white detection region varying unit 33 in accordance with relative position of the evaluation block on the screen.
[0040] In FIG. 2A, a white detection region 203 is obtained by setting white detection limits Ll1, Lh1 with respect to the white detection region 201 , thereby applying limits in such a manner that the range of Cx is made Ll1 to Lh1. A white detection region 204 in FIG. 2B is obtained by setting white detection limits Ll2, Lh2 with respect to the white detection region 201 , thereby applying limits that make the range of Cx equal to Ll2 to Lh2 of the white detection region 204 so as to cut the low region of color temperatures from the white detection region 203 .
[0041] The white evaluation unit 35 subjects the evaluation blocks to a white evaluation and the WB coefficient calculation unit 36 calculates the WB coefficients (white balance gains) from the summed values of the pixel values in evaluation blocks determined to be white and stores these coefficients in the WB coefficient storage unit 37 . The WB correction unit 38 subjects the input image to a WB correction using the coefficients stored in the WB coefficient storage unit 37 .
[0042] White evaluation processing will now be described with reference to FIGS. 2A to 4 B.
[0043] [0043]FIG. 3A illustrates a pattern setting example of a pattern stored in the pattern storage unit 34 in the automatic mode, and FIG. 3B illustrates a pattern setting example of a pattern stored in the pattern storage unit 34 in the portrait mode. Each pattern indicates a combination of the position of each evaluation block and the size of the changed white detection region used when subjecting the evaluation block at this position to white evaluation. It may be so arranged that even though the patterns are stored beforehand at the time of manufacture or shipping of the white balance correction apparatus, the user can alter the region settings.
[0044] First, at step S 11 in FIG. 4, the mode determination unit 30 determines whether the automatic mode or the portrait mode has been set. If the automatic mode has been set, control proceeds to step S 12 , at which the white evaluation unit 35 acquires the region data of the pattern shown in FIG. 3A from the pattern storage unit 34 . If the portrait mode has been set, control proceeds to step S 13 , at which the white evaluation unit 35 acquires the region data of the pattern shown in FIG. 3B from the pattern storage unit 34 .
[0045] Next, at step S 14 , the white evaluation unit 35 determines whether each evaluation block is in region ( 1 ) or region ( 2 ). If it is in region ( 1 ) (“YES” at step S 14 ), control proceeds to step S 15 , at which the color evaluation values of the evaluation block are compared with the white detection region 203 , which is shown in FIG. 2A, limited by the white detection region varying unit 33 .
[0046] If the evaluation block is in region ( 2 ) (“NO” at step S 14 ), control proceeds to step S 16 , at which the color evaluation values of the evaluation block are compared with the white detection region 204 , which is shown in FIG. 2B, limited by the white detection region varying unit 33 . There is a high likelihood that a human face will be included in the central area of the screen. Accordingly, the limitation on the side of low color temperature is set to be higher for the central area than for the periphery of the screen, thereby applying a limitation to the white detection region 204 in such a manner that a complexion tone will not be evaluated incorrectly as being white.
[0047] If the color evaluation values of an evaluation block are found to fall within the white detection region 203 or 204 at either step S 15 or S 16 , then control proceeds to step S 17 , at which the white evaluation unit 35 decides that this evaluation block is white. If the color evaluation values of an evaluation block are found not to fall within the white detection region 203 or 204 , then control proceeds to step S 18 , at which the white evaluation unit 35 decides that this evaluation block is not white.
[0048] An evaluation block thus determined to be white has its pixel values summed in order to calculate the white gains (WB coefficients), as described above.
[0049] Whether the decision as to whether an evaluation block is white has been rendered with regard to all evaluation blocks is determined at step S 19 . Steps S 14 to S 18 are repeated until all of the evaluation blocks have been evaluated.
[0050] Experiments have shown that excellent results can be obtained if the white detection limit Ll2 on the side of low color temperature is fixed at about 5000 K. However, it goes without saying that the present invention is not limited to 5000 K and that this can be changed as appropriate.
[0051] In accordance with the first embodiment, as described above, erroneous decisions regarding white evaluation can be reduced by using a white detection region that differs depending upon position on the screen. As a result, it is possible to perform a better white balance correction.
[0052] Further, by enlarging the area of the central region ( 2 ), as shown in FIG. 3B, in a case where the image sensing mode of the camera is made the portrait mode, erroneous decisions regarding white evaluation ascribable to complexion can be reduced.
[0053] However, though it may be considered that there is a high likelihood that complexion will be present at the central part of the screen if the mode is the portrait mode, it may also be considered that there are many instances where complexion is not present at the central part of the screen if the mode is the automatic mode. If the above-described setting of the screen and setting of white limits is made in a case where completion is not present at the central part of the screen, the result of color-temperature detection at the center of the screen will not fall below the white detection limit Ll2 (e.g., 5000 K) on the side of low color temperature. A problem that arises as a consequence is that the result of color temperature based upon an image captured under, e.g., the A light source will become higher than the actual light-source color temperature. Accordingly, a white balance correction of higher precision can be achieved by performing the determination regarding the absence or presence of complexion before the operation indicated at step S 12 in FIG. 4 and performing the operations from step S 12 onward if complexion is judged to be present. This operation will be described with reference to the flowchart of FIG. 5.
[0054] Evaluation blocks in which image data is determined to be white (these blocks shall be referred to as “white evaluation blocks” below) are detected at step S 21 using the same white detection region (a region delimited by the white detection limits or a region in which the color-temperature region of complexion is contained in a white detection region that is not limited; e.g., either the white detection region 201 or 203 ) with regard to all evaluation blocks in the central portion of the screen [region ( 2 ) in FIG. 3A] and peripheral portion [region ( 1 ) in FIG. 3A], light-source color temperature CtAround is obtained at step S 22 from data that is the result of summing and averaging the image data of the white evaluation blocks in the peripheral portion of the screen, and light-source color temperature CtCenter is obtained at step S 23 from data that is the result of summing and averaging the image data of the white evaluation blocks in the central portion of the screen. It should be noted that the order of the processing steps S 22 and S 23 may be reversed or the processing of steps S 22 and S 23 may be executed in parallel.
[0055] Next, CtAround and CtCenter are compared at step S 24 . If the color temperature CtCenter obtained from the central portion of the screen is less than the color temperature CtAround obtained from the peripheral portion of the screen, then it is judged at step S 25 that there is a high likelihood that complexion is present in the central portion of the screen. In other words, if
[0056] CtCenter<CtAround
[0057] holds, then the central portion of the screen is judged to contain complexion and the light-source color temperature is calculated at step S 26 by performing the white evaluation in the automatic mode shown in FIGS. 2A to 4 B.
[0058] On the other hand, if the color temperature CtCenter obtained from the central portion of the screen is substantially equal to or greater than the color temperature CtAround obtained from the peripheral portion of the screen, it is judged at step S 27 that there is a high likelihood that complexion is not present at the central portion of the screen. In other words, if
[0059] CtCenter≧CtAround
[0060] holds, then it is judged that complexion is not present, all evaluation blocks are compared with a common white detection region (step S 28 ), white evaluation blocks are detected and the light-source color temperature obtained is adopted.
[0061] Adding on the above processing makes it possible to reduce even further erroneous decisions regarding white evaluation and makes it possible to perform a better white balance correction.
[0062] If the manual mode is found to be in effect at the mode discrimination step S 11 , then, in a manner similar to that where absence of complexion is determined, all evaluation blocks are compared with a common white detection region, white evaluation blocks are detected and the light-source color temperature obtained from image data in the white evaluation blocks is adopted.
[0063] (First Modification)
[0064] [0064]FIGS. 6A and 6B illustrate pattern setting examples for suppressing erroneous decisions that blue sky is the color white. FIG. 6A illustrates an example of a pattern in the case of the automatic mode, and FIG. 6B illustrates an example of a pattern in the case of the scenery mode. In a manner similar to that of the first embodiment, whether an evaluation block is white or not is determined by comparing regions ( 1 ) and ( 2 ) with white detection regions limited using different white detection limits.
[0065] Color evaluation values of an evaluation block in an image region in which the sky appears close to thin clouds or the horizon have a distribution substantially the same as that of color evaluation values of white points in the shade, as mentioned earlier. Consequently, an evaluation block in a portion of an image that is the sky is judged erroneously to be white. In other words, the sky is judged erroneously to be white, which has a high color temperature. Accordingly, white evaluation is carried out using different white detection regions in the upper and lower parts of the screen, as shown in FIG. 6A, with a limitation being applied by the white detection region varying unit 33 using a different white detection limit on the side of high color temperature.
[0066] In the first modification, as shown in FIG. 7B, a white detection limit Lh4 on the side of high color temperature limiting the white detection region for the purpose of judging evaluation blocks at the upper portion of the screen is set to the side of low color temperature in comparison with a white detection limit Lh3 on the side of high color temperature shown in FIG. 7A for the purpose of judging evaluation blocks at the lower portion of the screen, thereby arranging is so that pale blue will not be judged erroneously as white.
[0067] Experiments have shown that excellent results can be obtained if the white detection limit Lh4 is fixed at about 5500 K. However, it goes without saying that the present invention is not limited to 5500 K and that this can be changed as appropriate.
[0068] In accordance with the first modification, as described above, erroneous decisions regarding white evaluation can be reduced by using a white detection region that differs depending upon position on the screen. As a result, it is possible to perform a better white balance correction.
[0069] Further, by enlarging the area of the upper region ( 2 ), as shown in FIG. 6B, in a case where the photographic mode of the camera is made the scenery mode, erroneous decisions regarding white evaluation at portions of blue sky can be reduced.
[0070] In the first modification, brightness Bv of a subject may be detected from the captured image data and white detection patterns of the kind shown in FIGS. 6A and 6B may be changed in accordance with brightness. For example, when Bv is greater than a preset value Bv2, the probability that the image was captured outdoors is high (the percentage of area occupied by the sky is large). Accordingly, the proportion of evaluation blocks ( 2 ) in the upper part of the screen in which the white detection range is limited by a white detection region 209 shown in FIG. 10A is enlarged, as shown in FIG. 16B. On the other hand, when Bv is less than a preset value Bv1 (<Bv2), the probability that the image was captured indoors is high, and therefore the proportion of evaluation blocks ( 2 ) in the upper part of the screen is reduced, as shown in FIG. 16A. If the brightness of the subject is between Bv1 and Bv2, the proportion of evaluation blocks ( 2 ) in the upper part of the screen in which the white detection range is limited by the white detection region 209 is decided by linear calculation at Bv as indicated by the graph of FIG. 16C. An even more suitable white balance correction can be performed by executing such processing.
[0071] (Second Modification)
[0072] [0072]FIG. 8 illustrates an example of pattern setting for suppressing erroneous decisions relating to both complexion and the sky. Excellent results are obtained if, by way of example, the following settings are made for white evaluation of evaluation blocks in region ( 1 ) of FIG. 8:
[0073] white detection limit Lh5 on the side of high color temperature: 5500 K;
[0074] white detection limit Ll5 on the side of low color temperature: brightness variable (FIG. 9A);
[0075] the following settings are made with respect to the region ( 2 ) in FIG. 8:
[0076] white detection limit Lh6 on the side of high color temperature: brightness variable;
[0077] white detection limit Ll6 on the side of low color temperature: brightness variable (FIG. 9B);
[0078] the following settings are made with respect to the region ( 3 ) in FIG. 8:
[0079] white detection limit Lh7 on the side of high color temperature: 5500 K;
[0080] white detection limit Ll7 on the side of low color temperature: 5000 K (FIG. 10A); and
[0081] the following settings are made with respect to the region ( 4 ) in FIG. 8:
[0082] white detection limit Lh8 on the side of high color temperature: brightness variable;
[0083] white detection limit Ll8 on the side of low color temperature: 5000 K (FIG. 10B).
[0084] It should be noted that the specific values indicated as the white detection limits Lh5, Lh7, Ll7 Ll8 are examples only. The present invention is not limited to these values and the values can be changes as appropriate.
[0085] In accordance with the second modification, as described above, use is made of patterns in which the area of the screen is more finely divided and white evaluation is performed using white detection regions that differ depending upon position on the screen. Accordingly, a white balance correction of even higher precision can be achieved.
[0086] It should be noted that the pattern used can be changed depending upon the image sensing mode in a manner similar to that of the first embodiment.
[0087] [Second Embodiment]
[0088] [0088]FIG. 11 is a block diagram illustrating the brief structure of a white balance correction apparatus according to a second embodiment of the present invention. This embodiment differs from that of FIG. 1 in that the mode determination unit 30 in FIG. 1 is replaced by a vertical/horizontal orientation determination unit 40 in FIG. 11 for discriminating horizontal and vertical orientations at the time of image sensing. Components in FIG. 11 identical with those shown in FIG. 1 are designated by like reference numerals, and explanation of them are omitted.
[0089] The characterizing feature of the second embodiment is that the vertical/horizontal orientation determination unit 40 discriminates horizontal and vertical orientations (rotation clockwise by 90° and rotation counter-clockwise by 90°) based upon the output of a gravity sensor (not shown) and makes it possible to change the setting of white detection limits depending upon the state of photography.
[0090] [0090]FIGS. 12A to 12 C are diagrams illustrating pattern setting examples. FIG. 12A illustrates an example of a pattern in a case where horizontal orientation has been determined by the vertical/horizontal orientation determination unit 40 , FIG. 12B an example of a pattern in a case where rotation counter-clockwise by 90° has been determined by the vertical/horizontal orientation determination unit 40 , and FIG. 12C an example of a pattern in a case where rotation clockwise by 90° has been determined by the vertical/horizontal orientation determination unit 40 . Point A in FIGS. 12A to 12 C indicates the same corner and is shown in order to facilitate an understanding of direction of rotation.
[0091] The evaluation blocks in the regions ( 1 ) to ( 4 ) of FIGS. 12A to 13 C are judged using, e.g., the white detection regions 207 to 210 shown in FIGS. 9A, 9B, 10 A and 10 B.
[0092] In accordance with the second embodiment, as described above, white evaluation of each evaluation block can be performed appropriately irrespective of camera orientation (horizontal or vertical) at the time of image sensing.
[0093] It should be noted that the pattern settings shown in FIGS. 12A to 12 C are one example. It may be so arranged that the pattern settings shown in FIGS. 3A, 3B and FIGS. 6A, 6B or other settings may be used, and the settings may be changed depending upon the image sensing mode.
[0094] In the above embodiments, a case in which the white detection region is limited by the white detection region varying unit 33 has been described. However, it may be so arranged that a plurality of white detection regions are stored in advance and any of the stored white detection regions is used in dependence upon the position of the evaluation block.
[0095] [Other Embodiments]
[0096] Software and hardware implementations of the above embodiments can be substituted as appropriate.
[0097] Further, the above embodiments or the technical elements thereof may be combined as necessary.
[0098] Furthermore, even if all or part of the structure of the claims or of the embodiments forms a single apparatus, or even if a connection is made to an image sensing apparatus such as a digital camera or video camera or to another apparatus such as an image processing apparatus that processes signals obtained from an image sensing apparatus, the present invention may serve as an element that constructs such apparatus.
[0099] Further, the object of the present invention can also be achieved by providing a storage medium storing program codes for performing the aforesaid processes to a computer system or apparatus (e.g., a personal computer), reading the program codes, by a CPU or MPU of the computer system or apparatus, from the storage medium, then executing the program.
[0100] In this case, the program codes read from the storage medium realize the functions according to the embodiments, and the storage medium storing the program codes constitutes the invention.
[0101] Further, the storage medium, such as a floppy disk, a hard disk, an optical disk, a magneto-optical disk, CD-ROM, CD-R, a magnetic tape, a non-volatile type memory card, and ROM, and computer network, such as LAN (local area network) and WAN (wide area network), can be used for providing the program codes.
[0102] Furthermore, besides aforesaid functions according to the above embodiments are realized by executing the program codes which are read by a computer, the present invention includes a case where an OS (operating system) or the like working on the computer performs a part or entire processes in accordance with designations of the program codes and realizes functions according to the above embodiments.
[0103] Furthermore, the present invention also includes a case where, after the program codes read from the storage medium are written in a function expansion card which is inserted into the computer or in a memory provided in a function expansion unit which is connected to the computer, CPU or the like contained in the function expansion card or unit performs a part or entire process in accordance with designations of the program codes and realizes functions of the above embodiments.
[0104] In a case where the present invention is applied to the aforesaid storage medium, the storage medium stores program codes corresponding to the flowcharts shown in FIG. 4 and/or FIG. 5 described in the embodiments.
[0105] The present invention is not limited to the above embodiments and various changes and modifications can be made within the spirit and scope of the present invention. Therefore to apprise the public of the scope of the present inventions the following claims are made.
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An entered image is divided into a plurality of blocks and it is determined, on a per-block basis, whether image data within an applicable block is indicative of the color white, based upon a condition, from among a plurality of conditions, that conforms to the position of each block in the image. A white balance correction is performed based upon data of a block determined to be indicative of the color white.
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RELATED APPLICATION
This application is a continuation of Ser. No. 07/874,094 filed Apr. 27, 1992, abandoned, which is a continuation-in-part of now pending application Ser. No. 07/706,378 filed on May 28, 1991, abandoned, and entitled "Peripheral Driven Composite Sockets And Drive Wrenches".
FIELD OF THE INVENTION
This invention relates to sockets and wrenches, and, more particularly, relates to peripherally driven sockets and associated drive mechanisms.
BACKGROUND OF THE INVENTION
In the manufacture and maintenance of aircraft, heavy equipment, machinery and appliances it is often necessary to remove and install hoses, lines and pipes that are attached to fittings by a threaded fastener (for example, a flare nut, B nut, or the like). Moreover, such equipment and machinery may often utilize a plurality of conduits that are placed close together, in confined or otherwise hard to access spaces, or at awkward angles.
These threaded fasteners, therefore, must often be rotated with open end wrenches and various types of pliers, risking damage to the fastener and providing only a slow manual manipulation of the fastener and little or no means for limiting the torque delivered to the fastener. Removal and installation of threaded fasteners on the various forms of conduit may thus be slow and tedious.
Several types of wrenches to rotate such fasteners in such a way as to make the process faster and cause less damage to the fastener have been heretofore suggested and/or utilized. U.S. Pat. Nos. 2,712,256, 2,712,257, and 2,758,493 disclose open ratchet wrenches which can turn a hex fastener encircling a line. U.S. Pat. Nos. 3,564,955, 3,668,949, 4,914,987, and 4,374,479 disclose gear driven tools for rotating fasteners or appliances that hold such fasteners.
These tools, however, suffer from many of the same problems as open end wrenches (such as the ratchet wrenches described above), in that when a plurality of hoses, lines or pipes are clustered together or are close to accessories of the equipment being worked on it is very difficult to find enough room to manipulate the tool in such a way as to engage and operate the tool. In addition, many such tools are unduly complex and/or are configured in such a way that they can slip off the fastener and cause damage to the fastener, the tool and/or the user.
Of those tools described above utilizing geared peripheries, some have utilized a single divided collet as a holder for nut rotating accessories thus practically negating use for flare nuts on continuous lengths of conduit (i.e., such tools, while providing a collet that can be split and opened to grip accessories, have not provided accessories that can be split and opened to encircle the length of conduit), and have not provided for their use with an assortment of interchangeable sockets for different applications. Often, complex closing and locking procedures are required which limit the applications and/or complicate usage of such tools.
SUMMARY OF THE INVENTION
This invention provides an improved peripherally driven socket and drive assembly for manipulating a work piece such as a fastener, the invention being compact and particularly useful for fasteners associated with continuous lengths of conduit. The socket can be opened and closed, for example around a conduit, positioned on the fastener and then rotated by a drive assembly, the socket preferably being closable without direct user intervention and self locking once positioned on the fastener.
The socket includes first and second parts having inner edges configured to abut the work piece, the parts being pivotably connected adjacent to first ends thereof and having projecting and receiving portions at the other ends thereof which are engageable in the closed position. The connection of the parts is preferably located so that portions of the inner edges, when abutting the work piece, overlap sufficiently to substantially preclude relative pivotal movement of the parts, and is preferably configured so that one of the first ends defines a lever portion for causing relative pivotal movement of the parts when acted upon, for example when brought to bear against a length of conduit thus moving one of the parts to the closed position.
The drive assembly is configured to accommodate reception of a socket without disassembly of the drive assembly and securement and proper positioning of the socket for rotation thereof, and includes a housing, a driving gear mounted in the housing, and means for positioning the socket mounted at the housing. The means for positioning the socket is preferably retractably mounted with the housing on a guide and is biased for urging movement in one direction on the guide.
It is therefore an object of this invention to provide an improved peripherally driven socket and drive assembly.
It is another object of this invention to provide a socket and drive assembly for manipulation of fasteners that encircle elements of continuous conduit and that require no necessity for travel of the drive assembly in order to rotate the fastener.
It is still another object of this invention to provide a socket which can be opened and closed with portions being engageable in the closed position.
It is yet another object of this invention to provide a peripherally driven socket that can be quickly opened, positioned around an element of conduit, closed therearound without direct user intervention, and positioned and consequently secured around a fastener for rotation thereof.
It is another object of this invention to provide a drive assembly for a peripherally driven socket which is configured to receive, secure and properly position the socket for rotation thereof, all without disassembly of the drive assembly.
It is still another object of this invention to provide a socket engageable with a drive assembly for manipulating a work piece, the socket including a first part having an inner edge configured to abut the work piece and first and second ends, the first end having a projecting portion formed thereat, a second part having an inner edge configured to abut the work piece and first and second ends, the first end having a receiving portion formed thereat, and a pivot connecting the first and second parts at a location adjacent to the second ends for accommodating relative movement of the parts between an open position and a closed position with the projecting portion of the first end of the first part engaged by the receiving portion of the first end of the second part.
It is yet another object of this invention to provide a socket engageable with a drive assembly for manipulating a work piece, the socket including a first part having an inner edge at least a first portion at one end and a second portion of which are configured to abut the work piece, and a second part having an inner edge at least a first portion at one end of which is configured to abut the work piece, the first and second parts being pivotably connected at a location adjacent to the ends so that the first portions of the edges, when abutting the work piece to be manipulated, overlap sufficiently to substantially precluded relative pivotal movement of the parts.
It is another object of this invention to provide a drive assembly for a socket engageable with the drive assembly having a housing, means for driving the socket mounted in the housing, and means for enabling reception at the housing of the socket without disassembly of the drive assembly and securing and properly positioning the socket at the housing for rotation thereof.
It is still another object of this invention to provide a drive assembly for a peripherally driven socket which is compact, and which includes a retractable means for receiving and positioning the socket.
With these and other objects in view, which will become apparent to one skilled in the art as the description proceeds, this invention resides in the novel construction, combination and arrangement of parts substantially as hereinafter described, and more particularly defined by the appended claims, it being understood that changes in the precise embodiment of the herein disclosed invention are meant to be included as come within the scope of the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate complete embodiments of the invention according to the best mode so far devised for the practical application of the principles thereof, and in which:
FIG. 1 is a top view of a socket of this invention encircling a fitting mounted on a conduit, with a first embodiment of the drive assembly engaged with the socket;
FIG. 2 is a side view of the drive assembly of FIG. 1 with a first embodiment of the socket engaged therein;
FIG. 3 is a side view of the socket in FIG. 2;
FIG. 4 is an exploded view of the drive assembly of FIGS. 1 and 2;
FIG. 5 is a partial exploded view of the socket of FIG. 2;
FIG. 6 is a side view of the socket of FIG. 2 in the unlocked and open position;
FIG. 7 is a side view of a second embodiment of the socket of this invention;
FIG. 8 is a perspective view of a second embodiment of the drive assembly of this invention;
FIG. 9 is a side view of a third embodiment of the socket of this invention;
FIG. 10 is a perspective view of a fourth embodiment of the socket of this invention;
FIG. 11A is a perspective view of the socket of FIG. 10 in the open position;
FIG. 11B is a side view of the socket as illustrated in FIG. 11A;
FIG. 12 is an exploded view of the socket of FIG. 10;
FIG. 13 is a perspective view of a third embodiment of the drive assembly of this invention;
FIG. 14A is an exploded view of the drive assembly of FIG. 13 with the socket of FIG. 10; and
FIG. 14B is a perspective view of the positioning member of the drive assembly of FIG. 13.
DESCRIPTION OF THE INVENTION
This invention includes a wrench unit, or drive assembly, and a peripherally driven composite socket. A first embodiment 16 of the drive assembly of the present invention is illustrated in FIGS. 1, 2 and 4 and comprises casing, or housing, 23 made in two halves 24A and 24B and secured together by any suitable means such as screws 46. If screws are used, casing half 24A is threaded, but otherwise the two halves are identical, each half having an outwardly projecting rectangular member 60 provided with a semicircular bore 62 and forming slot 48 when assembled.
At each side of slot 48 threaded holes 64 are provided in casing halves 24A and 24B for receipt of threaded boss projections 17. The boss projections may be provided with spring pressed balls (not shown) or the like, and cooperate with circumferential undercut guide channel 63 of composite socket 15 so that sockets are receivable and interchangeable without disassembly of the drive assembly, and are rotatable, guided, and held securely in alignment during use.
Slot 48 is in communication with rectangular chamber 16 in which worm gear 18 is rotatably mounted for engagement of worm toothed annulus 40 of the interchangeable socket 15 when in the operative position as illustrated in FIG. 2. Inner channels 20A and 20B of handle body halves 66 and 66 of casing halves 24A and 24B, respectively (shown in FIG. 4), receive shaft 22, one end of which has worm gear 18 thereat, while the other end of shaft 22 is adapted for connection to a driving gear and projects beyond the end of handle 50. As illustrated, the shaft is cylindrical to provide a secure coupling for a wrench, electric drill, or robotic arm, the actual source of rotation being any appropriate mechanical or electrical driving mechanism.
In a second embodiment 68 of the wrench, or drive assembly, of this invention illustrated in FIG. 8, head 70 of the wrench is transversely mounted to handle 50 and utilizes a socket with a spur geared periphery in driving mesh with a spur toothed drive gear attached to shaft 22.
A first embodiment 15 of the peripherally driven composite socket of the present invention is illustrated in FIGS. 3, 5 and 6. Two segments, or parts, 26A and 26B are shaped either with male arcuate projections 28 or female arcuate receivers 30. The male projections are formed with an arcuate convex projecting head with two arcuate concave supporting shoulders 29 at the base of the projecting head throughout one half of the thickness of segment 26A on each of its ends 71 and 72. Each female receiver of segment 26B is machined with an arcuate concave slot at each segment end 74 and 76 with a plurality of arcuate convex supporting shoulders 31 throughout one half of the segments thickness, thus providing entrapments for male projections 28 while enabling mounting of pivot 34.
End 76 at receiver 30 and projection 28 at end 72 are drilled and have pivot 34 installed for alignment of arcuate segments 26A and 26B. By forming the male projections and the female receivers in this fashion, the projections and receivers entrap and interlock with each other (at 36 in FIG. 3) to form the peripherally drivable socket. Bore 38 of the socket is provided (herein with a hexagonal shape, though any needed geometry may be provided) for the engagement and rotation of a work piece, such as a fastener. Outer spur or worm geared annulus 40 is maintained in complementary relation by the interlocking of the projections and receivers of segments 26A and 26B, respectively.
In FIG. 7, a second embodiment 78 of the peripherally driven composite socket includes two substantially "C" shaped parts, or segments, 80A and 80B each being formed with either a worm or spur geared annulus, or outer edge, 40. Segment 80A is bifurcated on each of its ends 82 and 84 to form two parallel spaced apart legs 52 (only one of which is shown) on each segment end forming two receiving slots 53. Projecting arcuate tongue member 56 at end 86 of segment 80B is engaged by slot 53 of end 82 of segment 80A when socket 78 is in the closed and locked position. Slot 53 of end 84 of segment 80A fits over arcuate radius 88 of projecting tongue 89 at end 90 of segment 80B near hinge 34 so that the socket can open and close freely.
The two arcuate "C" shaped segments are hinged in such a way that lower abutting portion 58 of segment 80A projects into the bore of the socket when the socket is in the open position forming a lever, pressure upon which by an element of conduit closes the socket. The socket (and drive assembly) is then moved axially along the conduit to encircling relation with the threaded fastener to be manipulated. When the socket encircles the fastener, the facets of the fastener lock the socket into the closed position and maintain the socket segments in mutual complementary relationship by trapping lever portion 58 (and overlapping portions 89 and 52 the inner edges of which abut the fastener) and maintaining it in flush relationship with the hexagonal bore defined by segments 80A and 80B in the closed position. This inhibits relative pivoting of the segments and totally negates the necessity for any form of external locking device for socket 78.
FIG. 9 shows a third embodiment 92 of the socket of this invention with a simpler means of joining the end segments thereof wherein the male and female members only overlap and do not interlock with each other and are held in mutual complementary position by holes drilled through the end members secured together with nuts and bolts which are flush mounted for clearing slot 48 of the wrench head during operation.
In using the above embodiments of the peripherally driven composite socket and drive assembly, first the peripherally driven composite socket with the correct geometry and size for the nut to be rotated is selected from a set covering an appropriate range of sizes. This socket is then inserted into slot 48 of housing 23 of the drive assembly. Boss projections 17 are engaged by rotating the threaded projection into position with a part thereof in guide channel 63 of the socket until they make contact with the bottom of channel 63 without binding against it. In the above disclosed embodiments there are three boss members that project through housing 23 at each side of slot 48 (for a total of six boss members). Once channel 63 is engaged, axle 22 projecting from the base of handle 50 is either manually or mechanically rotated until socket bisection line 44 (shown in FIG. 3 and generally defining the opening interface of the socket segments) is parallel to and above slot 48.
In the case of socket 15, in this position one half of the socket can be unlocked by moving the upper segment of the socket at right angles to the slotted head of the wrench (when the socket is in place in the slotted head as shown in FIGS. 1 and 2) so that segments 26A and 26B are no longer in planar engagement. By thus moving segment 26A, the upper socket half and its projections 28 are cleared from and thus escape their respective receivers 30 and the socket segment can be swung open on pivot 34. With the socket in the open position, the wrench is positioned axially to the section of conduit that has the flare nut to be manipulated and is maneuvered into position so as to allow the upper socket segment to be closed around the element of conduit and locked. Closing the socket is accomplished by rotating the upper socket segment downward until the male projections and female receivers are in complementary alignment and then pressing the two segments together until the segment ends are completely interlocked.
With the socket in locked position, the socket is moved axially with the element of conduit until the socket is maneuvered into position encircling the fastener with the fastener passing through center bore 38. Power is then applied to axle 22 in either a clockwise or counter clockwise direction which rotates the socket and fastener combination in the desired direction. The source of power can be manual, but an electric drill or robotic equipment is preferably utilized.
Once a fitting has been rotated free of its threads, the tool can be moved off the end without any requirement for again unlocking the socket. Of course, when installing or removing fasteners where there is no obstruction, no unlocking of the socket in order to place the socket on the fastener is required.
Worm gear drive assemblies of this nature develop significant mechanical advantages. Hence, a cylindrical shaft is utilized so that in the event a nut will not turn for any reason, the axle will spin in the jaw of the drill rather than cause damage to the fastener or its fixture by applying excessive torque.
The manner of using embodiment 78 of the peripherally driven composite socket is generally the same as described above, except that when the socket is opened on its pivot 34, segment end 84 of segment 80A projects into the bore of the socket defining lever portion 58. Then the socket and drive assembly combination are positioned axially with the element of conduit. When lever portion 58 of socket segment 80A makes contact with the element of conduit, segment 80A will close and slot 53 of end 82 of segment 80A will engage projecting tongue member 56. Once the socket is closed, the socket and wrench combination is moved axially along the element of conduit until the socket encircles the fastener.
With the socket in the encircled position around the fastener, the facets of the fastener maintain pressure on lever portion 58 (and overlapping portions 88 and 52) holding the segments in the locked position. Opening the socket is accomplished by moving the wrench and socket combination axially along the element of conduit until the fastener is no longer within the center bore of the socket. This removes the force on the lever portion and overlapping portions of the segments and allows the socket to swing open when pulled against the element of conduit.
Turning now to FIGS. 10 through 12, a fourth embodiment 95 of the socket is illustrated having first socket part 97 and second socket part 99 pivotably connected adjacent to ends 101 and 103, respectively, thereof by pivot pin 105. Parts 95 and 97, when in the closed position as illustrated in FIG. 10, together define bore 107 at inner edges 109 and 111 of parts 97 and 99, respectively, of a shape selected for use with the type of fastener to be manipulated, with part 97 alone preferably having sufficient arc at inner edge 109 to engage the work piece for manipulation thereof (in this case including all or potions of 5 facets of a hexagonal bore 107). Outer geared edge 113 is defined by the parts in the closed position and is configured for engagement with a drive assembly as discussed herein above or herein below (for example, a worm gear toothed configuration).
Guide channel 115 is formed in one or both of socket faces 117 of socket 95 by channel portions 119 and 121 in each of the parts for receipt therein of a guide member of the drive mechanism (such as the boss projections described herein above or an arcuate ridge as will be described herein below).
Projecting tongue portions 123 and 125 having a portion of inner edge 109 thereat are defined at part 97 adjacent to ends 101 and 127, respectively. Receiving portions 129 and 131, configured as spaced apart legs, are defined at ends 103 and 133, respectively, of part 99, with each leg of each receiver also forming a part of inner edge 111. As may be appreciated, when portions 123 and 129 are engaged and secured by pivot pin 105, the portions both abut the work piece at their overlap (as shown in FIG. 10), this arrangement, together with the location of pivot pin 105, being sufficient to substantially preclude relative pivotal movement of parts 97 and 99.
Portions 125 and 131, as before, are engaged when the socket is closed, with portion 125 being locked into position when edge 109 thereat is abutting the work piece thus avoiding spreading stresses which may in some cases be exhibited during use of the socket. Edge portions 135 and/or 137 again provide a self-closing lever. Matable arcuate edges 138 and 139 are provided to accomodate pivoting motion of the parts.
FIGS. 13 and 14 illustrate a now preferred embodiment of the drive assembly. Assembly 140 having socket 95 therein is connected with power driver 142 by flexible shaft 144. The drive assembly includes housing 146 having worm drive gear 148 mounted therein on shaft 150 with roll pin 152. Retractable positioning member 154 is slidably mounted on guide pins 156 connected with housing 146 and is biased outwardly therefrom by springs 158.
Slidable retainer 160 is mounted in dovetailed slot 162, dovetail 164 forming ledge 166 at the top thereof which is slightly lower than top edge 168 of the retainer. Retainer 160 is biased upwardly by spring 170 mounted between detent 172 and dovetail 164. Guide hole 174 and set screw 176 threaded into the housing limit travel of the retainer.
When retainer 160 is in the up position, with dovetail 164 abutting face 178 of positioning member 154, the positioning member is held adjacent to housing 146 with arcuate ridge 180 engaged in guide channel 115 of socket 95, thus securing and properly positioning the socket for engagement with, and thus rotation by, drive gear 148 (A similar guide ridge could be formed at back wall 182 of housing 146). When it is desired to change sockets, retainer 160 is manually moved downward, downward travel being limited to a position with ledge 166 level with top surface 184 of housing 164, so that positioning member 154 can retract under the influence of springs 158 to a position abutting the top of retainer 160 above dovetail 164. The socket may then be removed and replaced, member 154 being thereafter manually moved back into position abutting housing 146 and retainer 160 being urged back into securing contact with member 154 by spring 170.
Gear 148 and shaft 150 are held in place in housing 146 by threaded bushing 186 and end shaft bearing 188 both of which are secured to housing 146. Shaft 150 may be provided with configurations at its projecting end 190 suitable for attachment to appropriate driving tools (either manual or powered). A shaft driver connection could be provided at either or both ends of the shaft with appropriate reconfiguration of housing 146 and supporting bearings.
As may be appreciated, this invention can be utilized to quickly and easily remove threaded fasteners, and is particularly useful where these fasteners encircle elements of continuous conduit. The socket and drive assembly are easily manufactured through castings and other low cost manufacturing methods, allowing economical production of the tool.
While the description provides specific examples of the invention, modifications are of course possible. For example the projections and receivers of the composite socket could be a number of different shapes such as oval, trapezoidal, triangular or square, and arranged in any combination thereof. Additionally, the socket segment ends could be formed with many different types of interlocking projections and receivers, such as ball and detent or various latching arrangements. It should also be apparent that in some applications, the segments of the composite socket could be bolted or screwed together to prevent accidental opening of the socket from the locked position.
Further the boss projections of FIGS. 1, 2, 4 and 8 could be spring biased or cast into the slot of the wrench as a set of projecting radius or a combination of both. Also, the portion of axle portion 22 that extends beyond handle 50 could terminate in a fitting for engagement by a number of different hand tools such as conventional socket wrenches or pliers, or for engagement and utilization by robotic appendages. The axle could be any polygonal shape as well as cylindrical. The socket and drive assembly can be made of any suitably strong material, for example aluminum, steel, bronze or any number of strong rigid plastics or chemically produced stocks.
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A socket engageable with a drive assembly is disclosed, the socket having two segments pivotably connected with each having an engageable periphery for rotation of the socket by the drive assembly and together defining a center bore for engaging a work piece, the segments being self locking when the work piece is engaged. The drive assembly has a selectively accessible slot for receiving and holding the socket in the operative position, a mating drive gear for the rotation of the socket and a guide for assuring lateral and rotational stability of the socket.
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GOVERNMENT INTEREST
The invention described herein may be manufactured, used, and licensed by or for the Government for governmental purposes without payment to me of any royalty thereon.
SUMMARY OF INVENTION
In one aspect of this invention relates to conventional military weaponry. In a further aspect this invention relates to the bayonet and related equipment normally carried by soldiers for use in close combat situations.
The bayonet is a dagger-like weapon attachable to the muzzel of a firearm for use in close-in fighting has a long history and has been a standard item of gear for foot soldiers for more than a century. The bayonet comprises essentially a knife which can be carried in a scabbard by the infantryman and attached to small arms, such as rifles when needed for close-in combat.
The length and blade configurations employed have varied over time and with the country's Army. Examples include knifes which resemble small swords and three bladed needle type structures.
Most of the prior art bayonet assemblies and structures have only a limited number of uses in that they function primarily as knife or bayonet and are not adaptable to cope with many of the situations which present themselves to todays foot soldier. Therefore, certain obstacles common to battlefield conditions are not ameable to solutions using the conventional bayonet structures. Since the transportation and distribution of a number of specialized tools is impractical in combat situations, it would be desirable to equip the soldiers with a bayonet system which can perform many of the most common functions necessary to overcome the obstacles encountered by the normal foot soldier in standard battle conditions.
In addition to performing as a bayonet and a knife, the bayonet system should function as an insulated wire cutter suitable for cutting or severing standard type barbed-wire which may be electrified with a high voltage electrical current. The knife portion of the system can also be separated to allow sawing of small items and opening of crates and the like. One present construction has a bayonet with a slotted opening in the blade which mates with a part on the scabbard to form a wire cutter. This construction requires assembly which would be time consuming under normal conditions and would be extremely difficult in the darkness and stress of a battlefield. Also, because of the construction the wire cutters have the handles widely spaced when assembled so that it requires two hands to operate. Two handed operation implies that a soldier must have a substantial portion of his body off the ground and exposed to hostile fire when trying to cut a wire suspended in the air. It would be preferable for the wire cutters to be operable with only one hand to minimize the amount of the soldiers body which must be exposed. Also having a pre-assembled system saves time and avoids the possibility of an improper assembly.
A multi-purpose bayonet system meeting the essential characteristics described above is found in the present invention. The system includes a combat knife having a handle adapted to be griped by a human hand. Complimentary means will be attached to the barrel of the gun or other small arm suitable for attaching the handle portion of the knife to the barrel with the knife extending outward from the barrel. A combat knife according to this invention comprises a blade extending outward from the handle, the knife blade being adapted for cutting and piercing. The blade can be of various shapes and lengths with one or both sides sharpened. A hilt disposed between the handle and the blade prevents the users hand from slipping off the handle when the knife is used.
A scabbard is provided with the system having a first scabbard member formed as a hollow elongated body with a cavity opening at the one end of the scabbard member. The cavity is adapted to receive and enclose the knife blade portion of the combat knife securely and safely within the cavity and allow the rapid removal of the knife blade for use. A fixed metal cutting jaw is rigidly attached to the end of the scabbard opposite of the opening of the cavity and extends longitudely outward from the end of the scabbard. The fixed metal cutting jaw is formed with a cutting edge extending longitudely along the center line of the scabbard and pivot pin mounted on one side of the fixed jaw extending transversely from the face of the fixed jaw. A movable jaw having a second cutting edge complimentary to the cutting edge of the first fixed jaw is positioned so that it can be rotated from an open position into a closed cutting position, where the cutting jaws are engaged.
An intermediate portion of the movable jaw is offset to one side of the fixed jaw and extends diagonally across the fixed jaw. The intermediate portion is located on the same side of the fixed jaw as the pivot pin and is journaled on the pivot pin allowing rotation of the movable jaw between the open and close positions.
A handle extends from the intermediate portion of the movable jaw opposite the second cutting edge coaxially along one edge of the scabbard with a free end located near the open end of the scabbard. A clamping means is provided to hold the handle close to the scabbard's edge when the jaws are closed for storage and carrying.
An attachment means is fastened to the scabbard for consistency for attaching the scabbard to a soldier's belt, pack or other equipment allowing the multi-purpose bayonet system to be quickly and easily transported.
BRIEF DESCRIPTION OF THE INVENTION
A further understanding maybe had by referring to the accompanying drawing in which:
FIG. 1 is a side view of a bayonet system in accordance with this invention with the combat knife located in the scabbard;
FIG. 2 is a sectional view taken of the cutting jaws of FIG. 1 along the line 2--2;
FIG. 3 is a bottom view of the scabbard of FIG. 1 with a combat knife removed;
FIG. 4 is a side view of FIG. 1 with the combat knife removed and the cutting jaws in an open position.
FIG. 5 is a side view of a fabric carrying device for use with the scabbard; and
FIG. 6 is a bottom view of the carrying device of FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning to the drawing where in like numerals refer to like parts and initially to FIG. 1, a bayonet system according to this invention is shown with a combat knife designated generally 12 mounted within a scabbard 14. Hilt 16 of the combat knife 12 is firmly abutting the open end of the scabbard. The exact structure of the combat knife 12 is not critical in the present invention. The knife will generally comprise a handle 18 suitable for being gripped by the normal sized infantry soldier in one hand for use as a knife for cutting, piercing, or hand-to-hand combat and has the hilt 16 disposed between the handle and the blade 20 to prevent the soldier's hand from slipping off the handle unto the blade when the knife is in use. Blade 20 as shown is shaped essentially as a pointed short sword type structure of symmetrical design. The blade 20 could take many shapes other than that shown, including a modified spear design with a clipped false edge.
The blade length can be chosen to conform to good infantry practice a blade on the order of 7-8 inches in length and designed to extend a substantial percentage of its total length past the muzzel of a rifle when mounted being most common. One variation might include a serrated edge near the rear portion of one side of the blade to allow its use as a saw for cutting thick ropes, small trees and light metal.
The scabbard 14 provides the second part of the bayonet combination which is shown in FIG. 1. The scabbard 14 has a main body portion 22 which is formed as a hollow chamber adapted to form a scabbard for a knife blade with a flange 24 located at the end of the scabbard for consistency having an opening suitable for receiving the knife blade. The scabbard 14 is formed as a single piece with a thick solid portion 26 located at the end of the body portion 20 opposite the opening. The scabbard 14 has an attachment means or associated carrying structure discussed hereinafter with respect to FIGS. 5 and 6. The attachment means will be suitable for use with the standard GI belt and in conformance with service specifications for items to be carried. The attachment means allows the scabbard to be attached to the utility belt commonly worn by foot soldiers or attached to other parts of the GI gear to allow it to be carried without interference to the soldier's movement and in maintaining a knife firmly within the scabbard.
In general the scabbard 14 will be formed of impact resistant, non-electrically conductive materials. One example is the plastic material available under the trade name "Cardith" which is a good insulator and impact resistant. Other materials would include fiber-filled or reinforced resins such as urethanes, polycarbonates, or nylons.
The scabbard 14 has a fixed metal cutting jaw designated generally as 30 attached to the end of the scabbard opposite the opening. The metal cutting jaw 30 has a thick body portion which is normally the same shape and width as the remainder of the scabbard and is attached to the scabbard by means of a plurality of rivits 34 which mount the fixed jaw permanently to the scabbard. As shown a reinforcement portion 36 is also attached to the scabbard to provide additional rigidity to the scabbard and the cutting mechanism. The fixed metal cutting jaw 30 has a cutting surface 38 which is formed so as to extend along the center longitudinal axis of the scabbard 14. The cutting edge cross section is shown in greater detail in FIG. 2 and can be any normal shaped wire or metal cutting type configuration. As shown the jaws are rounded on one side to a blunt cutting edge located near one face of the jaws.
The fixed jaw 30 has a pivot pin 40 rigidly mounted near the longitudinal axis of the jaw and body which extends outwardly from the face of the fixed jaw. The pivot pin 40 extends outward and is suitable for being attached to a second member to form a cutting unit. The fixed jaw 30 is designed to mate with a rotatable jaw 42 shown in a closed position in FIG. 1 and in open position in FIG. 4 to allow cutting of wire and small metal sections. As shown the jaws 30, 42 can be formed with a small semi-circular aperature 43 so that they form a wire-stripping aperature when in the closed position. The particular wire cutting configuration is not a part of this invention and a further description is omitted in the interest of brevity.
The rotatable jaw 42 is formed with a cutting edge 44 shown in cross section in FIG. 2 which when closed will sever wire or light metal. The rotatable jaw 42 can be rotated between a open and closed position by means of a handle 46 which extends coaxially with the longitudinal axis of the scabbard 14 with the end of the handle located near the end of the scabbard. The handle 46 extends the length of the scabbard and provides additional leverage to provide the force necessary to sever wire or light metal cleanly and easily without the need to impose substantial pressure on the handle. As shown, the handle is located relatively close to the scabbard and can be operated with one hand by the normal GI in that the wire cutters can be operated with one hand and an object being cut can be held with the other hand provided there is no danger of electrocution. One handed operation is of benefit as discussed before in that it allows the soldier to use the wire cutter with minimum exposure of his body. Also, one handed operation allows the soldier to cut bands or wire with one hand while holding his weapon in a ready position.
The rotatable jaw 42 and handle 46 are connected by an intermediate portion 48 which extends diagonally across the scabbard 14 from the attachment end 50 of the handle to the rotatable jaw 42. The intermediate portion 48 is journeled on pin 40 to allow free rotation of the rotatable jaw 44 when the free end 52 of the handle is moved towards or away from the metal scabbard.
The free end 56 of the handle has a clamping means 58 associated therewith to hold the handle close to the scabbard when the cutters are not in use. In its simplest embodiment, the clamping means 58 would be an elastomeric band molded into or affixed to the scabbard and looped about the handle 46. A rubber coated spring clamp of spring metal could also be used with the tension of the metal spring used to hold the handle in position.
FIGS. 5 and 6 show a carrying board 60 for use with the scabbard 14 comprising a generally planer portion 62 formed of an impact resistant material or cloth. The carrying board 60 has a holder 64 formed on one end which receives the metal cutting jaws 30, 42 of the scabbard 14 to protect and hold the jaws. A spring 66 is fastened within the cavity of the holder 64 and is held in position by a rivit 68. As shown, the carrying board has a pair of straps 70 located on the end of the board to opposite the holder 64 which can be fastened around the scabbard 14 to hold it in position. The ends of straps 70 can be fastened by snaps, buckles, "Velcro" and the like.
The attachment clips 72 is fastened to the surface of the board 60 opposite the holder 64 the clips are adapted to be attached to the web belt normally worn by soldiers. The exact construction of the attachment means is not critical provided it will firmly attach the board and scabbard to the soldier's belt.
I wish it to be understood that I do not desire to be limited to the exact details of construction shown and described for obvious modifications will occur to a person skilled in the art, without departing from the spirit and scope of the appended claims.
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A multi purpose bayonet including a combat knife and scabbard is disclosed. The system can be used to sever wire and the like using one hand.
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This is a continuation, of application Ser. No. 470,191, filed Feb. 28, 1983, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates generally to the manufacture of candles and more particularly to a method of imparting color and/or fragrance to candle wax.
Owing perhaps to its ancient heritage or to the relative ease with which raw materials may be obtained, commercial candlemaking remains profitable, at least for some, even when conducted on a small, local scale. Machinery and mass production have not replaced manual techniques completely, especially where variously scented and colored candles are made from a single batch of candle wax.
In the past, candle wax was scented or colored by mixing the selected ingredients with wax in its unformed, molten state or by dripping formed and hardened candles in a solution of dye, pigment and/or perfume. The relative superiority, or inferiority, of these methods depended upon the ingredients to be added. Substantially more dye or pigment, for instance, had to be added to molten wax to obtain the same color provided by surface coating. On the other hand, it was preferable to add a perfuming agent to molten wax rather than to the surface of a preformed and hardened candle because surface evaporation would eventually eliminate the scent of a surface coated candle.
The present method combines some of the aesthetic properties achieved by mixing coloring or scenting agents with molten wax and some of the economy achieved by adding these ingredients to hardened, molded candles. This combination is accomplished by mixing the coloring and/or scenting agents with relatively small, uniform pieces of hardened wax. The treated pieces of wax may then be compression molded or otherwise formed into free-standing or container-filling candles. Unlike the molten wax mixture, only the particles' surfaces and in some cases, inner portions immediately adjacent thereto are able to absorb the coloring and scenting materials. And, unlike dipping shaped and hardened candles in the desired ingredients, the present invention provides treated wax that may be formed into a candle whose perfume or tint are more uniform throughout the candle. Thus the appearance and odor of candles made with wax that is treated according to the present invention are enhanced over those of a dipped candle without requiring the amounts of coloring and fragrance found in candles whose ingredients were added in the molten stage.
SUMMARY AND OBJECTS OF THE INVENTION
The present invention involves a method of imparting to candle wax a coloring and/or a scenting agent suitable for candles. The method comprises, basically, the steps of: (a) combining the selected agent or agents with a plurality of generally rounded particles of candle wax; and (b) coating these particles with the selected agent(s) by agitating the particles and agent(s) together.
The present invention also includes a method of making a scented and/or a colored candle which consists of: (1) forming a plurality of separate particles of candle wax; (2) combining the coloring and/or scenting agents with these particles; (3) coating the particles with the selected agent or agents by agitating the particles and agent(s) together; and (4) disposing the coated and dried particles in surrounding relation to a candle wick.
Finally, the present invention covers a candle that comprises a candle wick and candle wax disposed in surrounding relation to the wick and formed from a plurality of particles of candle wax, each of the particles of candle wax having a greater exterior concentration than interior concentration of a coloring and/or a scenting agent.
A primary object of the present invention is to provide a method of making colored and/or scented candle wax and candles that employs relatively small quantities of coloring and/or scenting agents without limiting unduly the color and/or scent of the product.
Another object of the present invention is to provide a method of making colored and/or scented candle wax and candles that is adaptable to large and small production runs.
A further object of the present invention is to provide a method that permits the number, quantity, and concentration of coloring and/or scenting agents added to candle wax to vary over a wide range.
Yet another object of the present invention is to provide a candle formed from a plurality of wax particles, each of which has a greater exterior than interior concentration of a coloring and/or scenting agent.
These as well as other objects and advantages may be appreciated in light of the description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of a manner in which wax particles suitable for use in the present method may be formed;
FIG. 2 is an enlarged perspective view of the prilled wax granules preferably employed in the present invention;
FIG. 3 is a diagram of a manner in which coloring and scenting agents may be combined with the wax particles;
FIG. 4 is a perspective view of a manner in which the wax particles may be coated with coloring and/or scenting agents;
FIG. 5 is a diagram of a manner in which the wax particles, once coated, may be formed into a candle;
FIG. 6 is an enlarged perspective view of the coated wax particles; and
FIG. 7 is a perspective view of a candle formed according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As indicated in FIGS. 2, 3 and 4, the present method basically comprises the steps of combining either a coloring agent 10, a scenting agent 11, or both with numerous, substantially solid particles of candle wax 12 and coating these wax particles 12 with the coloring and/or scenting agents 10 and 11 by agitating the particles and the agent together. The candlewax employed in this process may be practically any known type of fuel wax, with refined or semirefined paraffins, well known in the art of candlemaking, being the waxes of choice. The particles of wax so composed may exist in a variety of forms, ranging in size from powdered or ground wax particles approximately one-tenth of a millimeter in length or diameter to chips or other pieces of wax approximately two centimeters in length or diameter. Preferably, however, the wax particles 12 are generally spherical, prilled granules having an average mean diameter no greater than one (1) millimeter.
The prilled wax particles 12 may be formed conventionally as indicated in FIG. 1, by first melting a solid piece of paraffin 13 in a vat or similar vessel 14 and then spraying the molten wax 15 through a nozzle 16 into a cooling chamber 17. The finely dispersed liquid solidifies as it falls through the relatively cooler air in the chamber 17 and forms the prilled granules 12 that, to the naked eye, appear to be spheroids about the size of grains of sand. Once formed, the prilled wax 12 is deposited in a container 18 and combined with the coloring agent 10 and/or scenting agent 11, as diagrammed in FIG. 3.
While it is necessary to raise the temperature of the block of paraffin 13 above its melting point in order to form prilled wax granules 12, the steps of combining the particles of wax with a scenting and/or coloring agent and coating the particles with coloring and/or scenting agents, are conducted at a temperature that permits the particles to remain substantially solid. Thus, ambient temperatures may be employed advantageously throughout much of the present process.
A wide variety of coloring and scenting agents, well known in the art of candle making, are available for use with the prilled wax. As indicated diagrammatically in FIG. 3, one or more dyes 19 or pigments 20 provide the desired hue to the coloring agent 10, and one or more perfumes 21, fragrances 22, essences 23 or other aromatic oils provide the desired odor to the scenting agent 11. Preferably, the coloring and scenting agents also include liquid carriers 24 and 25, respectively, which vary, depending upon the type of color- or scent-imparting ingredient employed. The addition of liquid organic carriers 24 and 25 to the respective coloring and scenting agents 10 and 11 is preferred because such carriers are compatible with petroleum-based waxes and tend, therefore, to be more readily absorbed into the prilled wax granules 12.
A light grade of oil, such as paraffin or mineral oil, serves well as the carrier 24 for the coloring agent 10 when one or more pigments 20 are employed. The pigment 20 should be a finely ground, organic toner so that the wick 24 of a candle 25 (FIG. 8), formed eventually from pigment-covered wax particles, does not clog as the wax is burned. The preferred carriers 24 for use with dyes 19 are organic solvents, such as relatively low moleculor weight, aromatic hydrocarbon solvents; e.g. toluene and xylene. The dyes 19 ordinarily form true solutions with their carriers 24, whereas the pigments 20, even in finely ground toner forms, are in colloidal suspension with their carriers 24. Since dyes tend to ionize in solution, they are more readily absorbed into the prilled wax granules, whereas pigment-based coloring agents tend to remain closer to the surface of the wax.
Although candle perfumes 21, fragrances 22 and essences 23 are processed and supplied ordinarily in liquid form, an additional liquid organic carrier 25 is preferably added to make the scenting agent 11 more compatible with and hence, more easily absorbed into, the paraffin granules 12. Relatively thin plasticizers, such as diethyl phthalate, work well as carriers for relatively high viscosity essences 23, and relatively thick plasticizers, such as dipropylene glycol, work well as carriers for relatively low viscosity fragrances 22 and perfumes 21.
Once the coloring and scenting agents have been formulated, the desired quantities are combined with the prilled wax granules. When both coloring and scenting agents are employed, it is preferable to combine the agents together and then add the resulting mixture to the wax. It is also possible, however, to add the agents separately to the wax. Having added the agent or agents to the wax, the granules are coated by agitating the wax particles and the coloring and/or scenting agents together. The agitating step consists of tumbling and/or rubbing the particles and agent(s) together. Preferably, the agent or agents are distributed substantially uniformly among the particles of wax, although it is entirely possible, if desired, to have a more random pattern of distribution. The coating step may be accomplished by hand, as indicated in FIG. 4, or with the aid of mechanical tumblers and agitators when relatively large quantities of prilled wax are being colored and/or scented. The container 18 into which the particles and agent or agents are deposited is, preferably, a flexible plastic bag that can be sealed temporarily at its open end. Once excess air is removed, the bag 18 is sealed, and the operator squeezes or kneads the bag at various points to thoroughly rub or mechanical device the ingredients together.
The coloring and scenting agents 10 and 11 are preferably in liquid or semi-liquid form as a result of the use of the liquid carriers 24 and 25. As a result, the wax particles, once coated, tend to be slightly tacky and to clump together. As previously indicated, however, the use of organic carriers 24 and 25 enhance the absorbability of the respective coloring and scenting agents 10 and 11, thereby reducing the amount of liquid on the surfaces of the wax particles. In addition, excess surface liquid may be minimized by limiting the amount of carrier employed, as well as the quantities of coloring and/or scenting agents added to a given quantity of particles, so that said particles are not "swimming" in one or more of said agents. Preferably, the selected agent or agents do not permeate the granules, but are instead found in higher concentration on the exterior than on the interior of the particles. As indicated in FIG. 6, the coloring and scenting agents 10 and 11 inevitably migrate toward the center of the wax particles 26; nevertheless, it is undesirable to saturate the particles, as this adds little to the quality of the candle formed therefrom, requires larger quantities of coloring and/or scenting agent, and tends to leave the surfaces of the coated particles damp. If however, an excessive amount of dye-solvent coloring agent is added to the wax particles, the coated particles may be air-dried once the distribution step is completed. In this manner, an excessive quantity of solvent may be evaporated, leaving the coated granules 26 in a more free-flowing state. An excessive quantity of scenting agent should not be evaporated by air flow, however, as this process tends to remove too much of the fragrance.
Once the coated particles 26 have been prepared, a candle may be formed by disposing said particles 26 in a mold or container 28 in surrounding relation to a wick 24 (FIG. 5). Preferably variable amounts of pressure are applied to the particles. A free-standing candle 25 (FIG. 7) may be formed conventionally by applying relatively greater amounts of pressure and then removing the mold 28. Alternatively, the container 28 may be decoratively fashioned from metal, plastic or glass, and the particles 26 may be fixed in said container with relatively smaller amounts of pressure.
REPRESENTATIVE EXAMPLES
The following coloring and scenting agents are quantified in relative terms with respect to a constant quantity of wax particles. More or less of these ingredients may be combined with a given quantity of wax particles to vary the intensity of color and/or fragrance, as long as the relative quantities of the ingredients remain constant. The percentage figures provided with some of the specific scenting agents are by weight.
______________________________________ParticleCoatingNo. Coloring Agent Scenting Agent______________________________________ 1. 192 Parts Benzidine Banana CS-3984 Yellow LS 400 (toner) (2%) (Universal) 2. No Color Pineapple 2233 Coconut A-548 (3%) (Norotek) 3. 96 Parts Bontone Brown Chocolate FR-2136 LS 900 (organic toner) (3%) (Bell) 48 Parts Solvisperse Brown, 1141 (oil soluable dye) 4. 192 Parts Benzedine Patchouly A-545 Yellow, LS 400 (toner) (2%) 48 Parts Bontone Brown LS 900 (toner) 5. 96 Parts Cyan Blue Universal 511733 LS 600 (toner) (2%) 48 Parts Rose LS 501 (toner) 6. 48 Parts Cyan Blue A-550 LS 600 (toner) (supplier: Norotek) (2%) 7. 72 Parts Solvisperse A-515 Brown 1141 (oil (supplier: Norotek) soluble dye) 8 Parts Dianisidine Orange LS 700 (toner) 8. 144 Parts Solvisperse A-504 Green 1741 (oil (supplier: Norotek) soluble dye) 96 Parts Cyan Blue LS 600 (toner) 9. 24-Parts Carbon Black A-562 LS-100 (supplier: Norotek) 144 Parts Phthalocy- anine Green LS-800 (toner)10. 48 Parts Cyan Blue A-557 LS 600 (toner) (supplier: Norotek) 96 Parts Rose LS 501 3% (toner)11. 96 Parts Rose LS 501 #3286 (toner) (supplier: Norotek) 3%12. 96 Parts Dianisidine A-505 Orange LS-700 (toner) (supplier: Norotek) 3%13. 7 Parts Bontone Brown A-502 LS 900 (supplier: Norotek) 16 Parts Benzidine Yellow 2% LS-400 (toner)14. 96 Parts Phthalocyanine A-517 Green LS 800 (toner) (supplier: Norotek) 48 Parts Benzidine Yellow 21/2% LS 40015. 144 Parts Solvisperse A-503 Green 1741 (oil soluble (supplier: Norotek) dye) 3%16. 192 Part Solvisperse Red A-518 1641 (oil soluble dye) (supplier: Norotek) 96 Parts Benzidine Yellow 21/2% LS 40017. 96 Parts Rose LS 501 A-565 (toner) (supplier: Norotek) 24 Parts Carbon Black LS 10018. 192 Parts Rose LS 501 Cranberry (toner) Sfc-101 96 Parts Benzidine Yellow LS 400______________________________________
While a variety of embodiments and examples of the present invention have been described in some detail, it is intended that further refinements and formulas may be developed without departing from the spirit of the invention or the scope of the following claims.
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Prilled wax particles are coated by tumbling and rubbing the particles and a scenting and/or a coloring agent together in a flexible container, either by hand kneading or with a mechanical agitator. Liquid carriers compatible with the wax particles are included in the coloring and scenting agents to facilitate absorption of the agents into the particles. A candle is subsequently formed by molding the coated particles under pressure with a central wick into either a free standing form or pressed into a surrounding container.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a connecting device, more particularly to a plug with connecting device, one end thereof is connected to an AC power source through electrode sheets and the other end thereof is coupled with a power adapter through the connecting device so as to supply converted DC power to an electronic device.
[0003] 2. Description of Related Art
[0004] A conventional plug often only has two electrode sheets for being connected to a socket so AC power is gained through the socket. There is also a kind of plug whose electrode sheets are foldable, the electrode sheets are folded into the plug main body when not in use to prevent oxidation and danger caused by users' misuse, such as children.
[0005] As for the above mentioned plugs, before shipped out of factory, the plug has often been connected with a cable. And another end of the cable has a matching socket relative to the plug, for being connected to an electronic device, e.g. a computer, so AC power is able to be converted into DC power through a power supply device installed in the electronic device.
[0006] For a portable electronic device, e.g. a notebook computer or a digital camera, because of space limitation, a power adapter is often used to convert AC power to DC power for supplying to the portable electronic device. Thus the described combination of plug and socket is not able to be connected to the power adapter and additional cost is occurred due to purchase the power adapter.
SUMMARY OF THE INVENTION
[0007] One object of the present invention is to provide a plug with connecting device, one end thereof is connected to an AC power source through electrode sheets and the other end thereof is coupled with a power adapter through the connecting device, so converted DC power is obtained and is supplied to an electronic device.
[0008] Another object of the present invention is to provide a plug with connecting device, electrode sheets thereof are able to be folded in a bottom plastic housing of the plug and an electrical connection to AC power source is terminated.
[0009] For achieving the described objects, one solution provided by the present invention is to provide a plug with connecting device, includes: a top housing having a hollow main body, a connecting device is extended from one end of the hollow main body for being connected to a power adapter, and the connecting device has two ring-shaped slots; a retaining seat received in the hollow main body and has a first retaining slot; two copper contact rings, one end of each of the copper contact rings is in a gradually expanding shape and respectively installed in the ring-shaped slots of the connecting device, the other end thereof is extended with a contact sheet; an electrode sheet base having a pivotal shaft and one lateral side of the pivotal shaft is received in the first retaining slot and two ends of the pivotal shaft are respectively provided with a switch seat, the switch seat further has a seat hole, a positioning slot and a protruding block; two electrode sheets, respectively received in the seat holes, one end of each of the electrode sheets has a wire hole; a bottom plastic housing, engaged with the top housing, and has a bottom housing surface, the bottom housing surface has four sheet wings, a housing slot is defined by every two sheet wings and the bottom end of the housing slot is hollow, an end section thereof has a plane hole to allow the electrode sheets expose outside, a second retaining slot is provided between the two housing slots for fastening the other lateral side of the pivotal shaft; so when the two electrode sheets are longitudinally rotated, the two electrode sheets are able to be pivotally moved between the housing slots and positioned in the retaining seat; the other ends of the electrode sheets are in contact with the contact sheets, so an electrical conducting status is formed between the two ring-shaped slots and the two electrode sheets.
[0010] For achieving the described objects, another solution provided by the present invention is to provide a plug with connecting device, includes: a top housing having a hollow main body, a connecting device is extended from one end of the hollow main body for being connected to a power adapter, and the connecting device has two ring-shaped slots; a retaining seat received in the hollow main body and has a first retaining slot and a column slot; two copper contact rings, one end of each of the copper contact rings is in a gradually expanding shape and respectively installed in the ring-shaped slots of the connecting device, the other end thereof is extended with a contact sheet; an electrode column base having a pivotal shaft and one lateral side of the pivotal shaft is received in the first retaining slot and two ends of the pivotal shaft are respectively provided with a switch seat, the switch seat further has a seat hole; two electrode columns, respectively received in the seat holes, one end of each of the electrode columns has a sealing cover and the other end is provided with a contact section after passing through the hole seat and exposing outside the switch seat; and a bottom plastic housing, engaged with the top housing, and has a bottom housing surface, the bottom housing surface has four sheet wings, a housing slot is defined by every two sheet wings and the bottom end of the housing slot is hollow, an end section thereof has a plane hole to allow the electrode columns expose outside, a second retaining slot is provided between the two housing slots for fastening the other lateral side of the pivotal shaft; so when the two electrode columns are longitudinally rotated, the two electrode columns are able to be pivotally moved between the housing slots and positioned in the column slot; the electrode columns are in contact with the copper contact rings, so an electrical conducting status is formed between the two ring-shaped slots and the two electrode columns.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 a is an exploded view of the plug with connecting device of one preferred embodiment of the present invention;
[0012] FIG. 1 b is another exploded view of the plug with connecting device of one preferred embodiment of the present invention;
[0013] FIG. 2 a is a schematic view of one preferred embodiment of the present invention illustrating after the plug with connecting device is assembled the electrode sheets thereof extending outside the bottom plastic housing;
[0014] FIG. 2 b is a schematic view of one preferred embodiment of the present invention illustrating after the plug with connecting device is assembled the electrode sheets thereof folding into the bottom plastic housing;
[0015] FIG. 3 a is a schematic cross sectional view of the assembled plug with connecting device of one preferred embodiment of the present invention;
[0016] FIG. 3 b is another schematic cross sectional view of the assembled plug with connecting device of one preferred embodiment of the present invention;
[0017] FIG. 4 a is an exploded view of the plug with connecting device of another preferred embodiment of the present invention;
[0018] FIG. 4 b is another exploded view of the plug with connecting device of another preferred embodiment of the present invention;
[0019] FIG. 5 a is a schematic view of another preferred embodiment of the present invention illustrating after the plug with connecting device is assembled the electrode columns thereof extending outside the bottom plastic housing;
[0020] FIG. 5 b is a schematic view of another preferred embodiment of the present invention illustrating after the plug with connecting device is assembled the electrode columns thereof folding into the bottom plastic housing;
[0021] FIG. 6 a is a schematic cross sectional view of the assembled plug with connecting device of another preferred embodiment of the present invention;
[0022] FIG. 6 b is another schematic cross sectional view of the assembled plug with connecting device of another preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] Referring to FIG. 1 a to FIG. 3 b , wherein FIG. 1 a is an exploded view of the plug with connecting device of one preferred embodiment of the present invention; FIG. 1 b is another exploded view of the plug with connecting device of one preferred embodiment of the present invention; FIG. 2 a is a schematic view of one preferred embodiment of the present invention illustrating after the plug with connecting device is assembled the electrode sheets thereof extending outside the bottom plastic housing; FIG. 2 b is a schematic view of one preferred embodiment of the present invention illustrating after the plug with connecting device is assembled the electrode sheets thereof folding into the bottom plastic housing; FIG. 3 a is a schematic cross sectional view of the assembled plug with connecting device of one preferred embodiment of the present invention; FIG. 3 b is another schematic cross sectional view of the assembled plug with connecting device of one preferred embodiment of the present invention.
[0024] As shown in figures, the plug with connecting device provided by the present invention, able to be used in a portable electronic device, e.g. a notebook computer, includes: a top housing 10 , a retaining seat 20 , two copper contact rings 30 , 40 , an electrode sheet base 50 , two electrode sheets 60 , 70 , and a bottom plastic housing 80 .
[0025] The top housing 10 has a hollow main body 11 and a connecting device 12 is extended from one end of the hollow main body 11 for being connected to a power adapter (not shown), and the connecting device 12 has two ring-shaped slots 121 , 122 , the connecting device 12 is, e.g. but not limited to, a socket with a shape like the numeral 8 .
[0026] The retaining seat 20 is received in the hollow main body 11 and has a first retaining slot 21 with a semicircle shape; a bottom end of the retaining seat 20 is further provided with a retaining hole 22 and a top end thereof is provided with a buckling hook 23 .
[0027] One end of each of the copper contact rings 30 , 40 is in a gradually-expanding shape and is respectively received in the ring-shaped slots 121 , 122 of the connecting device 12 and the other end thereof is respectively extended with a contact sheet 31 , 41 , and one end section of each of the contact sheet 31 , 41 respectively has a sheet slot 32 , 42 .
[0028] The electrode sheet base 50 has a pivotal shaft 51 with a, e.g. but not limited to, round shape, one lateral side of the pivotal shaft 51 is received in the first retaining slot 21 , and two ends of the pivotal shaft 51 respectively has a switch seat 52 , the switch seat 52 further has a seat hole 521 , a positioning slot 522 and a protruding block 523 , wherein the seat holes 521 are served to respectively receive the electrode sheets 60 , 70 , the shape of the protruding block 523 is, e.g. but not limited to, an arc shape for being fastened on the retaining sheet 20 .
[0029] The two electrode sheets 60 , 70 are respectively received in the corresponding seat hole 521 , one end of each of the electrode sheets 60 , 70 has a sheet trench 61 , 71 , the other end thereof has a wire hole 62 , 72 ; the sheet trenches 61 , 71 are respectively received in the sheet slots 32 , 42 for being in contact with the ring-shaped slots 121 , 122 .
[0030] The bottom plastic housing 80 is able to be engaged with the top housing 10 , and has a bottom housing surface 81 , the bottom housing surface 81 has four sheet wings 82 , and a housing slot 83 is defined by every sheet wings 82 , the bottom end of the housing slot 83 is hollow and an end section of the housing slot 83 has a plane hole 84 with a width larger than the width of the housing slot 83 to receive the switch seat 52 and to allow the electrode sheets 60 , 70 expose outside, a second retaining slot 85 is provided between the two housing slots 83 , the shape thereof is, e.g. but not limited to, in a semicircle shape for fastening the other lateral side of the pivotal shaft 51 . The top housing 10 and the bottom plastic housing 80 are made of insulation materials, e.g. but not limited to plastic. The bottom plastic housing 80 further has a buckling slot 86 for being buckled with the buckling hook 23 so as to fasten the retaining seat 20 .
[0031] As shown in FIG. 2 a and FIG. 3 a , when assembled, the two copper contact rings 30 , 40 are respectively installed in the two ring-shaped slots 121 , 122 , so the contact sheets 31 , 41 expose outside the hollow main body 11 ; the pivotal shaft 51 of the electrode sheet base 50 is received in the first retaining slot 21 for positioning and fastening; then the two electrode sheets 60 , 70 are respectively installed in the corresponding seat hole 521 ; the other lateral side of the pivotal shaft 51 of the electrode sheet base 50 is received in the second retaining slot 85 and the buckling hook 23 is buckled with the buckling slot 86 for positioning and fastening, so the two electrode sheets 60 , 70 partially expose outside the housing slots 83 ; then the top housing 10 is engaged with the bottom plastic housing 80 , so the sheet trenches 61 , 71 are respectively received in the sheet slots 32 , 42 for being in contact with the ring-shaped slots 121 , 122 and the two electrode sheets 60 , 70 are outwardly pushed so the protruding block 523 is fastened on the retaining seat 20 for positioning; the plug with connecting device provided by the present invention is therefore obtained. After the assembly of the plug with connecting device provided by the present invention is assembled, the connecting device 12 is connected to a power adapter (not shown), an AC power source is therefore transferred to the power adapter through the copper contact rings 30 , 40 .
[0032] As shown in FIG. 2 b and FIG. 3 b , when folded, the two electrode sheets 60 , 70 are inwardly pushed into the bottom plastic housing 80 alongside the housing slot 83 and the plane hole 84 , and the sheet trenches 61 , 71 are released from the sheet slots 32 , 42 and the two electrode sheets 60 , 70 are aligned with the housing slots 83 to achieve a convenient storage purpose, thus the two electrode sheets 60 , 70 are not in contact with the ring-shaped slots 121 , 122 and a power supply terminating status is achieved.
[0033] Referring to FIG. 4 a to FIG. 6 b , wherein FIG. 4 a is an exploded view of the plug with connecting device of another preferred embodiment of the present invention; FIG. 4 b is another exploded view of the plug with connecting device of another preferred embodiment of the present invention; FIG. 5 a is a schematic view of another preferred embodiment of the present invention illustrating after the plug with connecting device is assembled the electrode columns thereof extending outside the bottom plastic housing; FIG. 5 b is a schematic view of another preferred embodiment of the present invention illustrating after the plug with connecting device is assembled the electrode columns thereof folding into the bottom plastic housing; FIG. 6 a is a schematic cross sectional view of the assembled plug with connecting device of another preferred embodiment of the present invention; FIG. 6 b is another schematic cross sectional view of the assembled plug with connecting device of another preferred embodiment of the present invention.
[0034] As shown in figures, the plug with connecting device of another preferred embodiment of the present invention, includes: a top housing 210 , a retaining seat 220 , two copper contact rings 230 , 240 , an electrode column base 250 , two electrode columns 260 , 270 and a bottom plastic housing 280 .
[0035] The top housing 210 has a hollow main body 211 and a connecting device 212 is extended from one end of the hollow main body 211 for being connected to a power adapter (not shown), and the connecting device 212 has two ring-shaped slots 2121 , 2122 , the connecting device 212 is, e.g. but not limited to, a socket with a shape like the numeral 8 .
[0036] The retaining seat 220 is received in the hollow main body 211 and has a first retaining slot 221 and a column slot 222 , wherein the first retaining slot 221 is in a semicircle shape and the column slot 222 is disposed at two ends of the first retaining slot 221 , the quantity of the column slot is e.g. two but not serve as a limitation; a bottom end of the retaining seat 220 is further provided with a retaining hole 223 and a top end thereof is provided with a tongue sheet 224 .
[0037] One end of each of the copper contact rings 230 , 240 is in a gradually-expanding shape and is respectively received in the ring-shaped slots 2121 , 2122 of the connecting device 212 and the other end thereof is respectively extended with a contact sheet 231 , 241 , and the contact sheet 231 , 241 respectively has a sheet slot 232 , 242 provided at the end section of the contact sheet 231 , 241 .
[0038] The electrode column base 250 has a pivotal shaft 251 , the shape thereof is, e.g. but not limited to, in a round shape, one lateral side of the pivotal shaft 251 is received in the first retaining slot 221 , and two ends of the pivotal shaft 251 respectively has a switch seat 252 , the switch seat 252 is received in the first retaining slot 221 for being fastened on the retaining seat 220 and the switch seat 252 further has a seat hole 253 .
[0039] The two electrode columns 260 , 270 are respectively received in the corresponding seat hole 253 , one end of each of the electrode columns 260 , 270 has a sealing cover 261 , 271 , the other end thereof is respectively provided with a contact section 262 , 272 , after passing through the seat hole 253 and exposing outside the switch seat 252 ; at least one sheet trench 263 , 274 are provided on the contact sections 262 , 272 for being received in the sheet slots 232 , 242 ; in this embodiment, the contact section 262 , 272 are respectively provided with two sheet trenches 263 , 274 for illustration and not serving as a limitation.
[0040] The bottom plastic housing 280 is able to be engaged with the top housing 210 , and has a bottom housing surface 281 , the bottom housing surface 281 has two housing slots 283 , the bottom end of the housing slot 283 is hollow and an end section of the housing slot 283 has a plane hole 284 with a width larger than the width of the housing slot 283 to receive the switch seat 252 and to allow the electrode columns 260 , 270 expose outside, a second retaining slot 285 is provided between the two housing slots 283 , the shape thereof is, e.g. but not limited to, in a semicircle shape for fastening the other lateral side of the pivotal shaft 251 . The top housing 210 and the bottom plastic housing 280 are made of insulation materials, e.g. but not limited to plastic. The bottom plastic housing 280 further has a slot 286 for being buckled with the tongue sheet 224 so as to fasten the retaining seat 220 .
[0041] As shown in FIG. 5 a and FIG. 6 a , when assembled, the two copper contact rings 230 , 240 are respectively installed in the two ring-shaped slots 2121 , 2122 , so the contact sheets 231 , 241 expose outside the hollow main body 211 ; the two electrode columns 260 , 270 are respectively provided in the corresponding seat hole 253 and exposed outside the switch seat 252 then provided with the contact section 262 , 272 ; the pivotal shaft 251 of the electrode column base 250 is received in the first retaining slot 221 for positioning and fastening; then the other end of the pivotal shaft 251 of the electrode column base 250 is received in the second retaining slot 285 and the tongue sheet 224 is received in the slot 286 for positioning and fastening, so the two electrode columns 260 , 270 partially expose outside the housing slots 283 ; then the top housing 210 is engaged with the bottom plastic housing 280 , and the two electrode columns 260 , 270 are outwardly pushed so the contact sheets 231 , 241 are respectively positioned in the sheet trenches 263 , 274 and are in contact with the contact sections 262 , 272 , then the switch seat 252 is fastened in the column slot 222 ; the plug with connecting device provided by the present invention is therefore obtained. After the assembly of the plug with connecting device provided by the present invention is assembled, the connecting device 212 is connected to a power adapter (not shown), an AC power source is therefore transferred to the power adapter through the copper contact rings 230 , 240 .
[0042] As shown in FIG. 5 b and FIG. 6 b , when folded, the two electrode columns 260 , 270 are inwardly pushed into the bottom plastic housing 280 alongside the housing slot 283 and the plane hole 284 , and the contact sections 262 , 272 are released from the contact sheets 231 , 241 , and the two electrode columns 260 , 270 are aligned with the housing slots 283 to achieve a convenient storage purpose, thus the two electrode columns 260 , 270 are not in contact with the ring-shaped slots 2121 , 2122 and a power supply terminating status is achieved.
[0043] Accordingly, the plug with connecting device provided by the present invention has a grounding sheet to provide a grounding function; and according to actual needs an AC plug is able to be changed for being adopted in various AC power systems.
[0044] It is to be understood, however, that even though numerous characteristics and advantages of the present embodiments have been set forth in the foregoing description, together with details of the structures and functions of the embodiments, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
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The present invention relates to a plug with connecting device, includes a top housing, one end thereof is extended with a connecting device for being connected to a power adapter; a retaining seat; an electrode sheet base having a pivotal shaft; two copper contact rings; two electrode sheets; one bottom plastic housing engaged with the top housing; when the two electrode sheets are longitudinally rotated, the two electrode sheets are able to be pivotally moved at the outside of the bottom plastic housing and then positioned, an electrical conducting status is formed between the electrode sheets and the connecting device so as to transfer power to a power adapter.
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BACKGROUND OF THE INVENTION
It is well known in the art that the hindered phenols are useful as antioxidants and stabilizers. The compounds are used to stabilize both petroleum producte and polymer compositions against oxidative, degradation.
Nitro containing hindered phenols are known in the art; see for example U.S. Pat. No. 3,867,467 which discloses a compound of the general formula ##STR3## wherein "X" represents a tertiary butyl radical, R 2 and R 3 are hydrogen or alkyl and R 4 is an alkyl group. The reference also teaches the use of these compounds as antioxidants. U.S. Pat. No. 4,014,943 claims a compound having a structure ##STR4## wherein R 1 and R 2 may be hydrogen, a lower alkyl or a radical of the structure ##STR5## These compounds are taught as being antioxidants according to U.S. Pat. No. 4,007,159.
SUMMARY OF THE INVENTION
It has surprisingly been found that certain nitroalkane-based hindered phenols of the general formula ##STR6## where R 1 and R 2 are independently selected from the group consisting of lower alkyl and a radical of the structure ##STR7## are exceptionally effective antioxidants in petroleum products and polymeric materials including synthetic and natural polymers.
DETAILED DESCRIPTION OF THE INVENTION
This invention relates to novel hindered phenolic compounds containing a nitro group. More particularly, the invention relates to compounds of the general structure ##STR8## wherein R 1 and R 2 are independently selected from the group consisting of linear or branched alkyl radical having 1 to 6 carbon atoms and a radical of the structure ##STR9## Preferably R 1 and R 2 are C 1 -C 4 alkyl such as methyl, ethyl, propyl and butyl. Representative compounds of this invention are 2-methyl-2-nitrohexyl 3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate; 2-ethyl-2-nitropentyl 3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate; 2-propyl-2-nitropentyl 3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate; 2-ethyl-2-nitro-trimethylenebis[3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate]; and 2,2 disapropyl-2-nitroethyl 3-(3,5-di-t-butyl-4-hydroxyphenyl). Illustrative of the types of products which are subject to oxidative degradation and can be stabilized with the antioxidants of this invention include, petroleum products such as lubricating fluids, plastics, and synthetic and natural rubbers. Among the organic materials which can be stabilized against such degradation are polyolefins such as polyethylene, polypropylene, polybutylene, polyoctene, polybutadiene, polymethylpentene etc. Illustrative examples of other polymers and resins which may be stabilized by the hindered phenols of this invention are acetal resins, polyacrylates, polymethacrylates, polydialkylphthalates, cellulosics materials, polyamides, polyesters, polyurethanes, polycarbonates, polystyrene, polyvinyl chloride and polyvinylidene chloride. The known rubbery and resinous copolymers commercially available may also be stabilized using the antioxidants of this invention. Illustrative of these copolymers are poly(ethylene/propylene) (EPM), poly(butadiene/styrene), poly(ethylene/vinyl acetate), poly(ethylene/ethyl acrylate) as well as terpolymers such as poly (ethylene/propylene/non-conjugated diene) (EPDM) and acrylonitrile/butadiene/styrene) interpolymers.
Other organic compositions that can be stabilized by the compounds of this invention include hot melt adhesives such as those based on polyesters, polyamides or poly(ethylene/vinyl acetate). Additionally, petroleum products such as fuels, automotive lubricating fluids, petrolatum jellies, etc., as well as natural rubbers, waxes, fat, tallow, linseed oil, corn oil, cottonseed oil, codliver oil, tall oil fatty acid, etc. with or in which the compounds of this invention are miscible or soluble can also be stabilized.
The preceding list of compounds is merely illustrative and not intended to be exhaustive. The only requirement for utilization of the hindered phenols of this invention as a stabilizer for organic compounds, is that it be soluble or miscible with the organic compound. The amount of hindered phenols of this invention which must be incorporated into an organic compound in order to achieve protection against oxidation will depend on the nature of the compound and the intended service conditions. Generally, 0.001 to about 10 parts by weight of the compound of this invention per 100 parts be weight of organic compound is used; preferably about 0.05 to about 5 parts by weight per 100 parts of organic compound; more preferably about 0.1 to about 2.0 parts by weight of the compound of this invention is used per 100 parts by weight of the organic compound.
The hindered phenols of this invention may be used as the sole stabilizer or in combination with other known stabilizers. Illustrative examples of such other known stabilizers are dialkyl-thio-dipropionates such as dilauryl-thiodipropionate, dimyristyl thiodipropionate, distearyl thiodipropionate; phosphites such as tris-nonylphenyl phosphite, trilauryl phosphite, phenyl dilauryl phosphite, diphenyl lauryl phosphite, distearyl pentaerythritol diphosphite; benzophenone U.V. stabilizers such as 2-hydroxy-4-octyloxybenzophenone, , 2-hydroxy-4-dodecyloxybenzophenone, 2-hydroxy-4-methoxybenzophenone; benzotriazole U.V. stabilizers such as 2-(2'-hydroxy-5'-methylphenyl)benzotraizole, 2-(3',5'-di-tert-butyl-2'-hydroxyphenyl)benzotriazole, 2(3',5'-di-tert-amyl-2'-hydroxyphenyl)benzotriazole, 2-(2'-hydroxy-5'-tert-octylphenyl)benzotriazole, 2-(3',5'-di-tert-butyl-2'-hydroxyphenyl)-5-chlorobenzotriazole, 2-(3'-tert-butyl-2'-hydroxy-5'-methylphenyl)benzotriazole; various ester U.V. stabilizers such as dimethyl p-methoxybenzylidenemalonate, p-octylphenyl salicylate, phenyl salicylate, p-tert-butylphenyl salicylate, 2-ethylhexyl 2-cyano-3,3-diphenylacrylate, ethyl cyano-3,3-diphenylacrylate, resorcinol monobenzoate, 2,4-di-tert-butylphenyl 3,5-di-tert-butyl-4-hydroxybenzoate; nickel type U.V. stabilizers such as nickel bisoctylphenylsulfide,[2,2'-thiobis (4-tert-octylphenolates)]-n-butylamine nickel, nickel dibutyldithiocarbamate, copper chelators such as N,N',N",N'"-tetrasalicyldienetetra(aminomethyl)methane, diphenyloxamide, oxalylbis(benzylidenehydrazide) and N,N'-bis(3,5-di-tert-butyl-4-hydroxyphenyl)propionylhydrazine. The compounds of our invention can also be used together with carbon black, fillers, pigments and other compounding ingredients. Notwithstanding the similarities in the structure between the hindered phenols of this invention and the aforementioned prior art nitro containing hindered phenols the compounds of this invention provide stabilization superior to that of those prior art compounds. The advantages of the instant invention may be more readily appreciated by reference to the following examples.
EXAMPLE 1
A mixture of 72g (0.27 mole) 3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionic acid and 25 ml (excess) thionyl chloride in 120 ml toluene was heated at reflux for 3 hours. The toluene and excess thionyl chloride is removed under vacuum in a rotary evaporator. The resulting acid chloride was dissolved in 100 ml toluene and was added to a mixture of 30g (0.25 mole) 2-nitro-2-methylpropanol and 50 ml pyridine in 80 ml toluene. The reaction mixture was stirred overnight at 50°-55° C. After cooling to room temperature, the reaction mixture was first washed with water, then with dilute hydrochloric acid and then again with water. After removal of the toluene a 99% yield of 2-methyl-2-nitropropyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate was obtained. The infrared spectrum indicated the crude product to be essentially free of acid or acid chloride. After recrystallization from hexane, the product had a melting point range of 68°-70° C.
ANALYSIS: Calculated for C 21 H 33 NO 5 - 66.5%C; 8.8%H; 3.7%N. Found - 66.7%C; 8.6%H; 3.5%N.
EXAMPLE 2
By esterifying one mole of 2-methyl-2-nitropropanediol with two moles of 3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionyl chloride in the manner described in Example 1, there was obtained 2-methyl-2-nitrotrimethylenebis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate]. M.P. 126°-129° C.
ANALYSIS: Calculated for C 38 H 57 NO 2 - 69.6%C; 8.7%H; 1.9%N. Found - 69.8%C; 8.8%H; 2.1%N.
EXAMPLE 3
By esterifying one mole of 2-ethyl-2-nitropropanediol with two moles of 2-(3,5-di-tert-butyl-4-hydroxyphenyl) propionyl chloride in the manner described in Example 1, there was obtained 2-ethyl-2-nitrotrimethylene bis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate]. The product obtained was an oil. The product was identified by its NMR Spectrum in carbon tetrachloride. The four phenyl protons appear as a singlet at 3.15τ, the two hydroxy protons appear as a singlet at 5.07τ, the four methylene protons next to the oxygen appear as a singlet at 5.67τ, the eight protons between the phenyl group and the carbonyl group appear as a multiplet centered around 7.32τ; the four tertiary butyl groups appear as a singlet at 8.64τ. The methyl of the ethyl group appears as a triplet centered around 9.23τ and the methylene of the ethyl appears as a quadruplet (somewhat obscured by the tertiary butyl group) centered around 8.7τ.
EXAMPLE 4
By esterifying one mole of tris(hydroxymethyl)nitromethane with three moles of 2-(3,5-di-tert-butyl-4-hydroxyphenyl) propionyl chloride in the manner described in Example 1, there was obtained 2-nitroisobutanetriyl tris[3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate]. M.P. 110°-112° C.
ANALYSIS: Calculated for C 55 H 81 NO 11 - 70.9%C; 8.8%H; 1.5%N. Found - 71.1%C; 8.9%H; 1.4%N.
EXAMPLE 5
The stabilizers of this invention and prior art nitro containing hindered phenols were compared by incorporating them into an unstabilized polypropylene resin (100 parts) having an initial melt flow index of 5 at 230° C. Blending was accomplished on a mill at 165° C., test samples were prepared of 1.9 mm-thick plaques by compression molding at 186 MPa and 177° C. These test specimens were then exposed in a test oven to forced air at 150° C., and the number of days to embrittlement was noted; Table 1 shows the results of these comparison studies.
TABLE 1______________________________________Stabilizer Parts by Weight Days to failure______________________________________None -- 1Example 2 compound 0.2 47Example 4 compound 0.2 61Prior Art 1 0.2 7Prior Art 2 0.2 6Prior Art 1 - Tris(3,5-di-tert-butyl-4-hydroxybenzyl) nitromethane.Prior Art 2 - 1,3-bis(3,5-di-tert-butyl-4-hydroxyphenyl)- 2-nitropropane.______________________________________
It is noted that at the 0.2 parts by weight level, the stabilizers of this invention are far superior to the prior art chemicals as antioxidants.
EXAMPLE 6
The stabilizers of this invention demonstrate synergism when used together with certain co-stabilizers. The stabilizers were incorporated into 100 parts of polypropylene resin as described in Example 5. Oven aging was carried out at 150° C., and the number of days to embrittlement was noted. The results are shown in Table 2.
TABLE 2______________________________________Stabilizer Parts Days to failure______________________________________ None -- 1DSTDP* 0.2 4Example 2 Product/DSTDP 0.1/0.1 93Example 4 Product/DSTDP 0.1/0.1 89Example 2 Product 0.2 47Example 4 Product 0.2 61______________________________________ *Distearyl thiodipropionate
EXAMPLE 7
Various stabilizers were dissolved into a rubber cement containing about 110g of ethylene-propylene-ethylidenenorbornene terpolymer having an ethylene/propylene weight ratio of 53/47, an iodine number of 8 and a Mooney viscosity (ML-4) of 58 at 125° C., was dissolved in 2000g of hexane. Thereafter, 0.15 parts (per 100 parts of polymer, by weight) of the stabilizers listed below were added. The hexane was removed by slowly adding the cement to boiling water. The rubber blend was dried on a mill for 5 minutes at a temperature of 135°-150° C. Samples were tested by measuring the time in minutes to absorb 20 cc of oxygen at 150° C. The results are shown in Table 3.
TABLE 3______________________________________Stabilizer T.sub.20 (minutes)______________________________________None 27Example 1 Product 480Example 3 Product 535Example 4 Product 420+Prior Art 3 315______________________________________ Prior Art 3 = 2,6-di-tert-butyl-4-(2-nitro-1-propyl)phenol.
It is noted that the stabilizers of this invention show antioxidative properties unexpectedly superior to the prior art compound.
EXAMPLE 8
The compound of Example 4 (0.3 parts) was milled into a blend (100 parts) of EPDM (80 parts; E/P weight ratio = 53/47, iodine No. = 8, Mooney viscosity (ML-4) at 125° C. = 58) and polypropylene (20 parts; Melt Flow Index 13 at 230° C.). Plaques were compression molded having 1.9 mm thickness and test buttons punched therefrom. The latter were exposed to a temperature of 150° C. in an air flow oven, and the time to embrittlement of the buttons was noted. The results were as follows:
______________________________________ Hours toAdditive Embrittlement______________________________________None 80of Ex. 4 334______________________________________
EXAMPLE 9
Into high impact polystyrene (100 parts; MFI = 2.1 at 200° C.) was milled the compound of Example 4 (0.25 parts) at 138° C. Notched Izod bars were molded at 77° C. and the impact strength was determined. After each measurement the samples were reground and remolded. The first and fifth test results were recorded.
______________________________________ Impact Strength* IS %Additive 1st 5th Retention______________________________________None 4.72 J 2.75 J 58.3of Ex. 4 4.73 J 3.93 J 83.1______________________________________ *ASTM D-256, Joules (N . m)
EXAMPLE 10
The chemical of Example 1 (1.0 part) was dissolved in 100 parts of mineral oil (spec. gravity 0.88-0.90 at 15.5° C.) and air was bubbled through the oil at a rate of 5 l/hr at 160° C. in the presence of a piece of copper/iron wire for 72 hours. The viscosity of the oil was measured initially and after 72 hours.
______________________________________ Viscosity*Additive Initial At 72 hrs. % Increase______________________________________None 406 734 81of Ex. 1 406 458 13______________________________________ *Saybold Universal Seconds (S.U.S.) at 38° C.
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A stabilizer suitable for use to protect organic materials into which it is soluble or miscible against oxidative degradation having the general formula ##STR1## wherein R 1 and R 2 are lower alkyl or a radical of the structure ##STR2## wherein "x" represents a tertiary butyl radical.
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REFERENCE TO RELATED APPLICATIONS
[0001] This application is a national stage application under 35 USC 371 of International Application No. PCT/EP2014/062864, filed Jun. 18, 2014, which claims priority to German Application No. 20 2013 005 959.1, filed Jul. 3, 2013, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to a determination device for hydrocarbon emissions, as originate in particular from engines. The determination device comprises a probe for taking a sample quantity, a measuring channel, and a measuring unit. In this case, this is a broadband measuring unit for determining the hydrocarbons over an entire mass spectrum.
BACKGROUND OF THE INVENTION
[0003] The reduction of harmful emissions from engines or other thermal engines plays a significant role in fulfilling environmental protection efforts, which are becoming larger and larger. This relates to emissions originating directly from the combustion process, on the one hand, but also emissions which originate from secondary procedures in or on the engine, on the other hand. In this case, this can relate to externally active emissions, on the other hand, but also procedures inside the engine can be included in this case, for example, the fuel introduction into the lubricant oil or the recirculation of blow-by gases into the combustion chamber. To be able to reduce the emissions, it is primarily necessary to detect and evaluate the actually occurring emissions. In this case, in particular lubricant oil emissions and unburned hydrocarbons are significant. These have to be able to be measured rapidly with a high level of accuracy, to also be able to depict internal engine procedures with sufficient dynamic response.
[0004] Various measurement systems are known in the prior art. The unburned hydrocarbons in the exhaust gas are determined with a high level of chronological resolution by flame ionization detectors. This method can claim the advantage that it is less complex. However, it is not specific by its nature, i.e., a determination of a mass spectrum of the detected molecules cannot be performed. Therefore, this method is excessively coarse and does not fulfill the modern demands with respect to an accurate assignment of the hydrocarbons according to fuel and oil fractions.
[0005] Mass spectrometers are used for accurate characterization of hydrocarbons. They consist of an ion source, a mass analyzer, and a detector.
[0006] The chronological resolution of the system is substantially also determined by the mass analyzer.
[0007] In a known embodiment, this mass analyzer is embodied as an electrical quadrupole, to which a voltage source is connected, so that a periodically oscillating electrical field arises (U.S. Pat. No. 2,939,952). Because of the field, only ions having determined, specific mass/charge ratio run on stable paths, all others are unstable and are eliminated. A time-consuming sequential measurement of the individual masses (scanning) is necessary to generate a mass spectrum. The realistic measurement time for generating a spectrum of 50 to 550 atomic mass units is 500 ms.
[0008] In time-of-flight mass spectrometers (TOF-MS) (DE 10 2012 203 150 A1), different ionic species of a sample are accelerated in an electrical field. Subsequently, the ions pass through a flight route. The different velocities of the various ionic species have the result that the ions having different mass-charge ratio separate with respect to the movement direction. At the end of the mass analyzer, the ions fall on the ion detector, which measures the frequency of the successive ions simultaneously. A time-of-flight spectrum in the range of 50 to 550 atomic mass units can be recorded in less than 20 μs. To achieve better mass accuracy and detection limit, a mass spectrum is calculated in 1 ms from multiple time-of-flight spectra.
[0009] If a double-focusing sector field mass spectrometer in Mattauch-Herzog geometry is used (DE 10 2010 056 152 A1), the energy bandwidth of the ion beam is reduced in the electrostatic analyzer, to achieve a high resolution of the mass separation in the following magnetic field. All ionic masses can be depicted simultaneously in one focal plane due to the geometry. A planar detector enables the simultaneous detection of the complete mass spectrum. A time-consuming sequential measurement is not necessary.
[0010] A typical technology for ionization of molecules in mass spectrometry is electron impact ionization (EI) at 70 eV. Depending on the high ionization energy in this hard ionization method, fragmentation of the molecules into smaller fractions occurs, which cannot be unambiguously assigned to the substances in a mixture.
[0011] The inadequacies of this technology have resulted in the development of soft ionization methods, in which essentially molecular ions are generated. Different technologies based on chemical ionization (CI), field ionization (FI), and photoionization (PI) have been developed. The use of matrix-assisted laser ionization (MALDI) and electrospray ionization (ESI) is widespread for polar molecules.
[0012] In the case of photoionization, molecular ions can be generated by targeted selection of the photon energy. The use of UV radiation results in a high level of selectivity in the case of aromatic hydrocarbons and is generated, for example, by pulsed lasers (REMPI; laser-based resonance enhanced multi-photon ionization). The detection of organic materials can be performed by single photon ionization (SPI) using VUV radiation (vacuum ultraviolet).
[0013] A further soft ionization method is based on taking samples using supersonics (SMB, supersonic molecular beam) and subsequent ionization of the energetically cold molecules using electron impact ionization (cold EI), which is described in U.S. Pat. No. 6,617,771 B2.
[0014] The required combination of detection limit, discrimination power, selectivity, and measurement speed of the known systems do not correspond to the demands currently placed on the observation of hydrocarbon emissions in dynamic engine procedures.
[0015] An improved method for determining the lubricant oil content in the exhaust gas is known from WO 2005/066605 A2. According to this, the exhaust gas mixture taken as a sample is supplied to an ion source and, after ionization, supplied to a combination comprising a mass spectrometry filter unit, which is designed as a multipole, and a detector unit.
[0016] The filter unit is embodied so that a specific transmission range is defined for mass-charge numbers to be transmitted. A lubricant oil fraction to be measured is therefore defined. The measurement over this fraction is carried out using the mass spectrometer as a global measurement of the intensity in one step simultaneously over the entire transmission range. This measurement system enables outstandingly rapid measurement with a measurement time of 1 ms over a settable measurement range. The dynamic response of this measurement system is good, but the spectral resolution is not completely satisfactory.
SUMMARY OF THE INVENTION
[0017] The invention is based on the object of achieving an improvement, proceeding from the last mentioned measurement system, such that an improved resolution is achieved with improved dynamic response at the same time.
[0018] The solution according to the invention are in the features as broadly described below. Advantageous refinements are described in the detailed embodiments below.
[0019] In a determination device for hydrocarbon emissions of a thermal engine, in particular an engine, having a sampling probe, which is designed to take a sample quantity from a fluid, a measuring channel, which conducts the sample quantity via an ion source unit to a measuring unit, and the measuring unit, which is embodied as a broadband measuring unit for determining a mass spectrum over a definable range, it is provided according to the invention that the ion source unit is designed so that a soft ionization takes place, and the measuring unit is embodied as a simultaneously measuring detector, for example, according to the “time-of-flight” type or as a “double-focusing sector field mass spectrometer in Mattauch-Herzog geometry”, which forms an intensity signal sequence over the mass spectrum.
[0020] Firstly, several terms which are used will be explained hereafter:
[0021] A fluid is understood as both a liquid and also a gaseous material. The gaseous material can be in particular exhaust gas or blow-by gas, and the liquid material can be in particular a large volume, such as the content of an oil pan, or a thin-layer volume, such as a wall film.
[0022] A mass spectrum is understood as a specific mass range, which is defined by a lower limit and an upper limit with respect to the mass/charge ratio.
[0023] A simultaneous measurement is understood as a rapid measurement over a determined mass range, which can be carried out without time-consuming sequential measurement (scanning) of the individual masses.
[0024] An intensity sequence is understood as a sequence of intensity signals, wherein an intensity signal is such a signal which describes the intensity of the occurrence of a specific mass/charge ratio within the mass spectrum.
[0025] For example, if a spectrum of 170 to 550 m/z is measured, the intensity sequence thus comprises 381 intensity signals, specifically one for each value within the spectrum from 170 to 550 m/z.
[0026] The invention is based on the combination of two measures. The first measure is to provide a “soft” ion source.
[0027] In contrast to the ionization unit used in the generic measurement system, a fragmentation of, in particular, the long-chain molecules in the sample quantity is avoided using the soft ion source provided according to the invention. This is the definition of “soft” in the scope of the present application, specifically that the ionization energy is sufficiently small that fragmentation of the hydrocarbons to be studied, which are generally long-chain, does not occur. The total number of such molecules in the sample quantity is therefore maintained. This improves the accuracy of the measurement of the downstream broadband measuring unit, on the one hand, and by maintaining the molecules, the formation of fragments is prevented, on the other hand, as would otherwise arise as a consequence of the breaking apart of the long-chain molecules. These fragments result in artifacts during the measurement in the range of short-chain molecules, i.e., the presence of short-chain molecules is simulated, which were not originally contained in the sample quantity at all. To avoid the corruption of the measurement result by way of such artifacts, filter units are required in the prior art, which hide the shorter-chain molecule range. The invention avoids the use of such a filter. Therefore, not only is the shorter-chain molecule range depicted accurately, but rather the long-chain molecules to be measured are also completely maintained. The soft ion source therefore not only provides a better measurement signal in the range of the longer-chain molecules, but rather also expands the measurement range by way of the avoidance of artifacts due to fragments in the range of the shorter-chain molecules.
[0028] A rapid measurement over the entire spectrum range from short-chain up to the long-chain molecules is achieved using the broadband measuring unit by using a detector according to the “time-of-flight” type or the “double-focusing sector field mass spectrometer in Mattauch-Herzog geometry”. These detectors can record the entire spectrum in less than 1 ms “at once” because of the construction, and at the same time generate an intensity signal in each case for the individual molecule sizes within the recorded spectrum. An intensity signal sequence therefore results, which depicts the occurring molecules over the entire spectrum, and with a high level of dynamic response. In that a separate intensity signal is provided for each individual molecular mass thanks to this detector type, the total material quantity can be ascertained reliably and rapidly by simple summation. Using the conventionally used measuring unit, as was provided in the generic prior art, a separate intensity could not be associated with each of the individual molecular masses. Therefore, the total material quantity could only be determined imprecisely. Such a fine allocation of the intensity over the spectrum can now be performed using the detector of the type provided according to the invention.
[0029] However, this fine allocation would be worthless solely per se, since in the case of the conventional ionization, the longer-chain molecules are destroyed by fragmenting and artifacts are thus automatically generated by the formation of shorter-chain fragments, which significantly corrupt the measurement result. The invention has recognized that the fine resolution achieved using this detector is only fully applied when it is combined with the soft ion source according to the invention. This does not have an example in the prior art.
[0030] The ion source unit is advantageously designed for ionization at an energy of less than 50 eV, but preferably at least at an energy of 5 eV. Therefore, on the one hand, reliable ionization of the molecules of the sample quantity to be analyzed is achieved, however, on the other hand, a fragmentation, in particular of longer-chain molecules, is reliably prevented.
[0031] An embodiment of the ion source unit according to the principle of chemical ionization (CI), photoionization (PI), or cold electron impact ionization (cold EI) is particularly advantageous.
[0032] The detector of the “time-of-flight” type preferably has an ion mirror, which is advantageously embodied as a reflectron. A reflection of the ion beam can therefore be achieved, so that with unchanged overall length of the detector, the length of run of the ion beam is approximately doubled. Both the sensitivity and also the resolution can thus be increased.
[0033] An embodiment of the detector having an orthogonal flight tube is particularly preferred in this case. This embodiment can win special advantages with respect to resolution fineness and resolution dynamic response.
[0034] In a proven embodiment, the detector of the “time-of-flight” type works together with an analysis unit, which is designed to determine a spectrum over a preferably preselectable range. Therefore, automated analysis can be carried out of the intensity signal sequence, which is generated by the detector with high dynamic response and resolution. The intensity signal sequence can be produced in this case based on time, however, it is also conceivable that it is produced based on a magnetic field using a “double-focusing sector field mass spectrometer in Mattauch-Herzog geometry”.
[0035] The analysis unit preferably comprises a quantity computer, to which an intensity vector and a mass spectrum are applied, and which links them via a preferably settable analysis field. Therefore, a total quantity can be determined over the mass spectrum from the intensity signal sequence in an automated manner. Thus, one is typically interested in a determination over the entire spectrum. However, it can also be provided that the quantity computer of the analysis unit is capable of subfields. Therefore, specific ranges can be analyzed separately, for example, high-volatility lubricant oil emissions having the moderate length molecules thereof and low-volatility fractions having longer molecules. Furthermore, a classifier is preferably provided for the analysis unit, which, for example, analyzes a range for longer-chain molecules (above 170 m/z) for lubricant oil emissions in gasoline engines and analyzes below this value for unburned hydrocarbons from fuel emissions.
[0036] The analysis unit particularly advantageously has a classification module for determining a type of fuel or lubricant oil. Therefore, selectable ranges can be related to one another, which can be used for the analysis of different fuels, lubricant oils, or additive components with respect to the specific basic building blocks of the material groups thereof, for example, with reference to the lubricant oil content of esters or PAO (polyalphaolefin) or the content of biofuels, for example, fatty acid methyl ester (FAME), rapeseed oil methyl ester (RME), and ethanol.
[0037] Auxiliary detectors, which respond to a predetermined type of material, can advantageously be provided in particular with reference to components such as, for example, esters, PAO, and ethanol.
[0038] To take the sample quantity, the sampling probe is preferably designed as an exhaust gas probe and/or fluid probe. The exhaust gas probe can be arranged in the combustion chamber or in the directly adjoining region of the exhaust gas train. The fluid probe can also be arranged in the combustion chamber, but can advantageously also be provided in the region of a lubricant oil container (for example, the oil pan). A mode switchover switch is preferably provided, which switches the analysis unit over between operation using the exhaust gas probe or the fluid probe as the sampling probe. Therefore, it is possible to switch back-and-forth between the different operating modes using the same analysis unit.
[0039] Not only can a statement be made about the emissions via the exhaust gas, but rather also, for example, about emission components in the lubricant, in particular fuel introduced into the lubricant oil of the engine.
[0040] The invention furthermore extends to a corresponding method, having the steps of taking a sample quantity from a fluid by means of a sampling probe, transferring the sample quantity to a measuring unit, ionizing the sample quantity by means of an ion source, characterized by carrying out the ionization as a soft ionization and determining an intensity signal sequence over a mass spectrum by determining flight times for the individual ion masses or by determining the deflection of the ion masses in a magnetic field, wherein the above-described determination device is advantageously used.
[0041] The invention is explained in greater detail hereafter with reference to the appended drawing, in which an advantageous exemplary embodiment is shown.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] FIG. 1 shows an overview illustration of a device according to one exemplary embodiment of the invention;
[0043] FIG. 2 shows a block diagram of the device;
[0044] FIG. 3 shows a view of a detector for the device according to FIG. 1 ;
[0045] FIGS. 4 a, b show a mass spectrogram to illustrate the effect of the ionization source;
[0046] FIG. 5 shows a mass spectrogram to illustrate the determination of a total quantity;
[0047] FIG. 6 shows a mass spectrogram for the determination of various types of oil, and
[0048] FIG. 7 shows a mass spectrogram for the determination of fuel introduced into oil.
DETAILED DESCRIPTION OF THE INVENTION
[0049] FIGS. 1 and 2 show an exemplary embodiment of a determination device according to the invention. The determination device is used to determine oil emissions and emissions of unburned hydrocarbons (HC), which originate from an internal combustion engine. The illustrated exemplary embodiment relates to an internal combustion engine according to the reciprocating piston principle, however, the exemplary embodiment of the invention is not restricted thereto.
[0050] An internal combustion engine, which is identified in its entirety with the reference sign 1 , has a cylinder 10 having a piston 11 mounted so it is movable up and down therein. A combustion chamber 13 is formed above the piston, to which fresh gas is supplied via valves 12 and from which exhaust gas is discharged into an exhaust gas manifold 14 . Below the cylinder 10 having the piston 11 , a crankcase 16 is arranged, which comprises a crankshaft drive 15 for the piston 11 and a crankcase ventilation 16 b for discharging blow-by gases. An oil pan 17 for lubricant oil is located at the bottom of the crankcase 16 .
[0051] The internal combustion engine is embodied as conventional per se, so that a detailed description can be omitted in this regard. It is to be noted that essentially the following emissions of the internal combustion engine occur and are depicted as follows in the mass spectrum (see also FIG. 5 ):
[0052] 1. High-volatility exhaust gas components, such as nitrogen, nitrogen oxides, oxygen, carbon monoxide, carbon dioxide, water, and argon. These components are comparatively light and have a specific mass (mass divided by valence m/z), which is in the range of <50 m/z.
[0053] 2. Unburned hydrocarbons from the fuel, which typically consist of at most 10 carbon atoms in the case of gasoline engine fuels. Ions formed therefrom have a specific mass of <170 m/z.
[0054] 3. Hydrocarbons from the lubricant oil, which create ions having a specific mass of >170 m/z. One example of this is docosane having 22 carbon atoms and 45 hydrogen atoms and a specific mass of 310.
[0055] An exhaust gas probe 2 , having a probe head 21 at the exhaust gas manifold 14 , is connected to the engine 1 . From the probe head 21 , a sample quantity moves via a transfer capillary 22 to a transfer unit 25 having a vacuum pump. The sample quantity is then supplied to an ion source unit 3 , which is designed so that the sample quantity exhaust gas stream flowing in through the capillary 22 is ionized. The ion source unit 3 is embodied as an ionizer according to the principle of chemical ionization (CI), photoionization (PI), or cold electron impact ionization (cold EI), and is designed so that soft ionization having an ionization energy of at most 50 eV takes place.
[0056] A prefilter 4 is arranged directly adjoining in the flow direction. It is furthermore used to transfer the ions into the downstream high vacuum region having the mass filter 5 . Therefore, a first mass filter 5 , and a collision cell 6 behind it, directly adjoins the prefilter 4 . The mass filter 5 is used to filter out ions having an undesired component. The mass filter 5 is designed as a quadrupole filter for this purpose. The construction of quadrupole filters in general is known in the prior art and does not have to be explained in greater detail here.
[0057] In the flow direction after the collision cell 6 , a detector 8 is arranged as a measuring unit, which is embodied as a “time-of-flight” type or as a “double-focusing sector field mass spectrometer in Mattauch-Herzog geometry”. An alignment value unit 9 works together with the detector 8 .
[0058] The “time-of-flight” detector 8 is embodied in the construction having orthogonal flight tube. It comprises an accelerator unit 80 , which accelerates the ions on a parabolic trajectory in the flight tube 81 . The flight tube 81 is evacuated by means of a high vacuum pump 84 . The ions firstly move toward the opposite end, where a reflectron is arranged as an ion mirror 82 . The ions are thus reflected and run back again in the flight tube 81 , until they are incident on an electron multiplier 86 . This multiplier outputs a signal pulse, which marks the time which the respective ion requires to run through its ion path. Heavy ions having a high specific mass (m/z) move on a trajectory and require a longer time for this purpose than lighter ions having a low specific mass. This means that ions having greatly varying mass can be introduced at the same time into the “time-of-flight” detector 8 , and depending on the frequency of the occurrence of the respective ions, an intensity signal is output, more precisely is output having an intensity signal sequence, wherein firstly the intensity signals for the ions having low specific mass and subsequently those having successively higher specific mass are output.
[0059] As a result, a broadband measurement “at once” having high resolution is then enabled. The measurement signal thus obtained is an intensity sequence signal and is transmitted to the analysis unit 9 . The detector 8 is made capable in this way of detecting the complete spectrum of the molecular ions with high dynamic response simultaneously, namely within less than 20 μs. Therefore, more than 5000 spectra per second are available for analysis.
[0060] The analysis unit comprises a quantity computer 91 , to which the intensity sequence signal and a signal for the mass spectrum are applied. The analysis unit furthermore comprises a classifier 92 , which is designed to determine fractions of the lubricant oil or of unburned hydrocarbons from the fuel or additive components in the ascertained mass spectrum. Furthermore, the analysis unit comprises a classification module 93 for determining the type of fuel and oil. The classification module 93 is designed in this case to evaluate specific components with respect to the frequency of occurrence thereof and then to perform an association. The components can be in particular ethanol and PAO (polyalphaolefins) or specific esters. The classification module 93 is preferably provided with an ester detector 94 for this purpose. Furthermore, a threshold value switch 95 is advantageously provided, which outputs a signal upon the occurrence of pre-selectable events, for example, the occurrence of emissions of a specific type of oil.
[0061] The effect of the ion source unit 3 is visualized in FIG. 4 . In the prior art, ionization is performed using comparatively high energy, so that long-chain molecules are split, such as docosane C22H45, which is shown as an example, having specific mass of 310. It can be seen that fragmenting occurs due to the prior art in the case of electron impact ionization at high energy, wherein many fragments are located outside the measurement range for lubricant oil, i.e., below a specific mass of 170 m/z. Only very few molecular ions remain in the actual measurement range for the lubricant oil (range>170 m/z). Therefore, a substantial signal loss results due to the fragmentation, since the fragments fall out of the actual measurement range for the lubricant oil. In the illustrated example in FIG. 4 a , the signal loss is almost 80%. This is avoided using the soft ion source 3 according to the invention. As can be recognized well from FIG. 4 b , the long-chain molecule is not fragmented, so that the molecular ions in the measurement range are completely maintained. A substantially more powerful signal therefore results and no fragments are formed.
[0062] A summation over the measurement range is performed to determine the total material quantity in relation to the lubricant oil emissions. With respect to the lubricant oil, the range of those having specific masses of >170 is of interest (lubricant oil range). For the determination, a product is formed from the intensity for a determined specific mass multiplied by the respective specific mass. By summation over the entire range, the total material quantity for the lubricant oil range hereby results. This lubricant oil range is shown in FIG. 5 by the shaded arrow. The total quantity of the lubricant oil nO is calculated by means of the illustrated formula. This applies accordingly to unburned hydrocarbons (HC) from the fuel. The range below a specific mass of 170 is decisive for them (fuel range). It is illustrated by the non-shaded arrow in FIG. 5 . For the determination, a sum is formed in a similar manner from the product of the intensity signal for the respective specific mass multiplied by the respective molecular mass. Therefore, the total material quantity nF is determined for unburned hydrocarbons from fuel. The total material quantity of the hydrocarbons in the exhaust gas mixture can be determined by addition of the two total material quantities nO for oil and nF for unburned hydrocarbons from fuel. This amount is particularly important for the certification with regard to fulfilling environmental standards.
[0063] Thanks to the fine resolution in the spectrum while avoiding fragmentation, it can be determined, with the aid of separate oil circuits having different lubricant oils, which assembly of an engine causes the lubricant oil emission. Reference is made in this case to FIG. 6 . Two non-overlapping fields are shown therein, which are identified with “A” and “B”. These are two different lubricant oils in this case, which differ with respect to the characteristic material groups thereof, in particular with respect to the polyalphaolefins (PAO) and the esters thereof.
[0064] Lubricant oil A is such an oil for the engine 1 itself, if the lubricant oil B is such an oil for a turbocharger (not shown) of the engine. By way of the application of the classification module 93 , it can be determined in the spectrum with which intensity which lubricant oils occur and therefore an association of the lubricant oil emission with the respective assembly can be performed. If it is a particularly critical component, such as the turbocharger, a corresponding signal can thus be output via a visual and/or acoustic output unit 96 .
[0065] In a variant shown in FIG. 7 , the size of the fuel fraction in the lubricant oil can also be determined. As also above, in this case, those molecular ions having lower mass, that is to say, having a specific mass of <170 m/z are defined as unburned hydrocarbons from fuels and the heavier ones, having a specific mass of greater than 170 m/z, are defined as lubricant oil components. To determine the fuel introduced into the lubricant oil, sampling is performed by means of a probe head 21 ′, which is mounted on the oil pan 17 . A mode switchover switch 29 switches over thereto, so that the sample quantity is then supplied to the ion source 3 from the exhaust gas probe 21 ′ and not from the exhaust gas probe 21 . In the same manner as described above, the fuel introduced into the lubricant oil can thus be analyzed rapidly and with a high level of accuracy.
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A determination device for hydrocarbon emissions of a thermal engine including an inspection probe for removing a sample volume from a liquid, a measurement channel for conducting the sample volume via an ion source apparatus to a broadband measurement apparatus that is configured to determine a spectrum to be measured in one step, wherein the ion source apparatus is configured for soft ionization and the measurement apparatus forms an intensity signal sequence across the mass spectrum and is configured as a simultaneously measuring “time-of-flight” detector or as a “double-focusing sector field mass spectrometer in Mattauch-Herzog geometry.”
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ELECTRONIC MOTOR MOUNT WITH MAGNETIC DECOUPLER
This is a continuation-in-part of U.S. patent application Ser. No. 049,787, filed May 15, 1987.
TECHNICAL FIELD
The present invention relates generally to hydraulic mounts for vibration damping and, more particularly, to a hydraulic mount assembly designed to provide infinitely variable damping characteristics.
BACKGROUND OF THE INVENTION
A variety of mount assemblies are presently available to isolate vehicle vibrations, such as for automobile and truck engines and transmissions. One of the most popular mounts today is the hydraulic elastomeric mount. Recent improvements in the decoupler mechanism, such as a mount shown in U.S. patent application No. 008,851, filed Jan. 30, 1987 and entitled "Hydraulic-Elastomeric Mount Displacement Decoupler", have provided significant improvement in the performance and efficiency of operation.
The hydraulic mount assembly of this prior invention includes a reinforced, hollow rubber body that is closed by a resilient diaphragm so as to form a cavity. This cavity is partitioned by a plate into two chambers that are in fluid communication through a relatively large central orifice in the plate. The first or primary chamber is formed between the orifice plate and the body. The secondary chamber is formed between the plate and the diaphragm.
The decoupler is positioned in the orifice of the plate and reciprocates in response to the vibrations so as to produce small volume changes in the two chambers. When, for example, the decoupler moves toward the diaphragm, the volume of the primary chamber increases and the volume of the secondary chamber decreases. In this way, at certain small vibratory amplitudes and high frequencies, the major fluid flow is through the decoupler and undesirable hydraulic damping is eliminated. In effect, this freely floating decoupler is a passive tuning device.
In addition to the large central orifice, a smaller orifice track is provided, extending around the perimeter of the orifice plate. Each end of the track has one opening; one communicating with the primary chamber and the other to the secondary chamber. The orifice track provides the hydraulic mount assembly with another passive tuning component, and when combined with the freely floating decoupler provides at least three distinct dynamic modes of operation. The operating mode is primarily determined by the flow of the fluid between the two chambers.
More specifically, small amplitude vibrating inputs, such as from the engine or the like, produce no damping due to decoupling, as described above. On the other hand, large amplitude vibrating inputs produce high velocity fluid flow through the orifice track, and accordingly, a high level of damping force and smoothing action. As a third (intermediate) operational mode of the mount, medium amplitude inputs produce lower velocity fluid flow through the orifice track resulting in the desired medium level of damping. In each instance, as the decoupler moves from one seated position to the other, a relatively limited amount of fluid can bypass the orifice track by moving around the sides of the decoupler to smooth the transition between the operational modes.
While the three distinct modes of operation provided by the present production hydraulic mounts thus provide generally satisfactory operation, they are not sufficient to furnish the desired maximum damping and noise suppression under all the continuously varying conditions encountered during vehicle operation. In response to this need, one approach is to provide a dynamic system that utilizes a pneumatic bladder to engage the diaphragm in such a way as to module fluid flow into the secondary chamber, as set forth in U.S. patent application No. 929,328, now U.S. Pat. No. 4,756,513 filed Nov. 10, 1986, entitled "Variable Hydraulic-Elastomeric Assembly".
Specifically, an inflatable bladder is mounted externally and in close proximity to the diaphragm, so when inflated, the bladder occupies the area of normal diaphragm expansion. This in effect creates an artificial stiffening of the diaphragm, and in turn adds resistance to the movement of the fluid between the chambers. Thus, operation of the hydraulic mount is variable in response to driving conditions by varying the air pressure inside the bladder. The pressure is controlled by a computer in response to transducers mounted on the vehicle. At a maximum bladder inflation, the diaphragm is forced toward the partition and into positive engagement with the decoupler. In this manner, the decoupler is disabled and forced into a seated position toward the primary chamber, creating a condition of maximum stiffness in the mount.
Another hydraulic mount assembly in the prior art is disclosed in U.S. Pat. No. 4,583,723 to Ozawa. The movement of a two portion plate between the two chambers is controlled by an electromagnetic coil. This system provides either minimum damping by allowing maximum plate movement when the coil is de-energized, or maximum damping by restricting the movement when energized. Hence, the mount operates as an ON/OFF device, without any appreciable intermediate decoupler control. The plate is not allowed to float with a varying degree of restriction, thus substantially limiting the modulation capability.
A need is therefore identified for an improved hydraulic mount assembly that provides for an active or variable control of the dynamic characteristics. The dynamic characteristics of the mount can then be tuned, either manually or automatically, to provide the most effective and efficient damping and noise suppression over the entire range of expected operating conditions. It is desirable that vibration/noise circumstances, and any combination, such as engine lugging, rough road conditions, sudden turning and/or rapid acceleration or deceleration, be controlled in a novel and more efficient manner.
SUMMARY OF THE INVENTION
Accordingly, it is a primary object of the present invention to provide an improved hydraulic mount assembly overcoming the above-described limitations and disadvantages of the prior art limited to passive tuning concepts.
An additional object of the present invention is to provide a hydraulic mount assembly with active tunable dynamic characteristics.
Another object of the present invention is to provide a hydraulic mount assembly that is infinitely tunable to more efficiently and effectively isolate vibrations and suppress noise over the full range of vehicle operating and road conditions.
Still another object of the present invention is to provide a reliable hydraulic mount assembly of simple construction and that is inexpensive to build and capable of furnishing infinitely variable dynamic characteristics.
A further object of the present invention is to provide a hydraulic mount that allows the dynamic characteristics to be actively controlled by varying the flow of fluid between the two chambers of the mount assembly in response to an all electronic control circuit.
According to the present invention, these objectives are accomplished by controlling the bypass fluid flow around the decoupler, so that for a given vibration of a certain amplitude and frequency, a different amount of fluid is displaced through the orifice track. Thus, the damping characteristics of the assembly may be actively tuned as required for maximum vibration isolation, and consequently a smoother, quieter ride.
Additional objects, advantages, and other novel features of the invention will be set forth in part in the description that follows and in part will become apparent to those skilled in the art upon examination of the following or may be learned with the practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
To achieve the foregoing and other objects, and in accordance with the purposes of the present invention as described herein, an actively tunable hydraulic mount assembly is provided for damping and isolating engine and transmission vibrations. The preferred embodiment of the mount assembly selected to illustrate the invention employs the basic structure including the passive tuning, orifice track feature, shown in the co-pending application, Ser. No. 008,851, referred to above. In particular, the mount assembly includes a pair of mounting members connected to each other through a hollow elastomeric body of natural or synthetic rubber. This hollow body is closed by a resilient diaphragm so as to form a cavity for a damping liquid, which may be a commercial engine antifreeze coolant. A partition or plate is provided to divide the fluid filled cavity into two distinct chambers. The primary chamber is formed between the partition and the interior wall of the hollow body. The secondary chamber is formed between the partition and the interior wall of the diaphragm.
The partition further includes a decoupler and an orifice track connecting the two chambers. Certain engine vibration forces within the design amplitudes and frequencies of the mount produce a contraction of the hollow body and primary chamber. Upon contraction (compression), the decoupler is actuated with some bypass liquid flowing from the primary to the secondary chamber, and additional liquid flowing around the orifice track. Once the decoupler is in a seated position in the direction of the fluid flow, fluid communication is limited to that through the orifice track at the designed rate of flow. This entering liquid causes stretching of the diaphragm, increasing the volume of the secondary chamber. Then upon reversal of the force, resulting in expansion of the primary chamber, the stretched diaphragm contracts forcing liquid back to the primary chamber, completing the damping cycle.
In addition to the above basic structure, the mount assembly of the invention is characterized by the active tuning concept referred to briefly above and specifically in the form of a variable control means for modulating bypass flow around the decoupler. In this way, the flow of damping liquid between the two chambers may be infinitely varied or adjusted as between the bypass and the full orifice track flow, and the dynamic characteristics of the mount assembly is thus actively tuned to the particular design parameters desired.
Of particular significance, the control means may be utilized to actively modulate the liquid flow between the chambers in response to the vibration being produced at any given time under any given vehicle operating and road conditions. Thus, the mount assembly is not only advantageously infinitely variable, but may be directly responsive to sensing means, such as vehicle mounted transducers, so as to more efficiently and effectively isolate vibrations. This active control means for the mount of the invention is highly effective over a broader range of amplitudes and frequencies than previously attainable.
Preferably, the control of bypass flow through the central orifice, past the decoupler, is accomplished by restraining the decoupler from floating freely to a seated position within the divider plate. Two seated positions are provided within the divider plate, with a first seated position being toward the primary chamber, and a second seated position being toward the secondary chamber. A variable force, that may be pulsed, is preferably applied to the decoupler to induce movement toward or away from the seated position and opposite to or in the direction of fluid flow so that the fluid flow through the orifice is actively controlled.
For example, as fluid is forced from the primary to the secondary chamber by vehicle vibrations, the decoupler may be restrained from being pushed by the fluid toward the second seated position by inducing it to move by an outside, magnetic force toward the first seated position. Thus bypass flow may continue through the central orifice in a controlled manner, thereby actively controlling the damping characteristics. Of course, if maximum damping stiffness is desired, the variable force can instead be utilized to seat the decoupler in either direction, completely stopping bypass flow through the central orifice.
The means for applying the variable magnetic force is supplied by an electric coil, preferably mounted exterior to the hollow cavity, but inside the confines of the mount assembly so as to be fully protected. The coil is preferably fixed on the inside of the mounting member adjacent the diaphragm so that only the wires to the coil are exposed.
The decoupler is made of a magnetically-responsive material, preferably steel, with the rim covered with a magnetic rubber or plastic. The divider plate is a non-magnetic material, such as aluminum or plastic. The coil is oriented so that the magnetic force produced restrains the magnetic decoupler from floating freely relative to the divider plate, and thereby controls liquid flow. And for more efficiency, a core is added and the diaphragm is modified so as to locate the former in close proximity to the decoupler.
The magnetic force intensity is infinitely variable by changing the control voltage supplied to the coil. Hence a small voltage produces minimal restraint of the magnetic decoupler, whereas a large voltage forces the decoupler to one of the seated positions against the orifice plate, completely stopping fluid flow past the decoupler. Of course, when the decoupler is in a seated position with no liquid flowing past it, the normal damping flow between the chambers still occurs via the orifice track, which yields the maximum stiffness condition of the mount.
If the decoupler is magnetized, then the direction of decoupler travel or restraint, toward the first or second seated positions, depends upon the direction of the magnetic field. By changing the polarity of the control voltage supplied to the coil, the magnetic field can be reversed from an attracting mode to a repelling mode, thus providing the bi-directional movement of the decoupler. The appropriate control voltage is supplied by a variable voltage source, which is responsive to the control means. If the decoupler is a steel plate then the direction of decoupler travel is always toward the coil, regardless of the direction of the magnetic field.
Thus, the fluid flow between the two chambers in response to a given amplitude and frequency of vibration is altered. As such, the dynamic characteristics of the assembly may be actively adjusted or tuned to provide the desired vibration/noise isolation in response to any particular vehicle operating conditions that can be expected to occur, or alternatively, that do occur during operation.
In accordance with another aspect of the present invention, a particularly advantageous approach is taken to assure that the dynamic characteristics of the mount assembly may be efficiently tuned in direct response to the varying operating and road conditions, that is simultaneously as they are encountered by the vehicle and without operator intervention. Specifically, a control circuit, including a microprocessor and associated on-board sensors or transducers, is provided. The transducers sense selected parameters, such as engine vibration amplitude and frequency that change, for example, when the engine is idling, lugging or being rapidly accelerated. The transducers indicate these vibration conditions to the microprocessor that is preprogrammed to then module the voltage supplied to the coil varying the magnetic force intensity and direction. In this way, the position of the magnetic decoupler can be varied to control fluid flow between the chambers. For example, a decrease in the magnetic force may produce an increase in bypass fluid flow while an increase in magnetic force decreases such fluid flow. Thus, the dynamic characteristics of the assembly are automatically controlled and actively tuned, providing maximum damping effect and noise suppression for smoother and quieter engine and/or transmission operation.
Still other objects of the present invention will become apparent to those skilled in this art from the following description wherein there is shown and described a preferred embodiment of this invention, simply by way of illustration of one of the modes best suited to carry out the invention. As it will be realized, the invention is capable of other different embodiments and its several details are capable of modifications in various, obvious aspects all without departing from the invention. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWING
The accompanying drawing incorporated in and forming a part of the specification illustrates several aspects of the present invention and together with the description serves to explain the principles of the invention.
FIG. 1 is a schematical representation of the control circuit and electromagnetic coil of the hydraulic mount assembly of the present invention.
FIG. 2 is a cross-sectional view of the hydraulic mount assembly with the decoupler in an intermediate position.
FIG. 3 is a partial cross-sectional view taken along line 3--3 of FIG. 2 showing the electromagnetic coil positioned in the mounting member of the hydraulic mount.
FIG. 4 is an enlarged cross-sectional view taken along line 4--4 of FIG. 2 showing the cavity within the partition where bypass fluid flows around the decoupler.
FIG. 5 is a view like FIG. 2 but with a modified electromagnetic coil and diaphragm.
Reference will now be made in detail to the present preferred embodiment of the invention, an example of which is illustrated in the accompanying drawing.
DETAILED DESCRIPTION OF THE INVENTION
Reference is now made to the drawing showing the improved hydraulic-elastomeric mount assembly of the present invention particularly adapted for mounting an internal combustion engine in a vehicle. The dynamic characteristics of the mount assembly may be adjusted or tuned to meet the specific application. As a result, the desired amplitude control, as well as the coefficient of damping and resulting dynamic rate best suited to isolate a particular set of vibration conditions, can be obtained.
The mount assembly includes a cast metal mounting member 10 and stamped sheet metal mounting member 12, as shown in FIG. 2. The mounting members 10 and 12 each have a pair of studs 14, 16, respectively. These studs 14, 16 project outwardly from the mounting members 10, 12 for attachment respectively to an engine (not shown) and an engine supporting cradle or frame of a vehicle (not shown).
A hollow elastomeric body 18 interconnects the mounting members 10, 12. The body 18 is constructed of natural or synthetic rubber. More specifically, the body 18 may be molded to and about the mounting member 10 and includes an embedded stamped sheet metal retainer 20.
The body 18 defines a hollow cavity 22 for receiving a damping liquid, such as commercial engine antifreeze/coolant. Oppositely located voids 24 are formed in the body 18 between the mounting member 10 and the retainer 20. These voids 24 provide directional dynamic rate control within the elastomeric body 18 itself and form a part of the damping liquid cavity 22. As is known in the art, such voids 24 are especially useful in isolating certain internal combustion engine vibrations.
Together, the mounting member 10, elastomeric body 18 and metal retainer 20 form a first subassembly or cover of the mount assembly. The retainer 20 includes an outwardly projecting collar 26 at its lower periphery. The collar 26 is formed to receive a second subassembly or base. The base comprises the mounting member 12 and elastomeric diaphragm 28 of natural or synthetic rubber, a partition 30 with the flow orifice and a damping decoupler 32 with a sealing ring 33, described in further detail below.
The elastomeric diaphragm 28 includes an annular rim portion 34 having peripheral groove formed between upper and lower shoulders 38, 40 respectively. The shoulders 38, 40 are flexible so as to receive the outer edge of the partition 30. Thus, the partition 30 is sealingly engaged by the shoulders 38, 40 on opposite sides of the groove.
The mounting member 12 is formed with a collar to receive the rim portion 34 of the diaphragm 28. The collar of the mounting member 12 fits within the collar 26 of the retainer 20. As is known in the art, tabs (not shown) may be provided on the collar 26 and bent over to retain the whole mount assembly together.
The elastomeric diaphragm 28 closes the elastomeric body 18 so as to form therewith the closed damping cavity 22. This cavity 22 is divided by the partition 30 into a primary chamber 46 enclosed by the elastomeric body 18 and a secondary chamber 48 enclosed by the diaphragm 28.
The partition 30 is formed of non-magnetic material, such as die cast aluminum as shown, or plastic; and includes a pair of plates 50, 52 with matching peripheries. As shown in FIG. 2, these plates span the cavity 22 and cooperate to define an extended damping orifice track 54 interconnecting the chamber 46, 48. One opening 56 is provided at the one end of the orifice track 54 in the plate 50 through which the orifice communicates with the primary chamber 46 (see FIG. 2). A similar opening (not shown) is provided in the plate 52 at the opposite end of the orifice track 54 for communication between the orifice and the secondary chamber 48. Thus, the orifice track 54 interconnects the chambers and may be formed to a selected length.
When a vibratory input is provided to the mount assembly, liquid flows through and around the extended orifice track 54. The fluid exchange between the primary and secondary chambers 46, 48 produces the passively tuned damping effect due to the designed resonance of the column of liquid in the orifice track 54. The increased resistance to flow along the orifice and the inertial effects of the liquid column provides this proven prior art tuning action.
From the above description of the basic mount assembly, it is clear that a passive tuning mode is employed. In our discovery, passive tuning is enhanced by the addition of active tuning of the damping characteristics. Thus, as will be more fully described below, and in accordance with the broad aspects of the present invention, the overall dynamic characteristics of the mount assembly are actively tuned to damp vibration at any particular amplitude and frequency produced during vehicle operation. In short, to achieve this result, the bypass flow of damping liquid between the two chambers 46, 48 is infinitely varied by continuously controlling the position of the decoupler 32, thus regulating the fluid flow around the decoupler to a desired valve.
The hydraulic damping decoupler 32, known in the art and fully described in the previously referenced co-pending patent applications, takes the form of a rectangular plate. However, to provide active, infinitely variable damping, the decoupler 32 of this invention must be magnetically responsive. That is, it must have a metal component with a ferrous content sufficient to move the decoupler in response to an applied variable magnetic field. The sealing ring 33 is also preferably formed of a magnetic rubber so as to also be responsive to an applied magnetic field. The decoupler 32 is otherwise free floating (see FIGS. 2 and 4) since the plates 50, 52 are non-magnetic.
The decoupler 32 is mounted for its limited free floating reciprocal movement in central orifice 60 (see FIG. 4). The respective upper and lower faces of the decoupler 32 are directly engaged by the damping liquid within the primary and secondary chamber 46, 48. A first seated position is attained when decoupler 32 is forced toward the primary chamber 46 and into positive contact with plate 50, forming a liquid-tight seal. A second seated position is similarly attained when the decoupler 32 is forced toward the secondary chamber 48, forming a liquid-tight seal at plate 52. The sealing ring 33 is molded to the perimeter of the decoupler 32, to effect the liquid-tight seal when the decoupler is in either the first or the second seated position.
Means for applying a variable force are provided to utilize the magnetically responsive characteristic of the decoupler 32 to regulate bypass fluid flow through the central cavity 60 to the desired value. The applying means includes a variable voltage source 80 to supply a control voltage, and an electric coil 70, powered by the control voltage. The coil 70 is secured to the inside of mounting member 12, just outside the diaphragm 28 and opposite the decoupler 32, as shown in FIGS. 2 and 3. Advantageously, the coil 70 is fully protected with only the wire leads 82 extending from inside the mount assembly (see FIG. 3).
The coil 70 is oriented so that a magnetic force produced by energization of the coil induces the decoupler 32 toward a seated position. If the decoupler is magnetized, then whether the decoupler 32 is forced toward the first or second seated position will depend upon the direction of the current flowing through the coil and whether the decoupler is magnetized. And this will be in accordance with the right-hand rule of electromagnetism. By controlling the direction of current flow, or in equivalent terms, by changing the polarity of the voltage applied to the coil, the decoupler is capable of bi-directional movement. Choosing the direction of movement of the decoupler within the plates 50, 52 to outward and away from the chamber 46, 48 produces a limited volume change in the chambers that effects hydraulic coupling.
Bypass fluid flow around all sides of the decoupler 32 (note flow arrows in FIG. 4) is selectively controlled by varying not only the direction, but also the intensity of the magnetic force produced by coil 70. The intensity of the magnetic force increases with an increase in the control voltage applied to the coil 70. Hence, the decoupler 32 can be either forced into a seated position at a maximum magnetic force, or variable restrained from being pushed toward a seated position by fluid flow, as a conventional, free floating decoupler would be.
For more damping effect, the decoupler 32 is restrained from moving from its normal seated position by the magnetic force, thus reducing the bypass fluid flow and forcing the fluid to flow around the orifice track 54. For less damping effect, the decoupler 32 is controlled by the infinitely variable magnetic force in the opposite direction; that is prevented from moving to and/or staying in the seated position (see FIGS. 2 and 4). For another mode of operation, the magnetic force is decreased or turned off all together, to allow the decoupler to more readily move to the seated position thus allowing the normal, design bypass flow to resume.
The operation of the coil 70 may also be pulsed to provide still another mode with the bypass fluid volume rapidly changing and in effect canceling similar undesirable vibrations imposed on the mount. By rapid, bi-directional pulsing, the effects of the decoupler 32 can also be infinitely varied.
The magnetic force produced by coil 70 may be enhanced by the inclusion of a magnetic core as shown in FIG. 5. This would produce a greater magnetic force for a given coil voltage, thereby advantageously conserving power as described in more detail later.
With the decoupler 32 firmly seated, producing a liquid-tight seal at the central orifice 60 of partition 30, the only fluid communication between chamber 46 and 48 is via orifice track 54, at the designed rate of flow which yields a condition of maximum stiffness of the mount.
At values of magnetic force less than the maximum, the total fluid flow between chamber 46 and 48 is the combination of flow through the orifice track 54 and through the central orifice 60 of partition 30, around decoupler 32. Flow through the orifice track 54 is restricted to a constant designed rate, whereas bypass flow around the decoupler 32 is varied by the intensity of the magnetic force. Hence, the total fluid flow is controlled by varying the magnetic force, thereby actively controlling the damping characteristics of the mount assembly.
To illustrate the operation of the mount assembly, first assume a compressive force from vibratory action being impressed across mounting members 10, 12 producing a contraction of the primary chamber 46. As this occurs, the liquid therein is forced to flow into the chamber 48 through the orifice track 54 and around the decoupler 32, if the magnetic force is below the maximum value. The chamber 48 then expands as permitted by the elasticity of the diaphragm 28. On reversal of vibratory force, that is release of the compressive force, the memory of the elastomeric body 18 and the diaphragm 28 causes the primary chamber 46 to expand and the stretched diaphragm 28 to retract. The contraction of the secondary chamber 48 forces the damping liquid back through the orifice track 54 and around the decoupler 32 if not seated, and into the primary chamber 46, completing the damping cycle.
The circuit for controlling the variable voltage source 80 to energize the coil 70 in precisely the desired manner is shown schematically in FIG. 1. As shown, the coil 70 is connected to variable voltage source 80 by wiring leads 82. The variable voltage source 80, which may include a rheostat and a switching means for reversing the voltage polarity, is responsive to a microprocessor 84, through line 86. The microprocessor 84 is connected through signal feed lines 88 to a series of transducers 90, which form a means for sensing vehicle operating conditions and resulting vibrations. The transducers 90 are mounted on-board the vehicle, such as on the engine and the frame of the vehicle at various locations in order to instantaneously sense vibration amplitude and frequency during operation. To be more specific, transducers 90 may be strain gauges and positioned in engagement with the engine block and frame (see FIG. 1) adjacent the mount assemblies. These transducers 90 are sensitive to the full range of vibratory conditions produced during, for example, idling, rapid acceleration and deceleration, highway cruising and engine lugging.
The information relative to vibration amplitude and frequency that is sensed by the transducer 90 is immediately communication along the lines 88 to the microprocessor 84. The information is then processed and a preprogrammed response output signal is communicated along line 86 to the variable voltage source 80. Specifically, the voltage to the coil 70 is modulated and either increased, decreased, and/or reversed in polarity as required, producing the most effective damping and isolation of engine vibrations for the smoothest possible ride.
The coil voltage is decreased or turned off by the microprocessor 84 in response to low vibration frequencies and amplitudes sensed by the transducers 90, such as during engine idling. This produces a corresponding reduction in the magnetic force, which allows an increase in the designed reciprocating motion of the decoupler and the accompanying designed bypass fluid flow around decoupler 32 to provide the smooth transition in damping action. Thus, in a no-voltage or minimum voltage state of the voltage source 80, the mount assembly exhibits relatively soft damping qualities to isolate the low frequency/small amplitude vibrations.
When, for example, the engine is then accelerated rapidly from idle, the frequency and amplitude of engine vibrations are increased. The microprocessor 84 processes the information and sends a response signal to the variable voltage source 80 to increase the voltage to the coil 70. This voltage increase produces a corresponding increase in the magnetic force, which selectively controls the decoupler 32 so as to move readily to a seated position and force the fluid around the orifice track 54. The bypass fluid moving around the decoupler 32 is reduced. As a result, the mount assembly exhibits relatively stiffer qualities than exhibited during engine idling. The mount assembly provides increased damping characteristics for accommodating vibration of increase amplitude.
During certain other operating conditions, such as under hard cornering or engine lugging, the mount assembly also exhibits peak damping levels at high amplitudes and low frequencies. Upon sensing such conditions, the microprocessor 84 directs the variable voltage source 80 to again momentarily increase the magnetic force to a maximum value. This forces the decoupler 32 into a seated position, completely sealing the central orifice 60 of partition 30. In this operational mode, the mount assembly exhibits the stiffest qualities. Fluid flow between the chambers 46, 48 is substantially limited to that through the orifice track 54, producing a large damping effect at the high amplitudes and low frequencies.
Of course, in between the three conditions described above are an infinite number of control variations, so that in effect the restriction of the fluid flow between the chamber 46, 48 is infinitely variable. This feature of active control allows the mount assembly of the invention to respond to virtually all conditions of vibrations that might be encountered for maximum damping action.
In summary, numerous benefits result from employing the concepts of the present invention. The hydraulic mount assembly incorporates a magnetically-responsive decoupler 32 that acts in cooperation with a variable magnetic force supplied by coil 70. The variable magnetic force is applied to either restrain the decoupler 32 from being pushed toward a seated position by fluid forces, or to force the decoupler 32 into a seated position, completely restricting bypass fluid flow around the decoupler. When the decoupler is firmly seated by a maximum magnetic force, fluid flow between the primary chamber 46 and the second chamber 48 is limited to that through the orifice track 54, providing a maximum stiffness for the mount. Specifically, by modulating the voltage supplied to the coil 70, the damping characteristic of the assembly so actively tuned so as to best dampen troublesome vibrations occurring during any particular operating conditions. The transducers 90 may be provided to instantaneously sense the amplitude and frequency of vibrations being produced at any given time. The preprogrammed microprocessor 84 is provided to instantaneously process the information from the transducers 90. The microprocessor 84 in turn operates a variable voltage source 80 to modulate the magnetic force produced by coil 70, automatically yielding the most effective and efficient damping and vibration isolation.
Moreover, the efficiency of the magnetic action on the decoupler can be significantly improved where desired by the addition of a core and modification of the diaphragm as shown in the embodiment in FIG. 5 wherein the same numerals are used to identify previously described parts and new numerals are used to identify the added and modified parts. In the FIG. 5 embodiment, a cylindrical iron core 100 is mounted centrally of the coil 70 with its base 102 fixed to the mounting member 12. The core extends upwardly substantially beyond the coil so that its upper end 104 is located in close proximity to the decoupler 32 as permitted by an accommodating cavity 106 now formed in the diaphragm 28 centrally thereof directly beneath the decoupler. As a result, the gap in the magnetic field is substantially reduced so that less magnetic force need be generated to control the decoupler action.
The foregoing description of the preferred embodiment of the invention have been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as is suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with breadth to which they are fairly, legally and equitably entitled.
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A hydraulic mount assembly is disclosed having a partition including a damping decoupler between two hydraulic chambers. One chamber is formed by an elastomeric member and the other by a resilient diaphragm. During dynamic loading of the mount, fluid passes between the two chambers of the mount by moving around an orifice track and/or by bypass around the decoupler causing expansion and contraction of the diaphragm. A magnetic coil is provided adjacent the diaphragm in alignment with the decoupler to supply a controlling magnetic field. The decoupler is made of a magnetic material and is positionally responsive to the variations in the intensity and direction of the controlling magnetic field. By actively controlling the decoupler position in this manner, the dynamic characteristics of the mount are varied. A control circuit with on-board transducers is provided to monitor vehicle operating and road response conditions and modulate the voltage to the magnetic coil for maximum damping effect. The on-board transducers sense selected parameters to indicate unusual conditions for which modulation is required, such as rough engine operation, engine lugging, rough road conditions, sudden turning and/or rapid acceleration/deceleration.
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CROSS REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part application of co-pending U.S. patent application Ser. No. 09/398,919 filed on Sep. 16, 1999.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to a golf ball. More specifically, the present invention relates to a dimple pattern for a golf ball in which the dimple pattern has different sizes of dimples.
[0005] 2. Description of the Related Art
[0006] Golfers realized perhaps as early as the 1800's that golf balls with indented surfaces flew better than those with smooth surfaces. Hand-hammered gutta-percha golf balls could be purchased at least by the 1860's, and golf balls with brambles (bumps rather than dents) were in style from the late 1800's to 1908. In 1908, an Englishman, William Taylor, received a patent for a golf ball with indentations (dimples) that flew better ad more accurately than golf balls with brambles. A. G. Spalding & Bros., purchased the U.S. rights to the patent and introduced the GLORY ball featuring the TAYLOR dimples. Until the 1970s, the GLORY ball, and most other golf balls with dimples had 336 dimples of the same size using the same pattern, the ATTI pattern. The ATTI pattern was an octahedron pattern, split into eight concentric straight line rows, which was named after the main producer of molds for golf balls.
[0007] The only innovation related to the surface of a golf ball during this sixty year period came from Albert Penfold who invented a mesh-pattern golf ball for Dunlop. This pattern was invented in 1912 and was accepted until the 1930's.
[0008] In the 1970's, dimple pattern innovations appeared from the major golf ball manufacturers. In 1973, Titleist introduced an icosahedron pattern which divides the golf ball into twenty triangular regions. An icosahedron pattern was disclosed in British Patent Number 377,354 to John Vernon Pugh, however, this pattern had dimples lying on the equator of the golf ball which is typically the parting line of the mold for the golf ball. Nevertheless, the icosahedron pattern has become the dominant pattern on golf balls today.
[0009] In the late 1970s and the 1980's the mathematicians of the major golf ball manufacturers focused their intention on increasing the dimpled surface area (the area covered by dimples) of a golf ball. The dimpled surface for the ATTI pattern golf balls was approximately 50%. In the 1970's, the dimpled surface area increased to greater than 60% of the surface of a golf ball. Further breakthroughs increased the dimpled surface area to over 70%. U.S. Pat. No. 4,949,976 to William Gobush discloses a golf ball with 78% dimple coverage with up to 422 dimples. The 1990's have seen the dimple surface area break into the 80% coverage.
[0010] The number of different dimples on a golf ball surface has also increased with the surface area coverage. The ATTI pattern disclosed a dimple pattern with only one size of dimple. The number of different types of dimples increased, with three different types of dimples becoming the preferred number of different types of dimples. U.S. Pat. No. 4,463 to Oka et al., discloses a dimple pattern with four different types of dimples on surface where the non-dimpled surface cannot contain an additional dimple. United Kingdom patent application number 2157959, to Steven Aoyama, discloses dimples with five different diameters. Further, William Gobush invented a cuboctahedron pattern that has dimples with eleven different diameters. See 500 Year of Golf Balls , Antique Trade Books, page 189. However, inventing dimple patterns with multiple dimples for a golf ball only has value if such a golf ball is commercialized and available for the typical golfer to play.
[0011] Additionally, dimple patterns have been based on the sectional shapes, such as octahedron, dodecahedron and icosahedron patterns. U.S. Pat. No. 5,201,522 discloses a golf ball dimple pattern having pentagonal formations with equally number of dimples therein. U.S. Pat. No. 4,880,241 discloses a golf ball dimple pattern having a modified icosahedron pattern wherein small triangular sections lie along the equator to provide a dimple-free equator.
[0012] Although there are hundreds of published patents related to golf ball dimple patterns, there still remains a need to improve upon current dimple patterns. This need is driven by new materials used to manufacture golf balls, and the ever increasing innovations in golf clubs.
BRIEF SUMMARY OF THE INVENTION
[0013] The present invention provides a novel dimple pattern that reduces high speed drag on a golf ball while increasing its low speed lift thereby providing a golf ball that travels greater distances. The present invention is able to accomplish this by providing multiples sets of dimples arranged in a pattern that covers as much as eighty-six percent of the surface of the golf ball.
[0014] One aspect of the present invention is a dimple pattern on a golf ball in which the dimple pattern has at least eleven different sets of dimples. The golf ball includes first, second, third, fourth and fifth pluralities of dimples disposed on the surface. Each of the first plurality of dimples has a first diameter. Each of the second plurality of dimples has a second diameter that is greater than the first diameter. Each of the third plurality of dimples has a third diameter that is greater than the second diameter. Each of the fourth plurality of dimples has a fourth diameter that is greater than the third diameter. Each of the fifth plurality of dimples has a fifth diameter that is greater than the fourth diameter. The first, second, third, fourth and fifth pluralities of dimples cover at least eighty percent of the surface of the golf ball.
[0015] Another aspect of the present invention is a golf ball having at least 382 dimples. The 382 dimples are partitioned into at least eleven different sets of dimples. Each of the eleven different sets of dimples have a different diameter than any other set of dimples. The 382 dimples cover at least 87% of the surface of the golf ball
[0016] Yet another aspect of the present invention is a golf ball having a core and cover. The core has a diameter of 1.50 inches to 1.56 inches, and is composed of a polybutadiene material. The cover encompasses the core and has a thickness of 0.05 inch to 0.10 inch. The cover is preferably composed of an ionomer blend of material. The cover has a surface which has 382 dimples. The 382 dimples are partitioned into at least eleven different sets of dimples. Each of the eleven different sets of dimples have a different diameter than any other set of dimples. The 382 dimples cover at least 87% of the surface of the cover.
[0017] Having briefly described the present invention, the above and further objects, features and advantages thereof will be recognized by those skilled in the pertinent art from the following detailed description of the invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0018] [0018]FIG. 1 is a cross-section of a golf ball of the present invention.
[0019] [0019]FIG. 2 is an equatorial view of a preferred embodiment of a golf ball of the present invention.
[0020] [0020]FIG. 3 is an equatorial view of a preferred embodiment of a golf ball of the present invention.
[0021] [0021]FIG. 4 is a polar view of the golf ball of FIG. 1.
[0022] [0022]FIG. 5 is an enlarged cross-sectional view of a dimple of a first set of dimples of the golf ball of the present invention.
[0023] [0023]FIG. 5A is an isolated cross-sectional view to illustrate the definition of the entry radius.
[0024] [0024]FIG. 6 is an enlarged cross-sectional view of a dimple of a tenth set of dimples of the golf ball of the present invention.
[0025] [0025]FIG. 7 is an enlarged cross-sectional view of a dimple of a twelfth set of dimples of the golf ball of the present invention.
[0026] [0026]FIG. 8 is an enlarged cross-sectional view of a dimple of a seventh set of dimples of the golf ball of the present invention.
[0027] [0027]FIG. 9 is an enlarged cross-sectional view of a dimple of a fifth set of dimples of the golf ball of the present invention.
[0028] [0028]FIG. 10 is an enlarged cross-sectional view of a dimple of a second set of dimples of the golf ball of the present invention.
[0029] [0029]FIG. 11 is the view of FIG. 1 illustrating the rows of dimples.
[0030] [0030]FIG. 12 is the view of FIG. 1 illustrating the transition region of dimples.
[0031] [0031]FIG. 13 is the view of FIG. 2 illustrating the cascading pentagons of dimples.
[0032] [0032]FIG. 14 is the view of FIG. 2 illustrating the single encompassing pentagon of dimples.
[0033] [0033]FIG. 15 is a graph of the lift coefficient for a Reynolds number of 70,000 at 2000 rotations per minute (x-axis) versus the drag coefficient for a Reynolds number of 180,000 at 3000 rotations per minute (y-axis).
DETAILED DESCRIPTION OF THE INVENTION
[0034] As shown in FIGS. 1, a golf ball is generally designated 20 . The golf ball is preferably a two-piece with a solid core and a cover such as disclosed in co-pending U.S. patent application 09/______ , for a Golf Ball, Assignee's corporate docket number PU1177, filed on an even date herewith, and incorporated by reference. However, those skilled in the pertinent art will recognize that the aerodynamic pattern of the present invention may by utilized on the three-piece golf ball, one-piece golf ball, or multiple-layer golf ball without departing from the scope and spirit of the present invention.
[0035] A cover 21 of the golf ball 20 may be any suitable material. A preferred cover 21 is composed of a thermoplastic material such as an ionomer material. However, those skilled in the pertinent art will recognize that other cover materials may be utilized without departing from the scope and spirit of the present invention. The golf ball 20 may have a finish of a basecoat and/or top coat with a logo indicia. A core 23 of the golf ball is preferably composed of a polybutadiene material.
[0036] As shown in FIGS. 2 - 4 , the golf ball 20 has a surface 22 . The golf ball 20 also has an equator 24 dividing the golf ball 20 into a first hemisphere 26 and a second hemisphere 28 . A first pole 30 is located ninety degrees along a longitudinal arc from the equator 24 in the first hemisphere 26 . A second pole 32 is located ninety degrees along a longitudinal arc from the equator 24 in the second hemisphere 28 .
[0037] On the surface 22 , in both hemispheres 26 and 28 , are a plurality of dimples partitioned into multiple different sets of dimples. In a preferred embodiment, the number of dimples is 382, and the different sets of dimples are 12. Sets of dimples may vary primarily by diameter, however, the edge radius and depth may also vary for different sets of dimples. In a preferred embodiment there are 11 different sets of dimples by diameters.
[0038] In a preferred embodiment, there is a first plurality of dimples 40 , a second plurality of dimples 42 , a third plurality of dimples 44 , a fourth plurality of dimples 46 , a fifth plurality of dimples 48 , a sixth plurality of dimples 50 , a seventh plurality of dimples 52 , an eighth plurality of dimples 54 , a ninth plurality of dimples 56 , a tenth plurality of dimples 58 , an eleventh plurality of dimples 60 and a twelfth plurality of dimples 62 .
[0039] In the preferred embodiment, each of the first plurality of dimples 40 has the largest diameter dimple, and each of the twelfth plurality of dimples 62 has the smallest diameter dimples. The diameter of a dimple is measured from a surface inflection point across the center of the dimple to an opposite surface inflection point. The surface inflection points are where the land surface 25 ends and where the dimples begin. Each of the second plurality of dimples 42 has a smaller diameter than the diameter of each of the first plurality of dimples 40 . Each of the third plurality of dimples 44 has a smaller diameter than the diameter of each of the second plurality of dimples 42 . Each of the fourth plurality of dimples 46 has a smaller diameter than the diameter of each of the third plurality of dimples 44 . Each of the fifth plurality of dimples 48 has a diameter that is equal to or smaller than the diameter of each of the fourth plurality of dimples 46 . Each of the sixth plurality of dimples 50 has a smaller diameter than the diameter of each of the fifth plurality of dimples 48 . Each of the seventh plurality of dimples 52 has a smaller diameter than the diameter of each of the sixth plurality of dimples 50 . Each of the eighth plurality of dimples 54 has a smaller diameter than the diameter of each of the seventh plurality of dimples 52 . Each of the ninth plurality of dimples 56 has a smaller diameter than the diameter of each of the eighth plurality of dimples 54 . Each of the tenth plurality of dimples 58 has a smaller diameter than the diameter of each of the ninth plurality of dimples 56 . Each of the eleventh plurality of dimples 60 has a smaller diameter than the diameter of each of the tenth plurality of dimples 58 . Each of the twelfth plurality of dimples 62 has a smaller diameter than the diameter of each of the eleventh plurality of dimples 60 .
[0040] In a preferred embodiment, the fourth plurality of dimples 46 are the most numerous. The second plurality of dimples 42 , the third plurality of dimples 44 , and the eighth plurality of dimples 60 are the equally the second most numerous. The next most numerous are the fifth plurality of dimples 48 . The next most numerous are the sixth plurality of dimples 50 , the seventh plurality of dimples 52 , the ninth plurality of dimples 56 , and the eleventh plurality of dimples 60 . The next most numerous are the first plurality of dimples 40 and the tenth plurality of dimples 58 . The twelfth plurality of dimples 62 is the least.
[0041] Table One provides a description of the preferred embodiment. Table One includes the diameter ( in inches), chord depth (in inches), entry angle, entry radius (in inches) and number of dimples.
TABLE One Dimple # of Dimple Chord Entry Entry Set Dimples Diameter Depth Angle Radius 1st 10 0.186 .0060 13.48 .0255 2nd 60 0.1698 .0059 14.31 .0382 3rd 60 0.1688 .0056 14.32 .0279 4th 70 0.1668 .0061 14.39 .0370 5th 30 0.1668 .0061 13.54 .0273 6th 20 0.161 .0055 12.92 .0286 7th 20 0.1606 .0058 14.67 .0144 8th 60 0.158 .0057 15.02 .0387 9th 20 0.148 .0055 14.18 .0265 10th 10 0.144 .0059 15.07 .0333 11th 20 0.124 .0055 14.95 .0336 12th 2 0.102 .0065 21.17 .0146
[0042] The two dimples of the twelfth set of dimples 62 are each disposed on respective poles 30 and 32 . Each of the tenth set of dimples 58 is adjacent one of the twelfth set of dimples 62 . The five dimples of the tenth set of dimples 58 that are disposed within the first hemisphere 26 are each an equal distance from the equator 24 and the first pole 30 . The five dimples of the tenth set of dimples 58 that are disposed within the second hemisphere 28 are each an equal distance from the equator 24 and the second pole 32 . These polar dimples 62 and 58 account for approximately 2% of the surface 22 of the golf ball 20 .
[0043] FIGS. 5 - 10 illustrate the cross-section of a dimple for some of the different sets of dimples.
[0044] A cross-section of a dimple of the first set of dimples 40 is shown in FIG. 5. The radius R 1 of the dimple 40 is approximately 0.093 inch, the chord depth C 1 is approximately 0.006 inch, the entry angle θ 1 is approximately 13.48 degrees, and the edge radius ER 1 is approximately 0.0255 inch. The ten dimples of the first set of dimples 40 cover approximately 3.8% of the surface 22 of the golf ball 20 . The ten dimples of the first set of dimples 40 that are disposed within the first hemisphere 26 are each an equal distance from the equator 24 and the first pole 30 . The ten dimples of the first set of dimples 40 that are disposed within the second hemisphere 28 are each an equal distance from the equator 24 and the second pole 32 .
[0045] Unlike the use of the term “entry radius” or “edge radius” in the prior art, the edge radius as defined herein is a value utilized in conjunction with the entry angle to delimit the concave and convex segments of the dimple contour. The first and second derivatives of the two Bézier curves are forced to be equal at this point defined by the edge radius and the entry angle, as shown in FIG. 5A. A more detailed description of the contour of the dimples is set forth in co-pending U.S. patent application Ser. No. 09/398,918, filed on Sep. 16, 1999, entitled Golf Ball Dimples With Curvature Continuity, which is hereby incorporated by reference in its entirety.
[0046] A cross-section of a dimple of the tenth set of dimples 58 is shown in FIG. 6. The radius R 10 of the dimple 58 is approximately 0.072 inch, the chord depth C 10 is approximately 0.0059 inch, the entry angle θ 10 is approximately 15.7 degrees, and the edge radius ER 10 is approximately 0.0333 inch.
[0047] A cross-section of a dimple of the twelfth set of dimples 62 is shown in FIG. 7. The radius R 12 of the dimple 62 is approximately 0.051 inch, the chord depth C 12 is approximately 0.0065 inches, the entry angle θ 12 is approximately 21.7 degrees, and the edge radius ER 12 is approximately 0.0146 inch.
[0048] A cross-section of a dimple of the seventh set of dimples 52 is shown in FIG. 8. The radius R 7 of the dimple 52 is approximately 0.0803 inch, the chord depth C 7 is approximately 0.0058 inch, the entry angle θ 6 is approximately 14.67 degrees, and the edge radius ER 7 is approximately 0.0144 inch. The ten dimples of the seventh set of dimples 52 that are disposed within the first hemisphere 26 are each an equal distance from the equator 24 and the first pole 30 . The ten dimples of the seventh set of dimples 52 that are disposed within the second hemisphere 28 are each an equal distance from the equator 24 and the second pole 32 .
[0049] All of the fifth set of dimples 48 are adjacent to at least one of the seventh set of dimples 52 . The thirty dimples of the fifth set of dimples 48 cover approximately 3.5% of the surface 22 of the golf ball 20 . The fifteen dimples of the fifth set of dimples 48 that are disposed within the first hemisphere 26 are each an equal distance from the first pole 30 . The fifteen dimples of the fifth set of dimples 48 that are disposed within the second hemisphere 28 are each an equal distance from the second pole 32 . A cross-section of a dimple of the fifth set of dimples 48 is shown in FIG. 9. The radius R 5 of the dimple 48 is approximately 0.0834 inch, the chord depth C 5 is approximately 0.0061 inch, the entry angle θ 5 is approximately 13.54 degrees, and the edge radius ER 5 is approximately 0.0273 inches.
[0050] A cross-section of a dimple of the second set of dimples 42 is shown in FIG. 10. The radius R 2 of the dimple 42 is approximately 0.0834 inch, the chord depth C 2 is approximately 0.0059 inch, the entry angle θ 2 is approximately 14.31 degrees, and the edge radius ER 2 is approximately 0.0382 inch. The sixty dimples of the second set of dimples 42 are the most influential of the different sets of dimples 40 - 62 due to their number, size and placement on the surface 22 of the golf ball 20 . The sixty dimples of the second set of dimples 42 cover approximately 12% of the surface 22 of the golf ball 20 . The thirty dimples of the second set of dimples 42 that are disposed within the first hemisphere 26 are disposed in the first row 80 above the equator 24 . Similarly, the thirty dimples of the second set of dimples 42 that are disposed within the second hemisphere 28 are disposed in the first row 90 below the equator 24 .
[0051] The one-hundred eighty dimples of the second, third and eighth sets of dimples 42 , 44 and 54 are the most influential of the different sets of dimples 40 - 62 due to their number, size and placement on the surface 22 of the golf ball 20 near the equator. The one-hundred eighty dimples of the second, third and eighth sets of dimples 42 , 44 and 54 cover approximately 50% of the surface 22 of the golf ball 20 .
[0052] As best illustrated in FIG. 11, each hemisphere 26 and 28 begins with three rows from the equator 24 . The first row 80 of the first hemisphere 26 and the first row 90 of the second hemisphere 28 are composed of the second set of dimples 42 . The second row 82 of the first hemisphere 26 and the second row 92 of the second hemisphere 28 are composed of the third set of dimples 44 . The third row 84 of the first hemisphere 26 and the third row 94 of the second hemisphere 28 are composed of the eight set of dimples 54 . This pattern of rows is utilized to achieve greater surface area coverage of the dimples on the golf ball 20 . However, as mentioned previously, conventional teaching would dictate that additional rows of smaller diameter dimples should be utilized to achieve greater surface area coverage. However, the dimple pattern of the present invention transitions from rows of equal dimples into a pentagonal region 98 .
[0053] The pentagonal region 98 is best seen in FIG. 12. A similar pentagonal region 98 a , not shown, is disposed about the second pole 32 . The pentagonal region 98 has five pentagons 100 , 102 , 104 , 106 and 108 expanding from the first pole 30 . Similar pentagons 100 a , 102 a , 104 a , 106 a and 108 a expand from the second pole 32 .
[0054] The first pentagon 100 consists of the tenth set of dimples 58 . The second pentagon 102 consists of the seventh set of dimples 52 . The third pentagon 104 consists of the fifth set of dimples 48 . The fourth pentagon 106 consists of the fourth set of dimples 46 . The fifth pentagon 108 consists of the first set of dimples 40 , the sixth set of dimples 50 , and the fourth set of dimples 46 . However, the greater fifth pentagon 108 ′ would include the fifth pentagon 108 and all dimples disposed between the third row 84 and the fifth pentagon 108 . The pentagonal region 98 allows for the greater surface area of the dimple pattern of the present invention.
[0055] [0055]FIG. 13 illustrates five triangles 130 - 138 that compose the pentagonal region 98 . Dashed line 140 illustrates the extent of the greater pentagonal region 98 ′ which overlaps with the transition latitudinal region 70 .
[0056] As best illustrated in FIG. 14, all of the dimples of the ninth set of dimples 56 and the eleventh set of dimples 60 are disposed within the transition latitudinal regions 70 and 72 . The transition latitudinal regions 70 and 72 transition the dimple pattern of the present invention from the rows 80 , 82 , 84 , 90 , 92 and 94 to the pentagonal regions 98 and 98 a . Each of the transition latitudinal regions 70 and 72 cover a circumferencial area between 40 to 60 longitudinal degrees from the equator 24 in their respective hemispheres 26 and 28 . The first transition latitudinal region 70 has a polar boundary 120 at approximately 60 longitudinal degrees from the equator 24 , and an equatorial boundary 122 at approximately 40 longitudinal degrees from the equator 24 . Similarly, the second transition latitudinal region 72 has a polar boundary 120 a at approximately 60 longitudinal degrees from the equator 24 , and an equatorial boundary 122 a at approximately 40 longitudinal degrees from the equator 24 .
[0057] Alternative embodiments of the dimple pattern of the present invention may variations in the number of dimples, diameters, depths, entry angle and/or entry radius. Most common alternatives will not have any dimples at the poles 30 and 32 . Other common alternatives will have the same number of dimples, but with less variation in the diameters.
[0058] The force acting on a golf ball in flight is calculated by the following trajectory equation:
F = F L + F D + G ( A )
[0059] wherein F is the force acting on the golf ball; F L is the lift; F D is the drag; and G is gravity. The lift and the drag in equation A are calculated by the following equations:
F L = 0.5 C L A ρ v 2 ( B ) F D = 0.5 C D A ρ v 2 ( C )
[0060] wherein C L is the lift coefficient; C D is the drag coefficient; A is the maximum cross-sectional area of the golf ball; ρ is the density of the air; and ν is the golf ball airspeed.
[0061] The drag coefficient, C D , and the lift coefficient, C L , may be calculated using the following equations:
C D = 2 F D / A ρ v 2 ( D ) C L = 2 F L / A ρ v 2 ( E )
[0062] The Reynolds number R is a dimensionless parameter that quantifies the ratio of inertial to viscous forces acting on an object moving in a fluid. Turbulent flow for a dimpled golf ball occurs when R is greater than 40000. If R is less than 40000, the flow may be laminar. The turbulent flow of air about a dimpled golf ball in flight allows it to travel farther than a smooth golf ball.
[0063] The Reynolds number R is calculated from the following equation:
R = v D ρ / μ ( F )
[0064] wherein ν is the average velocity of the golf ball; D is the diameter of the golf ball (usually 1.68 inches); ρ is the density of air (0.00238 slugs/ft 3 at standard atmospheric conditions); and μ is the absolute viscosity of air (3.74×10 −7 lb*sec/ft 2 at standard atmospheric conditions). A Reynolds number, R, of 180,000 for a golf ball having a USGA approved diameter of 1.68 inches, at standard atmospheric conditions, approximately corresponds to a golf ball hit from the tee at 200 ft/s or 136 mph, which is the point in time during the flight of a golf ball when the golf ball attains its highest speed. A Reynolds number, R, of 70,000 for a golf ball having a USGA approved diameter of 1.68 inches, at standard atmospheric conditions, approximately corresponds to a golf ball at its apex in its flight, 78 ft/s or 53 mph, which is the point in time during the flight of the golf ball when the travels at its slowest speed. Gravity will increase the speed of a golf ball after its reaches its apex.
[0065] [0065]FIG. 15 is a graph of the lift coefficient for a Reynolds number of 70,000 at 2000 rotations per minute versus the drag coefficient for a Reynolds number of 180,000 at 3000 rotations per minute for a golf ball 20 with the dimple pattern of the present invention thereon as compared to the Titlelist HP DISTANCE 202, the Titlelist HP ECLIPSE 204, the SRI Maxfli HI-BRD (from Japan) 206, the Wilson CYBERCORE PRO DISTANCE 208, the Titleist PRO V1 210, the Bridgestone TOUR STAGE MC392 (from Japan) 212, the Precept MC LADY 214, the Nike TOUR ACCURACY 216, and the Titlelist DT DISTANCE 218.
[0066] The golf balls 20 with the dimple pattern of the present invention were constructed as set forth in co-pending U.S. patent application Ser. No. 09/______, filed on an even date herewith, for a Golf Ball which pertinent parts are hereby incorporated by reference. The aerodynamics of the dimple pattern of the present invention provides a greater lift with a reduced drag thereby translating into a golf ball 20 that travels a greater distance than golf balls of similar constructions.
[0067] As compared to other golf balls, the golf ball 20 of the present invention is the only one that combines a lower drag coefficient at high speeds, and a greater lift coefficient at low speeds. Specifically, as shown in FIG. 15, none of the other golf balls have a lift coefficient, C L , greater than 0.19 at a Reynolds number of 70,000, and a drag coefficient C D less than 0.232 at a Reynolds number of 180,000. For example, while the Nike TOUR ACCURACY 216 has a C L greater than 0.19 at a Reynolds number of 70,000, its C D is greater than 0.232 at a Reynolds number of 180,000. Also, while the Titleist DT DISTANCE 218 has a drag coefficient C D less than 0.232 at a Reynolds number of 180,000, its C L is less than 0.19 at a Reynolds number of 70,000. Further, the golf ball 20 of the present invention is the only golf ball that has a lift coefficient, C L , greater than 0.20 at a Reynolds number of 70,000, and a drag coefficient C D less than 0.235 at a Reynolds number of 180,000. Yet further, the golf ball 20 of the present invention is the only golf ball that has a lift coefficient, C L , greater than 0.19 at a Reynolds number of 70,000, and a drag coefficient C D less than 0.229 at a Reynolds number of 180,000. More specifically, the golf ball 20 of the present invention is the only golf ball that has a lift coefficient, C L , greater than 0.21 at a Reynolds number of 70,000, and a drag coefficient C D less than 0.230 at a Reynolds number of 180,000. Even more specifically, the golf ball 20 of the present invention is the only golf ball that has a lift coefficient, C L , greater than 0.22 at a Reynolds number of 70,000, and a drag coefficient C D less than 0.230 at a Reynolds number of 80,000.
[0068] In this regard, the Rules of Golf, approved by the United States Golf Association (“USGA”) and The Royal and Ancient Golf Club of Saint Andrews, limits the initial velocity of a golf ball to 250 feet (76.2 m) per second (a two percent maximum tolerance allows for an initial velocity of 255 per second) and the overall distance to 280 yards (256 m) plus a six percent tolerance for a total distance of 296.8 yards (the six percent tolerance may be lowered to four percent). A complete description of the Rules of Golf are available on the USGA web page at www.usga.org. Thus, the initial velocity and overall distance of a golf ball must not exceed these limits in order to conform to the Rules of Golf. Therefore, the golf ball 20 has a dimple pattern that enables the golf ball 20 to meet, yet not exceed, these limits.
[0069] From the foregoing it is believed that those skilled in the pertinent art will recognize the meritorious advancement of this invention and will readily understand that while the present invention has been described in association with a preferred embodiment thereof, and other embodiments illustrated in the accompanying drawings, numerous changes, modifications and substitutions of equivalents may be made therein without departing from the spirit and scope of this invention which is intended to be unlimited by the foregoing except as may appear in the following appended claims. Therefore, the embodiments of the invention in which an exclusive property or privilege is claimed are defined in the following appended claims.
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A dimple pattern for a golf ball with multiple sets of dimples is disclosed herein. Each of the multiple sets of dimples has a different diameter. A preferred set of dimples is twelve different dimples. The dimples may cover as much as eighty-seven percent of the surface of the golf ball. The unique dimple pattern allows a golf ball to have shallow dimples with steeper entry angles. In a preferred embodiment, the golf ball has 382 dimples covering ninety percent of the surface.
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CROSS-REFERENCE TO RELATED APPLICATION
The present patent application is a continuation of co-pending application, Ser. No. 08/720,324, filed Sep. 27, 1996.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a character reader for entering characters into a word processor or the like, and particularly to an optical character reader (hereinafter, referred to as an OCR) for reading and entering characters written on paper or the like by optical methods.
2. Description of the Related Art
As a means of entering characters into a word processor or the like, an OCR is used in some cases to read and enter the characters written on paper or the like automatically, without typing with a keyboard. Input of the characters by means of an OCR involves the steps of reading the characters on paper or the like with a scanner to convert them into image data, analyzing the layout of the image data to discern the character portion and recognizing the characters by the technique of pattern recognition. In entering the characters by means of an OCR, however, if the direction of the image input portion of a scanner tilts on the surface of the paper having the characters written thereon at the time of reading the characters with a scanner, thereby to cause the tilt in the readout image. Accordingly, there have been such problems that the characters can't be correctly discerned by the layout analysis and the performance of recognition is decreased because of recognition processing being performed with the characters tilted.
As countermeasures of these problems, there have been various conventional techniques to improve the recognition performance by detecting the characters tilting on the paper and correcting the detected tilt. In this kind of the conventional technique for use in an OCR, for example, “A Character String Direction Discrimination Device” (Article 1) is disclosed in Japanese Patent Laid-Open No. 61-160180. A character reader described in the same patent, comprises a photoelectric converter for converting characters from analog data to digital data by photoelectric methods so as to deliver the quantum signals, an image data storing unit for storing the delivered quantum signals as image data, a marginal distribution creating unit for requiring a histogram obtained by performing projection as for one region or more within the stored image from several directions and accumulating the density, and a character direction judging unit for judging the direction of the character string on the basis of the created histogram. The character reader requires a histogram of black pixel by the projection performed on the character string from several directions and finds the sharpest portion in the directions, which is recognized as the tilt of the above character string.
As another conventional technique, “A Character Reader” (Article 2) is disclosed in Japanese Unexamined Patent Publication (Kokai) No. Heisei 2-116987. The character reader described in the same patent comprises an input means for entering image data, an extracting means for extracting character string from the entered image data, a character discerning means for discerning each character from the extracted character string, and a reference line extracting means in which assuming a certain straight line passing a specified position like the lower end portion of a circumscribed rectangle of each character having been discerned, a histogram on the parameter space is required as for a set of parameter defining this straight line and the tilt on the straight line which is defined by a set of parameter providing with the maximum frequency on the histogram is regarded as the tilt on the character string. The character reader once scans the whole image data to be entered, requires a histogram on a parameter space by assuming the above specified straight line, after roughly discerning the characters, and recognizes the tilt on the character string on the basis of the required histogram.
As described above, the conventional character reader has a drawback that it takes much time in processing because the processing amount becomes huge in case of recognizing the tilt on the character string in order to improve accuracy of character recognition.
More specifically, the conventional character reader described in the article 1 requires a histogram of black pixel by the projection performed from several directions for all the black pixels in order to improve accuracy, with the result that processing amount becomes huge.
Additionally, since the processing amount for requiring a set of parameter defining a straight line which passes a specified position of a circumscribed rectangle of each character, is proportional to the number of characters, processing amount becomes enormous when there are many characters.
SUMMARY OF THE INVENTION
A first object of the present invention is to provide a character reader capable of improving accuracy of character recognition by recognizing the tilt of image data and correcting the same so as to perform character recognition, without requiring a histogram of black pixel by the projection performed from several directions as for all the black pixels, discerning the characters from the image data and scanning the whole image data in order to require the tilt.
A second object of the present invention is, in addition to the first object, to provide a character reader capable of decreasing the processing amount for detecting and correcting the tilt of the image data so to improve the processing speed, by removing the steps of requiring a histogram of black pixel by the projection from several directions as for all the black pixels in order to detect the tilt on the image data, discerning the characters from the image data and scanning the whole image data in order to require the tilt.
According to one aspect of the invention, a character reader for reading and entering characters by optical methods, comprises:
an input means for photoelectrically reading characters as an image, creating image data formed by black pixels lying on a white surface, and entering the image data;
a tangent detecting means for generating at least two line segments, each line segment connecting two black pixels within a character string of the image data; and
a tilt deciding means for choosing a representative line segment from the at least two line segments which is representative of the tilt of the character string, on the basis that the distance between two black pixels specifying the representative line segment is longer than the distance between two black pixels specifying another line segment.
In the preferred construction, the tangent detecting means may define a black pixel first detected by scanning the image data from the top portion by one line in a constant direction as a first black pixel, so to detect a first line segment extending from the first black pixel on the opposite side to the scanning direction, and defines a black pixel at the distal end on the opposite side to a group of black pixels sequentially lying from the first black pixel in the scanning direction as a second black pixel, so to detect a second line segment extending from the second black pixel on the same side as the scanning direction; and the tilt deciding means chooses the longer one of the first and second line segments as the representative line segment.
In another preferred construction, the tangent detecting means includes a reference point detecting means for detecting a first black pixel that is a black pixel first detected by scanning the image data from the top portion by one line in a constant direction and a second black pixel that is a black pixel located at the distal end on the opposite side to a group of black pixels sequentially lying from the first black pixel in the scanning direction, a first quasi-reference detecting means for detecting a third black pixel that is a black pixel first detected by scanning a first region obtained by a predetermined condition on the basis of the coordinates of the first black pixel, from the top portion by one line in the same direction as the scanning direction, and a second quasi-reference detecting means for detecting a fourth black pixel that is a black pixel first detected by scanning the second region obtained by a predetermined condition on the basis of the coordinates of the second black pixel, from the top portion by one line in the same direction as the scanning direction; and
the tilt deciding means, by comparison between a first line segment connecting the first black pixel and the third black pixel and a second line segment connecting the second black pixel and the fourth black pixel, chooses the longer segment of the first and second line segments as the representative tangent.
In another preferred construction, the tangent detecting means may define a black pixel first detected by scanning the image data from the top portion by one line in the direction from left to right as a first black pixel, so to detect a first line segment extending leftward from the first black pixel, and defines a black pixel located at the distal end of a group of black pixels sequentially lying in the scanning direction from the first black pixel as a second black pixel, so to detect a second line segment extending rightward from the second black pixel; and the tilt deciding means chooses the longer one of the first and second line segments as the representative line segment.
In the above-mentioned construction, the tangent detecting means includes a reference point detecting means for detecting a first black pixel that is a black pixel first detected by scanning the image data from the top portion by one line in the direction from left to right and a second black pixel that is a black pixel located at the distal end on the right side of a group of black pixels sequentially lying from the first black pixel in the right direction, a first quasi-reference detecting means for detecting a third black pixel that is a black pixel first detected by scanning a first region extending leftward and downward from the coordinates of the first black pixel, which region is obtained by a predetermined condition, from the top portion by one line in the same direction as the scanning direction, and a second quasi-reference detecting means for detecting a fourth black pixel that is a black pixel first detected by scanning the second region extending rightward and downward from the coordinates of the second black pixel, which region is obtained by a predetermined condition, from the top portion by one line in the same direction as the scanning direction; and
the tilt deciding means, by comparison between a first line segment connecting the first black pixel and the third black pixel and a second line segment connecting the second black pixel and the fourth black pixel, chooses the longer segment of the first and second line segments the representative line segment.
Also, the tangent detecting means may require a first region including one distal end of the character string and extending at right angle to the direction of row of the character string with a constant width, and a second region including another distal end of the character string and extending at right angle to the direction of row of the character string with a constant width, define a black pixel first detected by scanning the first region from the top portion of the image data by one line in a constant direction as a first black pixel, and define a black pixel first detected by scanning the second region from the top portion of the image data by one line in a constant direction as a second black pixel; and the tilt deciding means chooses the line segment connecting the first black pixel and the second black pixel as the representative line segment.
Preferably, the tangent detecting means may require a first region including the left end of the character string and extending vertically with a constant width, and a second region including the right end of the character string and extending vertically with a constant width, define a black pixel first detected by scanning the first region from the top portion of the image data by one line in the direction from left to right as a first black pixel, and define a black pixel first detected by scanning the second region from the top portion of the image data by one line in the direction from left to right as a second black pixel; and the tilt deciding means chooses the line segment connecting the first black pixel and the second black pixel as the representative line segment.
According to another aspect of the invention, a character reader for reading and entering characters by optical methods, comprises:
an input means for photoelectrically reading characters as an image, creating image data formed by black pixels lying on a white surface, and entering the image data;
a tangent detecting means for generating at least two line segments, each line segment connecting two black pixels within a character string of the image data;
a tilt deciding means for choosing a representative line segment from the at least two line segments which is representative of the tilt of the character string, on the basis that the distance between two black pixels specifying the representative line segment is longer than the distance between two black pixels specifying another line segment;
a correcting means for correcting the imaged data on the basis of the tilt of the image data obtained by said tilt deciding means; and
a recognition means for performing character recognition by the use of pattern matching on the image data corrected by said correcting means.
In the preferred construction, the tangent detecting means may define a black pixel first detected by scanning the image data from the top portion by one line in a constant direction as a first black pixel, so to detect a first line segment extending from the first black pixel on the opposite side to the scanning direction, and defines a black pixel at the distal end on the opposite side to a group of black pixels sequentially lying from the first black pixel in the scanning direction as a second black pixel, so to detect a second line segment extending from the second black pixel on the same side as the scanning direction; and the tilt deciding means chooses the longer one of the first and second line segments as the representative line segment.
In another preferred construction, the tangent detecting means includes a reference point detecting means for detecting a first black pixel that is a black pixel first detected by scanning the image data from the top portion by one line in a constant direction and a second black pixel that is a black pixel located at the distal end on the opposite side to a group of black pixels sequentially lying from the first black pixel in the scanning direction, a first quasi-reference detecting means for detecting a third black pixel that is a black pixel first detected by scanning a first region obtained by a predetermined condition on the basis of the coordinates of the first black pixel, from the top portion by one line in the same direction as the scanning direction, and a second quasi-reference detecting means for detecting a fourth black pixel that is a black pixel first detected by scanning the second region obtained by a predetermined condition on the basis of the coordinates of the second black pixel, from the top portion by one line in the same direction as the scanning direction; and
the tilt deciding means, by comparison between a first line segment connecting the first black pixel and the third black pixel and a second line segment connecting the second black pixel and the fourth black pixel, chooses the longer segment of the first and second line segments as the representative line segment.
Also, the tangent detecting means may require a first region including one distal end of the character string and extending at right angle to the direction of row of the character string with a constant width, and a second region including another distal end of the character string and extending at right angle to the direction of row of the character string with a constant width, define a black pixel first detected by scanning the first region from the top portion of the image data by one line in a constant direction as a first black pixel, and define a black pixel first detected by scanning the second region from the top portion of the image data by one line in a constant direction as a second black pixel; and the tilt deciding means chooses the line segment connecting the first black pixel and the second black pixel as the representative line segment.
Other objects, features and effects of the present invention will be apparent from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be understood more fully from the detailed description given herebelow and from the accompanying drawings of the preferred embodiment of the invention, which, however, should not be taken to be limitative to the invention, but are for explanation and understanding only.
In the drawings:
FIG. 1 is a block diagram showing the constitution of a character reader according to a first embodiment of the present invention.
FIG. 2 is a view showing the stored image data received from the image storing unit on the surface X-Y.
FIG. 3 is a flow chart showing an operation by a left reference detecting unit.
FIG. 4 is a view showing the content of processing by the left reference detecting unit.
FIG. 5 is a flow chart showing an operation by a right reference detecting unit.
FIG. 6 is a view showing the content of processing by the right reference detecting unit.
FIG. 7 is a view showing an example of detecting each reference and quasi-reference point as well as an example of distances L and R between contact points.
FIG. 8 is a block diagram showing the constitution of a character reader according to a second embodiment of the present invention.
FIG. 9 is a view showing the content of processing by a tangent detecting unit.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of the present invention will be discussed hereinafter in detail with reference to the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be obvious, however, to those skilled in the art that the present invention may be practiced without these specific details. In other instance, well-known structures are not shown in detail in order to unnecessarily obscure the present invention.
FIG. 1 is a block diagram showing the constitution of a character reader according to a first embodiment of the present invention.
As illustrated in FIG. 1, the character reader of this embodiment comprises an input unit 10 for entering image data of handwritten characters and printed characters, an image storing unit 20 for storing the entered image data, a tangent detecting unit 30 and a tilt deciding unit 40 for detecting a tangent of black pixel forming character of the image data and detecting the tilt of the character string, a tilt correcting unit 50 for correcting the tilt on the image data according to the tilt of the character string decided by the tilt deciding unit 40 , and a recognition unit 60 for performing character recognition on the basis of the image data corrected by the tilt correcting unit 50 . FIG. 1 shows only the characteristic constitution of the embodiment, and other general constitution thereof is omitted here. It is needless to say that an input device such as a keyboard or the like for entering various instructions and an output device such as a display or the like for displaying the recognition result of the input image and character should be provided with the reader.
The input unit 10 is realized by an image input device such as an image scanner or the like, which reads printed characters on paper or the like as an image, and converts them into image data which is collection of pixels lying on the x-y surface, so to deliver the data to the image storing unit 20 . At this time, each pixel of the image data is classified into black pixel or white pixel and expressed, for example, by binary data “0” or “1”. More specifically, the portion having character is defined by black pixel and expressed, for example, by data value “1”, while the portion having no character (background) is defined by white pixel and expressed, for example, by data value “0”.
The image storing unit 20 is realized by an external storage such as a magnetic disk or the like, or an internal memory such as a RAM or the like, which stores the image data delivered from the input unit 10 and supplies the stored image data DC to the tangent detecting unit 30 and the tilt correcting unit 50 .
The tangent detecting unit 30 is realized by a CPU controlled by a program, or the like, which generates line segments connecting predetermined black pixels among the image data received from the image storing unit 20 . The tangent detecting unit 30 includes a reference point detecting unit 31 for detecting a reference point for requiring a line segment of the predetermined black pixel, and a left quasi-reference detecting unit 32 and a right quasi-reference detecting unit 33 for detecting quasi-reference point for specifying the line segment connecting the left and right reference points. A detailed operation of the tangent detecting unit 30 will be explained later.
The tilt deciding unit 40 is realized by a CPU controlled by a program, or the like, which chooses a representative line segment on the basis of the line segments generated detected by the tangent detecting unit 30 and requires the tilt of the character string in the image data according to the tilt of the representative line segment. A detailed operation of the tilt deciding unit 40 will be described later.
The tilt correcting unit 50 is realized by a CPU controlled by a program, which corrects the tilt of the image data DC received from the image storing unit 20 according to the tilt of the character string obtained by the tilt deciding unit 40 . More specifically, the image data DC is rotated for the angle θ of the character string received from the tilt deciding unit 40 , and creates the corrected image data DD. The created corrected image data DD is supplied to the recognition unit 60 .
The recognition unit 60 is realized by a CPU controlled by a program, or the like, which performs a layout analysis on the corrected image data DD by means of division by the use of projective distribution and performs character recognition by means of pattern matching by the use of direction feature extraction. General means can be used for each processing by the recognition unit 60 . The description of the layout analysis is found in “Document Image Structural Analysis by Split Detecting Methods” P.491-P.498, vol. 4, 1991, Part 74-D-II, D-II of The Transactions of the Institute of Electronics, Information and Communication Engineers. The structural analysis method of the document image described in this article is a recursive split detecting method which rebuilds a plurality of blocks newly in the region dividing process, and as generalized standard for dividing blocks, it is to introduce variance ratio to the block division by the use of the projective distribution.
Character recognition is described in, for example, “Normalization-cooperated Feature Extraction Method for Handprinted Kanji Character Recognition” in the literature “Pre-Proceedings of the third International Workshop on Frontiers in Handwriting Recognition” (P.343-P.348, 1993).
An operation of the tangent detecting unit 30 will be explained with reference to FIGS. 2 to 6 .
FIG. 2 is a view showing the stored image data DC received from the image storing unit 20 on the surface X-Y. In FIG. 2, one square of lattice formed by the straight lines in X direction and Y direction which are coming across at right angle, represents each pixel. In the embodiment, the X-axis represents the direction indicating a row of character string, and the Y-axis represents the direction indicating lines of character string. Specifically, in English documents and Japanese documents written from left to right, the X direction starts from left to right and the Y direction starts from up to down.
The reference point detecting unit 31 scans the image data DC downward from Y=0 by one line, from left to right in the direction of the X-axis, so as to retrieve black pixel. The black pixel detected at first is defined as a left reference pixel Cl. Starting from the reference pixel Cl, the unit 31 detects the sequential black pixels on the same line of the Y coordinate in the right direction. Then, the black pixel located at the right end is defined as a right reference pixel Cr. That is, in a line formed by the black pixels sequentially lying parallel to the X-axis, the left end thereof is defined as a reference pixel Cl and the right end thereof is defined as a reference pixel Cr. When there exist no black pixels sequentially lying on the same line of the Y coordinate as that of the reference pixel Cl, the left reference pixel Cl and the right reference pixel Cr are identified.
Next, the left quasi-reference detecting unit 32 and the right quasi-reference detecting unit 33 detect each reference pixel on the basis of the reference pixels Cl and Cr and the image data DC received from the image storing unit 20 .
FIG. 3 is a flow chart showing the operation of the left quasi-reference detecting unit 32 , and FIG. 4 is a view showing the content of processing by the left quasi-reference detecting unit 32 .
The left quasi-reference detecting unit 32 scans the region LS obtained by the following formula (1) on the basis of the coordinates (Xcl, Ycl) of the left reference pixel Cl, along the Y-axis downward from the top by one line and along the X-axis from left to right, until detecting a black pixel.
LS={( x, y )| x <Xcl, Ycl< y} (1)
FIG. 4 (A) shows the region LS (shaded portion). The black pixel first detected in the region LS is temporarily defined as a left quasi-reference point pixel Sl (Steps 301 and 302 ). When no black pixel is detected, the left reference pixel Cl and the left quasi-reference pixel S are identified and the processing is stopped here (Step 303 ).
When the left quasi-reference pixel Sl is detected in the region LS, the left quasi-reference detecting unit 32 scans the region LT obtained by the following formula (2) on the basis of the line connecting the left reference pixel Cl and the left quasi-reference pixel Sl and the coordinates (Xsl, Ysl) of the left quasi-reference pixel Sl, along the Y-axis downward from the top by one line and along the X-axis from left to right, until detecting a black pixel.
LT={( x, y )|(Xcl−Xsl)( y −Ycl)<(Ycl−Ysl)( x −Xcl), 0 ≦x , Ysl< y} (2)
FIG. 4 (B) shows the region LT (slashed portion). The black pixel first detected in the region LT is newly defined as a left quasi-reference pixel Sl (Step 304 ). In other words, the left quasi-reference pixel Sl already detected is replaced with the black pixel newly detected. Every time when a left quasi-reference pixel Sl is newly detected, the process of Steps 303 and 304 is repeated regarding to the region LT set up newly on the basis of the left quasi-reference pixel Sl newly detected. When any black pixel is not detected inside the region LT, the processing is stopped.
In order to reduce the processing amount by the left quasi-reference detecting unit 32 , it is possible to restrict the range of scan as follows. The range of the region LS may be defined as
LS={( x, y )|Xside1 ≦x <Xcl, Ycl< y ≦YMAX1} (3)
The range of the region LT may be defined as
LT={( x, y )|(Xcl−Xsl)( y −Ycl)<(Ycl−Ysl)( x −Xcl), Xside1 ≦x , Ysl< y ≦YMAX1} (4)
Where, Xside1 designates the limited value of the left quasi-reference point in the left direction on the basis of the X coordinate of the left reference point, and YMAX1 designates the limited value in the lower direction on the basis of the Y coordinate of the left reference point, each value being a constant arbitrarily set up.
FIG. 5 is a flow chart showing the operation of the right quasi-reference detecting unit 33 , and FIG. 6 is a view showing the content of the processing by the right quasi-reference detecting unit 33 .
The right quasi-reference detecting unit 33 scans the region RS obtained by the following formula (5) on the basis of the coordinates (Xcr, Ycr) of the right reference pixel Cr, along the Y-axis downward from the top by one line and along the X-axis from left to right, until detecting a black pixel.
RS={( x, y )|Xcr< x , Ycr< y} (5)
FIG. 6 (A) shows the region RS (slashed portion). The black pixel first detected in the region RS is temporarily defined as a right quasi-reference pixel Sr (Steps 501 and 502 ). When any black pixel is not detected, the right reference pixel Cr and the right quasi-reference pixel Sr are identified, and the processing is stopped here (Step 503 ).
When the right quasi-reference pixel Sr is detected in the region RS, the right quasi-reference detecting unit 33 scans the region RT obtained by the following formula (6) on the basis of the line connecting the right reference pixel Cr and the right quasi-reference pixel Sr and the coordinates (Xsr, Ysr) of the right quasi-reference pixel Sr, along the Y-axis downward from the top by one line and along the X-axis from left to right, until detecting a black pixel.
RT={( x, y )|(Xcr−Xsr)( y −Ycr)>(Ycr−Ysr)( x −Xcr), Ysr< y} (6)
FIG. 6 (B) shows the region RT (slashed portion). The black pixel first detected is newly defined as a right quasi-reference pixel Sr (Step 304 ). In other words, the right quasi-reference pixel Sr already detected is replaced with the black pixel newly detected. Every time when a right quasi-reference pixel Sr is newly detected, the process of Steps 303 and 304 is repeated regarding to the region RT newly set up on the basis of the new right quasi-reference pixel Sr. When any black pixel is not detected, the processing is stopped.
In order to reduce the processing amount by the right quasi-reference detecting unit 33 , it is possible to restrict the range of scan as follows. The range of the region RS may be defined as
RS={( x, y )|Xcr< x ≦Xside2, Ycr< y ≦YMAX2} (7)
The range of the region RT may be defined as
RT={( x, y )|(Xcr−Xsr)( y −Ycr)>(Ycr−Ysr)( x −Xcr), x ≦Xside2, Ysr< y ≦YMAX2} (8)
Where, Xside2 designates the limited value of the right quasi-reference point in the right direction on the basis of the X coordinate of the right reference point, and YMAX2 designates the limited value in the lower direction on the basis of the Y coordinate of the right reference point, each value being a constant arbitrarily set up.
Thus, the tangent detecting unit 30 supplies the information on the line segment connecting the left reference pixel Cl and the left quasi-reference pixel Sl and the information on the line segment connecting the right reference pixel Cr and the right quasi-reference pixel Sr to the tilt deciding unit 40 as the generated line segments.
This time, an operation of the tilt deciding unit 40 will be described in details.
Upon the receipt of the line segments generated by the tangent detecting unit 30 , the tilt deciding unit 40 makes a comparison between the distance L interconnecting contact points, that is length of the line segment interconnecting the left reference pixel Cl and the left quasi-reference pixel Sl, and the distance R interconnecting contact points, that is the length of the line segment interconnecting the right reference pixel Cr and the right quasi-reference pixel Sr. The reference pixel and quasi-reference pixel interconnected by the longer distance is defined as a representative line segment reference pixel Cc and representative tangent quasi-reference pixel Sc. The line segment connecting the representative line segment reference pixel Cc and representative line segment quasi-reference pixel Sc obtained in this way is the representative line segment serving as a reference for requiring the tilt of the character string.
FIG. 7 shows an example of detecting each reference point and each quasi-reference point, as well as each distance between contact points L and R. In this example, the distance R is longer than the distance L. Accordingly, the right reference point pixel Cr is regarded as a representative line segment reference pixel Cc and the right quasi-reference pixel Sr is regarded as a representative line segment quasi-reference pixel Sc. Additionally, as a special example, when the left reference pixel Cl and the left quasi-reference pixel Sl are identified, the right reference pixel Cr is regarded as the representative line segment reference pixel Cc and the right quasi-reference pixel Sr is regarded as the representative line segment quasi-reference pixel Sc. When the right reference pixel Cr and the right quasi-reference pixel Sr are identified, the left reference pixel Cl is regarded as the representative line segment reference pixel Cc and the left quasi-reference pixel Sl is regarded as the representative line segment quasi-reference pixel Sc. When the left reference pixel Cl and left quasi-reference pixel Sl are identified, and the right reference pixel Cr and right quasi-reference pixel Sr are identified, the left reference pixel Cl is regarded as the representative line segment reference pixel Cc and the right reference pixel Cr is regarded as the representative line segment quasi-reference pixel Sc.
The tilt deciding unit 40 requires the tilt angle θ of the representative line segment from the coordinates (Xcc, Ycc) of the representative line segment reference pixel Cc and the coordinates (Xsc, Ysc) of the representative tangent quasi-reference pixel Sc, by the following formula (9).
θ=Arctan((Ysc−Ycc)/(Xsc−Xcc)) (9)
The tilt θ of the representative line segment obtained by the above formula (9) is recognized as the tilt of the character string, which is supplied to the tilt correcting unit 50 . The tilt correcting unit 50 corrects the image data DC according to the tilt of the character string obtained as mentioned above.
As a special example, when the distance L is equal to the distance R, the tilt angle of the line segment interconnecting the left reference pixel Cl and the left quasi-reference pixel Sl and the tilt angle of the line segment interconnecting the right reference pixel Cr and the right quasi-reference pixel Sr are both required, and the tilt angle of which absolute value is closer to zero is defined as the tilt angle θ of the representative line segment. When the distances L and R are equal and the absolute values of the tilt angles of the both line segments are equal, the tilt angle is defined as zero (θ=0).
In the first embodiment as mentioned above, the reference point detecting unit 31 detects two points, the left reference pixel Cl and the right reference pixel Cr. However, when it is desired to speed up processing even if decreasing a bit of accuracy, assuming that the right reference pixel Cr and the left reference pixel Cl are identified, the detection of only the left reference pixel Cl allows the detection of the representative line segment and the calculation of the tangent angle θ, thereby decreasing the processing amount.
A second embodiment of the present invention will be described hereinafter.
FIG. 8 is a block diagram showing the constitution of a character reader according to the second embodiment of the present invention.
As illustrated in FIG. 8, the character reader of this embodiment comprises an input unit 10 for entering image data of handwritten characters and printed characters, an image storing unit 20 for storing the entered image data, a tangent detecting unit 130 and a tilt deciding unit 140 for choosing a representive line segment which is representative of the tilt of a character string of the image data and detecting the tilt of the character string, a tilt correcting unit 50 for correcting the tilt on the image data according to the tilt of the character string decided by the tilt deciding unit 40 , and a recognition unit 60 for performing character recognition on the basis of the image data corrected by the tilt correcting unit 50 . Of the above components, the input unit 10 , the image storing unit 20 , the tilt correcting unit 50 and the recognition unit 60 have the same structure as those of the first embodiment. Therefore, the description thereof is omitted here, with the same reference numerals attached thereto.
The tangent detecting unit 130 is realized by a CPU controlled by a program, or the like, which generates line segments connecting predetermined black pixels within the image received from the image storing unit 20 . The generation of the line segments by the tangent detecting unit 130 will be described with reference to FIG. 9 .
The tangent detecting unit 130 requires, in the image data DC, the two regions DL and DR obtained by the following formulas (10) and (11).
DL={( x, y )|Xlmin< x <Xlmin+W} (10)
DR={( x, y )|Xrmax−W< x <Xrmax} (11)
Where, XLmin indicates the minimum value in the direction of the X-axis, of the group of black pixels forming the character string on the same line, and XRmax indicates the maximum value in the direction of the X-axis, of the group of black pixels forming the character string on the same line. In other words, the both values are the coordinates of the X-axis, respectively indicating the black pixel located on the left end of the character which is located on the left end portion of the character string on the same line and the black pixel located on the right end of the character which is located on the right end portion thereof. W is a constant for specifying the width of the regions DL and DR set up larger than the width for one character. In the case as shown by the following formula,
Xlmin+W≦Xrmax−W (12)
the right end of the region DL is moved to the left end of the region DR as follows,
DL={( x, y )|Xlmin< x <Xrmax−W} (13)
so that the regions DL and DR should not overlap each other.
The tangent detecting unit 130 scans the regions DL and DR, respectively along the direction of the Y-axis downward from the top by one line, along the direction of the X-axis from left to right, until detecting a black pixel. The black pixel detected from the region DL is defined as a left reference pixel GL and the black pixel detected from the region DR is defined as a right reference pixel GR. FIG. 7 shows an example of the regions DL and DR as well as the left reference pixel GL and right reference pixel GR.
Then, the tangent detecting unit 130 supplies the information on the line segment connecting the detected left reference pixel GL and right reference pixel GR to the tilt deciding unit 140 as a generated line segment.
The tilt deciding unit 140 is realized by a CPU controlled by a program, or the like, which chooses a representative line segment according to the line segments generated by the tangent detecting unit 30 , and requires the tilt of the character string within the image data according to the tilt of the representative line segment. More specifically, the tilt angle θ of the representative line segment passing the coordinates (Xl, Yl) of the left reference pixel GL and the coordinates (Xr, Yr) of the right reference pixel GR is required by the following formula (14). Then, the tilt deciding unit 140 delivers the obtained tilt angle * being recognized as the tilt of the character string to the tilt correcting unit 50 .
θ=Arctan(Yl−Yr)/(Xl−Xr) (14)
Although the preferred embodiments have been described as mentioned above, the present invention is not restricted to the above embodiments, but it is to be understood that various modifications is possible in the light of the above teachings. For example, as a method of requiring a representative line segment decided by the longer distance between contact points, various methods can be used depending on the desired accuracy and processing speed, in which, e.g., it is possible to select the longest line segment by requiring all the line segments coming into contact with the region of the black pixels.
In the case of a document such that the writing starting position in each line is constant in the vertical direction, it is possible to obtain the tangent of the black pixel on the left end portion of the image by replacing the X coordinate with the Y coordinate and the Y coordinate with the X coordinate on the contrary, so to correct the tilt of the document by the use of the tilt of the line segment.
The character reader according to the present invention can be also adopted in the case of only detecting and correcting the tilt of the image in a filing system or in copying machine. The recognition unit for performing character recognition is not an indispensable component in such a case.
As set forth hereinabove, provided with the tangent detecting unit for detecting a representative line segment which can be a reference for requiring the tilt of a character string, from the line segments coming into contact with the black pixels forming the character string within the image data, and the tilt deciding unit for choosing the tilt of the character string on the basis of the tilt on the representative line segment, the character reader of the present invention is capable of requiring the tilt of the image data by the use of only the line segment in contact with the black pixel within the image data, without discerning the characters from the image data and scanning the whole image data in order to require the tilt. Accordingly, the character reader of the present invention has an effect such as to decrease the processing amount necessary for detecting and correcting the tilt of the image data, thereby speeding up the processing.
Although the invention has been illustrated and described with respect to exemplary embodiment thereof, it should be understood by those skilled in the art that the foregoing and various other changes, omissions and additions may be made therein and thereto, without departing from the spirit and scope of the present invention. Therefore, the present invention should not be understood as limited to the specific embodiment set out above but to include all possible embodiments which can be embodies within a scope encompassed and equivalents thereof with respect to the feature set out in the appended claims.
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A character reader for optically reading and entering characters. The character reader including: an input apparatus for photoelectrically reading characters as an image, creating image data formed by black pixels lying on a white surface, and entering the image data; a tangent detector for generating at least two line segments, each line segment connecting two black pixels within a character string of the image data; and a tilt decider for choosing a representative line segment from the at least two line segments which is representative of the tilt of the character string, on the basis that the distance between two black pixels specifying the representative line segment is longer than the distance between two black pixels specifying another line segment.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a vacuum pump and, more particularly, to a vacuum pump which is used when a process gas for a semiconductor manufacturing system, for example, is sucked and exhausted.
2. Description of the Related Art
In recent years, semiconductor devices such as memory and integrated circuit devices have been used extensively along with the development of electronics. Therefore, the demand for semiconductor manufacturing systems has experienced a sudden increase.
The semiconductor manufacturing system is provided with a high vacuum chamber in which etching or other work is performed. Generally, a vacuum pump is frequently used to evacuate the vacuum chamber.
The semiconductor device manufacturing processes include processes in which various kinds of process gases are applied to a substrate of a semiconductor, so that the vacuum pump is used not only to evacuate the vacuum chamber but also to suck and exhaust these process gases.
These process gases are sometimes introduced into the chamber in a high-temperature state to enhance the reactivity. However, these process gases are cooled during exhaustion, and thereby a chemical reaction takes place to form a solid product, which may adhere and accumulate in the vacuum pump.
For example, when silicon chloride (SiCl 4 ) is used as a process gas for an aluminum etching apparatus, in a low-vacuum region of 760 [torr] to 10 −2 [torr] containing much water, the chemical reaction of silicon chloride is promoted, and thus aluminum chloride (AlCl 3 ) is precipitated as a solid product, and adheres and accumulates in the vacuum pump. In a low-temperature region of about 20° C., the chemical reaction of silicon chloride is further promoted.
In the vacuum pump, a rotor provided with a large number of rotor blades rotates at a high speed of several ten thousand revolutions per minute. If precipitates accumulate on a stator blade disposed on the inner peripheral surface of a casing of the vacuum pump, for example, a disadvantage of contact with the rotor blade may occur. Also, in some case, the accumulated precipitates narrow a gas discharge path, which remarkably degrades the performance of the vacuum pump.
Thereupon, methods for restraining the precipitation of a solid product in the vacuum pump have so far been proposed.
Generally, there is used a method in which heating is performed from the outside to increase the internal temperature of the vacuum pump, by which the adhesion of process gas is restrained. An example of this method is briefly explained with reference to a turbo-molecular pump shown in FIG. 2. A location at which the solid product of process gas is precipitated most easily in the turbo-molecular pump is a base 101 which has a high pressure and moreover is close to a water cooled tube 102 (for temperature control). Therefore, the base 101 is heated by using a heater 103 so as to be kept at a high temperature.
However, the above-described method using a heater presents a problem with a heat conduction path.
The conduction path of heat generated by the heater 103 is indicated by the arrow marks in FIG. 2 . Thus, the heat generated by the heater 103 is transferred to a motor housing 106 and a substrate 104 located inside the vacuum pump through the base 101 . Since a motor section 105 disposed in the motor housing 106 and the inside substrate 104 have a design limit temperature set considering reliability, the vacuum pump must be used in the value range of design limit temperature when the vacuum pump is operated. In particular, the design limit temperature of the substrate 104 is as low as 80° C.
Thus, in the conventional construction, if a heater is used for heating, the motor section and the inside substrate, which are not desired to be heated, are also heated. Therefore, the temperature of the substrate disposed in the motor housing increases undesirably.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide a vacuum pump in which a discharge path for process gas in the vacuum pump is kept at a higher temperature than before, and in which an inside substrate is cooled effectively.
To achieve the above object, the invention of a first aspect provides a vacuum pump including a body which has a casing and a base having an opening communicating with the casing and is provided with a gas intake port and a gas discharging port; a rotor pivotally supported in the body so as to be rotatable; a motor for driving the rotor; a motor housing for supporting the motor; gas transfer means, which is provided between the casing and the rotor, for transferring gas sucked through the gas intake port to the gas discharge port; heating means for heating a gas discharge path for the gas transferred by the gas transferring means; a back cover for covering the opening of the base; and a substrate which is arranged on the motor housing side of the back cover.
The heating means is composed of, for example, a heater disposed around the base or the casing or in the vacuum pump.
To achieve the above object, in the invention of a second aspect, the vacuum pump further includes cooling means for cooling the back cover.
To achieve the above object, in the invention of a third aspect, the back cover is fixed via a heat insulating material.
To achieve the above object, in the invention of a fourth aspect, the cooling means is a water cooled tube provided on the back cover to circulate cooling water.
To achieve the above object, in the invention of a fifth aspect, the heat insulating material is formed of a heat insulating ceramic material or resin.
According to the present invention, by arranging the substrate on the inside of the back cover, the inside substrate can be cooled efficiently.
Also, by providing the cooling means for cooling the back cover, the efficiency in cooling the substrate is improved.
Further, by arranging the heat insulating material in the connecting portion between the back cover and the base, the heat of the base heated intentionally by the heater can be prevented from conducting to the back cover.
Thus, if the efficient cooling of the inside substrate is effective, the temperature in the pump can be increased further as compared with the conventional vacuum pump. Therefore, the temperature of the gas discharge path for process gas can be made higher than before, and hence the accumulation of solid product in the vacuum pump can be restrained further.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a turbo-molecular pump in accordance with the present invention; and
FIG. 2 is a sectional view of a conventional turbo-molecular pump.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A preferred embodiment of the present invention will now be described in detail with reference to FIG. 1 .
FIG. 1 is a sectional view of a turbo-molecular pump in accordance with the present invention, showing a cross-section in the axial direction of a rotor shaft 2 .
Although not shown in FIG. 1 , a gas inlet or intake port 3 of a turbo-molecular pump 1 is connected to a vacuum chamber of a semiconductor manufacturing system via a conductance valve (a valve for regulating conductance, i.e., flowability of exhaust gas by changing the cross-sectional area of flow path of pipe) and the like, and a gas outlet or discharge port 4 is connected to an auxiliary pump.
A casing 5 that forms a casing for the turbo-molecular pump 1 has a cylindrical shape, and a rotor shaft 2 is disposed in the center thereof. The casing 5 constitutes a body 31 of the turbo-molecular pump 1 together with a base 6 . The casing 5 has an interior space and the base 6 has an opening communicating with the interior space.
At the upper part, lower part, and bottom part in the axial direction of the rotor shaft 2 , there are provided magnetic bearing portions 7 , 8 and 9 , respectively. The rotor shaft 2 is supported in the radial direction (radial direction of the rotor shaft 2 ) in a non-contact manner by the magnetic bearing portions 7 and 8 , and is supported in the thrust direction (axial direction of the rotor shaft 2 ) in a non-contact manner by the magnetic bearing portion 9 . These magnetic bearing portions 7 , 8 and 9 constitute what is called a five-axis control type magnetic bearing, and the rotor shaft 2 has only the degree of freedom of rotation around the axis of the rotor shaft 2 .
In the magnetic bearing portion 7 , four electromagnets are arranged at 90° intervals around the rotor shaft 2 so as to be opposed to each other. The rotor shaft 2 is formed of a material with high magnetic permeability (for example, iron), and hence is attracted by a magnetic force of the electromagnet.
A displacement sensor 10 detects displacement in the radial direction of the rotor shaft 2 . When detecting displacement of the rotor shaft 2 in the radial direction from a predetermined position by means of a displacement signal sent from the displacement sensor 10 , a control section, not shown, operates to return the rotor shaft 2 to the predetermined position by regulating the magnetic force of each electromagnet. Thus, the magnetic force of electromagnet is regulated by feedback controlling the exciting current of each electromagnet.
The control section carries out feedback control of magnetic force of the magnetic bearing portion 7 by means of a signal sent from the displacement sensor 10 . Thereby, the rotor shaft 2 is magnetically levitated in the radial direction in the magnetic bearing portion 7 with a predetermined clearance being provided with respect to the electromagnets, and is held in a space in a non-contact manner.
The construction and operation of the magnetic bearing portion 8 are the same as those of the magnetic bearing portion 7 .
In the magnetic bearing portion 8 , four electromagnets are arranged at 90° intervals around the rotor shaft 2 , and the rotor shaft 2 is held in the radial direction in the magnetic bearing portion 8 in a non-contact manner by a suction force of magnetic force of the electromagnets.
A displacement sensor 11 detects displacement in the radial direction of the rotor shaft 2 .
Upon receipt of a displacement signal in the radial direction of the rotor shaft 2 from the displacement sensor 11 , the control section, not shown, carries out feedback control of the exciting current of electromagnet so as to hold the rotor shaft 2 at a predetermined position by correcting the displacement.
The control section carries out feedback control of magnetic force of the magnetic bearing portion 8 by means of a signal sent from the displacement sensor 11 . Thereby, the rotor shaft 2 is magnetically levitated in the radial direction in the magnetic bearing portion 8 with a predetermined clearance being provided with respect to the electromagnets, and is held in a space in a non-contact manner.
Thus, since the rotor shaft 2 is held in the radial direction at two places of the magnetic bearing portions 7 and 8 , the rotor shaft 2 is held at the predetermined position in the radial direction.
The magnetic bearing portion 9 provided at the lower end of the rotor shaft 2 is composed of a disk-shaped metallic disk 12 , electromagnets 13 and 14 , and a displacement sensor 15 , and holds the rotor shaft 2 in the thrust direction.
The metallic disk 12 , which is formed of a material with high magnetic permeability such as iron, is fixed perpendicularly to the rotor shaft 2 in the center thereof. Above and below the metallic disk 12 , the electromagnet 13 and the electromagnet 14 are provided respectively. The electromagnet 13 attracts the metallic disk 12 upward by means of the magnetic force, and the electromagnet 14 attracts the metallic disk 12 downward. The control section suitably regulates the magnetic force applied to the metallic disk 12 by the electromagnets 13 and 14 so that the rotor shaft 2 is magnetically levitated in the thrust direction and held in a space in a non-contact manner.
The displacement sensor 15 detects displacement in the thrust direction of the rotor shaft 2 , and sends the detection signal to the control section, not shown. The control section detects displacement in the thrust direction of the rotor shaft 2 based on the displacement detection signal received from the displacement sensor 11 .
When the rotor shaft 2 moves either way in the thrust direction and is displaced from a predetermined position, the control section operates so that the magnetic force is regulated by feedback controlling the exciting currents of the electromagnets 13 and 14 so as to correct the displacement, by which the rotor shaft 2 is returned to the predetermined position. The control section continuously carries out this feedback control so that the rotor shaft 2 is magnetically levitated in the thrust direction at the predetermine deposition and held there.
The rotor shaft 2 is provided with a motor section 16 disposed in a motor housing 24 and between the magnetic bearing portions 7 and 8 . In this embodiment, the motor section 16 is assumed to be formed of a dc brushless motor as an example.
In the motor section 16 , a permanent magnet is fixed around the rotor shaft 2 . This permanent magnet is fixed so that, for example, the N pole and S pole are arranged 180° apart around the rotor shaft 2 . Around this permanent magnet, for example, six electromagnets are arranged at 60° intervals symmetrically and opposingly with respect to the axis of the rotor shaft 2 with a predetermined clearance being provided with respect to the rotor shaft 2 .
Also, at the lower end of the rotor shaft 2 , a rotational speed sensor, not shown, is installed. The control section, not shown, can detect the rotational speed of rotor shaft 2 based on the detection signal from the rotational speed sensor. Also, for example, near the displacement sensor 11 , a sensor, not shown, is installed to detect the phase of rotation of the rotor shaft 2 . The control section detects the position of the permanent magnet by using the detection signals of this sensor and the rotational speed sensor.
At the upper end of the rotor shaft 2 , a rotor 17 is installed with a plurality of bolts 18 .
As described below, a portion ranging from a substantially middle position of the rotor 17 to the gas intake port 3 , that is, a substantially upper half portion in FIG. 1 is a molecular pump section, and a substantially lower half portion in the figure, that is, a portion ranging from a substantially middle position of the rotor 17 to the gas discharge port 4 is a screw groove pump section.
In the molecular pump section located on the gas intake port side of the rotor 17 , rotor blades 19 are installed at a plurality of stages radially from the rotor 17 so as to be inclined through a predetermined angle from a plane perpendicular to the axis of the rotor shaft 2 . The rotor blade 19 is fixed to the rotor 17 so as to be rotated at a high speed together with the rotor shaft 2 .
On the gas intake port side of the casing 5 , stator blades 20 are arranged toward the inside of the casing 5 alternately with the rotor blades 19 so as to be inclined through a predetermined angle from a plane perpendicular to the axis of the rotor shaft 2 .
When the rotor 17 is driven by the motor section 16 and is rotated together with the rotor shaft 2 , exhaust gas is sucked through the gas intake port 3 by the action of the rotor blades 19 and the stator blades 20 .
The exhaust gas sucked through the gas intake port 3 passes between the rotor blade 19 and the stator blade 20 , and is sent to the screw groove pump section formed in the lower half portion in the figure. At this time, the temperature of the rotor blade 19 is increased by friction between the rotor blade 19 and the exhaust gas and the conduction of heat generated in the motor section 16 . This heat is transferred to the stator blade 20 by radiation or gas molecule of exhaust gas.
A spacer 21 is a ring-shaped member, and is formed of a metal such as aluminum, iron, stainless steel, copper, or an alloy containing these metals as components.
The spacer 21 is interposed between stages of the stator blades 20 to keep the stage formed by the stator blades 20 at a predetermined interval, and holds the stator blades 20 at predetermined positions.
The spacers 21 are connected to each other in the outer peripheral portion, and form a heat conduction path for conducting the heat that the stator blade 20 receives from the rotor blade 19 and the heat generated by friction between the exhaust gas and the stator blade 20 .
The screw groove pump section formed on the gas discharge port side of the rotor 17 is composed of a rotor 17 and a screw groove spacer 22 .
The screw groove spacer 22 is a cylindrical member formed of a metal such as aluminum, copper, stainless steel, or iron, or an alloy containing these metals as components, and has a plurality of spiral screw grooves 23 formed in the inner peripheral surface thereof.
The direction of spiral of the screw groove 23 is a direction such that when molecules of exhaust gas move in the rotation direction of the rotor 17 , the molecules are transferred to the gas discharge port 4 .
When the rotor 17 is driven and rotated by the motor section 16 , the exhaust gas is transferred from the molecular pump section in the upper half portion in the figure to the screw groove pump section. The transferred exhaust gas is transferred toward the gas discharge port 4 while being guided by the screw groove 23 .
A heater 29 is mounted on the outer peripheral surface of the base 6 . The heater 29 is formed of an electrical heating member such as a nichrome wire, and is supplied with electric power from a temperature controller, not shown. The heater generates heat when being supplied with electric power, and heats the base 6 . By heating the base 6 , the temperature in a gas discharge path for process gas is kept at a high temperature, and thus the precipitation of solid product in the pump is restrained.
In the embodiment of the present invention, the heater 29 is mounted on the outer peripheral surface of the base 6 to heat the interior of a gas discharge path near the base 6 , which meets the conditions (low temperature, high pressure) for easy precipitation of solid product of process gas. Therefore, even if the heater 29 is mounted on the outer peripheral surface of the casing 5 , in which case the interior of gas discharge path can be heated, an effect of restraining the precipitation of solid product of process gas can be achieved. Also, the heater 29 can be incorporated directly in the turbo-molecular pump to heat the gas discharge path.
A cover member or back cover 26 is installed at the bottom of the base 6 for covering the opening of the base 6 . Since it is exposed to the outside air, the back cover 26 is in a relatively low temperature state in the turbo-molecular pump.
On the inside of the back cover 26 , there is arranged a substrate 25 in which various types of information on the vacuum pump are recorded. The substrate 25 comprises a substrate having circuits for controlling operation of the vacuum pump and in which pump operation time, error history, setting temperature for temperature control, etc. are stored. These circuits use a large number of semiconductor parts. Since the design limit temperature for the semiconductor part is set considering reliability, the semiconductor part must be used within the range of setting value of design limit temperature when the vacuum pump is operated. The design limit temperature is set at a value considering the guaranteed value of the parts maker and a margin.
The difference in arrangement position of the substrate 25 from that in the conventional vacuum pump can be seen by making comparison with the arrangement position of the substrate 104 in FIG. 2 .
Since the substrate 104 in the conventional vacuum pump is attached to a magnetic bearing portion 107 , the heat generated by a heater is transferred to the substrate 104 through a base 101 , a motor housing 106 , and the magnetic bearing portion 107 , or the heat from a motor 106 is transferred to the substrate 104 .
However, by locating the substrate 25 to the back cover 26 , the aforementioned heat conduction path for heating the substrate 25 can be cut off. Thereby, a rise in temperature of the substrate 25 can be restrained.
Since the pump substrate 25 in the present invention is arranged on the inside of the back cover 26 , the wires for the substrate 25 are designed so as to be longer than those in the conventional vacuum pump considering the efficiency of work for assembling the vacuum pump.
Although an example of a turbo-molecular pump using a magnetic bearing as a bearing has been described in the embodiment of the present invention, the present invention can also be applied to the case where, for example, a mechanical bearing is used.
As described above, the substrate 25 must be kept at a low temperature because of the parts mounted thereon. For this reason, a water cooled tube 30 is installed on the outside of the back cover 26 , on which the substrate 25 is arranged, to forcedly cool the back cover 26 by circulating cooling water in the water cooled tube 30 . Another water cooled tube 28 is arranged on a lower surface of the base 6 for cooling the base 6 .
An effect of cooling the back cover 26 can also be achieved by providing a forced air cooling device such as a fan in place of the water cooled tube 30 .
In a connecting portion 27 a and a contacting portion 27 b between the back cover 26 and the base 6 , a heat insulating material 27 with low heat conductivity is arranged. The heat insulating material 27 , which is an element for improving an effect of cooling the back cover 26 and an effect of heating the base 6 , serves to interrupt the transfer of the heat of the base 6 heated by the heater 29 to the back cover 26 . The heat insulating material is formed of a heat insulating ceramic material (for example, KO, nTiO, CaO, or SiO) or resin (for example, fluorine contained resin, acrylic resin, epoxy resin, or other high-temperature resins), or a metal with low heat conductivity (for example, stainless steel or chromium-nickel alloy (18Cr 2 Ni).
The process gas sucked through the gas intake port 3 moves in the gas discharge path toward the gas discharge port 4 while the temperature thereof decreases. However, since the base 6 is heated by the heater 29 , the process gas can be prevented from adhering and accumulating near the base 6 as a solid product.
Also, since the substrate 25 is arranged on the inside of the back cover 26 , the back cover 26 can be cooled efficiently by being cooled forcedly from the outside.
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A vacuum pump apparatus has a casing and a base connected to the casing. The base has an opening communicating with an interior space of the casing. A heater is mounted on the base for heating the base to maintain a gas discharge path at a temperature high enough to prevent solidification of processed gas in the vacuum pump. A cover member covers the opening of the base. The cover member has a first surface communicating with the interior space of the casing and a second surface exposed to the exterior of the vacuum pump. A substrate is connected to the first surface of the cover member and has at least one circuit for controlling operation of the vacuum pump.
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FIELD OF THE INVENTION
[0001] The present invention relates to a shade that protects the face from the sun while sunbathing, and more particularly a shade that is foldable, easy to store, and provides full coverage with minimal adjustments.
[0002] As more information is learned about the various harmful effects of sun exposure on skin, an assortment of sunshields and sun shelters have been formed to address concern the public has about dangerous UV sunrays.
[0003] U.S. Pat. No. 3,651,847 issued to Carole C. Casamassina on Mar. 28, 1972, and U.S. Pat. No. 4,379,349 issued to Betty D. Lawson on Apr. 12, 1983, shows devices that are both sunshields and tote bags, but unlike the present invention, these devices do not fold down to a simple flat compressed form when not in use.
[0004] U.S. Pat. No. 5,437,298 issued to Chen Y. Lin on Aug. 5, 1995, shows a sunshade arrangement containing several retractable posts, but unlike the present invention, the device includes many pieces. The leg posts of the device have spikes on the lower ends to pierce into the sand on the beach, yet unlike the present invention, users may accidentally pierce their skin with the sharp objects.
[0005] U.S. Pat. No. 5,634,210 issued to Thomas W. King and Annette King on Jun. 3, 1997 shows a face covering sunshield, but unlike the present invention, the user must wear this sunshield directly on the face, which may cause sweat in areas where the sunshield has direct contact with skin and a feeling of discomfort on a warm, humid day.
[0006] Each of these inventions attempts to shelter the user's face from sun or wind. Some are flexible and collapsible, while others are part of lawn or beach furniture. However, these inventions still contain difficulties that are not found in the present invention.
[0007] Sunbathing requires exposure of portions of the body to the sun. While many enjoy sunbathing, direct exposure to the sun may result in eye irritation and sunburn on sensitive areas of the skin, such as the face. There have been a variety of methods attempting to solve this problem including placing a towel over the face or using beach umbrellas, sunscreen and sunglasses. Yet, using a towel to cover the face while sunbathing often causes insufficient ventilation leading to uncomfortable breathing and sweating. Furthermore, beach umbrellas are often bulky to carry as well as to store, and entail the user to move the umbrella consistently as the sun changes positions through out the day. Other types of shelters often consist of many support rods that make these structures difficult to set up or bulky to carry. U.S. Pat. No. 5,823,217 issued to Paul Rice on Oct. 20, 1998, shows a sun-shelter consisting of a floor and canopy attached to the floor. Yet unlike the present invention, this sunshade contains numerous parts and pieces for the user to deal with.
[0008] Sunglasses are common devices used to protect the eyes from the sun. Nonetheless, sunglasses are easy to loose and expensive to replace multiple times. Also, sunglasses only shield the eye area of the face, leaving the rest of the face exposed and unprotected. Although sunglasses do provide great protection for the eyes, they are not “one-size-fits-all.” For example, an adult's sunglasses would not fit properly on a child's face thus allowing sun to peep in to the child's eyes, defeating the purpose of the child wearing sunglasses.
[0009] Various sunscreens have become a popular method to protect skin from the sun, but these lotions can become only partially effective due to their tendency to wash off and wear off because of sweat or pool/beach water. Also these lotions are not able to protect the eyes from the glare of the sun. Their effect can be strengthened when used collectively with other items such as an umbrella or towel covering the face. Yet, the usage of a towel over the face can remove an application of sunscreen. Both doctors and scientist claim that prolonged exposure to the sun without protection can cause not only sunburn but also eye cataracts and skin cancer, so one shouldn't take any chances on sunscreen wearing off.
[0010] Thus, there is a need for an invention that protects the face from the sun, yet is inexpensive, easily stored/carried, and gives guaranteed protection to the whole face.
SUMMARY OF INVENTION
[0011] The present invention improves upon the various previous methods of sun protection and cited patents by being effortless to use, lightweight, convenient, portable, as well as containing features that enable comfortable air circulation and easy storage.
[0012] The sunshade is constructed of a lightweight material that does not permit bright sunrays to transmit by reflecting sunlight away. The covering is formed into a cylinder canopy shape by enveloping a frame consisting of two metal rings connected on the top center of each ring by a thin metal reinforcement rod. An alternative embodiment forms the cylinder shape with a frame consisting of two metal rings connected on the top center of each ring by a thin spiral metal reinforcement rod. Such a cylinder canopy shape provides for simple assembly as well as strengthens the firmness and sturdiness of the structure, without fastening it to the ground. Also, the diameter of the sunshade is spacious enough to encompass sufficient air circulation and allow the occupant, if they choose, to use a small pillow to rest their head on while sunbathing.
[0013] The thin metal reinforcement rod is attached to the metal rings so that it is free to rotate about the spot of attachment toward the top center of the rings. Thus, to open the sunshade for use, the metal rings are turned apart in opposite directions till the cylinder canopy shape is formed. The rings are turned inward to close the sunshade so that it forms a small compressed configuration, providing for easy storage or transport of the device.
[0014] In the alternative embodiment the thin spiral reinforcement rod is also attached to the metal rings. The thin spiral reinforcement rod operates like a slinky or accordion. Thus, to open the sunshade for use, the metal rings are pulled apart from one another until the cylinder canopy shape is formed. The rings are pushed together, causing the thin spiral reinforcement rod to compress and the sunshade to collapse into a small compact configuration for easy storage and transport.
[0015] The sunshade also is equipped with a small carrying bag to carry the compressed sunshade with more ease. The bag is constructed of a similar lightweight material as the sunshade and contains a shoulder carrying strap as well as a handle. Inside the bag, a small soft foam cushion is sewn in, so the user may employ the bag as a pillow while using the sunshade to sunbathe.
BRIEF DESCRIPTION OF THE DRAWING
[0016] FIG. 1 is an environmental perspective view of the present invention deployed.
[0017] FIG. 2 is an environmental perspective view of the frame of the present invention deployed.
[0018] FIG. 3 is an environmental perspective view of the carrying bag of the present invention.
DETAILED DESCRIPTION
[0019] Referring to FIG. 1 and FIG. 2 , the present invention is a sunshade that has a lightweight covering ( 10 ) stretching over a frame ( 20 ), shown in FIG. 2 , for protecting a user's face from the sun's bright light. The lightweight covering ( 10 ) envelops the frame ( 20 ), which has a first ring ( 30 ) and a second ring ( 40 ). Connected on the top center of both first and second ring ( 30 , 40 ) by one thin reinforcement rod ( 50 ).
[0020] The lightweight covering ( 10 ) includes sheathings ( 60 ) along the sides ( 70 ). The sheathings ( 60 ) are made to encase the first ring ( 30 ), the second ring ( 40 ), and the reinforcement rod ( 50 ).
[0021] The covering ( 10 ) is made of lightweight material, preferably polyester, nylon, or a nylon/polyester blend. The lightweight covering ( 10 ) provides UV protection by deflecting sunlight, and is also lightweight enough to create a breathable, cool temperature setting for the sunbather. The covering's ( 10 ) lightweight allows the present invention not to collapse, as well. Plastic or metallic aluminum are materials that can also be used for the covering ( 10 ). The covering ( 10 ) is made out of one continuous piece of material but also can be made by stitching multiple sheets together.
[0022] The frame ( 20 ) has a first ring ( 30 ) and a second ring ( 40 ) attached together by a thin reinforcement rod ( 50 ), which slightly touches both first and second rings ( 30 , 40 ). The thin reinforcement rod ( 50 ) is preferably flat, and like the first and second rings ( 30 , 40 ), is formed of a lightweight metal material such as aluminum or steel. In an alternative embodiment, the thin reinforcement rod ( 50 ) coils in a spiral configuration and contracts and expands like an accordion or metal spring. In both embodiments, the thin metal reinforcement rod ( 50 ) in combination with the first ring ( 30 ) and second ring ( 40 ) forms the cylinder canopy shape of the present invention.
[0023] The present invention is put together for use by turning the first ring ( 30 ) apart from the second ring ( 40 ) in opposite directions until the cylinder canopy shape is formed. When the first ring ( 30 ) is turned in an opposite direction apart from the second ring ( 40 ), reinforcement rod ( 50 ) is then unwrapped or unfurled because of lack of pressure keeping first ring ( 30 ), second ring ( 40 ), and reinforcement rod ( 50 ) together. Typically, first ring ( 30 ), second ring ( 40 ), and reinforcement rod ( 50 ) are held together in a compact fashion until use via any conventional strap.
[0024] In an alternative embodiment, the present invention is assembled for use by pulling the first ring ( 30 ) apart from the second ring ( 40 ). Once the present invention is in its cylinder canopy structure, it will remain in this form without attaching the present invention to the ground with items such as stakes. The cylinder shape also allows the present invention to provide ample shade and full coverage. Even on windy days, the present invention will remain standing because of the cylinder shape and the weight of the users head and upper shoulders inside the present invention.
[0025] First and second rings ( 30 , 40 ), are the basis of the cylinder shape, each having exactly the same diameter, which allows for sufficient air to circulate through the present invention. This aspect is important because when the user puts its head and upper shoulders into the present invention for use, the top of the present invention shifts closer to the users face because the applied body weight on the first and second rings ( 30 , 40 ) bends the first and second rings ( 30 , 40 ) downward, thus bringing whole structure closer to the ground. If the first and second rings ( 30 , 40 ) were of different diameter, a slope, measured from the first ring ( 30 ) to second ring ( 40 ), would be present along the length of the present invention. Consequently, when the user puts its weight into the present invention for use, the top of the present invention shifts and becomes even closer to the users'face causing insufficient air ventilation and the feeling of being “closed in.” Preferably the first ring ( 30 ) and the second ring ( 40 ) are the same size, because similar sizes yield the present invention to be simplistic and easy to use. Yet, rings of different sizes can also be employed in an alternate embodiment if the first ring ( 30 ) is of a smaller diameter than the second ring ( 40 ). An arrangement such as this would also be desirable because when the present invention shifts towards the users face, the hot air will rise upward and out of the sunshade. Allowing to the user to sunbathe comfortably. Also, in addition to the cylinder shape, a semi-circle shape may be employed in because of its small configuration.
[0026] The diameter of the first and second rings ( 30 , 40 ) is big enough to fit the head and upper shoulders of the user, and also allow for ample air circulation. The length of the sunshade is long enough to provide sufficient coverage from the sun in these areas. The sunshade diameter and length are small enough not to allow children to use the present invention as a piece of playground equipment, climbing on or through the structure. The size of the present invention is not so large that the average sunbather would look awkward using the present invention at the beach or in any other public atmosphere. Yet, the sunshade is large enough to provide sufficient ventilation and sun coverage.
[0027] To close the present invention the first and second rings ( 30 , 40 ) are turned inward so that it forms a small compact item, making the present invention easy to carry and store. In the alternative embodiment the first and second rings ( 30 , 40 ) are pushed together like an accordion or slinky, so that the present invention forms a small compact item. In the alternative embodiment, provided hook and loop straps are attached on the sides ( 70 ) of the compressed configuration to keep it compact.
[0028] Shown in FIG. 3 , the present invention also is equipped with a small carrying bag ( 80 ) to carry the compressed configuration with more ease. The bag is constructed of nylon or polyester material and has a shoulder carrying strap ( 90 ) as well as a handle ( 100 ), both made out of a durable material such as nylon or polyester much like the straps typically used on a conventional duffel bag. The bag also contains a zipper ( 110 ) for easy opening and closing of the carrying bag ( 80 ). Inside the carrying bag, a small cushion ( 120 ), made of soft foam, is sewn in. Thus, the user may employ the carrying bag ( 80 ) as a pillow while using the present invention to sunbathe. When the user is finished sunbathing they can compress the present invention, place it in the carrying bag ( 80 ), zip up the bag, and carry around with little effort.
[0029] The present invention has benefits not present in other known sunshields in that the present invention is extremely lightweight, very easy to assemble and efficient and simple in design due to its few parts and pieces.
[0030] Having illustrated the present invention, it should be understood that various adjustments and versions might be implemented without venturing away from the essence of the present invention. The present invention is not limited to the embodiments described above, and should be interpreted as any and all embodiments within the scope of the following claims.
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A face sunshade for sunbathing use. In order to reflect sunlight, the sunshade is formed of a lightweight nylon/polyester or metallic aluminum material. The lightweight material envelops a frame consisting of two metal rings that are connected on the top center of each ring by a thin flat metal rod, creating a self-support structure. The rings, connected by the thin metal rod, form a cylinder canopy shape, which supports the sunshade when open and in use. The sunshade can be folded into a small lightweight structure, and placed into a carrying bag for easy carrying and storage. The carrying bag also converts into a pillow for the user when the sunshade is in use.
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BACKGROUND OF THE INVENTION
In positioning and assembling systems, such as for example SMD (surface mounted device) automatic placement machines, the positioning unit must be moved in the X and Y directions. For the X, Y positioning axes, a space-saving portal type of construction is preferred here, in which a positioning arm itself can be moved for example in the X direction, while a slide unit arranged in the horizontal region of the positioning arm permits the moving of the positioning unit fastened thereto in the Y direction. To achieve high accelerations for positioning arms of this type, which may also be designed as a portal, with low driving power and braking power, the moved mass must be kept as small as possible. On the other hand, however, there is the necessity of making the positioning arms resistant to bending and twisting.
Bending- and twisting-resistant positioning arms for positioning and assembling systems are usually produced as welded constructions, as a high-grade steel precision-casting construction or as a composite of high-grade steel precision-cast and welded parts. Furthermore, aluminum extruded shapes, aluminum castings and ceramic materials as well as fiber composites such as glass-fiber or carbon-fiber reinforced laminates are used.
In the production of the bending- and twisting-resistant positioning arms by precision casting, first corresponding models are prepared, these so-called “lost” models usually consisting of waxes, thermoplastic materials, urea or mixtures thereof.
CH 686 251 discloses a method for producing lightweight, bending- and twisting-resistant portals, in particular portals in automatic placement machines, in which a model is produced from a material capable of melting, dissolving out and/or burning out and is subsequently provided with a ceramic slip by coating and with a ceramic shell by subsequent drying. After removal of the model, for example by melting out, the portal is completed by firing. Disadvantages of the use of ceramic materials are on the one hand the lack of suitable, inexpensive techniques for connecting ceramic workpieces to one another and to workpieces based on a different material, for example a metallic material, and on the other hand the high brittleness of ceramic material, which under loading can easily lead to the breaking up of a portal.
Lightweight, bending-resistant materials based on metal foams are likewise known. DE 42 06 303 discloses a method for producing metal foam bodies in which a metal powder is mixed with a blowing agent powder, the powder mixture is brought to an elevated temperature in a recipient and is extruded through a die. Thereafter, the extruded part is expanded by heating, with the blowing agent powder being decomposed, and is cooled as the finished foam body.
DE 195 01 508 discloses a component for the chassis of a motor vehicle and a method for producing such a component, the component consisting of an aluminum diecasting and having a cavity profile, in the cavity of which there is a core of aluminum foam.
However, the foam-like structure of the workpieces makes it difficult to realize releasable connections between these workpieces and other workpieces. Semifinished products incorporated into the metal foam generally do not withstand strong tensile or torsional stress, since the contact surface with respect to the semifinished product is reduced on account of the structure of the metal foam.
SUMMARY OF THE INVENTION
It is an object of the invention specify a positioning arm and a flexible method for producing positioning arms, it being intended for these positioning arms to have on the one hand the highest possible resistance to bending and twisting and on the other hand the lowest possible weight. The method is at the same time intended to be particularly suitable for the production of lightweight, bending- and twisting-resistant positioning arms for positioning and assembling systems.
According to the method and apparatus of the invention for a positioning arm for positioning an assembling system, at least one core and an outer layer enclosing the core are provided. The core is formed of a metal or surrounding foam and the outer layer is formed of a non-expanded material.
In another embodiment of the apparatus and method of the invention, a positioning arm is provided for positioning and assembling systems wherein at least one core and an outer layer enclosing the core are provided. The core is formed of a non-expanded material and the outer layer is formed of a metal or ceramic foam.
Consequently, a positioning arm of the composite material: metal or ceramic foam/metallic or ceramic material is not to be regarded as hollow, like castings of steel, aluminum or ceramic, but as solid material, and therefore has a high twisting resistance and does not spring back when subjected to accelerations.
In this case, both cores of metal or ceramic foam which are surrounded by non-expanded material and cores of non-expanded material as the core which are surrounded by an outer layer of metal or ceramic foam can be realized, which leads to great flexibility in the shaping of the positioning arms.
In one embodiment of the invention, instead of one core, a plurality of cores are jointly surrounded by the outer layer, which allows more flexible shaping of the positioning arm while retaining a standard form for cores. In addition, separating walls of solid material are produced between the cores, thereby increasing the rigidity of the positioning arm. In the case of conventional sand casting methods, such separating walls are not feasible, since the sand has to be removed again after the casting.
In a further advantageous configuration of the positioning arm further flexibility is provided in the shaping of the positioning arm by the use of multilayer structures, with metal or ceramic foams and non-expanded materials alternating.
Semifinished products are at least partly arranged in the non-expanded material. This produces a solid connection of the semifinished product in the positioning arm and consequently simple connections of the positioning arm to further workpieces can be realized. For example, in this way it is possible to provide a casting around threads, which are then used for screw connections or else tubular semifinished products as a simple form of cable bushings, which when used in automatic placement machines serve for supplying power and data to placement heads attached to the positioning arm.
The use of aluminum or aluminum alloys as the metal foam and/or non-expanded material leads to particularly positioning arms by virtue of the low specific weight of aluminum. Although the modulus of elasticity of aluminum foam materials, at approx. 5 GPa, is lower than for aluminum (69 GPa), ceramic (approx. 300 GPa) or steel (approx. 210 GPa), its low density (300-1000 kg/m 3 ) in comparison with the other materials (aluminum: 2700 kg/M 3 , ceramic: approx. 4000 kg/m 3 , steel approx. 8000 kg/m 3 ) has the effect of producing a high specific bending resistance, which is further improved by combination with other materials.
On account of its high rigidity, a ceramic material is also suitable in an advantageous lacuna as a non-expanded material.
Exemplary embodiments of the invention are described in more detail below and are represented in the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a shows a core of a metal or ceramic foam with an outer layer of a non-expanded material,
FIGS. 1 b and 1 c show a core of a metal or ceramic foam which is surrounded by an outer layer of a non-expanded material, in longitudinal section and in cross section,
FIG. 2 a shows part of a positioning arm which has been produced by casting around a plurality of cores, with the associated longitudinal section in
FIG. 2 b and cross section in FIG. 2 c,
FIG. 3 shows a layered structure of metal or ceramic foam and non-expanded materials,
FIG. 4 shows part of a positioning arm with a layered structure around a core,
FIG. 5 a shows the cross section of a semifinished product in part of a positioning arm based on metal or ceramic foam,
FIGS. 5 b and 5 c show in cross section two possibilities for arranging a semifinished product in a positioning arm based on a cast-around metal or ceramic foam,
FIG. 6 shows part of a positioning arm with cast-around tubular semifinished products,
FIG. 7 shows a plan view of a positioning arm with a placement head in use in an automatic placement machine and
FIG. 8 shows a section along the line II—II of FIG. 7 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 it is shown how part of a positioning arm 1 of a positioning and assembling system is constructed from a core 2 of metal or ceramic foam which is cast around by an outer layer 3 of a metallic or ceramic material. For the casting-around operation, a low-pressure casting method is used here. In a preferred embodiment, a core 2 of aluminum foam has aluminum or an aluminum alloy cast around it. On account of the lower density of the aluminum foam, a weight reduction in comparison with solid positioning arms formed of aluminum is achieved. In comparison with known methods of weight reduction by casting around cores which can be dissolved out, in the method according to the invention the cores remain in the positioning arm, which simplifies production. Suitable for example as the ceramic foam are aluminum silicate or aluminum oxide fibers or alkaline earth metal silicate fibers treated by the vacuum suction method.
As shown in FIG. 2, the method can be varied, in that for example a plurality of cores 2 of aluminum foam material have a metallic or ceramic material 3 jointly cast around them. This produces between the cores 2 separating walls 3 a of the metallic or ceramic material 3 , which ensure a greater rigidity of the positioning arm. In the case of conventional casting methods with sand cores, such separating walls cannot be produced, since the sand cores have to be removed again through holes after the casting.
By repeated application of the methods of casting around and surrounding with metal or ceramic foam, layered structures are possible, as shown by way of example in FIG. 3 . Here, a core 2 of metal or ceramic foam has had a metallic or ceramic material 3 cast around it, which is subsequently surrounded by a further layer 4 , for example of a further metal or ceramic foam, which absorbs impact energy particularly well.
In FIG. 4 it is shown how a core 3 of a non-expanded material, such as for example a semifinished product or a metal casting or metal extruded part is surrounded by an outer layer 3 of metal or ceramic foam, which in turn has a further layer 4 of a metallic or ceramic material cast around it. Suitable for example as semifinished products are threaded inserts or bodies with mounting surfaces, which serve for the connection of the positioning arms to other components. In FIGS. 5 a , 5 b and 5 c , three possibilities for arranging semifinished products in positioning arms are shown. In FIG. 5 a it is shown how a semifinished product 5 of metal or ceramic foam 6 is surrounded. This embodiment has the disadvantage that, on account of the low surface adhesion between metal or ceramic foam 6 and semifinished product 5 , the connection often cannot be adequately subjected to loading. Higher load-bearing capacities are achieved by the embodiment according to FIG. 5 b , in which the semifinished product 5 is surrounded both by the core 2 of metal or ceramic foam and by the outer layer 3 of metallic or ceramic material. The embodiment according to FIG. 5 c , in which the semifinished product 5 is surrounded in a known way by the outer layer 3 of the metallic or ceramic material and has no contact with the core 2 of metal or ceramic foam, is also suitable for withstanding high loads.
The surrounding of tubular semifinished products 7 , as shown in FIG. 6, makes it possible to receive cables, which can be led from one end of the positioning arm to the other in the tubular semifinished products, without the risk of cables becoming tangled when the positioning arm is moved.
Shown in FIG. 7 is the positioning arm 1 comprising cores 2 and outer layer 3 , as it is used in an automatic placement machine. The positioning arm 1 can in this case be moved in the X direction on a rail, 10 . Attached in the horizontal region of the positioning arm 1 is a slide 11 , which is moved in the Y direction. Connected to the slide 11 is a placement head 12 , which receives a plurality of suction pipettes 13 along its circumference. The suction pipettes 13 serve for transporting components 14 from feeding units (not shown) to the desired position of the components 14 on a printed-circuit board 15 , as is shown in FIG. 8 . The placement head 13 is in this case rotatably mounted, so that altogether, for example, twelve suction pipettes 13 can be used for initially removing twelve components 13 from the feeding units, before these twelve components 13 are placed one after the other onto the printed-circuit board 15 .
The cross section in FIG. 8 reveals the connection between the slide 11 and the positioning arm 1 , which is ensured by a semifinished product 5 introduced by the method according to the invention.
The invention comprises all further conceivable combinations of metal foams with metallic and/or ceramic materials not presented here in detail but obvious to a person skilled in the art. For example, layered structures can also be realized by surrounding metallic or ceramic cores with metal or ceramic foam and subsequent further casting around with metallic and/or ceramic materials.
The methods described are suitable in particular for realizing positioning arms in automatic placement machines, which are subjected to particularly strong acceleration forces. The method is also suitable for highly accelerated components on machines of which the transient characteristics have a strong influence on positioning duration and positioning accuracy.
As already mentioned, the use of aluminum or aluminum alloys as the metal or ceramic foam and/or non-expanded material leads to particularly lightweight positioning arms by virtue of the low specific weight of aluminum.
Although various minor changes and modifications might be proposed by those skilled in the art, it will be understood that our wish is to include within the claims of the patent warranted hereon all such changes and modifications as reasonably come within our contribution to the art.
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Positioning arms for positioning and assembling systems are subjected to high accelerations and must therefore be made lightweight but nevertheless resistant to bending and twisting. The use of composite materials based on metal or ceramic foams and non-expanded materials for positioning arms in positioning and assembling systems allows these positioning arms to be lightweight and nevertheless to have high rigidity. Semifinished products are arranged in the non-expanded material, since a better connection between the semifinished product and material is ensured there than in the metal or ceramic foam.
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FIELD
[0001] The present disclosure relates to a rotating gauge pointer and a light guide that rotates between a liquid crystal display and a light source.
BACKGROUND
[0002] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art. Indicating instruments or gauges for viewing by drivers of automobiles generally include an analog portion for displaying operational information such as vehicle speed and engine RPM and, in more recent technologically advanced vehicles, a liquid crystal display for displaying information related to vehicle operating condition such as fuel efficiency, outside temperature, engine functions, and other information related to driving or vehicle conditions. An analog gauge typically includes a faceplate having indicia thereon such as numbers and a pointer for rotating to the appropriate number. While such analog indicating instruments and liquid crystal displays have generally proven satisfactory for their intended purposes, they have been associated with their share of limitations.
[0003] One such limitation of current vehicles with both analog and liquid crystal display devices is their packaging requirements. Because such devices are normally located in separate locations on a vehicle dash, extensive amounts of space are normally required in a dash. This generally leaves little packaging space for other gauges, such as temperature, fuel, and engine RPM gauges.
[0004] Another limitation of current vehicles with both analog and liquid crystal display devices is also related to vehicle packaging. More specifically, because incorporating analog and LCD devices within a vehicle dash presently means locating such devices in separate areas of the dash, even if they are adjacent to each other, the time necessary to view both, the analog and digital gauges, and the human movements required to view both, may be cumbersome for a vehicle driver.
[0005] What is needed then is a device that does not suffer from the above disadvantages. This, in turn, will provide an analog and an LCD device that is quickly and easily discernible in a short amount of time and that does not require extensive head or eye movements by a viewer of the gauges.
SUMMARY
[0006] An indicating instrument, such as a speedometer gauge, may employ a pointer arranged on a rotatable pointer disk, a liquid crystal display arranged over the pointer disk, a first dial located outboard of the liquid crystal display, and a second dial located over the liquid crystal display. The pointer disk may be a translucent light collector for the pointer, provide consistent, even lighting to the adjacent liquid crystal display, and transmits light to backlight the liquid crystal display. Depending upon the installation requirements of the indicating instrument, the pointer may point outboard of the pointer disk, inboard of the pointer disk, or be a dual pointer, and point outboard and inboard to respective scales. Regardless of the application, the liquid crystal display is viewable by a person viewing the instrument.
[0007] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
[0008] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
[0009] FIG. 1 is a perspective view of an interior dash of a vehicle depicting a location of an indicating instrument;
[0010] FIG. 2 is a front view of an indicating instrument constructed in accordance with an embodiment of the present invention;
[0011] FIG. 3 is a cross-sectional view of the indicating instrument of FIG. 2 ;
[0012] FIG. 4 is a cross-sectional view of an embodiment of the indicating instrument in accordance with the present invention;
[0013] FIG. 5 is a front view of an indicating instrument constructed in accordance with an embodiment of the present invention; and
[0014] FIG. 6 is a cross-sectional view of the indicating instrument of FIG. 5 .
DETAILED DESCRIPTION
[0015] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. Turning now to FIGS. 1-6 , the teachings of the present invention will be explained. With initial reference to FIG. 1 , depicted is a vehicle 10 having a dashboard 12 (“dash”) and an instrument cluster 14 , both of which may be situated in front of a driver's seat 16 in the interior cabin 18 of the vehicle 10 . As part of the instrument cluster 14 , a viewed component 20 is depicted and hereinafter, the viewed component 20 is exemplified by an indicating instrument or gauge, such as a speedometer. It is appreciated that the viewed component 20 may be exemplified by other gauges or instruments, such as a tachometer, fuel gage, temperature gage, etc.
[0016] Turning now to FIGS. 2 and 3 , the speedometer 20 generally includes a first dial 22 , a second dial 24 , a pointer 26 , a liquid crystal display 28 (“LCD”), a printed circuit board 30 (“PCB”), and a light source such as light emitting diodes 32 (“LED”). More specifically, the first dial 22 may denote miles per hour (mph) to a driver using indicia 34 and associated graduations 36 while a second dial 24 may denote kilometers per hour (km/h) using indicia 38 denoted by graduations 40 . Such indicia 34 , 38 and graduations 36 , 40 may be spaced around their respective dial at a predetermined interval. As depicted in FIG. 2 , the speedometer 20 is a typical US configuration insofar as the first dial 22 has mph indicia 34 that are larger than the corresponding Km/h indicia 38 , which apply to countries using metric measurements, such as Canada.
[0017] Continuing with FIGS. 2 and 3 , the speedometer 20 depicts an LCD 28 screen that may be rectangular, circular, triangular or other shape, as appropriate for the respective speedometer application. The pointer 26 is an indicating portion of the speedometer that is attached to a circular pointer disk 42 that is mounted to a spindle 44 that is driven by an electric motor 46 . The motor 46 rotates the spindle 44 , pointer disk 42 and associated pointer 26 so that the pointer 26 may indicate the correct speed at which a vehicle is traveling. In addition to acting as a portion of the pointer 26 , the pointer disk 42 serves an additional role as a light collector for the LCD 28 . More specifically, because the pointer disk 42 is situated between the PCB 30 and the LCD 28 , the LEDs 32 of the PCB 30 provide the necessary backlighting for the LCD 28 . To properly distribute and provide light to the LCD 28 , the LEDs 32 may direct light rays into the pointer disk 42 such that the light is reflected within the pointer disk 42 . While being reflected within the pointer disk 42 , some of the light is reflected and directed to the pointer 26 to illuminate the pointer 26 , while some of the light passes out of the pointer disk 42 and into the LCD 28 and becomes a source of light for the LCD 28 . Depicted in FIG. 2 , the area 25 of the pointer disk 42 may be a plated area for specific color enhancement, or opaque.
[0018] Regarding placement of the dials 22 , 24 of the embodiments of FIGS. 3 and 4 , the dial 22 may be considered to be above, below, or at the same level as the LCD 28 . The dial 22 shown in phantom is depicted approximately at the same level as the LCD 28 . The dial 22 is depicted outboard of the LCD 28 , while the dial 24 is depicted over the LCD 28 . The dial 66 of FIGS. 5 and 6 , to be described in more detail later, may also be described as being over the LCD 28 , much like the dial 24 of FIGS. 3 and 4 . Additionally, the pointer disk 42 , as depicted in FIGS. 2 , 3 and 4 , may have the plated area 25 about its periphery for color enhancement. Alternatively the area 25 may be opaque or no treatment may be applied to the pointer disk 42 .
[0019] With continued reference to FIG. 3 , light may pass into the pointer disk 42 in at least two ways; first, as discussed above, light from the LEDs 32 located under the pointer disk 42 may pass light into the pointer disk 42 and subsequently the LCD 28 , and second, LEDs 48 may pass light into a pointer hub 50 . In passing light into the pointer hub 50 , the LEDs 48 may be situated directly under the pointer hub 50 such that light may pass directly through the hub 50 and pointer disk 42 and then into the LCD 28 . To effectively reflect and transmit light through the pointer disk 42 en route to the pointer 26 , the interior of the pointer disk 42 is equipped with a surface treatment 43 , such as angled edges, textures or plated surfaces or layers, for example, that facilitate light reflectivity, light transmission and color changes or enhancements. The material of the pointer disk 42 may be acrylic or another plastic material that facilitates light reflection and transmission. Not only may the pointer disk 42 be equipped with a surface treatment 43 , but the pointer 26 may also be equipped with a surface treatment 27 , such as angled edges, textures or plated surfaces or layers, for example, that facilitate light reflectivity, light transmission or color changes or enhancements. Although such treatment areas 27 and 43 are only shown on FIG. 3 , they may be applied to the structure of FIG. 4 .
[0020] Turning to FIG. 4 , an alternate embodiment of the invention is depicted. The embodiment of FIG. 4 is similar to that of FIG. 3 ; however, the embodiment of FIG. 4 depicts a dual pointer 52 , which includes the primary pointer 26 as depicted in FIGS. 2 and 3 , and additionally, a secondary pointer 54 . The secondary pointer 54 may be used to more precisely point to secondary indicia 38 , such as that on a second dial 24 as best depicted in FIG. 2 . As with the pointer 26 , the secondary pointer 54 is illuminated by the LEDs 32 , 48 located under the LCD 28 . An advantage of the dual pointer 52 as depicted in FIG. 4 is that two different scales may be simultaneously indicated without any portion of a pointer passing over or through a set of indicia, as commonly occurs with many current art pointers. That is, because may current art pointers originate in the center of a dial and pass over a first set of indicia to indicate a second set of indicia, the pointer obstructs part of the first set of indicia. With the dual pointer 52 depicted in FIG. 4 , no indicia of any scale need be obstructed. In addition to the improved viewing of the indicia 34 , 38 , the embodiments depicted in FIGS. 3 and 4 provide a clear, unobstructed line of sight to the LCD 28 .
[0021] Turning now to FIGS. 5 and 6 , a speedometer 60 is again depicted as an example of a viewed component. The speedometer 60 has a U-shaped portion 62 extending from the pointer disk 42 that permits the pointer 64 to be directed toward a center portion of an LCD 28 and a surrounding dial 66 . The dial 66 is a ring structure, which contains indicia 68 denoted by graduations 70 , that is located over the LCD 28 , yet permits viewing of the LCD 28 by a driver, for instance. The pointer disk 42 and LEDs 32 , 48 function in a similar fashion to those of the embodiments of FIGS. 2-4 ; that is, light from the LEDs 32 , 48 is permitted to pass into the pointer disk 42 en route to the end of the pointer 64 and additionally, light is permitted to pass out or through the pointer disk 42 to backlight the LCD 28 . Additionally, light may pass to the dial 66 to illuminate any indicia 68 on the dial 66 . Because the structure of FIGS. 5 and 6 utilizes a U-shaped portion 62 with the pointer pointing in an inboard direction (toward the center of the LCD 28 ), the overall gauge packaging may be made smaller, with a reduced overall diameter, than a gauge whose pointer points in an outboard direction (away from the center of the LCD 28 ), all else being equal. The pointer 64 may also be equipped with a surface treatment 65 , such as angled edges, textures or plated surfaces or layers, for example, that facilitates light reflectivity, light transmission or color changes or enhancements. The pointer disk 42 may also have such a surface treatment as applied to the pointer 64 .
[0022] There are many advantages to the embodiments of the present invention. First, because of the design and layout of the pointer disk 42 and LCD 28 , the LEDs 32 , 48 are able to serve as lighting for the pointers 26 , 54 , 64 and as lighting for the LCD 28 and adjacent dials. By using the LEDs 32 , 48 in a dual or multi-function role, the number of LEDs may be reduced. Second, the pointer disk 42 serves as a light collector for the pointer 26 . Because the pointer disk 42 serves as a light collector for the pointer 36 and because of its translucence may supply light to the LCD 28 , the LCD 28 may not require another, supplemental, light source.
[0023] Still yet, another advantage of the embodiments of the present invention is that a compact gauge with an LCD may be provided. That is, the embodiments of FIGS. 1-6 provide a structure in which the LCD is positioned on top (with respect to the cross-sectional drawings) or in front (with respect to a driver's viewing perspective in a vehicle) of the pointer structure. Thus, with such a structure, the LCD does not need to be located separately from the workings of the pointer structure, which would require additional dash space. Additionally, the analog pointer will not obstruct the view of the LCD, and finally, with the embodiments of FIGS. 1-6 , a structure results in which a centralized motor 46 may be used. With a centralized motor, there is no need for offset motors and associated gearing to drive a pointer or an affiliated indicator, and weight distribution of the pointer disk about the driving shaft of the motor may remain consistent.
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An indicating instrument for a vehicle may employ an analog type lighted pointer arranged on a rotatable, circular shaped pointer disk, a liquid crystal display arranged over the pointer disk, and a first dial with indicia located outboard of or adjacent to and/or inboard of the LCD. A second or inboard dial may be located over the liquid crystal display. The pointer disk may be a translucent light collector for the pointer yet also transmit light to provide backlighting for the LCD. Depending upon the analog gauge arrangement, the pointer may point outboard of the pointer disk or toward the LCD center. The dials, especially the second dial, may be in the shape of rings to permit viewing of the LCD from the perspective of a viewer, such as a vehicle driver.
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FIELD OF THE INVENTION
[0001] The present invention relates to the field of screws. More particularly, the present application relates to the field of jackscrews used to secure electronic and computer components.
BACKGROUND OF THE INVENTION
[0002] Jackscrews are specialized screws used in electronics and computer equipment. Jackscrews are used, for example, to attach printed circuit assemblies and other components in, or to, the housing or chassis of an electronics assembly or to other structural members in an electronic device.
[0003] Jackscrews typically have many threads per centimeter so as to make a very secure connection. The relatively high thread count makes it necessary to make relatively more radial turns of the jackscrew in order to thread the jackscrew completely into a threaded hole.
[0004] Often, jackscrews must be removed and reinserted in order to maintain, inspect, replace or repair components of the electrical device in which the jackscrew is used. With the amount of threads per centimeter on a typical jackscrew, this repeated removal and reinsertion of the screw causes significant wear and tear on the jackscrew. Frequently, this wear and tear causes fragments of the jackscrew to be dislodged, scratched off or otherwise worn from the jackscrew.
[0005] Having material dislodged from the threads or other parts of a jackscrew is disadvantageous for several reasons. For example, the jackscrew becomes less useful as a fastener as its threads become worn. The wearing of screw threads decreases the ability of a screw to make a tight connection and secure the components through which it is placed.
[0006] Another problem is that these fragments of screw threads can damage the electronics in which the screw is used. For example, these fragments can cause electrical shorts when they are brought into contact with printed circuit boards or other electronic components.
[0007] Additionally, metal shavings or slivers generated when a jackscrew or other type of screw is inserted into a threaded hole can cause binding between the screw and the threaded hole that is to receive the screw. This situation occurs especially in off-axis loading of the screw, where the screw may not be correctly aligned with the threaded receiving hole. Binding between these two members in this fashion will prevent the screw from being properly threaded into the hole and may create further metal contamination in electrical assemblies of all kinds.
SUMMARY OF THE INVENTION
[0008] In one of many possible embodiments, the present invention provides a jackscrew for use in securing electronic assemblies. The jackscrew preferably includes a threaded shaft, a head at one end of the threaded shaft, and a protective coating disposed on the threads of the threaded shaft. The protective coating prevents fragments from being dislodged from the jackscrew.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The accompanying drawings illustrate various embodiments of the present invention and are a part of the specification. Together with the following description, the drawings demonstrate and explain the principles of the present invention. The illustrated embodiments are examples of the present invention and do not limit the scope of the invention.
[0010] [0010]FIGS. 1 a and 1 b illustrate a jackscrew to which the principles of the present invention may be applied.
[0011] [0011]FIG. 2 illustrates an end-on view of head of the jackscrew of FIGS. 1 a and 1 b.
[0012] [0012]FIG. 3 illustrates a conventional jackscrew with problematic fragments of metal worn from the jackscrew.
[0013] [0013]FIG. 4 is an illustration of one embodiment of the present invention in which a jackscrew is coated with a protective coating.
[0014] [0014]FIG. 5 is an illustration of an embodiment of the present invention showing the threaded portion of a coated jackscrew, which is being used in an electronics assembly.
[0015] [0015]FIG. 6 is an illustration of an embodiment of the present invention showing a threaded nut plate that would receive a jackscrew.
[0016] [0016]FIG. 7 is an illustration of an embodiment of the present invention showing a coated jackscrew, which is used in an electronics assembly and is secured in a threaded nut plate incorporated into the housing (or chassis) of the electronics assembly.
[0017] [0017]FIG. 8 is an illustration of an embodiment of the present invention in which a coated jackscrew resists damage during off-axis loading.
[0018] Throughout the drawings, identical reference numbers designate similar, but not necessarily identical, elements.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] [0019]FIGS. 1 a and 1 b illustrate a jackscrew ( 100 ) that is used in electrical components. Jackscrews ( 100 ) are usually composed of a threaded shaft ( 120 ) and a head ( 130 ). The threads ( 110 ) are typically zinc-coated steel. The head ( 130 ) may have knurling around its circumference to facilitate the ability of a user of the jackscrew ( 100 ) to grip the head ( 130 ) for hand tightening of the jackscrew ( 100 ).
[0020] The jackscrew head ( 130 ) also includes a recess into which the tip of a tool, such as a screwdriver, can be inserted to drive the screw by rotation into or out of a threaded hole. This recess can have a wide variety of shapes, including, but not limited to, a single slot, cross-slots, a hexagon shape, a square shape, etc.
[0021] [0021]FIG. 2 is an illustration of a preferred recess ( 140 ) in the head ( 130 ) of a jackscrew ( 100 ). The recess ( 140 ) shown in FIG. 2 is star-shaped such that the screw ( 100 ) could be driven with an appropriately shaped tool tip inserted into the recess ( 140 ). Jackscrews with this type of recess ( 140 ) are made by Textron Industries, Inc. of Rockford, Ill. under the trademark TORX®.
[0022] Jackscrews ( 100 ) are typically used in conjunction with stainless steel nuts or nut plates that are threaded into in chassis or housing of an electronic device in order to hold a printed circuit assembly safely in the housing of that electronic device. This will be illustrated in greater detail below.
[0023] As indicated above, the threads ( 110 ) on the shaft ( 120 ) are relatively dense and close together, thus creating more threads ( 110 ) per centimeter than, for example, a conventional wood screw would have. Due to the case of wear that a jackscrew ( 100 ) of this composition can undergo, fragments of metal from the jackscrew ( 100 ) can be chipped, worn or otherwise dislodged from the jackscrew ( 100 ). This results in the wide variety of problems discussed above.
[0024] [0024]FIG. 3 illustrates a conventional jackscrew ( 100 ) with flakes of separated metal ( 220 ) that have been dislodged from the jackscrew ( 100 ). Often, during installation and removal of the jackscrew ( 100 ), these flakes of metal ( 220 ) will be produced. Installation of jackscrews ( 100 ) can often be off-axis, meaning that the male and female thread axis are misaligned when torque is applied to drive the screw into the threaded hole. This misalignment causes the threads ( 110 ) of the jackscrew ( 100 ) to bear down against the harder metal of the female portion of the system, i.e., the threads of the hole into which the screw is being seated. Consequently, flakes or fragments of metal ( 220 ) are sheared off the jackscrew ( 100 ).
[0025] These flakes or fragments of metal ( 220 ) that are produced from the jackscrew ( 100 ) can contaminate printed circuit assemblies and other vulnerable electronic components. Contamination of electronic assemblies with these flakes of metal ( 220 ) can cause electrical shorts due to the conductivity of the flakes or fragments ( 220 ). The more fragments of metal ( 220 ) produced that may come in contact with any electrical system in the electrical device, the more likely those fragments ( 220 ) are to cause a failure in the circuitry of the device.
[0026] [0026]FIG. 4 illustrates an embodiment of the present invention in which a jackscrew ( 100 a ) is coated with a protective coating ( 400 ). Under the principles of the present invention, the protective coating ( 400 ) serves a number of purposes. First, the protective coating ( 400 ) covers the threads ( 110 ) of the screw ( 100 a ) to prevent flakes or fragments of metal from being sheared or worn off the screw ( 100 a ). The coating ( 400 ) may absorb pressure and force applied to the screw ( 100 ) that would otherwise tend to dislodge fragments of metal from the screw ( 100 a ). The coating ( 400 ) increases the surface strength of the screw ( 100 a ) and may hold fragments to the screw ( 100 a ) even if those fragments are broken from the surface of the screw ( 100 a ) under the coating. The coating ( 400 ) may be applied over the entire exterior surface of the jackscrew ( 100 a ), including the head ( 130 ) to prevent unwanted fragments from being dislodged from any part of the screw ( 100 a ).
[0027] Additionally, the protective coating ( 400 ) can cause the surface of the jackscrew ( 100 a ) to have a lower coefficient of friction. A lower coefficient of friction causes the jackscrew ( 100 a ) to rotate more freely as torque is applied in order to twist the jackscrew ( 100 a ) into the female portion of the system, i.e., into a threaded hole. Since the jackscrew ( 100 a ) rotates more freely as it is torqued, less binding of the jackscrew ( 100 ) in the nut or female portion of the system will occur. Consequently, fewer or no fragments of metal ( 220 ) will be broken off the jackscrew ( 100 ).
[0028] A preferred material for the protective coating ( 400 ) is Xylan® 1052. Xylan® is a chemical compound made by the Whitford Corporation of West Chester, Pa. The chemical compound of Xylan® 1052 ( 400 ) is composed of a unique combination of PTFE (polytetrafluoroethylene) and MoS 2 (molybdenum disulfide) chemical compounds.
[0029] Molybdenum disulfide (MoS 2 ) is a chemical known for its low coefficient of friction and high load-bearing properties. This chemical helps contribute to Xylan® 1052's ( 400 ) low coefficient of friction (“slipperiness”) and durability. PTFE (polytetrafluoroethylene) is a thermoplastic member of the fluoropolymer family of plastics. PTFE is considered to have the lowest coefficient of friction of any known solid, and the highest operating temperatures of the fluoropolymer family. These remarkable qualities allow this substance to eliminate wear on any jackscrew that is coated in Xylan® 1052 ( 400 ). Therefore, Xylan® 1052 makes a preferred protective coating ( 400 ) for jackscrews ( 100 a ) that may encounter wear and tear and heavy, off-axis load pressures. Through the application of Xylan® 1052 ( 400 ), metal particle ( 220 ) contamination among printed circuit assemblies and any other electronic assembly is minimized or eliminated.
[0030] [0030]FIG. 5 is an illustration of an embodiment of the present invention in which a coated jackscrew ( 100 a ) is used to secure a printed circuit assembly ( 500 ). This illustration depicts the possible proximity of the printed circuit ( 500 ) and other electronic components to the jackscrew ( 100 a ). Due to this proximity, if any tiny fragments of metal were dislodged from the jackscrew ( 100 a ), they would easily and likely come in contact with the printed circuit ( 500 ) or other electronic components. As noted above, this would very likely cause a short or other malfunction in the circuit ( 500 ) or other components.
[0031] However, with the coating ( 400 ) applied on the screw ( 100 a ) according to the principles of the present invention, the release of any problematic metal fragments is minimized. Consequently, the reliability of the circuit ( 500 ) will be enhanced, even if the screw ( 100 a ) is frequently engaged and disengaged to allow maintenance or access to the circuit ( 500 ) or other components.
[0032] [0032]FIG. 6 is an illustration of a threaded hole ( 600 ) in a nut plate ( 610 ) in which the jackscrew ( 100 a ) may be engaged after being installed through a circuit board assembly (e.g., 500 ; FIG. 5). A printed circuit board may be secured in a chassis or housing with a jackscrew that extends through the circuit board and into a threaded hole ( 600 ) in a nut plate ( 610 ) that is secure to or part of the chassis or housing. The housing or chassis provides stability and protection for the electronic assembly that includes the secured circuit board.
[0033] The threaded nut plate ( 610 ) is preferably made of stainless steel. Stainless steel is a harder substance than the typical zinc coating on the threads of the steel jackscrew ( 100 ). It is due to this fact that the zinc coating of the jackscrew is frequently sheared off and becomes the main source of the metal fragments ( 220 ; FIG. 3) discussed above that contaminate and may damage electronic components, such as printed circuits ( 500 ; FIG. 5).
[0034] [0034]FIG. 7 illustrates an embodiment of the present invention in which a coated jackscrew ( 100 a ) is used to connect to a printed circuit assembly ( 500 ) to a chassis ( 610 ) or frame of an electrical device ( 700 ). After the printed circuit assembly ( 500 ) is correctly positioned, the jackscrew ( 100 a ) is tightened to secure the assembly ( 500 ) in place.
[0035] “A” represents the angle of rotation through which the printed circuit assembly ( 500 ) swings as it is correctly installed. This angle of rotation (A) results from the printed circuit assembly ( 500 ) pivoting about a pivot point ( 710 ) at the bottom of the printed circuit assembly ( 500 ). The printed circuit assembly ( 500 ) must rotate on this pivot ( 710 ) through the angle of rotation (A) in order to be installed correctly.
[0036] However, this angle of rotation (A) can also cause an off-axis alignment of the jackscrew ( 100 ) with the threaded hole ( 600 ) of the nut plate ( 610 ) located on the chassis. As mentioned above, this off-axis alignment can cause the jackscrew ( 100 a ) to be misthreaded as it is screwed into the threaded nut plate ( 610 ). This results in increased pressure and wear on the screw ( 100 a ). More specifically, this off-center installation of the jackscrew ( 100 a ) would normally cause the jackscrew to wear and could shear off metal fragments ( 220 ) from the jackscrew. However, with the implementation of a protective coating ( 400 ), such as Xylan® 1052, a lower coefficient of friction of the coating ( 400 ) causes the jackscrew ( 100 a ) to rotate more freely even with off-axis loading as caused by the rotation through angle “A.”
[0037] [0037]FIG. 8 further illustrates the situation in which a jackscrew is subject to off-axis loading. In order to properly thread a jackscrew ( 100 a ) into a threaded hole ( 600 ) of a nut plate ( 610 ), the axis of both the jackscrew ( 100 ) and the threaded hole ( 600 ) must be aligned. As illustrated in FIG. 8, the axis ( 801 ) of the threaded hole ( 600 ) and the axis ( 801 ) of the jackscrew ( 100 a ) are not aligned. This causes binding or striping of the jackscrew threads ( 110 ). The application of the protective coating ( 400 ), preferably being a Xylan® 1052 protective coating ( 400 ), causes the coefficient of friction to decrease and causes the jackscrew ( 100 a ) to twist more freely into the threaded hole ( 600 ) and to engage without binding. Thus, even though the screw ( 100 a ) is inserted “off-axis,” the problems associated with such off-axis loading and the resulting metal fragments are minimized.
[0038] The preceding description has been presented only to illustrate and describe the invention. It is not intended to be exhaustive or to limit the invention to any precise form disclosed. Many modifications and variations are possible in light of the above teaching.
[0039] The preferred embodiment was chosen and described in order to best illustrate the principles of the invention and its practical application. The preceding description is intended to enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims.
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A jackscrew for use in securing electronic assemblies preferably includes a threaded shaft, a head at one end of the threaded shaft, and a protective coating disposed on the threads of the threaded shaft. The protective coating prevents fragments from being dislodged from the jackscrew.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. application Ser. No. 09/204,067, filed Dec. 3, 1998, now U.S. Pat. No. 6,726,650, which claims priority to and benefit of European Application No. 97810947, filed Dec. 4, 1997, all of which are hereby incorporated by reference in their entirety.
FIELD OF THE INVENTION
The present invention concerns the administration by injection to patients of liquid compositions for therapeutic or diagnostic purposes. It more particularly concerns a power assisted method and device for controllably dispensing a liquid medicament or diagnostically active contrast agent, the homogeneity of which is preserved throughout delivery. Typically, the contrast agent is an aqueous suspension of gas filled microvesicles, namely microbubbles bounded by a surfactant stabilized gas/liquid interface, or microballoons bounded by a tangible material envelope.
BACKGROUND ART
Power injectors and mechanically assisted infusion systems for controllably dispensing therapeutically active medications are well known in the art. Typically, such devices include an automatic injector for syringes containing an injectable liquid and a plunger or piston movable within the barrel of the syringe to expel said liquid through a tip thereof and injecting into a patient via a tubing connected to an injecting needle or catheter. For controlling the injections parameters, the plunger is driven by means of an electromechanical arrangement organised to push the plunger at a desired rate, continuously or at chosen intervals, so that the amount of medication is delivered to the patient's body under strictly determined conditions. For instance, in the case of intravenous dispensing contrast agent formulations for diagnostic purposes (X-ray, MRI or ultrasound), the rate and the mode of injection can be accurately controlled to match the requirements of the imaging methods and detector systems used to investigate the circulation or a specific organ in the body. Typical automated injection devices are illustrated and described in U.S. Pat. No. 5,176,646 incorporated herein by reference.
Although the automated injectors known are highly sophisticated instruments capable of mastering most injection problems experienced in practice, there remains at least one variable factor not yet under control. Indeed the known power injectors have no control of the homogeneity of the liquid stored within the syringe barrel during the course of its application. This kind of problem is of course non-existent with “true solutions” (i.e. solutions to the molecular level) since in this case no concentration change can occur in the course of time; it however may become important when the injectable formulation is a suspension or dispersion of active particles which tend to settle, coalesce or segregate with time in the syringe. Indeed, even some modest separation of the particles by gravity or otherwise from the carrier liquid in the course of administration of the formulation may have very important influence on reproducibility and reliability of the tests. Hence, in this case, a method and means to keep the syringe content homogeneous during injection is highly desirable. The present method and device constitute a very effective solution to the aforediscussed problem.
SUMMARY OF THE INVENTION
Briefly stated, in order to secure homogeneity of a liquid suspension of particles within the barrel of an injector device, the invention provides a method and means whereby the particles are kept under sufficient agitation so as not to settle, segregate or agglomerate in the carrier liquid. This may involve acting on the carrier liquid itself, i.e. on the bulk of the suspension, or may involve acting only on the particles (in this case, one would expect the moving particles to impart motion to the carrier liquid by viscous friction). The agitation means may be provided within the syringe or in some cases outside thereof; for instance with magnetic particles, the particles can be subjected to an external variable magnetic field, the oscillation or rotation of which will set them into motion, the moving particles then acting on the carrier liquid and keeping the suspension homogeneous.
In the case of particles not sensitive to external fields, mechanical agitation is provided to the extent that it is sufficient to keep the suspension homogeneous but insufficient to break or damage the particles or disturb their distribution. For this, the syringe barrel may be subjected to motion, said motion being continuous or discontinuous, regular or irregular; the motion can possibly have a shaking, rocking or oscillating effect on the syringe. The frequency, intensity and rate of the motion is such that it will not interfere with the control of delivery parameters of the suspension.
The embodiments disclosed below in connection with the annexed drawings provides very effective means to keep the syringe content under sufficient agitation to secure injection of a homogeneous therapeutic or diagnostic liquid compositions into a patient.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view in perspective of a device for agitating a liquid within the syringe of a power driven automatic injector system of the invention.
FIG. 2 is a graph illustrating the homogeneity variations in a suspension of microbubbles contained in a syringe, the latter being either still or subjected to motion according to the invention.
FIG. 3 is a graph illustrating the gas volume and in vitro intensity of samples with and without treatment according to the invention.
FIG. 4 a is a schematic view in perspective of another device for agitating a liquid within the syringe of a power driven automatic injector system of the invention. In this embodiment, the syringe is held by a supporting bracket, the latter being driven into motion by a motor.
FIG. 4 b is a schematical sectional view of the motor driving means of the embodiment of FIG. 4 a.
DETAILED DESCRIPTION OF THE INVENTION
The device represented schematically in FIG. 1 comprises a series of co-operating elements mounted on a board 1 . Such schematic representation of the present device is only for clarity and better understanding of the device's operation. Obviously, in its actual commercial construction, the device is in the form of a much more compact and sophisticated apparatus, for instance in the form of an instrument like the Perfusor® fm of the Firm BRAUN Meslungen AG, D-34209, Meslungen, Germany (displayed in Publication B.03.01.95 No 0879 0744), or like the apparatuses disclosed in U.S. Pat. No. 4,652,260 and U.S. Pat. No. 5,176,502, both being incorporated herein by reference.
The present device comprises the following working components: a syringe 2 shown in an uplifted position, an automatic power driving unit 3 for acting on the syringe, a pair of syringe motioning units 4 for liquid agitation, and a control box 14 for controlling operation of the units 4 .
The syringe 2 has a barrel 5 , a plunger 6 sliding in the barrel and a tip connector 7 linked to a tubing 8 , the latter leading to an injection needle 9 . The needle 9 is for injecting an administrable liquid into the tissues or the circulation of a patient.
The power driving unit 3 has an electromechanically controlled pusher rod 10 for acting on the rear end 11 of the syringe plunger, and a control knob 12 for setting the automatic driving parameters that will rule the action of the rod 10 .
Each unit 4 is equipped with two rollers 13 , themselves driven into rotation by electric motors within the units and not represented in the drawing. The rotation of the rollers 13 is governed by means of a box 14 via lead wires 15 connected to said motors.
In operation, an injectable carrier liquid with particles (e.g. gas-filled microballoons) in suspension is introduced into the barrel 5 of the syringe 2 through the tip 7 , this being consecutive to the retraction (manual or mechanical) of the plunger 6 , so that an adequate pumping action is provided. Then the syringe is placed on the rollers 13 , so that the flange 16 thereof abuts the roller's edge 17 , this being for retaining the syringe in its relative position against unwanted longitudinal translation. In this situation, the pushing rod 10 of the driving unit 3 couples with the plunger's end 11 , so that any forward displacement of the rod 10 is transferred to the plunger with consequent expelling of the liquid toward the needle 9 for injection.
During injection, the rollers will alternately rotate the syringe a certain angle in one direction, say 30°, 60°, 90°, 180°, 270° or 360° and then, reciprocably, in the opposite direction. This balancing motion, which may be carried out in a stepwise manner, will move the liquid carrier to such an extent that any separation or segregation of the particles is hindered. This is very efficient for instance in the case of suspensions of gas-filled microbubbles used in echography since there is always a bubble size distribution in such suspensions, the larger bubbles tending to rise faster than the smaller ones by buoyancy. In a variant, the syringe can be made to rotate in one direction only, provided that the connector tip 7 thereof is made to freely rotate in order to prevent distortion of the tubing 8 . Normally, the rate of rotation impressed by the rollers 13 is from about 0.5 to 200 rpm depending upon the suspension viscosity. This rate should be sufficient to keep the particles in homogeneous suspension but insufficient to break the particles or disturb their distribution in the carrier liquid. If necessary, in the case of more viscous suspensions, an additional vibrational motion of a few Hz to a few hundreds of Hz can be applied to the syringe by means of a pitch-fork or pitch-pipe. It should be mentioned that at very high rotation rates (e.g. 1,000 rpm or more) the radial speed may become dominant which will result in axial concentration of the microbubbles in the middle of the syringe. Rotational speeds at which the radial component becomes important are to be avoided as under such conditions the suspension will become non-homogeneous again. This is clearly undesired.
In a variant, the unit 4 can have the form of a closable housing equipped with fixed syringe retaining means, i.e. other than the rollers edges 17 and, possibly if required, pressure resisting means (like a pressure mantle or jacket) in case the suspension is viscous and exerts undue pressure efforts to the syringe barrel. Also the syringe components can be made of moulded plastic (disposable syringes) and the barrel external surface provided with an integrally moulded relief pattern mating with corresponding pattern on the roller's surface, so that positive grip drive of the syringe is ensured.
Also, the rod 10 and the plunger 6 can be made integral with each other so that filling of the syringe can be controlled by the power unit 3 , the pumping action then resulting from a backward displacement of rod 10 .
The power unit per se is standard and its nature and operation well known to the skilled person. Embodiments thereof are disclosed in the cited references and also in U.S. Pat. No. 5,456,670. The power unit usually contains an electrically powered and controlled helical screw means for mechanically advancing or retracting rod 10 continuously or intermittently, so that the liquid in the syringe can be dispensed continuously or by increments. The various parameters ruling said motions of the syringe piston can be monitored and adjusted by the control 12 and possible other control means not represented in the drawing. Means of unit 3 also ensure that such delivery parameters can be monitored and recorded for display. An instant stop switch (not shown) may also exist, in case the operation of the system should be suddenly interrupted due to a problem with the patient or otherwise.
It should be incidentally noted that although the present embodiment involves rocking the syringe only, one may also consider a modification involving a back and forth rotation of the pumping ensemble, this being achieved by well known mechanical means adapted to support said pumping ensemble and to impart motion thereto.
Furthermore, although the present embodiment involves motion around the longitudinal axis, a variant may include rocking the syringe about a transversal axis.
A second device embodiment illustrated schematically in FIGS. 4 a and 4 b comprises a syringe 22 with a barrel 25 supported in a rotatable fashion by a bracket 30 a - 30 b and a plunger 26 sliding in the barrel whose displacement therein is controlled by a power driven unit 23 capable of moving forward and backward in engagement with the back pusher end of the plunger 26 . The device also comprises a motor driven unit 24 encompassing a portion 30 b of the supporting bracket, the latter being rotated through gears 31 , as better shown on FIG. 4 b , for agitation of a liquid suspension in the syringe barrel. The longitudinal forward or backward displacement of the unit 23 (acting on the plunger 26 ) is effected via a motor 31 which rotates a screw-bar 32 , the latter engaging with a matching threaded portion (not shown) within the unit 23 . The device further comprises an electronically computerized control box 34 for controlling operation of the units 23 (via motor 31 ) and 24 , and for processing the signals from a laser detector 35 designed to read an identifying mark 36 on the syringe; this mark is for preventing errors in the selection of the syringe, especially if the syringe is of the prefilled type. The code of the mark can be according to standard bar codes. Note in this regard that since the syringe barrel is set into rotation in the present device, one can use a fixed detector instead of a mobile one which is advantageous designwise. By counting and recording via box 24 the number of turns of the screw bar 32 , the position of the unit 23 (and consequently of the plunger 26 ) can be monitored and regulated at will. The control box 34 can of course comprise further monitoring and visualizing means (not shown) to optically display and appropriately regulate the various parameters involved in operation of the device. As in the previous embodiment, the syringe has a tip 27 for connecting to a liquid dispensing tubing 28 , the latter leading to means for injecting an administrable liquid into a patient.
The operation of the present device is very similar to that of the earlier embodiment and hence needs not be discussed further at length. Suffice to say that it may also comprise security means intended to automatically interrupt the operation in case troubles develop with the patient or otherwise during injection. For instance, the pressure in the syringe barrel can be monitored by registering the force required to push the plunger, this being via the power absorbed by the driving motor 31 . A sudden surge, for instance a rapid increase of current in said motor can trigger via the control unit 34 an emergency stop of the device. Alternatively, this effect could also be detected according to usual means by a strain gauge installed in the drive 23 .
As already said, the particles of the suspensions in this invention may be of various kinds and involve for instance microspheres containing entrapped air or other gases used in echography. These microspheres may be bounded by a liquid/gas interface (microbubbles), or they may have a tangible membrane envelope of for instance synthetic polylactides or natural polymer like denatured protein such as albumin (microballoons). The carrier liquid for the microbubble suspensions comprises surfactants, preferably saturated phospholipids in laminar or lamellar form such as diacylphosphatidyl derivatives in which the acyl group is a C 16 or higher fatty acid residue.
The gases used in the microbubbles or microballoons are pure gases or gas mixtures including at least one physiologically acceptable halogenated gas. This halogenated gas is preferably selected among CF 4 , C 2 F 6 , C 3 F 8 , C 4 F 8 , C 4 F 10 , C 5 F 12 , C 6 F 14 or SF 6 . The gas mixtures can also contain gases such as air, oxygen, nitrogen, helium, xenon or carbon dioxide. In fact in a number of cases microbubbles or microballoons will contain mixtures of nitrogen or air with at least one perfluorinated gas in proportions which may vary between 1 and 99%.
In the microballoons the membrane is made from a biodegradable material such as biodegradable polymers, solid triglycerides or proteins and are preferably selected from the polymers of polylactic or polyglycolic acid and their copolymers, denatured serum albumin, denatured haemoglobin, lower alkyl polycyanoacrylates, and esters of polyglutamic and polyaspartic acid, tripalmitin or tristearin, etc. In an embodiment, the microballoons are filled with C 3 F 8 and the material envelope is made of albumin.
Homogeneity of suspensions of microballoons whose membrane is made of saturated triglycerides such as tripalmitin, trimyristin or tristearin and their mixtures with other tri- or di-glycerides, fatty acids or polymers is particularly interesting as those are used for delivering active ingredients to specific sites within the body. Homogeneity of suspensions of such microballoons has been effectively maintained using the method and the device of the invention.
Other particles whose density is different from that of the carrier liquid may include liposomes filled with iodinated X-ray opacifiers such as iomeprol, iopamidol, iopentol, iohexyl, metrizamide, iopromide, iogulamide, iosimide or ioversol or, for instance, coated and uncoated magnetic particles which tend to precipitate in saline or other carriers.
The present injector system can be used in imaging organs, blood vessels and tissues of mammalians, e.g. the ultrasonic imaging of the heart, the liver or spleen, the brain, the kidneys, the blood vessels, etc.
The invention is further illustrated by the following Examples:
EXAMPLE 1
A solution of gas filled microbubbles stabilised by a phospholipids interface was prepared according to Example 1 of U.S. Pat. No. 5,445,813. The dry matter concentration was 5 mg/ml in a saline solution (0.9% NaCl). Typically, the bubble size distribution extended from 0.2 to 15 μm. The concentration of bubbles between 2 and 5 μm was 5×10 7 microbubble/ml.
The solution was transferred in a 50 ml plastic syringe and samples were taken in time intervals for analysis. This represent the starting 100% of the bubble concentration. The syringe was mounted in the infusion unit and the elution started. The elution flow was fixed at 1.6 ml/min.
Aliquots of the eluted solution were analysed by Coulter measurement (bubbles distribution; size and concentration) and imaging.
TABLE 1
Radius
Va
Radius
Va
Radius
Va
Radius
Va
1.0
0.131
4.5
2.648
8.0
8.368
11.5
17.291
1.5
0.294
5.0
3.269
8.5
9.446
12.0
18.828
2.0
0.523
5.5
3.955
9.0
10.590
12.5
20.429
2.5
0.817
6.0
4.707
9.5
11.800
13.0
22.096
3.0
1.177
6.5
5.524
10.0
13.075
13.5
23.829
3.5
1.602
7.0
6.407
10.5
14.415
14.0
25.626
4.0
2.092
7.5
7.355
11.0
15.820
14.5
27.489
In water, the rate of rise (Va) by buoyancy of air filled microbubbles of radius (a) can be obtained from the following Stokes relation
Va = 2 gr 9 h × a 2
where g is the gravitation constant (9.81 ms −2 ), r is the density of water 1000 g/l) and h is the viscosity (10 −3 Kg[s·m]). Table 1 shows a range of such rates (in mm/min) in function to the bubble radius in μm. The tangential speed (V r =2 pnR) of a syringe barrel of 28 mm diameter (R=14 mm) in function to the rotation rpm (n) is given in the next Table 2.
TABLE 2
n
V r
(rpm)
(mm/min)
0.5
2539
1
5278
2
10556
3
15834
4
21112
5
26389
10
52779
It is seen from the foregoing figures that in the case of a suspension of microbubbles of size in the range of 1-10 μm, very low rates of rotation of the syringe are sufficient to prevent segregation of the bubbles by buoyancy. This means that even at low rates of rotation the tangential speed of the microbubbles in suspension is much larger than buoyancy and that the microbubbles will move together with the rotating liquid and will not rise to the top of the syringe.
In a comparative study, the syringe was rotated along its axis in an alternative mode at a speed of 60 rpm. The results were compared with an experiment where the syringe was not rotated (under otherwise same experimental conditions).
FIG. 2 shows the evolution of the concentration of the total microbubble population and, separately, microbubbles above 8 μm along the elution while FIG. 3 shows the evolution of imaging intensity and the total bubble volume in the course of elution. In the case of no-agitation, the concentration decreases rapidly due to decantation. At the end of the infusion, the concentration rises sharply (not shown) because all the bubbles accumulate in the upper part of the barrel.
When the syringe is rotated, the bubble concentration remains constant throughout the entire infusion.
The same type of experiments were carried out under different experimental conditions including different microbubbles sizes and concentrations, different elution rates, different rotation types and speed, different syringe types and different particles such as heavy magnetite particles or other microbubble structures including phospholipid, tripalmitin or albumin encapsulated microbubbles. All experiments invariably showed that the method of infusion disclosed delivers homogeneous suspensions of active agents.
EXAMPLE 2
Preparation of Contrast Agents for Infusion
To test the efficiency of the present invention (a system of rotary syringe pump), different contrast agents for ultrasound echography were prepared.
Microbubble Suspensions
Phospholipid stabilised microbubbles were obtained in the following manner. 500 mg DAPC and 50 mg DPPA (Avanti Polar Lipids, Inc.) were dissolved in hexane/iso-propanol 8/2 (v/v) and dried in a round-bottomed flask using a rotary evaporator and, further, in a vacuum dessicator. After addition of water (100 ml), the suspension of lipids was heated at 75° C. for 1 hour under agitation and then extruded through a 0.8 am polycarbonate filter (Nuclepore®). The resulting suspension and 10 g of poly-ethyleneglycol (M w 4000) were mixed and lyophilised. 2 g of the lyophilisate was introduced into a glass vial and sealed under SF 6 or an air/C 4 F 10 mixture. After reconstitution with 25 ml NaCl 0.9%, the resulting suspensions contained about 6×10 8 (SF 6 ) or 1×10 9 (C 4 F 10 ) bubbles per ml with a mean diameter in number of 2 μm (Coulter Multisizer).
Microballoon Suspensions
Gas filled albumin microspheres were prepared as described by Porter T. R. ( J. Am. Coll. Cardio. 23 (1994) 1440 and PCT/WO 96/38180). 16 ml of human serum albumin (HSA) diluted 1:3 with dextrose (5%) was introduced into a 20 ml syringe and sonicated (sonifier 250 Branson) for 80 seconds in the presence of a flux of C 3 F 8 gas (octafluoropropane) at liquid/air interface. The sonicator tip was immersed at about 1 cm below the surface of the solution, the ultrasound energy level was set at output −40 and the temperature of the solution was monitored at 75° C. After removing the foam phase by decantation, the final suspension contained 8×10 8 gas microspheres per milliliter with a mean diameter in number of 2 μm (9/m in volume) determined by Coulter®. The suspensions are stored at 4° C. until use.
EXAMPLE 3
Determination of the Limit of Rotation Rate for the Syringe Used for Infusion
The effect of syringe rotation on stability of gas microbubble suspensions in the syringe used for infusion has been tested using a 50 ml syringe which was mounted on a rotation system which allows very low rotation speeds (about 1 rpm). Prior to its mounting the syringe was filled with 30 ml of phospholipid stabilised microbubble suspension. The mounted syringe was then rotated at different speeds: 0 (no rotation) 1.3, 2 and 60 rpm (1 Hz) and the suspension monitored taking one sample every 5 minutes. The samples were then analysed using Coulter counter. Table 3A shows the results obtained with a suspension of 3.1×10 8 microbubbles/ml having a mean diameter of 2.1 μm.
TABLE 3A
Homogeneity of microbubble suspensions in the syringe
as a function of the rotation rate and time (microbubble
concentration 3.1 × 10 8 bubbles/ml)
Syringe rotation rates
rpm
0
1.3
2
60
0
1.3
2
60
0
1.3
2
60
Vr
0
114
176
5278
0
114
176
5278
0
114
276
5278
t(min)
Nb total (%)
Nb > 8μ (%)
Volume (%)
0
100
100
100
100
100
100
100
100
100
100
100
100
5
68.7
77.6
90.4
97.4
23.5
48.0
73.3
95.4
37.5
55.6
80.4
97.7
10
53.7
77.3
88.8
100.6
1.1
43.9
70.9
98.9
19.8
44.8
73.3
99.4
15
48.2
72.8
89.5
96.2
1.9
38.0
74.1
96.5
14.5
44.0
75.7
98.1
20
43.5
73.8
86.6
99.0
0.8
37.2
77.9
97.3
10.8
42.5
73.6
98.6
25
39.9
76.4
88.5
100.3
0.5
36.9
84.6
99.5
9.6
43.0
81.6
99.7
Nb total (%): percentage of the total bubble concentration as compared to value at t = 0.
Nb > 8μ (%): percentage of the bubbles above 8 μm as compared to value at t = 0.
Volume (%): percentage of total bubble volume per ml of solution as compared to value at t = 0
rpm: rotation per minute; Vr (mm/min) = tangential speed of the syringe (radius = 14 mm)
Gas microbubbles: air/C 4 F 10 (50:50).
The above results clearly indicate that even at very low rotation rates (1.3 and 2 rpm), the buoyancy rise of the microbubbles is prevented. This is because even at low rotation rates, the tangential velocity of the microbubble is far greater than that of buoyancy. As previously shown, microbubbles of 3 and 10 μm have the respective rising rates of 0.29 and 3.3 mm/min. At 1.3 rpm rotation, the tangential speed is 114 mm/min (Vr=2p×rpm×R syringe ) which makes the tangential component of the 3 μm microbubble 390 times greater than the buoyancy. For 10 μm microbubble the tangential component is 35 times greater than the ascension rate. It should be mentioned that at very high rotation rates (e.g. 1,000 rpm) the microbubbles will concentrate in the middle of the syringe (as the radial component becomes dominant). Rotational speeds at which the radial component becomes important are not of interest as under such conditions the suspension becomes non-homogeneous again. The rotational speed at which the radial force is becoming significant depends on the syringe size (diameter, size of microbubbles and viscosity of the suspension) hence the exact value of the rotational speed at which the radial component becomes important is to be established for each individual case. However, as already pointed out such rotational speeds are to be avoided.
TABLE 3B
Homogeneity of microbubble suspensions in the syringe
as a function of the rotation rate and time (microbubble
concentration 1.3 × 10 9 bubbles/ml)
/
Syringe rotation rates
rpm
0
3
12
60
0
3
12
60
0
3
12
60
Vr
0
264
1056
5278
0
264
1056
5278
0
264
1056
5278
t(min)
Nv total (%)
Nb > 8μ (%)
Volume (%)
0
100
100
100
100
100
100
100
100
100
100
100
100
5
6.0
26.0
76.8
81.3
0.5
16.0
73.1
83.4
1.5
17.2
81.4
87.7
10
3.2
26.3
78.8
81.3
0.2
19.1
71.5
79.9
1.0
20.0
81.9
79.4
15
3.9
27.3
81.5
82.2
0.6
16.8
78.0
80.5
1.1
20.3
84.9
90.8
20
4.3
32.0
76.6
95.0
0.2
19.2
79.6
85.9
1.8
21.5
92.3
92.6
25
0
31.7
78.9
95.3
0
16.9
78.6
85.5
0
18.4
83.4
91.1
Nb total (%): percentage of the total bubble concentration as compared to value at t = 0.
Nb > 8μ (%): percentage of the bubbles above 8 μm as compared to value at t = 0.
Volume (%): percentage of total bubble volume per ml of solution as compared to value at t = 0
rpm: rotation per minute; Vr (mm/min) = tangential speed of the syringe (radius = 14 mm)
Gas microbubbles: air/C 4 F 10
For more concentrated suspensions (e.g. 1.3×10 9 bubbles/ml) the microbubble ascension rate increases in the syringe. This is probably due to microbubble interactions (associations, dragg etc.) indicating that higher rotation speeds are required for prevention of microbubble ascension in the suspensions with higher microbubble concentrations. However, the lower limit of the syringe rotation is not easy to determine as the microbubble ascension rate is also a function of viscosity and density of the suspension, the nature of the gas used, the microbubble diameter and size distribution as well as the type of the microparticles (i.e. microbubbles having just a layer of a surfactant stabilising the gas, microballoon with a tangible membrane or microemulsion).
EXAMPLE 4
Evaluation of the Efficiency of the Rotary Pump
A. Infusion of Gas Microbubble Suspensions at Low Bubble Concentration and “Fast” Infusion Rate (3.3 ml/min)
In this study, the phospholipid stabilised gas microbubbles were prepared with a gas mixture (air/perfluorobutane 50:50) as gas phase.
The efficacy of the rotary pump of the present invention was evaluated by checking the homogeneity and stability of the bubble suspensions during the infusion. During a continuous infusion, the bubble suspensions were successively sampled at different infusion times with an interval of about every 5 minutes. The syringe used for infusion had a effective volume of 60 ml with a diameter of 28 mm (Braun Perfusor, Germany). The rotation rate of the syringe was fixed at 60 rpm or 1 Hz (in order to compare different suspensions) and the direction of rotation was reversed for each turn. Infusion was stopped after 15 minutes while maintaining syringe rotation and then restored at the same rate during one minute after 30 minutes and 60 minutes. The bubble concentration, sizes and size distribution were assessed with Coulter® Multisizer II and the echo contrast effect of the suspensions was simultaneously examined with an echographic imaging device (Acuson 12BXP10, USA). For Coulter® and echo evaluation, the native samples taken from the syringe were further diluted 1000 and 3000 folds (in some experiences 1/750). For in vitro imaging evaluation, an acoustic phantom ATS (Peripheral Vascular Doppler Flow Phantom, ATS Laboratories Inc., USA) was used and the image was visualised in B-mode with a 3.5 MHz ultrasound probe. The acoustic energy was set to minimum (−9 dB) in order to prevent bubble destruction. The results are summarized in the Table 4.
TABLE 4
Evaluation of the efficacy of the rotary pump
(Coulter and Echo imaging)
Gas microbubbles: air/C 4 F 10
Pump flow rate 3.3 ml/min
Coulter
measurement
Imaging
Nbtot/ml ×
Nb >
VI
t(min)
10 8
8μ/ml × 10 6
Diam (μm)
Vol/ml
(pixels)
0
3.26
4.90
2.09
7.33
62
2
2.97
4.90
2.15
7.12
59
8
3.31
4.50
2.06
7.15
59
15
3.06
3.55
2.09
5.82
59
30
3.12
4.82
2.15
6.96
59
60
3.15
4.66
2.10
7.03
59
Nb > 8μ/ml: number of bubbles above 8 μm.
Nb total/ml: total bubble concentration.
Volume (μl/ml): total bubble volume per ml of solution
Diameter (μm): mean diameter in number.
VI: video intensity(dilution 1:3000)
These results show that even at a small rotation rate (1 Hz), the bubble suspension was fairly stable and homogeneous: both the total bubble count and bubbles>8 μm remain constant during the entire infusion.
B. Infusion of Gas Microbubble Suspensions at High Bubble Concentration and “Slow” Infusion Rate (1.2 ml/min)
The example A was repeated at a “slow” infusion rate and a higher concentration of the microbubbles. One can note from the Table 5 that even at very slow infusion rate (corresponding to 0.017 ml/kg/min for a 70 kg person) and a very high bubble concentration (Nb/ml>10 9 /ml), the present rotary infusion pump is capable to ensure the stability and the imaging performance of the bubble suspensions during the entire infusion (24 min).
TABLE 5
Evaluation of the efficacy of the rotary pump (Coulter
and Echo imaging)
Gas microbubbles: air/C 4 F 10
Pump flow rate 1.2 ml/min
Coulter measurement
Imaging
Nb >
Diameter
VI
t(min)
Nb/ml × 10 9
8 μ/ml × 10 7
(μm)
Volume/ml
(pixels)
0
1.10
2.2
2.09
32.5
60
5
1.03
2.2
2.15
30.9
60
13
1.01
2.1
2.06
30.5
55
18
1.03
2.1
2.09
30.0
58
24
1.04
2.1
2.15
30.5
57
Nb > 8μ/ml: number of bubbles above 8 μm.
Nb total/ml: total bubble concentration.
Volume (μl/ml): total bubble volume per ml of solution
Diameter (μm): mean diameter in number.
VI: video inteneity(dilution 1:3000)
EXAMPLE 5
Evaluation of the Efficacy of the Rotary Pump—Comparative Tests with and without Syringe Rotation
The procedure of Example 4 was repeated except that the phospholipid stabilised microbubbles were prepared with gas SF 6 instead of air/C 4 F 10 . Moreover, the stability of the gas bubble suspensions during infusion was compared using the same pump in the presence and absence of rotation of the syringe (R=28 mm, rotation rate=60 rpm and 0 rpm). The experimental results of a concentrated bubble suspension (Nb>10 9 /ml) infused at an infusion rate of 1.1 ml/min are shown in Table 6. Without syringe rotation, the amount of microbubbles delivered from the syringe decrease rapidly during infusion, especially for the large bubbles (see Nb>8 μm and the volume). After 5 minutes of infusion, the total bubble concentration decreased by 83%, >99% for the bubbles larger than 8 μm and 90% for the bubble volume. After 10 minutes, the video intensity had decreased by a factor 3 and the contrast effect of the microbubbles was almost non detectable (IV=6 ±3 pixels for the background) at 10 minutes of the infusion. In contrast, in the presence of rotation the bubble suspension remained stable during the entire infusion (30 min).
TABLE 6
Evaluation of the efficacy of the rotary pump: comparative test
Gas microbubbles: SF 6
Pump flow rate: 1.1 ml/min
Coulter measurement
Imaging
t(min)
Nb/ml × 10 9
Nb > 8μ/ml × 10 7
Diameter (μm)
Volume/ml
VI (pixels)
rot
with
w/out
with
w/out
with
w/out
with
w/out
with
w/out
0
1.2
1.1
1.58
1.32
2.09
2.22
24.3
20.4
32
54
5
1.16
0.19
1.41
0.008
2.09
2.14
22.6
2.0
30
16
10
1.06
0.15
1.37
0.012
2.13
1.96
21.4
1.2
30
10
15
1.15
0.13
1.38
0.00
2.11
1.92
22.5
0.9
30
8
20
1.38
0.12
1.81
0.00
2.13
1.83
28.5
0.7
31
7
30
1.25
0.11
1.53
0.00
2.11
1.79
24.4
0.6
32
6
Nb > 8μ/ml: number of bubbles above 8 μm.
Nb total/ml: total bubble concentration.
Volume (μl/ml): total bubble volume per ml of solution
Diameter (μm): mean diameter in number.
VI: video intensity (dilution 1:3000)
TABLE 7
Evaluation of the efficacy of the rotary pump: comparative tests
Gas microbubbles: SF 6
Pump flow rate: 3.3 ml/min
Coulter measurements
t(min)
Nb tot/mix 10 6
Nb > 8μ/ml × 10 6
Diam. (μm)
Vol./ml
Vol %
rotat
with
w/out
with
w/out
with
w/out
with
w/out
with
w/out
0
2.73
2.48
3.14
2.99
2.22
2.09
5.5
4.9
100.0
89.4
5
2.57
2.05
3.21
0.5.4
2.23
1.94
5.3
2.1
96.7
39.1
10
2.53
1.71
3.42
0.01
2.27
1.81
5.8
1.1
105.7
20.6
15
2.48
1.41
3.28
0.00
2.28
1.64
5.2
0.6
96.1
10.8
20
2.35
1.16
1.33
0.00
2.21
1.54
4.6
0.5
83.6
8.3
Nb > 8μ/ml: number of bubbles above 8 μm.
Nb total/ml: total bubble concentration.
Volume (μl/ml): total bubble volume per ml of solution
Diameter (μm): mean diameter in number.
VI: video intensity (dilution 1:3000)
In Table 7, the comparative infusion was conducted at a lower bubble concentration (2.7 10 8 /ml) and an infusion rate of 3.3 ml/min. Again, these results show a very good efficacy of the rotary infusion system to maintain the homogeneity and stability of the microbubble suspensions during infusion. In contrast, the syringe pump without rotation was completely inadequate for microbubble infusion.
EXAMPLE 6
Evaluation of the Efficiency of the Rotary Pump Application to Gas Microspheres (Comparative Tests)
The Example 5 was repeated with the gas albumin microspheres prepared as described in Example 2. For the infusion, the bubble concentration was adjusted to 6×10 8 /ml by diluting the suspension with HSA/dextrose (1:3). In the present experience, the in vitro characteristics of the microspheres during infusion (2.7 ml/min) with and without the syringe rotation were compared to assess the homogeneity of the suspensions delivered from the syringe. The results are gathered in Table 8.
TABLE 8
Evaluation of the efficacy of the rotary infusion pump
with gas albumin microspheres
Gas microbubbles: C 3 F 8
Pump flow rate: 2.7 ml/min
t(min)
Nbtot/ml × 10 8
Nb > 8μ/ml × 10 6
Diam (μm)
Vol/ml
VI (pixels)
rot
with
w/out
with
w/out
with
w/out
with
w/out
with
w/out
0
6.64
6.7
9.6
7.6
2.03
1.97
15.4
12.3
47
46
5
6.4
6.6
8.0
4.5
1.96
1.93
13.1
8.8
47
38
10
6.4
6.3
6.0
2.6
1.91
1.8
10.3
5.0
45
23
15
6.4
6.0
6.5
0.38
1.92
1.65
10.5
3.5
45
19
20
6.25
5.2
6.15
0.15
1.92
1.61
9.9
3.8
43
26
Nb > 8μ/ml: number of bubbles above 8 μm.
Nb total/ml: total bubble concentration.
Volume (μl/ml): total bubble volume per ml of solution
Diameter (μm): mean diameter in number.
VI: video intensity (dilution 1:3000)
Background: VI = 9 pixels
The albumin microspheres appear to be more homogeneous in the syringe than phospholipid microbubbles in the absence of rotation. This is likely to be due to the higher viscosity of the albumin/dextrose solution (5%) and possibly to the thicker wall of the microspheres (about 15 times thicker than a phospholipid monolayer). Nevertheless, large microspheres (>8 μm) still decanted in the syringe and their concentration decreased progressively during infusion. After 10 minutes, the volume of microspheres and the video intensity decreased to half of the initial values. It was been reported that the myocardial perfusion with a similar agent—FSO69 (Optison®, HSA-C 3 F 8 microsphere suspensions) was attributed essentially to a small number of large microspheres (10-15 μm) entrapped in the tissue (Skyba et al., J. Am. Coll. Cardio. 28 (1996) 1292-1300). Therefore, on can speculate that for such clinical application this kind of contrast agents could hardly be infused by a classic infusion pump as demonstrated in the present example.
EXAMPLE 7
Tetracaine filled tripalmitin microcapsules made according to Example 6 of WO96/15815 were suspended in 50 ml of saline solution (0.9% NaCl). The suspension with a concentration of tetracaine of 0.06 mg/ml was placed into a 50 ml syringe. The syringe was placed on the rotational pump of the invention and the exit concentration of tetracaine measured using UV spectrophotometer (in THF/water 60/40% at 307 nm). The syringe was rotated at a rate of 1 Hz (alternating direction of rotation every 180°). The rate of infusion was 1.5 ml/min. The UV analysis showed constant concentration of tetracaine over the entire period of infusion. In the parallel experiment in which the tetracaine filled syringe was kept stationary the exit concentration of the medicament varied with time.
EXAMPLE 8
Fifty milligrams of Amphotericin B in the deoxycholate form (Fungizone® Bristol Mayers Squibb) were dispersed in 50 ml of Intralipid® 20%. (Pharmacia) and the emulsion obtained (Chavanet, P., Rev. Med. Interne 18 (1997) 153-165) introduced into a 50 ml syringe. The syringe was placed on the rotational pump and infused at 1 ml/min rate and rotation of 1 Hz (alternating direction of rotation every 360°. Exit concentration of Amphotericin B was followed by HPLC (detection UV/visible at 405 nm). The HPLC analysis confirmed constant concentration of the medicament during the entire infusion. The experiment clearly showed that the separation of Amphotericin B reported by several research groups (Trissel, L. A., Am. J. Health Syst. Pharm. 52 (1995) 1463; Owens, D., Am. J. Health Syst. Pharm. 54 (1997) 683) was successfully suppressed using the method disclosed.
EXAMPLE 9
A liposome solution was prepared from 9/1 molar ratio of hydrogenated soy lecithin (DPPC) and dipalmitoylphosphatidic acid disodium salt (DPPA) in chloroform according to a well known procedure (e.g. EP 0 514 523). After extrusion and cooling of MLV suspension the same was concentrated to 30 mg/ml by microfiltration. To 1 l of the concentrated liposome solution, 1 l of an aqueous solution containing 1040 g of (S)—N,N′-bis[2-hydroxy-1-(hydroxymethyl)-ethyl]-2,4,6-triiodo-5-lactamido-isophtalamide (Iopamidol®, an X-ray contrast agent of BRACCO S.p.A.) was added and the resulting mixture having an iodine concentration of 260 g/l was incubated. The density of the Iopamidol® solution was 1.29 g/cm 3 .
An aliquot of the liposome preparation was dialyzed against saline (NaCl 0.9% in water) until all iopamidol outside the liposomes vesicles was removed. The iodine-to-lipid ratio of the preparation obtained (I/L) was between 3 and 5 mg of entrapped iodine per mg lipid.
Part of the preparation of contrast agent-loaded liposomes was introduced into a syringe which was placed on the rotational pump of the invention and the exit concentration of the contrast agent measured using HPLC. The syringe was rotated at a rate of 1 Hz (alternating direction of rotation every 180°). The rate of infusion was 1.5 ml/min. The HPLC analysis showed constant concentration of the iodinated contrast agent over the entire period of infusion.
When, in the foregoing example, the Iopamidol was replaced by Iomeprol (N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodo-5-glycolamido-isophtal-imide), another iodinated contrast agent from BRACCO S.p.A., similar results were experienced.
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A power assisted method and injector device for controllably delivering to patients a dispersion medicament or diagnostically active agent, the homogeneity of which is preserved throughout delivery. Diagnostically active agents disclosed are gas microbubble suspensions useful in ultrasonic diagnostic imaging and liposomal formulations in which liposome vesicles are loaded with iodinated compounds.
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BACKGROUND OF THE INVENTION
This invention relates to a novel catalytic reactor and method for loading thereof. Apparatuses for catalytic treatment, for example, desulfurization, of distillate fractions are known. In operation, such an apparatus generally contains 10-100 m 3 of catalyst distributed over one or more beds which have to be purified after a period of time, not so much on account of a decline in catalyst activity, but rather as a consequence of contamination ultimately resulting in an excessive pressure drop across the catalyst bed. For the purpose of this purification, it is frequently necessary for the contaminated catalyst to be removed from the apparatus, requiring entry by personnel into the opened reactor in order to remove consecutively the supporting means of the beds situated one above the other. Since any iron sulphide formed during desulphurization is often pyrophoric, it is desirable that the catalyst should first be deactivated in this respect. After dismantling, the reactor beds have to be built up again by reassembling the supporting means and loading with fresh or purified catalyst. The rate at which catalyst can be unloaded from such a reactor is approximately 4 m 3 /hr, and the loading rate is approx. 6 m 3 /hr. Since this unloading of the catalyst is necessary at most once a year, the loss of time involved in the shut-down and renewal of the bed does not form an insuperable drawback in the case of this size of apparatus. It is a more serious matter, however, in the case of larger apparatuses designed for the desulphurization of petroleum residues. To operate efficiently and economically, such an apparatus often has a much larger catalyst charge of the order of 500-1000 m 3 . In residue desulphurization, the bed not only becomes contaminated but moreover the catalyst activity declines relatively rapidly not so much because of coke formation as a result of the presence of asphaltenes, but rather by deposition, in the pores of the catalyst, of metals present in the petroleum residue. This may contribute towards necessitating much more frequent loading with fresh catalyst, for example once every six months. At the above-mentioned average catalyst handling rate of 5 m 3 /hr., 10 to 20 days are required for the unloading of the catalyst and the loading of the fresh catalyst. This means an annual loss of 10% or more of the operating time on account of this catalyst replacement. If an effort is made to compensate for this loss of time by increasing the capacity of the reactor, considerable additional capital expenditure is required.
SUMMARY OF THE INVENTION
The invention provides an apparatus suitable for the catalytic treatment of hydrocarbons, particularly, for the catalytic desulphurization of petroleum residues, comprising a reactor vessel containing at least one tray and catalyst support means for one or more catalyst beds, said support means being permeable to fluids and impermeable to catalyst particles, the supporting means are attached to the inner wall of the reactor and are at least partly in the shape of a conical surface of a truncated cone converging downwardly to an aperture permeable to catalyst particles; and located beneath each supporting means is a fluid permeable tray which is impermeable to catalyst particles, and having an aperture which is permeable to catalyst particles.
The invention also relates to a method for unloading and loading the catalyst beds.
The invention therefore provides an apparatus for the catalytic treatment of hydrocarbons, which apparatus is constructed in such a manner that the catalyst can be replaced without dismantling and reassembling the bed-suporting means, as a result of which it is now unnecessary for personnel to work in the reactor to replace the catalyst. Consequently, it is now also possible for the step of deactivation of the reactor contents to be omitted, provided that the catalyst is unloaded without coming into contact with air. The apparatus permits a significantly higher average catalyst handling rate on the order of 50-60 m 3 of catalyst per hour.
DESCRIPTION OF DRAWINGS
FIG. 1 is a longitudenal cross-section of a preferred embodiment of an apparatus according to the invention.
FIG. 2 is a cross-section of the apparatus shown in FIG. 1 taken on line 2--2.
FIG. 3 is a perspective view of a detail of the conical surface shown in FIG. 2.
DESCRIPTION OF PREFERRED EMBODIMENTS
The supporting means may be in the shape of interconnected cylinders and/or surfaces of truncated cones of which the descriptive lines are at different angles to the axis of the reactor. It is advantageous for the supporting means of each catalyst bed to comprise a conical surface of one truncated cone, converging downwardly to an aperture permeable to catalyst particles, which aperture is situated centrally in the reactor.
The acute angle formed by a (the) descriptive line(s) of the conical surface(s) and the axis of the reactor is preferably between 35° and 45°. If this angle is larger, the catalyst particles will not slide downwards, or only do so with difficulty, while if considerably smaller angles are used, the empty space between the conical surface and the underlying tray is larger than necessary, and consequently the reactor can contain less catalyst at a given reactor volume.
The conical surface(s) may be, for example, manufactured of perforated plate with round or oblong openings. Preferably, however, the conical surface is a grid built up of groups of rods, wherein all the rods in each group run parallel to one another. More preferably the rods in each group run parallel to a descriptive line of the conical surface. The rods of the grid preferably have smooth lateral faces and are preferably so positioned that lateral faces of the rods form the bearing surface for the catalyst. This provides a smoother bearing surface than if rods of circular section are used. Rods having a triangular, trapezoid or rectangular section are very suitable.
It is preferred for the aperture of the supporting means which is permeable to catalyst particles, and the similarly permeable aperture of the tray underneath to be situated in a vertical line. In this way, if more than one catalyst bed is used, the catalyst spaces delimited by the reactor wall, the bottom of a tray and the top of the supporting means underneath the said tray are interconnected via the (preferably central) opening of the supporting means and the (preferably central) opening of the tray. The opening of the supporting means is preferably connected to a pipe which debouches in the catalyst space underneath and passes through the opening of the tray. The diameter of the pipe may be selected depending upon such factors as the quantity of catalyst which it is desired to pass through per unit of time when loading and unloading the beds, the quantity of feed desired to be passed through the pipe in the operational mode of the apparatus without detracting from the requirement that it is desired to pass as much feed as possible through the tray, and, further, taking into account the desirability that the diameter should be large enough to allow a man to pass, if necessary, should the interior of the empty reactor require inspection. In general, a pipe diameter of 45-70 cm is suitable. In the case of, for example, a reactor diameter of 350 cm, a pipe diameter of 60cm will satisfy these requirements. The space velocity of the catalyst during loading and unloading can then be in excess of 50-60 m 3 /hr., the slip of the feed along the tray when the reactor is operational is then of the order of only 1-4% and this pipe diameter allows a man to pass.
During loading and unloading of the beds -- which may be effected by means of an upward-flowing carrier liquid -- the trays, which are impermeable to catalyst particles, prevent catalyst particles from contacting the underneath of the supporting means and remaining fixed there or being pushed between the wall of the reactor and the supporting means. In this combination of supporting means and of pipe connected to the opening thereof and passing through the opening of the tray, the catalyst stream is able to pass only through this pipe. Moreover, this tray is very useful in the operational mode because on exothermal reaction then takes place in the catalyst beds and the tray effects a redistribution of the liquid flowing out of the catalyst bed, as a result of which local overheating is avoided. When the reactor is operational, the tray therefore acts as a redistribution tray. The tray may be of the conventional type, for example a sieve tray made of perforated plate impermeable to catalyst and having a circular circumference which is attached thereby to the wall of the reactor. Preferably, the tray is also provided with devices for letting through gas or vapor, for example one or more cylinders or troughs arranged on the tray, at which areas the tray is gas-permeable but does not allow catalyst particles to pass. Preferably, the upper part of such a cylinder or trough is provided with an impermeable plate parallel to the plane of the distribution tray, in such a manner than the gas or vapor can flow through between the plate and the upper edge of the cylinder or trough.
The bottom of the upright reactor is preferably provided with a device for the unloading or catalyst, comprising a guide face permeable to liquid but impermeable to catalyst particles, which face is in the shape of a conical surface of a truncated cone attached by its circumference to the wall of the reactor and of which the central opening serves as outlet for catalyst particles when the catalyst is unloaded from the reactor. This central opening preferably connects to a pipe of which the wall is provided with orifices for liquid, preferably covered with a metal screen or gauze that does not allow catalyst particles to pass, which pipe connects to a closing device, for example a valve. The guide face may, if desired, be supported by filler elements between the conical surface and the wall of the reactor. A closable liquid line is connected to the space situated between the guide face and the wall of the reactor. Preferably, a line is also present for the supply of liquid to the orifices of the latter pipe.
The apparatus according the the invention will now be elucidated with reference to FIGS. 1, 2 and 3.
Referring to the apparatus of FIG. 1, 1 is an inlet for feed which is used as an outlet for carrier liquid when the apparatus is being loaded with catalyst using a carrier liquid. 2 is a manhole through which catalyst can be added, 3 and 3a a conical surface which, with conduit 4 (4a), passed through the liquid-permeable tray 5 (5a) underneath, which is provided with cylindrical gas orifices 6 (6a). 7 is a liquid-permeable guide face for the unloading of catalyst, which face is in the shape of a conical surface of which the central opening connects with pipe 8 of which the wall is provided with orifices for liquid, which orifices are sealed with gauze (not shown) which does not allow catalyst particles to pass. 9 is a valve for the unloading of catalyst particles, 10 is an end plate and 11 is an outlet for feed which acts as inlet for carrier liquid when the apparatus is being loaded with catalyst. 12 is a supply line for liquid or gas. During operation, gas is supplied through 12, so that the space between the reactor wall and pipe 8 cannot fill up with hot liquid, which might lead to coke formation in the said space.
FIG. 2 is a top plan view, in enlarged scale, of the arrangement of rods 31 of which the conical surface 3 shown in FIG. 1 is built up. The rods are supported on supporting beams 30.
FIG. 3 shows in perspective, in enlarged scale, a number of rods 20 of triangular cross-section supported on an underlying supporting beam 21 (not shown in FIG. 2) which is positioned between two beams 30 shown in FIG. 2.
In order to load the apparatus with catalyst, a carrier liquid, for example a distillate hydrocarbon fraction such as kerosine, gas oil, a cycle oil from a catalytic cracking plant, or feed which is to be catalytically treated, is supplied to the apparatus through the liquid inlet 11 (FIG. 1) and after flowing through the apparatus removed through outlet 1.
Catalyst is introduced into the apparatus through the manhole 2. This may be effected in any desired manner, for example pneumatically, but preferably the catalyst is introduced as a slurry in a liquid, which is preferably said carrier liquid.
The flow velocity of the carrier liquid is so chosen that the settling velocity of the catalyst particles exceeds the upward velocity of the carrier liquid. Using gas oil as carrier liquid, this flow velocity is very suitably between 0.001 and 0.01 m/sec. The flow velocity is of course also dependent on the shape and the specific gravity of the catalyst particles, but for many commercially available desulphurization catalysts this flow velocity is generally very suitable with said carrier liquids. In quiescent gas oil, the settling speed of a customary desulphurization catalyst is of the order of 0.1 m/sec and in kerosine and cycle oil it is of the same order of magnitude.
The catalyst particles settling in the upward flow of carrier liquid form a bed on the upper conical surface, fall through the central openings of the conical surface and the tray in the catalyst spaces beneath and the bottom of the apparatus until ultimately all the catalyst spaces formed by a conical surface 3a and the superior tray 5, in addition to the pipes 4 (4a) and the space formed by the lowest tray, the guide plate 7 and the pipe 8 are entirely filled with catalyst particles. The flow of carrier liquid is then stopped and the addition of catalyst ceased. This method of loading the apparatus with catalyst may also be very suitably effected at a carrier liquid speed equal to 0, in other words in a still or quiescent carrier liquid. In that case, however, it is desirable to intermittantly cause the liquid to flow and to fluidize the particles, in order to obtain homogeneous loading of the catalyst beds.
After loading with catalyst, the apparatus may be put into operation, feed being supplied at 1 and leaving the apparatus at 11 and the carrier liquid being replaced by the feed.
When it becomes necessary, owing to contamination and deactivation of the catalyst, to replace the catalyst mass, it is possible to replace, as a preparatory measure, the liquid present in the reactor by gas oil or another carrier liquid in order to cool the hot catalyst until the desired lower temperature is reached. In most cases, by opening valve 9, as a result of which the catalyst mass is no longer supported from underneath, it is possible to cause the catalyst together with the carrier liquid to flow out of the apparatus as a slurry. Should the catalyst particles cohere to a certain extent and no longer form a loose mass, the catalyst can first be fluidized by introducing a carrier liquid via inlet 11 and via the liquid orifices of pipe 8. As a rule, a flow velocity of 0.01-0.03 m/sec is sufficient for the fluidization. After fluidization, valve 9 can be opened in order to unload the catalyst particles distributed in the carrier liquid. During this unloading the supply of carrier liquid may be stopped or the supply of carrier liquid may be continued in such a manner that less is unloaded per unit of time via the outlet 1 than is introduced via 11. In this way fluidization is continued while slurry is being unloaded via 9.
The apparatus according to the invention is by virtue of its design also suitable for a catalytic desulphurization of hydrocarbons with a moving bed, in which process the feed and the moving bed are passed co-currently downwards through the apparatus, as is, for example, described in the Netherlands patent application No. 7302262. In this case the catalyst and the reaction conditions as described in the said patent specification can be applied.
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Apparatus for catalytic processes such as desulfurization of hydrocarbons comprises an upright reactor vessel containing at least one tray and catalytic support means for one or more catalyst beds; said support means, being permeable to fluids and impermeable to catalyst particles, are attached to the inner wall of the reactor vessel and are at least partly in the shape of a conical surface of a truncated cone converging downwardly to an aperture permeable to catalyst particles; located beneath each supporting means is a fluid permeable tray which is impermeable to catalyst particles and having an aperture permeable to catalyst particles. A method for loading said apparatus with catalyst by means of a carrier oil is also disclosed.
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FIELD OF THE INVENTION
The present invention relates to the amorphous form of 4-acetoxy-2α-benzoyloxy-5β,20-epoxy-1-hydroxy-7β,10β-dimethoxy-9-oxotax-11-en-13α-yl(2R,3S)-3-tert-butoxycarbonylamino-2-hydroxy-3-phenyl-propionate, i.e., cabazitaxel, methods for its preparation and pharmaceutical composition thereof.
BACKGROUND OF THE INVENTION
Cabazitaxel, chemically known as 4-acetoxy-2α-benzoyloxy-5β,20-epoxy-1-hydroxy-7β,10β-dimethoxy-9-oxotax-11-en-13α-yl(2R,3S)-3-tert-butoxycarbonylamino-2-hydroxy-3-phenyl-propionate, is represented by formula (I).
It is a microtubule inhibitor, indicated in combination with prednisone for treatment of patients with hormone-refractory metastatic prostate cancer previously treated with a docetaxel-containing treatment regimen, under the trade name Jevtana®.
Cabazitaxel is known from U.S. Pat. No. 5,847,170. The process for the preparation of cabazitaxel as described in U.S. Pat. No. 5,847,170 involves column chromatography, which is cumbersome, tedious and not commercially viable.
The acetone solvate of 4-acetoxy-2α-benzoyloxy-5β,20-epoxy-1-hydroxy-7β,10β-dimethoxy-9-oxotax-11-en-13α-yl(2R,3S)-3-tert-butoxycarbonylamino-2-hydroxy-3-phenyl-propionate (Form A) is formed by crystallization by using acetone and is characterized by X-ray diffraction in U.S. Pat. No. 7,241,907.
U.S. Patent Application Publication No. 2011/0144362 describes anhydrous crystalline Forms B to Form F, ethanolates Form B, D, E and F and mono and dihydrate forms of cabazitaxel. All of the anhydrous crystalline forms are prepared either from the acetone solvate or ethanol solvate. Mono and dihydrate forms are formed at ambient temperature in an atmosphere containing 10% and 60% relative humidity, respectively.
From the above mentioned references, it is evident that pure polymorphic forms of cabazitaxel prepared in the literature were prepared from solvates and not directly from cabazitaxel.
None of the literature reported earlier mentions the amorphous form of cabazitaxel. The present invention provides a novel form of cabazitaxel, i.e., amorphous cabazitaxel which is directly obtained from crude 1 cabazitaxel without formation of any solvate or hydrate of cabazitaxel.
SUMMARY OF THE INVENTION
In a first aspect, there is provided an amorphous form of cabazitaxel.
In a second aspect, there is provided a process for the preparation of an amorphous form of cabazitaxel comprising the steps of:
a) preparing a solution of cabazitaxel in a suitable solvent and mixture thereof; and b) recovering the amorphous forms of cabazitaxel from the solution thereof by removal of the solvent.
In another aspect, there is provided a pharmaceutical composition that includes a therapeutically effective amount of an amorphous form of cabazitaxel and one or more pharmaceutically acceptable carriers, excipients or diluents.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
FIG. 1 , which represents the X-ray (powder) diffraction (XRD) pattern of the amorphous form of cabazitaxel of the present invention.
FIG. 2 , which represents the Differential Scanning Calorimetry (DSC) analysis for the amorphous form of cabazitaxel of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The amorphous form of cabazitaxel may be characterized by XRD as depicted in FIG. 1 .
The amorphous form of cabazitaxel is totally and completely devoid of any signal due to a crystalline form in its X-ray (powder) diffraction pattern.
4-acetoxy-2α-benzoyloxy-5β,20-epoxy-1-hydroxy-7β,10β-dimethoxy-9-oxotax-11-en-13α-yl(2R,3S)-3-tert-butoxycarbonylamino-2-hydroxy-3-phenyl-propionate, i.e., cabazitaxel used as starting material, may be prepared according to methods known in art, such as described in U.S. Pat. No. 5,847,170.
In general, the solution of cabazitaxel may be obtained by dissolving cabazitaxel in a suitable solvent.
The suitable solvent may be selected from the group comprising alcohols, such as methanol, ethanol and isopropanol; nitriles, such as acetonitrile; chlorinated hydrocarbons, such as methylene chloride and ethylene dichloride; esters, such as ethyl acetate and isopropyl acetate; cyclic ethers, such as dioxane and tetrahydrofuran and mixtures thereof. The most preferred solvent is methylene chloride.
The volume of the solvent that can be used in step a) depends on the polarity and the solubilizing capacity of the solvent and typically can be employed in the range of between 2 to 100 times by volume per gram of cabazitaxel.
The solution of cabazitaxel in a suitable solvent may be obtained at ambient temperature.
Removal of solvent may include one or more of the techniques of distillation, distillation under vacuum, evaporation, spray drying and freeze drying.
The temperature at which the solvent is removed depends on the solvent employed and generally can be from about 20° C. to about 200° C.
After evaporation of the solvent, the residual solid may optionally be treated with an organic solvent. The organic solvent may be selected from hydrocarbon solvents such as hexane, heptane, toluene and benzene.
The amorphous form of cabazitaxel may be recovered from the solution using a spray drying technique. A mini-Spray dryer (Model: Labultima (LU228) can be used. Labultima (LU228) Mini-Spray Dryer operates on the principle of nozzle spraying in a parallel flow, i.e., the sprayed product and the drying gas flow in the same direction. The drying gas can be air or an inert gas such as nitrogen, argon and carbon dioxide.
The air inlet temperature of the spray drier can be from about 40° C. to about 100° C.
After removal of the solvent, the process may include drying of the residual solid in a drying oven.
The resulting amorphous form of cabazitaxel may be formulated into ordinary dosage forms such as, for example, tablets, capsules, pills, solutions, etc. In these cases, the medicaments can be prepared by conventional methods with conventional pharmaceutical excipients. In addition to the common dosage forms set out above, the amorphous form of cabazitaxel may also be administered by controlled release means and/or delivery devices.
Further, the amorphous cabazitaxel described herein can be used in a method for treatment of hormone-refractory metastatic prostate cancer. The method of treatment includes administering to a mammal in need of treatment a dosage form that includes a therapeutically effective amount of the amorphous form of cabazitaxel.
The methods for the preparation of the amorphous form of cabazitaxel of the present invention may be illustrated by way of the following examples, which in no way should be construed as limiting the scope of the invention.
Example 1
2.0 g of cabazitaxel was dissolved in 20 ml of dichloromethane and concentrated at 35-40° C. under vacuum to obtain a solid product. The product was further dried for 1 h at 35-40° C. under vacuum. Crude product was stirred with 40 ml n-hexane at room temperature for 15-20 min and filtered. The solid material obtained was washed with 40 ml n-hexane and dried for 6-7 hrs at 50-55° C. under reduced pressure.
Example-2
2.0 g of cabazitaxel was dissolved in 20 ml of dichloromethane. The solution was then filtered through 0.5 micron filter and filtrate was spray dried for 6 hrs at 40-45° C. to obtain amorphous cabazitaxel.
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An amorphous form of cabazitaxel is disclosed. It is preferably characterized by an X-ray powder diffraction (XRD) pattern as depicted in FIG. 1 . It is prepared by (a) preparing a solution of cabazitaxel in a suitable solvent and mixture thereof; and (b) recovering the amorphous forms of cabazitaxel from the solution by removal of the solvent.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of application Ser. No. 11/182,937, filed Jul. 15, 2005, which is a continuation-in-part of application Ser. No. 10/965,384, filed Oct. 14, 2004.
BACKGROUND OF THE INVENTION
The invention concerns a procedure for feeding balls into the projectile chamber of a handgun, in particular the projectile chamber of a paintball gun. A ball container is connected with the projectile chamber via a feeder tube. The balls are fed from the ball container into the projectile chamber via the feeder tube by means of a motor. The invention further concerns a device designed to carry out the procedure.
A device in which the balls are fed into the projectile chamber in this manner is described in detail, for example, in U.S. application Ser. No. 10/965,384 filed Oct. 14, 2004 submitted by the same Applicant, the disclosure of which is incorporated by reference into the present application. It has turned out to be a problem to control the motor in such a way as to allow fast feeding of the balls and to provide the feeding force at the right moment.
SUMMARY OF THE INVENTION
The invention is based on the object of providing a procedure and a device that allow fast and reliable feeding of the balls into the projectile chamber and that avoid unnecessary operation of the motor.
According to the invention, the motor is controlled as a function of the movement of the balls in the feeder tube. In this way it is possible to suitably control the feeding force supplied by the motor as a function of the actual status of the balls in the feeder tube.
Information about the balls is needed in order to perform the control operations as a function of the movement of the balls. In order to obtain the information, the device according to the invention may comprise a sensor to monitor the movement of the balls in the feeder tube and to provide status reports on the presence or absence of balls in the feeder tube. By mounting the sensor on the device itself, and not on the weapon, the device can be operated in conjunction with various weapons.
The sensor may comprise a light barrier arranged on the feeder tube. When there is no ball situated in the light path, the light barrier is not interrupted, but it is interrupted when a ball is situated in that location.
In an advantageous embodiment of the invention the sensor is arranged close to the end of the feeder tube pointing towards the projectile chamber. The balls located in this zone are just about to enter the projectile chamber and direct information can be obtained.
The device may further comprise a spring element for storing the drive energy of the motor. The energy stored in the spring element can be used to feed several balls into the projectile chamber without it being necessary to start up the motor. Drive energy supplied by the motor while the balls are not moving can be stored in the spring element. In order to protect the spring element from becoming overloaded, the spring element may be connected to the motor via a slip clutch. If the motor supplies more energy than can be stored in the spring element, the excess energy can be dissipated via the slip clutch.
The sensor is preferably designed in such a way that it reports the two statuses “ball present” and “no ball present”. A change in status occurs when, after a certain period of time during which it has reported one of the statuses, the sensor reports the other status. A resting phase occurs when the row of balls present in the feeder tube is stationary relative to the feeder tube. In the reports generated by the sensor, a resting phase is characterized by the fact that no change in status is reported for a period of time that is longer than the period of time required to feed two successive balls into the projectile chamber during a burst of firing.
A change in status following immediately after a resting phase is referred to as a first change in status. Changes in status following a first change in status, without any intervening resting phase, are referred to as further changes in status.
The motor is preferably switched on for a start-up period following a first change in status. The start-up period lasts for a defined length of time which is adapted to the interplay between the feeder device and the handgun.
After the balls have started to move in the feeder tube, it takes a certain amount of time until the sensor detects the first change in status. This is because the balls are of a certain size and must cover a distance dependent on this size before any change in status occurs from “ball present” to “no ball present”, or vice versa. This period is referred to as the first period of ball movement that triggers the first change in status. The start-up period is advantageously longer than the first period of ball movement. The excess operating time of the motor compared with the duration of the movement takes account of the fact that, after it has been idle, a certain amount of time is needed to start the motor up again.
The start-up period is preferably at least twice as long as the first movement period. In particular, the length of the start-up period may be between 60 ms and 100 ms, and preferably between 70 ms and 90 ms.
Depending on how many balls are discharged during a burst of firing, the first change in status may be followed by further changes in status. After each further change in status the motor advantageously continues to operate for a certain period of working time. Unlike in the case of the start-up period, the motor is not set in motion but continues to operate because a working period follows immediately after the start-up period or after a preceding working period. At the start of a working period the motor is thus already operating and no acceleration phase is any longer needed. For this reason, a working period can be shorter than the start-up period. The total period of time for which the motor is operating while a burst is being fired is determined by the total of the start-up period and the working periods.
In order for the sensor to report a further change in status following a previous change in status, the balls must move a certain distance inside the feeder tube. The period of time during which the balls are in motion and trigger a further change in status is referred to as the further period of ball movement. The working periods are preferably longer than the further periods of ball movement. As a result, the motor remains in operation for a longer period of time than the balls are moving in the feeder tube. The period of time during which the motor continues to operate, while the balls, however, are once more at rest, is referred to as the run-on time. During the run-on time the motor can resupply the spring element with the energy which the spring element had discharged in order to set the balls in motion before the first change in status.
The sensor can be arranged in such a way that, during the resting phase, a ball is present in front of the sensor. In this case, the first change in status is a change from “ball present” to “ball not present”. The second change is a change from “ball not present” to “ball present”. In this case, the sensor is set up in such a way that it reports two changes in status when the balls move by the length of one ball in the feeder tube. When the balls move by the length of one ball in the feeder tube, the operating period of the motor is thus extended by two working periods. The length of these working periods can be between 20 ms and 60 ms, and is preferably between 30 ms and 50 ms. In an alternative embodiment, the sensor can also be set up in such a way that it reports only one change in status per ball. In this case, the working periods chosen should be twice as long.
Depending on what is practical, the sensor can also be arranged in such a way that no ball is present in front of the sensor during the resting phase. The sequence described is then reversed.
The more shots that are fired in a burst, the longer will be the run-on time, because for each individual shot the working period is longer than the movement period. Since the spring element has only a limited capacity for storing the drive energy supplied during the run-on period, the latter period can be limited to a maximum duration. The maximum duration of the run-on time is preferably between 170 ms and 400 ms, and furthermore preferably between 320 ms and 360 ms.
Before the device is put into operation, all the balls are present in the ball container and the feeder tube is empty. In order to get the device ready for use, the feeder tube must be filled with balls. For this purpose, when the device is started up, the motor can be switched on for a preparatory period of time which is preferably sufficiently long for the feeder tube to become completely filled with balls. The preparatory period may have a predetermined duration. Independent of the predetermined duration, or in addition to it, the end of the preparatory period can be determined by the fact that the sensor arranged at the end of the feeder tube reports a change in status, i.e. the presence of a ball.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in the following, on the basis of an advantageous embodiment and making reference to the attached drawings.
FIG. 1 shows the device which is the subject of the invention being used;
FIG. 2 shows a partially cut-away view of the ball container with the feeder;
FIG. 3 shows a cross section through the ball container, looking down on the feeder;
FIG. 4 shows a diagrammatic view of a feeder tube filled with balls in three different configurations; and
FIG. 5 shows the temporal sequence of reports from the sensor and of the operation of the motor for three different bursts of fire.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A shooter shown in FIG. 1 is using a weapon 1 , for example an air rifle used to fire paintballs, which is connected via a feeder channel, which is designed here in the form of a flexible feeder tube 2 , to a ball container 3 . The ball container 3 holds balls which are fed by means of a feeder 8 in an unbroken sequence through the feeder tube 2 to the projectile chamber 11 of the gun 1 . During this process, a spring force is applied to the balls so that in each case, when a ball has been fired and the empty projectile chamber 11 opens up, a new ball is fed from the feeder tube 2 into the projectile chamber. The ball container 3 is attached to the belt 4 of the shooter. In an alternative embodiment, the ball container may be firmly attached to the weapon via a rigid feeder channel.
As shown in FIG. 2 , the ball container 3 is cylindrical in shape and is provided with a lid 5 which is connected via a diagrammatically arranged pressure spring 6 to a pressure plate 7 . Under the action of the spring 6 the pressure plate 7 forces the contents of the container away from the open end of the container, which is closed off by the lid 5 , and towards the other end of the container. At this other end is located the feeder 8 which transports the balls 14 into the outlet channel 9 of the ball container 3 . The outlet channel 9 is attached to the inlet end of the feeder tube 2 .
The feeder 8 can be caused to rotate in the direction indicated by the arrow 10 by means of an electric motor, not depicted here, arranged in the lower area of the ball container 3 . The motor is connected via a spring element and a slip clutch, neither of which are depicted here, to the feeder 8 . Rotation of the motor drive shaft is transmitted via the spring element to the feeder 8 . As soon as the feeder tube 2 is completely filled with balls, the feeder 8 is prevented from rotating any more. If further drive energy is supplied by the motor while the feeder 8 is stationary, this causes the spring element to become tensioned, so that the spring element stores the drive energy of the motor. If the spring element is tensioned to the maximum extent, further drive energy supplied by the motor is dissipated via the slip clutch. The features of this drive mechanism with spring element and slip clutch are described in detail in U.S. application Ser. No. 10/965,384 filed by the same applicant. A control unit 18 which controls the motor as a function of the reports received from the sensor 16 is arranged in the lower area of the ball container 3 .
If shots are fired from the rifle 1 , the first balls 14 can be conveyed into the projectile chamber of the weapon 1 by means of the energy stored in the spring element. However, because the energy stored in the spring element is sufficient only to convey a few of the balls 14 , the motor must be controlled in such a manner that it provides new drive energy in a timely fashion. The procedure which is the subject of the invention is concerned with controlling the motor.
A sensor 16 is arranged at the end of the feeder tube 2 adjoining the weapon 1 and is used to determine whether a ball 14 is present in this area of the feeder tube 2 . The sensor 16 comprises a light barrier whose light beam runs in the cross-sectional plane of the feeder tube 2 . The light beam is interrupted if a ball 14 is present at that location, and it is not interrupted if no ball is present there. The motor is controlled as a function of the status reports put out by the sensor 16 .
In FIG. 4 , one end of the feeder tube 2 adjoins the inlet to the projectile chamber 11 of the weapon 1 . A light barrier 17 in the sensor 16 intersects the feeder tube 2 in a direction perpendicular to the plane of the drawing. During the resting phase depicted in FIG. 4A , the feeder tube 2 is completely filled with balls 14 , and the frontmost ball 141 is situated at the entrance to the projectile chamber 11 of the weapon 1 . The entrance to the projectile chamber 11 is closed, and all the balls are at rest within the feeder tube 2 . The series of balls 14 contained in the feeder tube 2 is acted on by the spring force transmitted via the feeder 8 . The light barrier 17 is interrupted by the ball 141 and the sensor 16 reports the presence of a ball.
After a shot is fired by the weapon 1 , the inlet to the projectile chamber 1 opens up, and the frontmost ball 141 , driven by the force of the spring, moves into the projectile chamber 11 . Once the ball 141 has partially entered the projectile chamber 11 , in the status as depicted in FIG. 4B , the light barrier 17 detects a first change in status, namely that there is no longer a ball present in the area of the light barrier 17 . As the ball 141 continues to move into the projectile chamber 11 , the next ball 142 enters into the area of the light barrier 17 , interrupting the latter as shown in FIG. 4C . The sensor 16 reports a further change in status.
The control of the motor as a function of the changes in status reported by the sensor 16 is depicted in diagrammatic form in FIG. 5 . FIG. 5A shows the sequence occurring when a single shot is fired; FIG. 5 b shows the sequence occurring when three shots are fired in a burst; and FIG. 5C shows the sequence occurring when twenty shots are fired in a burst. In each case, in FIGS. 5A , 5 B, 5 C, the status of the sensor 16 is shown above the time axis in Diagram 12 and the status of the motor is shown above the time axis in Diagram 13 . Both the sensor and the motor alternate only between the states 0 and 1. In state 1 a ball is present in front of the sensor, and in state 0 no ball is present in front of the sensor. In state 0 the motor is stationary and in state 1 it is in operation. All the numerical data shown in FIG. 5 indicate time in ms.
FIG. 5A shows the temporal sequence when a single shot is fired from the weapon 1 . The point in time S designates the starting point at which, following the firing of the shot, the entrance to the projectile chamber 11 opens up and the ball 141 starts to move into the projectile chamber 11 . As soon as the status shown in FIG. 4B is reached, the sensor reports at time 151 that the first change in status has occurred following a resting phase. The first change in status at time 151 is reported to the control unit 18 which thereupon causes the motor to start operating for a start-up time of 80 ms. As the ball 141 penetrates further into the projectile chamber 11 , the status shown in FIG. 4C is reached, where the ball 142 enters the zone of the light barrier 17 . At time 152 the sensor reports a further change in status. The control unit 18 causes the motor to continue operating after the further change in status at time 152 for a working period of 40 ms duration immediately following the start-up period. Since the sensor 16 no longer reports any further changes in status after time 152 , the motor is switched off after the first working period.
A period of time which triggers the first change in status elapses between the point in time S, when the movement of the balls 14 in the feeder tube 2 commences, and the time 151 , when the balls 14 are located in position 4 B. It is assumed here that the length of this period of time is 25 ms. Once the first change in status has occurred, the motor is set in operation for a start-up time of 80 ms. The start-up time is more than twice as long as the movement period that triggers the first change in status. This takes account of the fact that it requires a certain amount of time to set the motor in motion.
The period of time between the first change in status 151 and the further change in status 152 corresponds to the time required by the balls 14 in the feeder tube 2 to move from status 4 B to status 4 C. The length of this period of movement by the balls 14 , which triggers the further change in status 152 , is also assumed to be 25 ms. The working period associated with the movement period 151 to 152 is at 40 ms longer than the movement period. This difference between the working period and the movement period results in a run-on time during which, on the one hand, the balls are returned from status 4 C to the position shown in 4 A, and the spring element is tensioned.
The overall operating duration of the motor when a shot is fired is made up of the start-up time of 80 ms and a working period of between 40 ms and 120 ms. After the last reported change in status at time 152 , the motor continues to run for a further 95 ms.
FIG. 5B shows the temporal sequence 12 of the changes in status reported by the sensor 16 and the temporal sequence 13 of the operation of the motor for the case in which a burst of three shots is fired. Exactly as in the case when a single shot is fired, the sensor 16 reports the first change in status at time 151 and a further change in status at time 152 . After the first change in status 151 the motor is set in motion for a start-up period of 80 ms; after the further change in status 152 , the motor continues to operate for a working period of 40 ms. Following the changes in status 153 to 156 , the motor continues to run in each case for a further working period of 40 ms, with each successive working period following immediately after a preceding working period. The overall operating time of the motor when a burst of three shots is fired is made up of the start-up time of 80 ms and the five working periods, each of 40 ms, for a total of 280 ms. Following the last reported change in status 156 the motor runs on for 155 ms. The run-on time is sufficient to bring the balls 14 back to the resting phase 4 A and to fully tension the spring element.
When a burst of twenty shots is fired, as shown in FIG. 5 c , the sensor 16 reports a first change in status 151 followed by 39 further changes in status 152 to 1540 . After the first change in status 151 , the motor is set in motion for a start-up time of 80 ms. For each of the further changes in status 152 to 1540 , the motor continues to run for working periods of 40 ms. The movement periods of the balls 14 which trigger the changes in status 151 to 1540 add up to an overall duration of 975 ms. The total amount of time made up of the start-up period of 80 ms and 39 working periods each of 40 ms is 1640 ms, which would give a calculated run-on time of 665 ms. However, the operating duration of the motor required to convey the balls 14 back to the starting status 4 A and to fully tension the spring element is substantially shorter than 665 ms. For this reason, the run-on duration is limited to a maximum length of 340 ms. If the calculated run-on time, as the difference arising from the sum of the start-up period and the working periods as well as the movement periods, adds up to more than 340 ms, this excess portion of the run-on time is ignored. The run-on time remains fixed at 340 ms regardless of how many further changes in status the sensor 16 reports.
At the time of start-up the ball container 3 is filled with balls 14 and there are no balls in the feeder tube 2 . In order to fill the feeder tube 2 with balls, the motor is switched on for an adequately long period of time. As soon as the sensor 16 at the end of the feeder tube 2 close to the projectile chamber 11 reports the presence of a ball 14 , this means that the feeder tube 2 is filled with balls. After receiving the report from the sensor 16 , the control unit 18 allows the motor to continue running for a short period of time to ensure that the spring element is fully tensioned. This completes the preparatory period and the weapon 1 is ready to be used.
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The procedure for feeding balls ( 14 ) to the projectile chamber ( 11 ) of a handgun ( 1 ), in particular to the projectile chamber of a paintball weapon, whereby the balls ( 14 ) are fed by means of a motor from a ball container ( 3 ), through a feeder tube ( 2 ) into a projectile chamber ( 11 ), is characterized by the fact that the motor is controlled as a function of the movement of the balls ( 14 ) in the feeder tube ( 2 ). The feeding of the balls ( 14 ) to the projectile chamber ( 11 ) is controlled in accordance with the procedure which is the subject of the invention. The invention has the advantage that the motor is controlled as a function of the actual conditions prevailing inside the feeder tube ( 2 ).
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The present invention is concerned with the manufacture of an aerosol dip tube and more particularly with a microporous aerosol dip tube.
History of the Art and Problem
In general, it has been practice in aerosol packaging of sprayable materials (excluding foams and pastes) to provide a single phase material (product concentrate plus propellant) which as a liquid is expelled from the nozzle of the aerosol container and which, by virtue of propellant vaporization, formed a fine mist or spray immediately upon leaving the nozzle. Briefly, the aerosol container comprises a containing means or can adapted to withstand the pressure of a liquefied propellant material. At the top of the can, as it is normally employed, is a valve which upon opening by pressing permits passage of material from the can to the exterior. In most instances, the force which causes the material to be propelled from the interior of can through the valve nozzle or orifice is the vapor pressure of a liquefied material known as the propellant. In the past, propellants have commonly been of the fluorinated hydrocarbon type such as sold under the trademark "FREON" by E.I. duPont Nemours Company. In relatively recent times it has been proposed that the use of fluorinated hydrocarbon propellants is deleterious to that portion of the upper atmosphere which provides protection from high energy ultraviolet light. Because of this fear, the use of fluorinated hydrocarbon propellants has diminished. In their place, the art has turned to liquefied hydrocarbons such as, butane, propane, etc. which, as liquids, have high vapor pressures at normal temperatures, i.e., from about 0° C. to about 45° C. One difficulty with use of liquefied hydrocarbons is that, in contrast to fluorinated hydrocarbons, hydrocarbons are flammable. It is, of course, desirous to avoid or minimize if possible the flammability of aerosol dispensed products. Other difficulties are that these hydrocarbons have little or no miscibility with aqueous media and they have poor solvent power for many resinous binders used in aerosol spray compositions.
In general, the aerosol art has tried to provide single phase liquid materials in the aerosol container, which single phase contains both the liquefied propellant and the concentrate of material being dispensed from the aerosol container. When a single phase can be employed, the material being dispensed from the container and the propellant are used up in substantially equal amounts unless the aerosol container valve is accidentally or deliberately opened when the container is in an inverted position. In the usual aerosol container employing a solid dip tube extending from a top-sited valve to the bottom of the can, the propellant and concentrate will not be used up in equal amounts or in the relative amounts present in the can if the propellant phase and the concentrate phase are separated by gravity. If the propellant is heavier than the concentrate phase, depressing the valve mechanism at the top of the can will result in expulsion or pure or relatively pure propellant. On the other hand, if the propellant is lighter than the concentrate phase, which situation normally exists in the case of an aqueous product concentrate and a hydrocarbon propellant, the concentrate will be expelled first and will be exhausted prior to the can being depressurized. This situation can be alleviated somewhat by requiring the user of the aerosol composition, having distinct propellant and concentrate phases, to shake well before using. However, this solution is not very satisfactory because of the normal variations of shaking and the fact that the temporary emulsion which is formed will normally break quickly.
From the point of view of the character of the aerosol spray produced, it is highly advantageous that regardless of whether there is phase separation in the can, the concentrate of effective material and the propellant should be expelled simultaneously. When the concentrate and propellant are expelled simultaneously, the propellant serves not only to force the concentrate from the aerosol container but also to break up the droplets of concentrate as they pass through the valve nozzle and thus produce a fine spray rather than a stream of concentrate or a coarse spray of concentrate. Of course, there are times when a stream of the contained material in an aerosol can is desirable and under those circumstances one does not need simultaneous delivery of propellant and concentrate. On the other hand, for uses such as hair spray, insecticide, deodorizers, oven cleaners and release agents, a fine spray is highly desirable.
The problem of simultaneously expelling propellant and concentrate where the propellant and concentrate are in separate phases and are separated by gravity in an aerosol container has been attacked previously, particularly in the teachings in U.S. Pat. No. 3,260,421 by B. Rabussier. In this patent it is taught to use a dip (or eduction) tube, which is perforated along the whole or part of its length. According to this prior disclosure, the eduction tube passes through layers of liquid in the aerosol container which layers are separated from each other by gravity. The active ingredients in the aerosol container of U.S. Pat. No. 3,260,421 are apparently necessarily contained in the liquefied propellant phase. Upon activating the valve of the prior art aerosol container, the liquefied organic propellant phase containing the active substance is forced into the eduction tube along with an aqueous phase. In the eduction tube the two phases mix and, aided by a separate propellant gas flow into the valve body, the mixed phases are in a satisfactory state for expulsion from the oriface of the valve to provide a finely misted product. U.S. Pat. No. 3,260,421 teaches that the simultaneous expulsion of water and a flammable hydrocarbon propellant phase containing the active ingredient not only affords the means of reducing the cost, but also inhibits flammability of the sprayed aerosol product thus providing a considerable advantage to the user and recovering one advantage of the formerly used fluorinated propellants. When fluroinated propellants could be used, a single phase in an aerosol can could contain flammable organic solvents such as alcohols, ketones, etc. Without danger that the spray would be dangerously flammable because the propellant was a flame depressant. With hydrocarbon propellants, however, the organic solvents necessary to provide single phase stability in aerosol packaged products contribute greatly to the fire damages.
OBJECTS AND DISCOVERY
It is an object of the present invention to provide an improved method of manufacturing an aerosol dispensing means of the type employable when separate phases, eg., aqueous and organic phases, are co-present in an aerosol container.
Another object of the present invention is to provide a method of manufacturing a means whereby active ingredients can be contained in an aqueous phase of an aerosol container containing separate organic and aqueous phases.
A further object of the present invention is to provide a method of manufacturing an aerosol dispensing means whereby the limitations inherent in requiring that an active ingredient be soluble in a liquefied hydrocarbon propellant are avoided.
In furtherance of these objects, it has now been discovered that by means of a microporous eduction tube, limitations inherent in the system of U.S. Pat. No. 3,260,421 can be avoided.
Other objects and advantages of the present invention will become apparent from the following description taken in conjunction with the drawing which is a reproduction of a scanning electron microphotograph of an eduction tube of the present invention.
DESCRIPTION OF THE INVENTION
In general, the present invention comprises a novel method of manufacturing a microporous dip or educt tube adapted to connect with a top-sited valve on an aerosol container and extend from said valve through separate liquid layers of propellant and product concentrate to the bottom of the container. The tube is made of plastic and has an essentially uniform bore and wall thickness. The tube wall is microporous along its length.
For purposes of this specification and claims, the term "microporous" in reference to the novel dip tube, shall mean an essentially continuous porosity in three dimensions, the average size of the pores being of a maximum of about 10 μm, as measured prior to any swelling of the tube by propellant or product concentrate.
The porosity of the tube wall, conveniently measured by air flow in a given time under a given pressure differential, is governed by the volume percent of microporosity, the average pore size and the wall thickness. For any given combination of product concentrate and propellant phases, the porosity of the tube wall and the tube bore dimension prior to any swelling effects are adjusted generally within the extremes set forth in the following Table to provide satisfactory product spray characteristics.
______________________________________Extremes of Tube Characteristics______________________________________Bore (mm) .76 to 1.52Wall thickness (mm) .51 to .89Vol % Porosity in Walls 30 to 80Average Pore Size (μm) 1 to 10______________________________________
Product spray characteristics may, of course, also be altered by means well known to those of normal skill in the aerosol art other than by altering the microporous dip tube characteristics. For example, propellant gas can be by-passed to a conventional vapor tap valve, special expansion chambers in valve bodies can be employed and special orifices such as a reverse taper orifice can be used. It is contemplated that, as used, the microporous dip tube of the present invention can be used in conjunction with none, any or all of these and other means of modifying product spray characteristics. Some factors which should be considered in adjusting the aforetabulated tube characteristics are relative viscosities of product concentrate and propellant, wetting characteristics of product concentrate and propellant relative to the dip tube material and relative quantities of propellant and concentrate in the aerosol container.
A typical dip tube of the present invention is depicted in the drawing. Referring now thereto, the scanning electromicrophotograph shows the essentially smooth, uniform bore of the tube and the microporosity of the walls. In the tube as illustrated in the drawing, the walls are about 60 volume percent porous, the wall thickness is about 0.64 mm, the bore is 1.27 mm in diameter and the average pore size in the walls is about 8 μm. Generally, as depicted in the drawing, dip tubes of the present invention are circular in cross section and have a bore of circular cross section. This is merely a matter of convenience. If desired, the dip tubes of the present invention can be of any cross-sectional shape which can be extruded in the size range required.
The dip tube illustrated in the drawing is made of medium density type polyethylene. Generally speaking, it is made in accordance with the teachings of U.S. Pat. No. 3,375,208 to Duddy except as to establishing the product form by extrusion. Fine solid thermoplastic resin, in this case medium density type polyethylene sold under the trademark "MICROTHENE" by U.S.I. Chemical Company is mixed with a second solid thermoplastic resin which is soluble in a leaching solvent, in this case polyethylene oxide type resin sold under the trademark "POLYOX" by Union Carbide Corporation along with a finely ground water soluble solid, in this case -200 mesh sodium chloride and fume silica. The mixed solids are then hot worked to provide a plasticized viscous mass which mass is extruded into tube form by conventional means. The extruded tube, after cooling, is then leached with a leaching solvent, in this case water, to provide the microporous tube structure as depicted in the drawing. Of course resins other than polyethylene can be employed. For example, the basic resin can be polypropylene, polyvinyl chloride, nylon 66 and the like. Water soluble resins other than polyethylene oxide which can be used include polyethylene glycol and polyvinyl pyrrolidone. Those skilled in the art will appreciate that although using a water-soluble resin as a pore former in the manufacture of dip tubes of the present invention is highly advantageous, other resins soluble in solvents which do not dissolve the principal resin can be used in conjunction with such selective solvents. When a non-aqueous solvent is used to selectively leach a resin in the manufacture of the dip tubes of the present invention, a second leach of water soluble solid can be employed or any other appropriate leachant can be used to leach the leachable solid. In addition to the insoluble resin, soluble resin and soluble solid pore former, the blended mass used to manufacture the microporous dip tubes of the present invention can also contain other ingredients which do not destroy the basic character of the tube. For example, the basic insoluble resin can be modified by a plasticizer or plasticizers insoluble both in the leaching solvent and in the ingredients in the aerosol container or by a fugative plasticizer. Furthermore the basic insoluble resin can be compounded with a substance or substances which will modify the surface characteristics thereof to provide for selective wetting or non-wetting by product concentrate and propellant phases.
In operation, under pressure of a liquefied propellant, the eduction (or dip) tube of the present invention carries the lowermost liquid phase present in an aerosol can generally longitudinally along the bore, the liquid of this phase predominately entering the bore at the bottom open end of the tube. The liquid phase or phases above the lowermost phase in the aerosol container enter the dip tube via the porous walls either as fine gas bubbles or as finely dispersed streamlets of liquid. In either event, the phases travelling in the novel dip tube toward the aerosol can valve are in most intimate contact and are suitable for providing good, acceptable aerosol spray characteristics. In particular when a basically aqueous product concentrate is the lowermost layer and a liquefied hydrocarbon propellant such as butane is the upper liquid phase layer, the product expelled from the can is fire resistant and of commercially acceptable spray characteristics.
While the dip tube of the present invention has been described as particularly adapted to be used with aqueous concentrates and hydrocarbons propellants for spray purposes, it is not intended thereby to so limit the applicability of the product claimed herein. The product can be used in any aerosol container having separate liquid phases regardless of the nature or character of those phases.
Although the present invention has been described in conjunction with preferred embodiments, it is to be understood that modifications and variations may be resorted to without departing from the spirit and scope of the invention, as those skilled in the art will readily understand. Such modifications and variations are considered to be within the purview and scope of the invention and appended claims.
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A process for making a porous dip tube for use in a pressurized container dispensing liquid material in which a mixture of polymers, one insoluble in the liquid material and a second soluble in a solvent, is extruded to form a tube and thereafter the second polymer is removed from the extruded tube to provide porosity in the wall of the tube. In use, the bulk of liquid material is forced from the bottom of the pressurized container through the tube longitudinally while gaseous matter passes through the wall of the tube to provide means to atomize the liquid material as it passes into the atmosphere.
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This is a continuation in-part application of my co-pending application Ser. No. 08/158,463, filed on Nov. 29, 1993.
SUMMARY OF THE INVENTION
The present invention relates to a block used in the construction of retaining walls in landscaping applications. Such walls are used to provide lateral support between differing ground levels where the change in one elevation to the other occurs over a relatively short distance.
Such retaining walls have been in existence for many years and have taken a variety of forms. Some have been constructed of wood timbers, others of rock in a natural form (such as limestone). Still others have been constructed of manufactured aggregate or concrete blocks. The present invention relates to a manufactured block.
When constructing a retaining wall, a number of design features must be considered. Generally, the wall will have to be backsloped toward the higher level to provide the wall with sufficient strength. This requires careful attention to the spacing of successive block courses so that the proper backslope is imparted to the wall. In addition, the wall must be anchored in a manner that will prevent blowouts and the like. The configuration of the wall must also be considered so that curves and corners can be constructed. In the prior art blocks, this last consideration has often necessitated the use of differently shaped or sized blocks to be used at curves or corners, depending on whether they are concave or convex. The present invention is designed to eliminate or minimize the various problems associated with each of these design considerations.
It is one object of the present invention to provide for a retaining wall block that is rearwardly horizontally "self-spacing" with respect to the blocks of the next lower course upon which the block is placed and supported, so as to thereby ensure a properly angled, uniform backslope along the wall.
It is another object of the present invention to provide for a retaining wall block that is "self-spacing" with respect to the blocks of the next lower course upon which the block is placed and supported, so as to thereby ensure a properly angled, uniform backslope along the wall, wherein the angle of the backslope may be varied according to the circumstances in which the wall is constructed.
It is another object of the present invention to provide for a retaining wall block that provides for a "self-locking" mechanism between various courses of the wall.
It is another object of the present invention to provide for a retaining wall block that is "self-anchoring" upon the backfilling of the area behind the wall.
It is yet another object of the present invention to provide for a retaining wall block that can be used in any area of the wall, including straight portions, curves or corners.
It is a further object of the present invention to provide for a retaining wall block that can be quickly and easily modified so as to be useful in walls having tightly curved or right angle corners.
To these ends, a retaining wall block is provided that comprises a first, forward face portion including a face surface, a second, rearward tail portion generally parallel to and spaced rearwardly of the face portion, and a central web portion connecting the face portion to the tail portion. The face portions are wider than the tail portions and designed to be laid in such a fashion that the ends of each face portion abut an end of each of the face portions of the next adjacent blocks. The face portions have a forward facing outer face surface and a rearward facing inner surface. A downwardly projecting abutment member is formed on the underside of each face portion and acts as a spacer when the block is supported (in a staggered fashion) upon a lower course of blocks by virtue of the fact that the abutment member is placed in abutting relation to the inner surfaces of the face portions of the blocks of the lower course. When the area behind a course of blocks is backfilled, it will be seen that the dirt will fill the areas between the face portion and the tail portion of adjacent blocks and the tail portion will thereby act as an anchor resisting lateral force upon the wall.
The abutment member may be scored or notched parallel to its forward surface in one or more places such that the width of the abutment member may be easily altered or varied by removing a portion of the abutment member with a hammer and chisel. Similarly, the top of the outer ends of the face portion may also be scored or notched parallel to the inner surface such that a portion of the inside of the face portion against which the abutment member of the block in the next above course abuts may be easily removed with a hammer and chisel.
Lastly, the face portion is notched to allow portions thereof to be easily removed with a hammer and chisel to modify the shape of the block for use in tight curves or right angle corners.
DESCRIPTION OF THE DRAWING
FIG. 1 is a front elevational perspective view of the top of a block according to the present invention.
FIG. 2 is a front elevational perspective view of the bottom of a block according to the present invention.
FIG. 3 is a front elevational view of a retaining wall constructed with blocks embodying the present invention.
FIG. 4 is a top plan view of a portion of a wall constructed with blocks embodying the present invention showing obscured portions of the blocks in dashed line.
FIG. 5 is a side sectional view of a portion of a wall constructed with blocks embodying the present invention taken generally along the line 5--5 of FIG. 4.
FIG. 6 is a top plan view of a retaining wall having a right angle corner wherein blocks according to the present invention have been modified for use at the corner.
FIG. 7 is a top view of retaining wall blocks according to the present invention wherein a portion of the tail portion has been removed to form a tightly curved portion of wall.
FIG. 8 is a top and bottom plan view of a corner block modified for use as shown in FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 3, there is shown a retaining wall 10 consisting of a number of courses of blocks 11 extending from just below the surface of a lower level (not illustrated) to just above the surface of an upper level (not shown). The top of the last course of blocks 11 in any given portion of the wall 10 is capped with a plurality of caps 12 which do not form a basis or a part of the present invention.
Each course of blocks 11 comprises a plurality of blocks 11 arranged side to side in the conventional fashion to present a continuous forward surface extending generally horizontally. Except for the lower course, which is laid upon a prepared base slightly beneath the surface of the lower level, each course is laid upon the preceding course in the manner hereafter described, with each block 11 in the higher course being staggered with respect to the blocks 11 upon which it rests in the lower course in the manner shown.
FIGS. 1 and 2 illustrate the composition of each block 11. The blocks 11 are advantageously formed of a poured aggregate material such as concrete to define a unitary piece. Each block 11 comprises a forward face portion 13, a tail portion 14, and a central web portion 15 extending between the face portion 13 and the tail portion 14. Thus, it will be seen that the block 11 has somewhat of an "H" shaped configuration except that the width of the face portion 13 is greater than that of the tail portion 14.
The face portion 13 comprises a forward, face surface 16, a rearward inner surface 17, a top surface 18 and a bottom surface 19. Similarly, the tail portion 14 comprises a rear surface 20 and a forward inner surface 21, a top surface 22 and a bottom surface 23. The web portion 15 extends between the spaced, inner surfaces 17, 21.
A downwardly depending abutment member 24 is formed on the bottom surface 19 of the face portion 13 at a point where the web portion 15 joins a face portion 13. The abutment member 24 has a rear surface 25 and a front surface 26 generally parallel to and spaced approximately one inch forwardly of the plane of the inner surface 17. The abutment member 24 serves as a spacing mechanism in the manner which is hereafter described.
To construct a retaining wall 10, a first course of blocks 11 is laid in a prepared, leveled area slightly below the lower level. In each course, including the first, the blocks 11 are laid in such a fashion that the ends of the face portions 13 of each block 11 abut one side of the face portions 13 of the next adjacent block 11. When a course has been laid, dirt is backfilled behind the blocks 11 into the space between the inner surfaces 17, 21 of face portions 13 and tail portions 14. Thus, it will be seen that the accumulation of backfill stabilizes the wall 10 and the tail portions 14 act to anchor the wall 10.
The next course is laid upon the previous course in staggered fashion as best seen in FIGS. 3 and 4. The center of each block 11 is placed over the abutting ends of two blocks 11 in the lower course. This not only adds to the wall 10 aesthetically, but also stabilizes the wall 10 against lateral movement. When placing a block 11, the abutment member 24 is placed in abutment against the outer ends of the inner surfaces 17 of the two blocks 11 immediately below. This ensures a uniform horizontal offset between courses equal to the extent to which the front surface 26 of abutment member 24 is spaced forwardly of inner surface 17. As is discussed in more detail below, the amount of horizontal offset between blocks 11 of successive courses (and thus the angle of backslope in the wall) may be varied by removing a portion of the abutment member 24 or by removing a portion 17a of the outer ends of the inner surfaces 17 against which an abutment member 24 of the next above course abuts.
The face surface 16 of the blocks 11 are tapered rearwardly at their outer ends as seen in FIGS. 1 and 2. This facilitates the orientation of successive blocks 11 at oblique angles to one another as in the case of a concave curve in the wall 10. Similarly, to facilitate the orientation of successive blocks 11 at oblique angles to one another as in the case of a convex curve in the wall 10, the tail portions 14 are narrower in width than the face portions 13 and taper forwardly at their ends.
The block 11 incorporates a number of features that make it easily modified to change the angle of backslope in a wall or to accommodate tightly curved or even right angle corners in the wall. Vertical V-shaped notches 30 are formed in the inner surface 17 of face portion 13. The notches 30 extend along the entire height of the face portion 13 and are positioned with respect to the outer ends of inner surface 17 such that the portion (designated 17a) of inner surface 17 against which an abutment member 24 will abut when the wall 10 is constructed, is outside of each notch 30. The top surface 18 of face portion 13 has one or more scores or notches 31 running generally parallel to surface 17 at a depth of slightly more than the depth of abutment member 24. Selected portions of the face portion 13 between the scores or notches 31 can be easily removed with a chisel and hammer. Removal of such a portion will have the effect of advancing abutment portion 17a of inner surface 17 closer to face surface 16 thereby lessening the horizontal offset spacing between blocks 11 in successive courses and, consequently, the amount of backslope in the wall 10.
The amount of backslope may similarly be altered by removing a portion of abutment member 24. Abutment member 24 may also have one or more scores or notches 33 running essentially parallel to front surface 26. One or more portions of the abutment member 24 may be easily removed by a chisel and hammer to alter the width of the abutment member 24. It will be evident that changing the width of the abutment member 24 in this fashion will also change the amount of horizontal offset spacing between successive courses and, consequently, the backslope of the wall 10.
A modification of a block 11 for use on tightly curved wall segments is best seen in FIG. 7. In order to accommodate the short radius of curvature, a side of the tail portion 14 may be easily removed by placing a chisel on top surface 22 in extension of one side of web portion 15 and striking it with a hammer.
Another modification of a block 11 for use on right angle wall corners is shown in FIGS. 6 through 8. The face portion 13 is squared to remove the tapered outer ends by placing a chisel on top surface 18 in alignment with notch 30 and striking it with a hammer. Web portion 15 is then broken away by a chisel and hammer in such a fashion that abutment member 24 remains attached to face portion 13. This will leave a corner block 11 consisting of a rectangular face portion 13 and an abutment member 24. Because of the staggering of blocks 11 in successive courses, the orientation of the corner block 11 will also be staggered, thereby adding strength to the corner.
While I have described the preferred embodiment of my invention, it will be apparent to persons of ordinary skill in the art that other embodiments are possible within the scope of the invention.
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A retaining wall block is provided which comprises a forward, face portion and a tail portion spaced rearwardly of said face portion and extending generally parallel thereto, said face portion and said tail portion being connected by a central web. A downwardly depending abutment member is formed on the bottom of said face portion to serve as a spacing mechanism for offsetting successive courses of block, thereby imparting a uniform backslope to the retaining wall. The block is designed in such a fashion that portions of the spacing mechanism may be easily removed or modified so as to permit different angles of backslope.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application Ser. No. 61/870,281, filed Aug. 27, 2013, titled “Electric UAV Launcher,” the entire contents of which are hereby incorporated by reference.
FIELD OF THE DISCLOSURE
Embodiments of the present disclosure relate generally to an electrically powered launcher system designed to launch an unmanned aerial vehicle (UAV). The embodiments of this electrically powered launch system provided are generally more lightweight than current hydraulic-pneumatic launching systems. They also do not use hydraulic fluids and fuel for an engine for the launching process. This renders the system environmentally sound because fumes and spills may be eliminated. Through the use of feedback-based controls tied into a drive motor, the launch acceleration profile can be programmed and potential g-load spikes mitigated.
BACKGROUND
Launching systems for unmanned aerial vehicles (UAV) are designed to create enough force and speed that the UAV can be ejected into the air. The general concept behind a UAV launching system is to take a vehicle from rest to the desired flight velocity in a minimum distance, without imparting destructive forces to the vehicle. UAV launcher systems for vehicles weighing thirty pounds or more typically use a pneumatic or pneumatic/hydraulic system as the prime propulsion system.
The traditional approach to take-off for many UAVs (including taxi, accelerate, lift-off, and climb) often requires a distance of 200 feet or more. This traditional take-off minimizes the acceleration (g-load) on the vehicle because it is accelerated over a longer distance. However, there is a desire to design systems that can obtain the desired launch velocity in less than 50 feet in some instances. For example, on shipboard applications and other instances, space may be limited. In addition, the landing gear associated with runway take-off and landing operations adds weight and thus requires more power and fuel to sustain flight operations.
However, the use of a launcher that allows shorter distance to achieve flight (because the acceleration is faster) generally means higher g-loads. There are often expensive electronics on-board the UAV that cannot withstand such high g-loads. Other limitations to launch parameters include a minimum launch velocity or a maximum space to launch. The design and optimization of the launcher then becomes a balance of launch stroke length, vehicle acceleration, vehicle weight to be launched, and launch angle.
The power source for the UAV launchers designed to date has typically been a self-contained power source in the form of a closed loop hydraulic/pneumatic system, which stores energy when dry nitrogen is compressed in an accumulator by pumping in hydraulic fluid. The hydraulic pump is usually driven by either an electric motor, a gasoline engine, or by a multi-fuel engine.
Historically, closed loop hydraulic-pneumatic systems have proven to be the most reliable and repeatable under the widest range of environmental conditions. To prevent condensation at extreme temperatures, dry nitrogen (GN 2 ) is used, instead of air, to fill the “pneumatic” side of a piston accumulator. The nitrogen is pre-charged to a pre-determined pressure. A hydraulic pump then pressurizes the hydraulic side of the accumulator piston, which compresses the nitrogen and raises the launch pressure. Once the optimal launch pressure is reached, the system holds the pressure via check valves until launch is initiated. Upon launch initiation, the valve opens, the nitrogen expands, pushing the fluid out of the accumulator and into the cylinder. This accelerates the cylinder piston, the reeving cable, shuttle and vehicle.
However, there are some limitations and problems associated with pneumatic launchers. For example, there is typically an accumulator associated with the system that must be pre-charged to a specific pressure to achieve the desired launch velocity for a given UAV weight. If a different speed is required or if the weight of the UAV varies (due to fuel load or ordinance), the pre-charge pressure must be adjusted accordingly. This generally requires that gas (typically air or dry nitrogen) either be bled from or added to the system via a separate gas bottle. The need to vary the pressure adds to system complexity and potentially increases the overall system weight (e.g., if a gas bottle positioned on-board the launcher is used).
With a pneumatic launcher, it can be also difficult to control the g-load imparted to the UAV when the pressure is released into the mechanical drive components at the initiation of the launch cycle. These spikes in the g-load at the beginning of the launch cycle can have potentially disastrous impacts on the UAV and the on-board electronics and other systems. These initial g-load spikes can be mitigated through control valves that release the hydraulic fluid from the accumulator into the drive cylinder in a controlled fashion. However, these valves are often expensive and add weight to the overall system.
Additionally, many UAV launchers are used in an expeditionary mode, where they need to be mobile and capable of being transported to a location for deployment. In some cases, they may be mounted to the back of a truck. In other cases, they may be trailer mounted and either towed into position or slung from the underside of a helicopter and air lifted into position. In most cases, the overall size and weight of the launcher system must be minimized to ensure that it can fit within certain aircraft or transport containers. The main drive components of a hydraulic/pneumatic launcher (accumulator, pump, launch cylinder, gas bottle, reservoir, etc.) add substantial weight to the system, and weight is a primary limitation to mobility of the system.
With any hydraulic/pneumatic system, leaks are always a concern. Loss of gas pressure or a hydraulic leak could potentially shut down operations. Once fielded, it is unlikely that there will be access to gas cylinders to address leaks in the system.
Launch timing can also be an issue with a hydraulic/pneumatic system. Depending on the differential between the pre-pressure and final launch pressure, the size of the pump and amount of hydraulic fluid to be moved, it can take up to several minutes to bring the system up to launch pressure. The UAV is typically mounted on the launcher, and its engine is running during this pressurization time, making it susceptible to overheating.
Reset can be another challenge presented by a hydraulic/pneumatic system. Resetting a hydraulic/pneumatic launcher after completion of a launch requires that the shuttle be pulled back into the launch position. This may take several minutes because, as the shuttle is pulled back, the hydraulic fluid needs to be pushed out of the cylinder and back into the reservoir. The time required to reposition the shuttle negatively impacts the overall cycle time.
One launcher design that does not use a hydraulic system is described in U.S. Pat. No. 4,678,143. The launcher described by this patent uses a flywheel that provides the energy required for the launch sequence. The flywheel is spun up by a small electric motor that is powered by a generator, and an electric clutch engages the flywheel when the launch cycle is initiated. The flywheel drives a cable drum that wraps cable around the drum during the launch sequence. One of the disadvantages with this launcher is that the flywheel may take several minutes to come up to launch speed. Another disadvantage is the requirement of a generator as a power source, which can add a great deal of weight to the system.
BRIEF SUMMARY
Improvements to UAV launching systems are thus desirable. In particular, improvements that eliminate the use of hydraulic fluid and compressed nitrogen or air are desirable. Improvements that eliminate the use of a flywheel to provide energy fix a launch sequence are desirable. Systems that are lighter, more reliable, allow more control of g-load, that do not threaten leaks, that do not take several minutes to launch, and that do not take several minutes to reset are desirable.
Embodiments described herein thus provide a launching system for an unmanned aerial vehicle that uses a launcher rail, a shuttle configured to travel along the launcher rail, and a drive mechanism for moving the shuttle along the launcher rail. The drive mechanism can include a length of tape secured to the shuttle, an electric drive motor that drives movement of the tape, and a drive reel to which one end of the tape is secured and around which the tape is wound during launch. The tape may be nylon, a nylon blend, or some other material. The electric motor may be a DC motor or some other motor that comports with the weight and size requirements for the particular system. The electric motor may be battery powered. In a specific design, the electric motor is powered by a Lithium Ion battery.
This disclosure provides a UAV launching system that provides launch using completely electric launch components, including the braking and control system. There are no hydraulic systems on board that could present environmental issues in the event of a leak. The launch system described may be mounted to a base or pallet that can in turn be mounted to a trailer, dolly type wheel base, a flat bed truck, train flat car, ship deck, or any other appropriate launching location or surface. The modularity of the components used also allows scalability for higher energy UAV launches.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a side plan schematic view of one embodiment of a launching system, using an electric motor-driven power reel and a payout reel to move a shuttle along a tape.
FIG. 2 shows a perspective view of a launcher rail at an angle, without a shuttle in place.
FIGS. 3A-C show a launch series with a UAV being released from a shuttle.
FIG. 4 shows a side plan schematic view of the launching system of FIG. 1 , with the shuttle being detached from the tape.
FIG. 5 shows a side plan schematic view of a launching system that uses end sheaves for controlling winding of the tape.
FIG. 6 shows a side plan schematic view of a launching system with a shuttle that remains secured to the tape.
FIG. 7 shows a side plan schematic view of a launching system that uses a power reel, without a payout reel.
FIG. 8 shows a side perspective view of a launching system that uses a cable wrapped around a drum, driven by the motor, and pulleys on the shuttle.
FIG. 9 shows a free body diagram of the embodiment of FIG. 8 .
FIG. 10 shows a side view of a launching system with panels that can be used to help raise the tape for folding of the rail.
FIG. 11 shows a side plan schematic view of a launching system that uses a conveyor belt.
FIG. 12 shows a side view of an alternate conveyor belt system.
FIG. 13 shows a side view of a launching system using a steel cable wound around a drum and driven by an electric motor.
FIG. 14A shows one embodiment of a braking system that may be used for a launching system.
FIG. 14B shows a schematic view of the braking system of FIG. 14A .
FIG. 15 shows a side plan schematic view of a launching system in use.
FIG. 16 shows a schematic illustration of a mechanism that may be used to secure a shuttle to a cable.
DETAILED DESCRIPTION
UAV launchers may be offered with fixed or mobile installation, various rail options (telescoping rails or elongated fixed rails), manual or automated operation, and designed for a variety of UAV configurations and designs based on desired performance and cycle times. The systems described herein may be used on any of the various types of launching systems. In one embodiment, the launching system described may be mounted on a motor vehicle that can transport the launching system to the desired location for launch. The launch may occur while the system is on the vehicle, or the system may be removed from the vehicle for launch. In another embodiment, the launching system described may be installed at a fixed location.
As shown in FIG. 1 , in one embodiment, there is provided a launching system 10 that uses a motor-driven belt or tape mechanism 12 that is attached to a shuttle assembly 14 . The shuttle 14 is the carrier that transfers the energy required for launch to the UAV. As shown in FIG. 2 , the shuttle 14 may travel along a length of a launcher rail 16 . The launcher rail 16 is typically inclined. This incline may be achieved by struts 18 that rest on a surface or are secured to a surface. Struts may be secured to a base or pallet that may be mounted to a trailer, wheel base, flat bed truck, train flat car, ship deck, or any other surface or vehicle designed for launching. Alternatively, the struts may rest on a ground surface. The launcher rail 16 may be a fixed track of fixed length or it may have an extendable boom that elongates the rail. For example, the extendable boom may be hinged, such that it could be folded and the length would not be obtrusive to typical transport methods. In another embodiment, the extendable boom may be driven out from a retracted position, or may be extended in any other appropriate manner to elongate the launcher rail 16 into an extended track if needed. The launcher rail 16 length is typically contingent on the distance required to achieve the desired final launch velocity, without exceeding a pre-defined g-load threshold of the UAV, as well as the distance required to stop or arrest the shuttle. FIG. 2 also shows that one or more batteries 64 may be positioned on a base 66 , along with one or more motor control components 68 .
The launcher rail 16 may be used to guide the shuttle 14 along the drive length 20 of the rail 16 , in the direction of launch, illustrated by the arrow in FIG. 1 . (For ease of review, FIG. 1 does not show a launcher rail or an incline, although both would generally be incorporated into a final launch system.) As the shuttle 14 travels along the rail 16 , the motion of the shuttle 14 transfers the launch velocity to the UAV. ( FIG. 1 does not show a UAV secured to the shuttle 14 . FIGS. 3A-C show a potential launch sequence.)
Rather than securing a cable to the front of the shuttle, which is how most current launching systems work, the shuttle 14 is secured to a tape 12 that runs the length of the launcher rail 16 . More specifically, a belt or tape 12 is used to cause movement of the shuttle 14 along the launcher rail 16 . The shuttle 14 is generally secured to the tape 12 at a shuttle to tape interface 22 . This interface 22 may be any appropriate connection. In one embodiment, the shuttle to tape interface 22 may be provided as a pin 24 attached to the tape that cooperates with a corresponding structure on the shuttle 14 . This embodiment is shown in FIGS. 3A-C and 15 . For example, the undercarriage of the shuttle may have a hook 26 or some other detachable connection feature attached thereto that cooperates with the pin 24 . In another embodiment, the interface 22 may be formed from any type of upward protrusion 28 on the tape 12 that is shaped to cooperate with a lower protrusion or hook on the shuttle. In another embodiment, the interface 22 may be an non-detachable connection between the shuttle and the tape. In another embodiment, the interface may be formed as a clamp, where the shuttle secures two ends of the tape to one another at a location on the shuttle. Other connections are possible and within the scope of this disclosure.
In use, a UAV is secured to an upper surface of the shuttle 14 as shown in FIGS. 3A-C . The attachment of the UAV to the shuttle 14 may be via any appropriate connection currently in use or as may be developed, including any of the above described options. An abrupt stoppage of the shuttle 14 causes the UAV to launch off of the shuttle 14 .
The tape 12 may run along the drive length 20 of the launcher rail 16 . In one embodiment, its ends are generally secured to one or more of a payout reel 36 and/or a power reel 30 , as shown in FIGS. 1, 4-6, and 15 . In another embodiment, one end of the tape 12 may be detachably secured to the shuttle and one end is secured to a power reel, as shown in FIG. 7 . In another embodiment, a cable is used, and the cable is wrapped around a drum, driven by the motor, as shown in FIGS. 8-9 . In another embodiment, the tape 12 is a continuous tape that runs as a conveyor belt along the launcher rail, as shown in FIGS. 11-12 . In another embodiment, a steel cable or rope may be wound around a pair of drums 90 , as shown in FIG. 13 . In another embodiment, an alternate braking system may be provided, as shown in FIGS. 14A-B . Each of these embodiments is described in further detail below.
The tape 12 may be formed of a material that has more elasticity or stretch than cables used in typical launching systems. For example, the tape 12 may be formed from nylon, a nylon blend, or another synthetic material. In some embodiments, the tape may be formed of a material that has an amount of inherent stretch. The stretch inherent in the material used can help mitigate the g-force during the initial application of launch load. However, the stretch of the material is not required. In other embodiments, tapes or belts containing metallic reinforcing fibers may be used. The electronic control system in conjunction with the electric motor can be used to tightly control the acceleration profile of the launch cycle.
In the embodiment shown in FIG. 1 , a tape 12 is attached at one end to a power reel 30 , which is mounted to a drive shaft 32 of an electric motor 34 . Details of the electric motor are described more below, but in one embodiment, the electric motor 26 may be a DC motor. The electric motor 34 is what drives movement of the tape 12 . In use, the electric motor 34 remains stationary with respect to the launcher rail 16 and the remainder of the shuttle guiding components.
The opposite end of the tape 12 may be attached to a payout reel 36 . As shown in FIG. 1 , the payout reel 36 may generally be positioned near a battery position end 38 , and the power reel 30 is generally positioned near a launching point 40 of the launching system 10 . Once the electric motor 34 is energized, the motor rotates the power reel 30 , which winds in the tape 12 from the payout reel 36 . This winding of the tape 12 accelerates the shuttle 14 , which is attached to the tape 12 (and consequently accelerates the UAV, which is attached to the shuttle 14 ). The payout reel 36 contains at least a sufficient length of tape 12 that allows full travel of the shuttle 34 up the rail.
As shown in FIG. 1 , the shuttle 14 may be connected to the tape 12 via a hook 26 (or some other detachable connection on the undercarriage of the shuttle 14 ) that attaches to an interface 22 on the tape. In the embodiment shown, the interface 22 is provided as a pin, protrusion 28 , or other raised structure that can interface with the shuffle hook. Actuation of the electric motor 34 causes movement of the shuttle 14 along the power zone 100 . The shuttle 14 accelerates to launch velocity over the entire length of the tape 12 in this zone 100 . It should be understood that the rail is not shown in FIG. 1 and that there will be sufficient rail length beyond the shuttle to tape separation point 40 in order to bring the shuttle to an abrupt stop.
FIGS. 3A-C show a sequential series illustrating a shuttle 14 with a UAV 70 positioned thereon, and its travel along the tape 12 . In FIG. 3A , the shuttle 14 is shown traveling along the rail 16 . In FIG. 3B , the shuttle 14 is shown engaging an arrestment strap 72 . The arrestment strap 72 functions to stop forward momentum of the shuttle 14 . In this figure, the shuttle 14 has just engaged the arrestment strap 72 and the UAV 70 is ready to depart the shuttle 14 . In FIG. 3C , the arrestment strap 72 has stretched to absorb shuttle energy, and the UAV 70 has been released.
In some examples, when the shuttle 14 reaches a shuttle to tape separation point 40 or another launching point, the shuttle 14 may be released from the tape 12 . This release generally occurs once the interface 22 on the tape is wrapped around the end of the power reel 30 , as shown in FIG. 4 .
In the embodiment of FIG. 4 , the shuttle 14 is allowed to release from the tape 12 . A shuttle 14 that separates from the tape 12 can eliminate the need for precise timing because the tape does not have to stop at a particular point. Stopping the released shuttle 14 may be accomplished via an arrestment strap, a braking mechanism at the end of the rail, a braking system on-board the shuttle itself, or any other appropriate system. As shown in FIG. 4 (and as also illustrated by the launch series of FIGS. 3A-C ), an abrupt stop of the shuttle 14 in the shuttle braking zone 102 may release the UAV from the shuttle 14 . (This may be in addition to the shuttle 14 also releasing from the tape 12 .)
In the embodiment shown in FIG. 5 , end sheaves or pulleys that provide a path for the tape may be mounted on or below or otherwise with respect to the launcher rail 16 . A first sheave 46 may be mounted at the battery position end 38 . A second sheave 48 may be mounted at or near the launching end 40 . In another embodiment, the second sheave 48 may be mounted at some length before the launching end 40 of the rail 16 in order to allow distance for the shuttle 14 to be arrested at the end of the power stroke. In use, the first sheave 46 routes the tape 12 from the payout reel 36 over the upper horizontal surface 50 of the launcher rail 16 to the second sheave 48 . The tape 12 may then be routed over the second sheave 48 down to the power reel 30 . The power reel 30 and the payout reel 36 may be mounted to the underside of the launcher rail 16 , as shown in FIG. 5 . In an alternate embodiment, the power reel 30 and the payout reel 36 may be mounted to a base on which the launcher rail 16 may be mounted.
Use of first and second sheaves 46 , 48 can lend advantages to the system 10 . For example, the increase in the diameter of the power reel 30 due to the tape 12 being wrapped onto it during the power stroke could lead to interference with the shuffle 14 . Routing the tape 12 over an end sheave 48 and positioning the power reel 30 underneath the launcher rail can lessen the chance that the increase in the tape 12 stack could impact movement of the shuttle 14 . Likewise, the same condition exists at the payout reel 36 end, but the diameter of the tape 12 on the payout reel 36 decreases during the power stroke, due to the tape 12 being pulled from the payout reel 36 . This could also lead to the tape 12 interfering with the launcher rail 16 . Positioning the payout reel 36 under the launcher rail 16 also provides space at the battery position end 38 of the rail, where the UAV is to be loaded onto the shuttle carriage 14 . Additionally, the added distance between the power reel end sheave 48 and the power reel 30 itself can allow the power stroke to be shut down prior to when the shuttle/tape interface 22 would be wrapped onto the power reel 30 . Wrapping tape 12 over this interface 22 could potentially deteriorate the tape.
In another embodiment shown in FIG. 6 , the shuttle 14 may be non-removeably secured to the tape 12 . For example, the undercarriage of the shuttle 14 may feature a connection that completely captures the shuttle to tape interface 22 , which may be a pin or other component secured to the tape 12 . The tape 12 may be manufactured from a continuous strip of material. In another example, the tape 12 may be manufactured from a non-continuous strip of material. For example, if the tape 12 is not fabricated from a single continuous strip, two sections can be used and connected to the tape interface 22 . Using two tape sections may be advantageous in that the section connected to the braking reel could be fabricated from a different and potentially higher strength material to help aid in braking the weight of the shuttle. This interface 22 generally prevents the shuttle 14 from disengaging from the tape 12 . As shown, the shuttle 14 stops in a braking zone 102 before the end of the rail. The UAV is released from the shuttle 14 in this braking zone 102 . The tape 12 may be used to arrest the shuttle 14 via a braking system 54 contained on the payout reel 36 . In one embodiment, electrically actuated brakes may be used to prohibit the use of hydraulic fluids or pneumatic brakes. An optional arrestor strap or secondary braking system (as described previously) may also be used to supplement the shuttle 14 arrestment.
In another embodiment, the payout reel 36 could be eliminated, as shown in FIG. 7 . In this embodiment, the power reel 30 is used to accelerate the shuttle 14 and the tape 12 . The power reel 30 may be associated with the electric motor 34 as described above. After the shuttle 14 disengages, the tape, including the interface/pin 22 , would wrap completely around the power reel 30 . The shuttle 14 arrestment may be through an arrestment strap, a rail based brake, or an on-board shuttle brake.
Another embodiment may use a cable 78 that is wrapped around a drum 82 , driven by the motor 84 . One example of which is shown in FIGS. 8 and 9 . In this embodiment, the shuttle 14 has two pulleys 74 , 76 located on its lower surface. One pulley 74 may serve as the launch guide for the cable 78 . The other pulley 76 may serve as an arresting guide. A braking drum 80 may act as an anchor point for launch. A winding drum 82 reels in the cable 78 to propel the shuttle 14 down the rail 16 . Two fixed pulley assemblies 120 , 122 may be located along the rail 16 , mounted to opposite sides of the rail 16 . Each fixed pulley assembly 120 , 122 may actually comprise two or more pulleys, as shown. In the embodiment shown, the fixed pulley assemblies 120 , 122 may be located on the rail 16 , at the location where the cables come in from the braking drum 80 and the winding drum 82 . The cable 78 pulls against pulley 76 (on the shuttle) until the shuttle 14 crosses the rail section where the cables come in from the braking drum 80 and the winding drum 82 . At that point, the cable 78 flips to pulley 74 on the shuttle for the braking action. This may be referred to as “flexing.” Accordingly, when the shuttle 14 crosses the point on the rail 16 where the two fixed pulley assemblies 120 , 122 are located, the cable 78 transitions from the shuttle's launch pulley 76 to its arresting pulley 74 . The winding drum 82 may be stopped with a brake. The braking drum 80 may allow some pay-out of the cable 78 as it brings the shuttle 14 to a stop. FIG. 8 also shows an arresting strap 72 in place along the rail 16 . The strap 72 extends along either side of the rail with a center strap portion 73 crossing over the rail.
In a specific example, a synthetic rope may be used as the cable 78 . This may help alleviate possible issues with flexing a steel cable around a small pulley and then reversing the direction of flex suddenly.
Many of the particular designs described herein have generally used a flat tape 12 that runs almost the entire length 20 of the launcher rail 16 . In some embodiments, the rail 16 may need to be folded for transport and the tape may lie perpendicular to the direction of the fold. In this case, it is possible to provide a set of “paddles” 86 that may be added to the rail sections 16 adjacent to hinges. One example of this is shown in FIG. 10 . The paddles 86 may be provided in order to raise one edge of the tape 12 above the rail flanges 17 , such that the paddles 86 facilitate folding of the rail 16 through the thin section of the tape 12 . The paddles 86 may tilt the tape 12 at an angle to allow it to fold through its thin section. In another variation, the tape 12 could be mounted at about 90 degrees to this design such that the flat section would be in the plane that the hinge rotates.
In a further embodiment shown in FIG. 11 , a conveyor configuration may be used. In this embodiment, one or more electric motors 34 drive a pulley that moves a continuous loop belt or chain 56 . The continuous loop belt or chain 56 can engage the shuttle 14 in any of the above-described ways. Once the shuttle 14 reaches the end of the power stroke, it disengages from the belt 56 . The shuttle 14 may be arrested via an arrestment strap or any other braking system. In another embodiment, the shuttle may be securely attached to interface 22 and the braking forces applied through the conveyor belt.
FIG. 12 shows a schematic of an alternate conveyor concept. This concept utilizes a shuttle 14 that is restrained to a drive belt 56 as the tape 12 that provides a continuous loop. The shuttle 14 may function as a clamp that holds the end of the belt together. A drive motor 34 may connect to an input shaft 104 . A drive pulley 106 may be connected via a sprocket and chain to the drive motor output shaft or it may be directly connected to the motor output shaft. Shuttle braking may be accomplished by variable electric braking, by an arresting strap variation, or by any other appropriate method. In this embodiment, the shuttle is connected directly to the belt to form the continuous loop. This implies that the shuttle must be stopped prior to reaching the end pulley 108 during a launch or the shuttle would attempt to wrap around 108 . Another embodiment may have the shuttle 14 disconnect from the drive belt prior to reaching pulley 108 .
An alternate launching embodiment is shown in FIG. 13 . This concept may use a continuous steel rope 88 wound around a pair of drums 90 which have spring tension forcing them apart and applying force to increase friction between the steel rope 88 and the drums 90 . One of the drums may be coupled to the drive motor assembly 92 through a belt or chain. This allows the capstan drums 90 to be mounted to the rail for ease of rail tilting for adjustment of launch angle. The shuttle 14 may be attached to the rope 88 by a mechanism 126 similar to that used for a ski lift. At the end of the stroke, variation in the shuttle wheel guide space can allow a clamping mechanism to open, and the shuttle 14 can freewheel into an arresting strap.
In one example, as shown in FIG. 16 , the clamping mechanism 126 may be attached to the bottom of a shuttle and may be used to secure the shuttle to the cable. In the clamped position, wheels 128 may ride within rail slots in order to constrain the clamp mechanism. Upper rail guides 134 may hold the cable gripping jaws 132 closed such that the gripping jaws 132 are clamped over cable 88 . In the released position, the jaws 132 release. This can be accomplished when the wheels 128 , which may be spring-loaded wheels, proceed beyond the upper rail guide 134 . In one embodiment, the upper rail guides are tapered along the length of the rail to allow transition from the open to the clamped position.
In another embodiment, an alternate braking mechanism may be provided. One example is shown in FIGS. 14A and B. This variation provides an arresting tape 97 that may be attached to the shuttle. For example, the back end of the shuttle 14 may be connected to an arresting tape 97 that trails behind the shuttle. The arresting tape 97 can be wound onto the tape reel 96 with a clutch, brake, and rewind motor. The launch tape 12 may be secured to the shuttle 14 using any of the options described herein. The launch tape may be driven by the drive motor assembly 94 for moving the shuttle 14 along the rail 16 as described herein. The drive reel 92 is shown directly to the right of the braking reel 96 , and a sprocketed drive reel 124 is shown just under the drive reel 92 . As shown, a sprocket 124 and chain may be used between the motor 94 and the drive reel 92 . FIG. 14B shows a schematic of this braking option.
The launch tape 12 and the arresting tape 97 may be of different materials to obtain different performance characteristics. Although this may add drag to the system, it allows for automatic rewind and can provide a “hands off” arrangement. This may provide a launching system that can be a self-deploying launcher.
For this braking embodiment, the timing of the launch to arrestment sequence may be critical. The shuttle 14 can be traveling up to about 140-145 feet per second when the transition from launch to arrestment takes place. The timing of the launch signal may be delivered from a Programmable Logic Controller (PLC) to a drive controller in order to shift the motor from powered launch to coast, while engaging the brake. A fast responding and repeatable brake may be provided to ensure success. This system may be provided with an electric brake to eliminate the need for hydraulic braking systems. However, a hydraulic brake may be used. The brake may be variable in order to adjust to different weights and speeds.
FIG. 15 shows one embodiment of a launcher system 10 with the launcher rail 16 inclined at an upward angle, and with the shuttle 14 positioned on the tape 12 on the rail 16 . This embodiment provides a battery position sensor 58 , which is activated when the shuttle 14 is in a battery, or pre-launch, position. When the shuttle 14 is pulled back to the battery position, it activates sensor 58 . Activation of the sensor 58 activates a brake on the payout reel 36 to keep the tape taught. (In some embodiments, for safety purposes, the launch sequence cannot be initiated unless the shuttle has been secured in the battery position.) When launch is activated, the electric motor 34 is energized and the brake on the payout reel 36 is disengaged. Disengaging the brake allows the shuttle 14 to move along the rail 16 . The motor 34 activates the power reel 30 to wind the tape, causing movement of the tape 12 and the attached shuttle 14 . A power reel shutdown sensor 60 may be positioned along the rail 16 , toward the launching end 40 . When the shuttle 14 reaches this sensor 60 , a signal is sent to the motor 34 to stop movement of the power reel 30 and/or to activate payout reel 36 brakes. The tension in the tape 12 created by the stopping and/or braking action abruptly stops the shuttle and causes release of the UAV. If the embodiment in which the shuttle releases from the tape 12 is used, then the shuttle may be stopped by an arrestment strap or other stopping features, which abruptly stops the shuttle and causes release of the UAV.
In many of the above embodiments, the electric motor 34 is shut down immediately prior to the arrestment of the shuttle 14 such that the motor does not continue to supply power and potentially damage the shuttle or drive mechanisms. The payout reel 36 may also be connected to a rewind motor that can retract the tape 12 into the battery (or launch) position such that another UAV could be quickly loaded and readied for launch. Applying the power stroke by reeling in tape 12 in this manner to achieve the launch velocity is not used on any other commercially available launchers.
In some embodiments, it has been found that a DC motor provides desirable driving features and speeds. The electric motor may be used in conjunction with a battery system to enhance portability. The battery may be a Lithium Ion battery system. The electric motor may also be used in conjunction with a Programmable Logic Controller (PLC). The PLC can allow the motor RPM (revolutions per minute) to be adjusted as required throughout the launch sequence to provide a controlled acceleration and thus mitigate the high initial G-spikes typical of a hydraulic/pneumatic system. Use of a PLC also allows the ability to dial in the launch loads, making it easy to adjust for weight or speed variances and eliminating the need for time consuming changes to the launch pre-pressure by adding or purging gas from the system. For example, the G force may be minimized by programming the shape of the G force curve in the controller.
The functions of the PLC could possibly be integrated into drive control functions and be combined into one unit. Alternatively, the PLC may be a separate component that can be optionally added to the system.
One specific embodiment of a motor that may be used with the electric launcher is a DC motor propulsion system and controller. This motor can be powered by a Lithium Ion battery. Other types of electric motors may be used. For example, an AC motor with a similar torque output may be used. However, it is believed that such an AC motor would be significantly larger and heavier than the DC motor. The DC motor was chosen for the initial application based on the ability of the batteries to supply a surge of current that is typically not available from AC power sources. Alternately, AC power with suitable transformers and discharge capability could be used to power the DC motor.
Additionally, more than one motor can be used to provide the load required for launch. Through modularization, it is possible to use multiple motors to scale up the system to accept UAV's with greater weight or where increased power is required for higher launch velocities.
Use of one or more electric motors means that the acceleration achieved can be tightly controlled along the entire length of the power stroke without the need for complicated control valves and manifolds required on hydraulic/pneumatic systems. In pneumatic and pneumatic/hydraulic systems, the maximum acceleration typically occurs at the beginning of the launch because this is where the system pressure is at its maximum. As gas expands into the cylinder, the pressure drops and the force applied to the shuttle decreases. By contrast, a constant acceleration can be provided over the entire launch stroke utilizing the electric motor-driven tape described herein, because the motor RPM can increased throughout the stroke. The use of the DC motor in conjunction with the PLC to accurately control the launch profile is a unique to many of the above-described problems with commercially available launch systems.
The use of the tape 12 , which may be fabricated from nylon or some other synthetic material, offers a degree of cushioning during the initial application of the launch load since there is an inherent amount of stretch associated with this type of material. Most hydraulic/pneumatic systems connect the drive cylinder to the shuttle via a steel cable that does not have as much compliance or stretch during the application of the load and can exacerbate the g-load spikes seen. Use of a tape that has some cushioning, flexibility, stretchability or other features that allow a slight elongation and retraction of the material can be beneficial in the launching systems disclosed. It should be noted, however, that the stretch in the synthetic tape or belt is not required. Tapes or belts containing steel reinforcing fibers that would lesson or eliminate stretch may also be used. The use of a shuttle to tape interface allows the ability to control the acceleration by programmatically increasing the launch speed. This can be a prime contributor to eliminating the g-load spikes that occur with other systems.
The use of the Lithium Ion battery power source and electric motor as the drive mechanism can greatly reduce the overall system weight when judged against a comparable system containing the required hydraulic/pneumatic components (accumulator, pump, launch cylinder, gas bottle, reservoir, weight of hydraulic fluid, and so forth). It also allows for greater flexibility in the layout of the system and the ability to potentially modularize some of the subsystems. The components used may be smaller and do not require large tubes or pipes to route the pressured hydraulic fluid or gas. Power cables or flexible bus bars containing connectors can be used to route DC current from the battery to the motor. This will allow rapid replacement of a discharged battery unit.
It should be understood, however, that the battery need not be Lithium ion. Any other battery system capable of providing the required load and discharge rates may be used. Lithium Ion was chosen for an initial application due to its low weight and rapid discharge characteristics. It is expected, however, that other battery types and systems may be used in connection with this disclosure.
Since there are no pressure vessels utilized in this disclosure, the problem of gas or hydraulic leaks has been eliminated and the overall safety of the system has been enhanced. In many of the hydraulic/pneumatic systems, the cylinder and possibly the accumulator are attached to the rail. The accumulator is often piped over to a large gas bottle that serves as a reserve vessel to store pressured GN 2 . Due to the piping between the various hydraulic and pneumatic components, it can be difficult to allow the rail to move relative to the base if an adjustable launch angle is desired. By contrast, the ability to mount the drive motor 34 and payout reel assembly 36 to a base plate or pallet under the launcher rail 16 allows the rail to be unencumbered by excess weight and complexity. Utilizing a tape path that routes around the two end sheaves 46 , 48 on the rail can allow the rail to be pivotable about an axis 62 to provide an adjustable launch angle. In an alternate embodiment, the drive pulley may be driven by the motor via a sprocket and chain. One example of this is shown in FIG. 14A .
In most operational specifications, the deployment and tear down time of the launching system are critical parameters. The time to set-up the system, bring it to ready mode, perform a launch, and then reset the system for subsequent launches is crucial. Because there is no time associated with a pressurization cycle or spinning up a flywheel when using this battery/motor/tape combination, the time to energize the system, which involves charging up a set of capacitors to achieve a ready signal following system set-up, is minimal. The batteries can be sized to achieve a number of launches before recharging is required. In a specific embodiment, the batteries can be sized to allow four launches to be achieved prior to recharging or before battery replacement is required. More or fewer launches may be provided per charge, depending upon the size of the battery selected, the weight of the UAV to be launched, and the speed of the motor required. Additional battery packs could be charged separately and swapped out to continue operation in the field without waiting for on-board batteries to recharge. In one embodiment, quick disconnects may be provided to speed the battery change over process. A greater number of launches may be possible with a larger battery configuration, but this would impact system weight. The weight to launch cycles can be optimized based on the customer requirements.
In addition to the faster time to launch, the reset time for the disclosed system is faster because retraction of the shuttle does not require the movement of hydraulic fluid back into the reservoir typical of hydraulic/pneumatic launchers. To further enhance the reset time, the payout reel 36 could be motorized to retract the shuttle 14 back into the battery position 38 .
In the systems described, in one example, the operator's station may be wired, but remote from the launcher. In another example, the operator's station may be made wireless. The systems may be designed so that once set up with a UAV, they may be remote controlled.
Changes and modifications, additions and deletions may be made to the structures and methods recited above and shown in the drawings without departing from the scope or spirit of the invention and the following claims.
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Embodiments of the present invention provide improvements to UAV launching systems. The disclosed launching system eliminates the use of hydraulic fluid and compressed nitrogen or air by providing an electric motor-driven tape that causes movement of a shuttle along a launcher rail.
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REFERENCE TO RELATED APPLICATION
[0001] Under 35 U.S.C. § 119(e) this application claims the benefit of U.S. Provisional Application No. 60/657,676 filed Mar. 1, 2005, which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a nutritional composition comprising an entire daily dose of a quinone, for example, ubiquinone, but substantially avoids the problem of quinone recrystallization. In another aspect the invention relates to a ubiquinone-containing composition with improved solubility, bioavailability, and storage capabilities. In other aspects, the invention relates to a composition comprising an entire daily dose of at least one active ingredient, for example, a ubiquinone and, optionally, at least one pharmaceutically acceptable excipient.
BACKGROUND OF INVENTION
[0003] Ubiquinone or coenzyme Q10 (CoQ10) is an essential antioxidant found in every cell in the body, and is especially concentrated in heart tissue. CoQ10 functions in the mitochondria where it is a critical component of the electron transfer chain, which produces the energy required for a cell's survival. The electron transfer function of CoQ10 is mediated by its ability to undergo cycles of oxidation and reduction within the mitochondrial inner membrane. Due to the action of dehydrogenases within the mitochondria, CoQ10 is efficiently reduced by the acceptance of electrons. It is the ability to subsequently donate electrons or reduce downstream components of the transport chain that results in the critical proton gradient, which mediates the production of cellular energy. This step in the electron transport chain is so critical that the equilibrium is shifted nearly completely to the right in favor of reduced ubiquinone (i.e., ubiquinol). This ensures that the reduction of ubiquinone is not the rate limiting step in energy synthesis. Therefore it is not surprising that essentially all the CoQ10 found in the body is in the reduced form. CoQ10 can only be reduced through the action of dehydrogenase enzymes but once it is reduced CoQ10 also functions as a key antioxidant. Recently it has been shown that reduced CoQ10 is important for the antioxidant activity of vitamin E (tocopherol) in the prevention of lipid peroxidation.
[0004] It is estimated that the total CoQ10 content in the body is about 1.5 to about 2 grams. Generally, plasma CoQ10 baseline values range from about 0.60 to 0.80 μg/ml plasma. Assuming a typical individual circulates about 3000 ml of plasma; that means there is approximately 2 mg of CoQ10 in the blood. Only about 3-5 mg is thought to be consumed by humans on a daily basis, mostly from meat and poultry sources. Early studies on CoQ10 indicate that dietary supply contributes 50%, while the other 50% is internally produced. The body normally produces all-trans CoQ10, which can also be produced commercially by microbiological fermentation (Kaneka Q™ brand).
[0005] Certain factors accelerate normal metabolic loss of CoQ10. For example, the administration of some pharmaceuticals, such as statins for the lowering of blood cholesterol, can result in up to a 70% CoQ10 reduction in blood plasma, and cause potentially serious side effects. However, because the majority of CoQ10 is not in the blood it is difficult to estimate the amount of CoQ10 that would replenish the losses caused by statins. Some studies suggest that 50-100 mg of CoQ10 per day would be required to counteract a (roughly) 50% drop in plasma CoQ10, and presumably, whole body CoQ10.
[0006] Several problems confound the simple administration of CoQ10. The first is that it is relatively insoluble (i.e. hydrophobic), making administration of high doses impractical. Because of CoQ10's low solubility in aqueous solutions and its relatively high molecular weight (863.36 daltons), orally administered CoQ10 is very poorly absorbed. The poor absorption results in a low percentage of the administered dose being bioavailable, even at relatively large doses. For example, studies indicate that administration of 300-1200 mg/day of CoQ10 only results in a plasma CoQ10 concentrations of 3-4 μg/ml.
[0007] Next, the oxidized form of CoQ10 is not effective as an antioxidant until it has been reduced. In vivo this requires the interaction of dehydrogenases present only in the mitochondria of cells. Futhermore, the spontaneous oxidation of reduced CoQ10 makes production and storage problematic.
[0008] The use of nutritional or dietary supplements to reduce cholesterol is continuing to grow as an alternative to prescription medications. However, currently available CoQ10 supplements are of limited usefulness due to minimal CoQ10 bioavailability related to low absorption, CoQ10 recrystallization, oxidation or a combination of both. In addition, currently available CoQ10 supplements require multiple doses per day, making consumption of adequate dosages problematic.
[0009] These shortcomings may be addressed by delivery of a single, solubilized, high-concentration CoQ10 composition. Therefore, there exists an overwhelming need for a CoQ10 supplement that is comprised of natural ingredients that are effective, without the significant side effects which addresses the current shortcomings in the art.
SUMMARY OF THE INVENTION
[0010] The current invention relates to a quinone composition, for example, ubiquinone that is present in a form that provides for adequate bioavailability, eliminates the problem of recrystallization, reduces or eliminates the need to take multiple daily doses as well as prevents the oxidative damage to the nutrient components.
[0011] The present invention relates generally to a nutritional composition comprising a quinone compound, for example, ubiquinone or CoQ10, and at least one of an emulsifier, water, additional nutrients, a reducing agent, a solubilizing agent, an oil, a volatile or essential oil, flavoring, excipients, another biologically active agent or combinations thereof.
[0012] Emulsifiers utilized in any of the embodiments of the invention include, for example, a phospholipid, for example, a lecithin or phosphotidylcholine; a monoglyceride; casein; gums or modified gums (for example, Arabic, Xanthin, Acacia, or the like); egg yolks; or Phosall 75SA (phophatidylcholine and glyceryl monostearate), with casein and ticamulsion (modified gum arabic); a polyoxyl, for example, Cremophor; medium chain glycerides or combinations thereof. It will be understood by one of ordinary skill in the art that the relative viscosity of the emulsion may be varied by altering the proportions of the various ingredients. As such, emulsions demonstrating a range of potential viscosities are contemplated and should be considered as being within the scope of the present invention.
[0013] Solubilizing agents utilized in any of the embodiments of the invention include, for example, an oil, a glyceride or triacylglyceride, volatile or essential oils (for example, terpenes (hemi-, mono-, diterpenesl; for example, the monocyclic monoterpene, limonene, and the like) isolated from peppermint, orange, menthol, spearmint, anise, lemon or mixtures thereof), fibersol-2, maltodextrin, polyoxyethanyl-sitosterol sebacate, polyoxyethanyl-cholesteryl sebacate or polyoxyethanyl-.alpha.-tocopheryl sebacate.
[0014] The use of essential oils to increase solubility of an insoluble agent, for example, CoQ10, has been demonstrated in U.S. patent application Ser. No. 10/293,932 (U.S. Patent Pub. No.: US2003/0147927A1) to Khan et al., which is hereby incorporated in its entirety for all purposes. In particular, Khan shows binary mixtures of CoQ10 with essential oils (e.g., peppermint, spearmint, anise, lemon, and menthol) that results in increased solubility of the CoQ10. However, Khan does not show whether bioavailability is increased nor does it show a high-concentration dose of CoQ10 suitable for once-daily administration. While essential oils, for example, lemon or orange, may contain 90-99% limonene some evidence suggests that crude extracts may also contain agents known to cause phototoxicity (e.g., oxidized limonene or limonene-1,2-oxide; furocourmarin; oxypeucedanin; and bergapten). Therefore, in any of the embodiments described herein, the inventors contemplate the use of purified limonene, for example, D-limonene, the major limonene enantiomer produced in nature. The hermetically sealed CoQ10 composition of the invention also provides the addition benefit of essentially eliminating any oxidation of limonene making it particularly useful for topical use.
[0015] The reducing agent may be, for example, antioxidants, polyphenols, flavonoids, thiols tocopherols, carotenoids, or water-soluble reductants, for example, riboflavin, glutathione, or ascorbate. In a preferred embodiment, the proportion of reducing agent present is sufficient to result in the reduction of substantially all of the ubiquinone (1, see below) to ubiquinol (2, see below). In an additional aspect, the invention relates to an ubiquinol-containing composition containing a solubilizer present in a suitable volume and concentration to substantially eliminate recrystallization of the ubiquinol, and improve absorption and bioavailability. Non-ionic detergents or surfactants may also be useful in the composition of the invention to increase the bioavailability of the CoQ10. In addition, the nutritional composition of the invention may contain other biologically active agents, nutrients, and/or excipients in addition to CoQ10 at varying ratios. Additional ingredients may be added to provide desired qualities in the product, such as, for example, excipients or additives which will cause the nutritional composition to have an attractive or pleasing taste, consistency, prolong shelf-life or additives that provide additional nutrients, for example, a fatty acid, a lipid, a carbohydrate, an herbal extract, a mineral, a vitamin or any combination thereof.
[0016] To minimize oxidation and recrystallization of the ubiquinol, the nutritional composition is packaged, stored, and transported in a hermetically sealed container that contains the nutritional composition. The nutritional compositions may be prepared in a substantially air or oxygen free condition, placed in the container, and hermetically sealed to prevent exposure of the nutritional composition to oxygen. The container may be made from a material, such as a foil, which is substantially impermeant to air, and light so that there is no substantial oxidative or UV-induced damage to the CoQ10, thereby substantially extending the mixture's shelf-life and substantially preserving the beneficial properties of the CoQ10. In one embodiment, the volume inside the container is substantially the same as the volume of the nutritional composition contained therein, such that substantially no air spaces exist within the container.
[0017] The hermetically sealed container may be sized to contain substantially an entire daily oral dose of CoQ10, obviating the need for an individual to consume excessive quantities of a CoQ10-containing liquid or swallow numerous large capsules several times per day. In one embodiment, the container is substantially sturdy and flexible, for example a plastic bag, or a foil packet such as is used with food condiments. In this form the nutritional composition is substantially more convenient to transport, store, and use. As one of ordinary skill in the art will recognize the hermetically sealed container may be of any suitable material, size, shape, or color, and the above embodiments are given by way of nonlimiting example.
[0018] Among the advantages of the invention is that the CoQ10 can be made, stored and transported in a manner which substantially increases the shelf-life of the nutritional composition, and may substantially decrease or eliminate the requirement for the addition of preservatives. Another advantage is that the nutritional composition may provide for easy consumption of an entire daily oral dose. These advantages are given by way of example and are in no way intended to be limiting. Other advantages of the present invention will become apparent to those skilled in the art in view of the following detailed description of preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 shows one embodiments of a hermetically sealed packet containing a ubiquinone composition.
DETAILED DESCRIPTION OF THE INVENTION
[0020] As is used herein, the terms “quinone” and “ubiquinone” are used generally to refer to both their oxidized and reduced forms, except where specifically distinguished. For example, the term “ubiquinol” can be substituted anywhere that “ubiquinone” is used and vice versa, except where the specification makes a clear distinction to one form or the other. Furthermore, the term “quinone” is used in a general sense to include any suitable quinone, such as, for example, a benzoquinone, tocoquinone, plastoquinone, coenzyme Q10 or ubiquinone, menaquinone, or phylloquinone, and is further understood to encompass the oxidized or reduced forms.
[0021] In a preferred embodiment the composition includes a quinone, and at least one of a solubilizing agent, an emulsifier, and optionally a reducing agent, flavorings, excipients or preservatives contained in a hermetically sealed packet at concentrations that increase the bioavailability, and inhibit recrystallization of CoQ10. In another embodiment of the current invention other biologically active agents or nutrients may be included in the CoQ10 composition to further enhance, for example, the beneficial health effects of CoQ10 or to provide other health benefits when the composition is administered. Nutrients which may be included in the CoQ10 composition include, for example, a fatty acid, a lipid, a carbohydrate, water, an herbal extract, a mineral, a vitamin or any combination thereof.
[0022] Pharmaceutically acceptable excipients or carriers may be used to create a suitable form or consistency for administration to an individual, and may include, for example, dicalcium phosphate, silicon dioxide, modified cellulose gum, stearic acid, magnesium stearate, modified cellulose or any combination thereof. In addition, non-ionic detergents and surfactants, for example, polysorbate 80, quillaja extract or the like could be added to increase bioavailability.
[0023] In one aspect, the nutritional composition comprises an oil-in-water emulsion. To reduce the amount of oxygen present in the composition, the water may be made substantially air free, for example through boiling under conditions of negative pressure, such as under a vacuum. The oil-in-water emulsion is made using any appropriate technique for producing an oil-in-water emulsion known to those skilled in the art. Preferably, the emulsion is made in an inert atmosphere to prevent oxygen from being entrained in the emulsion. For example, the emulsion may be produced in a nitrogen atmosphere.
[0024] In another aspect, the nutritional composition comprises an amount of CoQ10 suitable for a single daily dose and an essential oil disposed in a hermetically sealed container that is substantially free of oxygen. In a particular embodiment, the composition comprises from about 90% to about 99% reduced CoQ10, and an essential oil disposed in a hermetically sealed container which is substantially impermeable to oxygen.
[0025] The nutritional composition preferably comprises from about 2% to about 90% by weight CoQ10, from about 10% to about 80% of an oil, for example, an essential oil; and optionally, from about 1% to about 20% of an additional component for example a carrier, an excipients, antioxidant, flavor enhancers, additional active ingredients or nutrients or combinations thereof, the remaining percentage to be made up by water or other solvent.
[0026] In another embodiment, the nutritional composition contains from about 20% to about 70% of an oil, for example, an essential oil; from about 1.5% to about 10% by weight CoQ10; and optionally, from about 5% to about 15% of an emulsifier or solubilizer, the remaining percentage to be made up by water or other solvent. Using the proportions described results in a composition which is more viscous than water alone, and reduces the total volume of the composition required to provide a single daily oral dose of CoQ10. As discussed above, the nutritional composition may contain additional components to impart additional desired characteristics or nutrients to the composition.
[0027] In an embodiment of the invention, the nutritional composition contains the following components:
1. Medium Chain Triglycerides 63% by weight 2. Water 24% by weight 3. Emulsifiers 9% by weight 4. Ubiquinone 2.5% by weight
[0028] The remainder, up to 100% is made up of flavoring, reducing agents, excipients, and preservatives. The composition of the particularly preferred embodiment weighs about 4 grams and will deliver about 100 mg of CoQ10 in a single dose.
[0029] In an embodiment of the invention, the nutritional composition contains the following components:
1. Essential Oil 30% by weight 4. Ubiquinone 60% by weight
[0030] The remainder, up to 100% is made up of flavoring, reducing agents, excipients, and preservatives.
[0031] It is desirable to prepare the nutritional composition in a manner which minimizes exposure of the CoQ10 to oxygen during preparation and storage. In a preferred embodiment the composition may be packaged in a hermetically sealed container to prevent exposure to oxygen during transportation and storage. Minimizing the oxygen content and exposure of the nutritional composition reduces or prevents oxidation and degradation of the CoQ10 in the composition.
[0032] In one embodiment the body portion of the container may be comprised of a flexible, liquid impervious material, for example plastic. In a preferred embodiment the container may be a foil packet similar to those used for transport and storage of food condiments as shown in FIG. 1 . The foil packet 10 may be any desired shape. In the embodiment shown in FIG. 1 , the packet is generally rectangular in shape. The edges of the packet 20 , 25 , 30 , 40 are heat sealed to hermetically seal the packet. The compositions described above are contained within the packet in a volume 50 . The packet may be sized to hold any pre-selected volume of the composition. A notch 35 may be provided at one end of the packet to provide a location for easy tearing of the packet to allow access to the contents of the volume 50 .
[0033] The invention is not limited in this regard, and any appropriate material or means for providing a hermetically sealed container for the composition may be used. For example, in another embodiment the container is in the form of a sealed bag or a pouch. However, as will be understood by one of ordinary skill, the container may be of any suitable shape, size, or color. Additionally, while the container of the preferred embodiment may be constructed out of flexible plastic or foil, it will be recognized by one of ordinary skill that this is not absolutely required. The container may be constructed of any of various materials, and be any of various degrees of rigidity, so long as the substantial air-resistant transport of a nutritional composition is possible. The container may include any type of suitable opening means located in any portion of the container that is adapted for accessing the nutritional composition.
[0034] In further embodiments, the composition comprises a nutritional supplement useful for improving health and treating disease. Research indicates that CoQ10 deficiencies are associated with many diseases and conditions. For example, the composition of the invention is useful for treating, and improving: oxidative phosphorylation, cellular survival, humoral immunity, reduce the oxidation of LDL cholesterol, resistance to viruses, athletic performance, the health of those with diabetes mellitus, and prevent damage to muscles that can occur as a result of intensive exercise.
[0035] For example, the composition of the invention is useful for treating, preventing or ameliorating: certain cancers, such as, cervical cancer and its precursor—cervical intraepithelial neoplasia, malignant and nonmalignant breast tumors, arrhythmia, atherosclerosis, hypertension, cardiovascular disease, congestive heart failure, angina, hypoxia, mitral valve prolapse, and progression to full-blown AIDS, allergies, lung cancer, laryngeal cancer, pancreatic cancer, and prostate cancer, proliferation of cancer cells, gingivitis, psoriasis, neuron damage that leads to Alzheimer's disease, and Parkinson's, endothelial function in patients with ischemic heart disease and chronic heart failure.
[0036] As will be understood by those of ordinary skill in the pertinent art based on the teachings herein, numerous changes may be made to the above-described and other embodiments of the invention without departing from its scope as defined in the appended claims. For example, the relative quantities of the ingredients may be varied to achieve different desired effects, additional ingredients may be added, and/or similar ingredients may be substituted for one or more of the ingredients described. Accordingly, this detailed description of preferred embodiments is to be taken in an illustrative rather than a limiting sense.
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The present invention relates to a combination of a hermetically sealed, substantially air-tight container, and a quinone-containing composition disposed therein. The container of the present invention is adapted for the convenient transport, and storage of an effective amount of an active ingredient, for example, ubiquinone, ubiquinol or a mixture thereof, and at least one pharmaceutically acceptable excipient. In another aspect the invention relates to a hermitically sealed container comprising an composition containing a single daily dose of ubiquinone, ubiquinol or both.
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FIELD OF THE INVENTION
[0001] This invention relates in general to submersible well pumping assemblies, and in particular, to a rod-driven progressing cavity pump assembly with a gas separator.
BACKGROUND OF THE INVENTION
[0002] One use for a progressing cavity pump is as a well pump. A progressing cavity pump has a stator with an elastomeric liner in its interior. The liner has a passage through it that has a helical contour. A helical rotor, typically of metal, locates within the stator and is rotatable relative to it. Rotating the rotor causes the well fluid to pump through the stator.
[0003] In one type of installation, the stator is secured to the lower end of a string of tubing that is suspended in the well. The rotor is secured to a string of drive rods and lowered through the tubing into the stator. After reaching the lowermost point, the operator lifts the rods and rotor a short distance to properly align the rotor with the stator. The drive rods are driven by a drive source at the surface, typically a bearing box and electrical motor. As the well fluid fills the tubing, the rods will stretch to some extent due to the weight of the well fluid. The rotor will thus move downward a short distance relative to the stator.
[0004] Some wells produce a combination of liquid and gas. The gas entrained within the liquid is detrimental to the efficiency of the progressing pump. Gas separators have been utilized with electrical submersible well pumps for many years. One type of gas separator has a rotating member, typically a set of vanes that spins with the pump to impart centrifugal force to the well fluid. The centrifugal force results in the heavier components flowing to the outer portion and the lighter components are gas remaining in the center. A crossover member at the top diverts the gas out into the casing and directs the liquid component up into the pump.
[0005] The centrifugal pump is made up of a large number of stages of impellers and diffusers. A centrifugal pump is not driven by rods and does not experience any downward movement of the drive shaft as a result of the weight of liquid in the tubing.
[0006] Progressing cavity pumps with gas separators are known, both for rod-driven types as well as the type that utilizes a downhole submersible electrical motor to drive the rotor. However, provisions to accommodate the rod stretch for the rod-driven type are not known in the prior art.
SUMMARY OF THE INVENTION
[0007] In this invention, a gas separator is secured to the lower end of the stator of a progressing cavity pump assembly. The gas separator is of a rotary type, having a rotary member for imparting centrifugal force to the well fluid flowing into the gas separator. The gas separator has a drive shaft that is operably engaged by the rotor for causing rotation of the rotary member.
[0008] The rotor is axially movable a limited amount relative to the stator during operation of the pump as a result of stretch of the rods. The drive shaft is axially movable in unison with the rotor after it is in operative engagement with the stator.
[0009] In one embodiment of the invention, the drive shaft is fixed to the rotary member, and both the drive shaft and the rotary member are movable axially within the housing of the gas separator. The rotor has a flex shaft on its lower end with a splined end that stabs into engagement with a coupling on the upper end of the gas separator drive shaft. Once in engagement, the drive separator drive shaft and the rotor are axially movable as well as rotationally movable in unison with each other.
[0010] In another embodiment, the drive shaft is secured to the lower end of the rotor at the surface and lowered through the tubing with the drive rods. The drive shaft stabs into a bushing located in the rotary member of the gas separator. The bushing has splines that engage splines on the lower end of the drive shaft. The drive shaft is movable in unison with the rotor, both axially and rotationally, but the rotary member is only rotationally engaged with the drive shaft.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIGS. 1A and 1B comprise a side view, partially sectioned, of a well pump assembly constructed in accordance with this invention.
[0012] FIGS. 2A and 2B comprise a sectional view of the pump and gas separator of FIGS. 1A and 1B and showing the drive shaft and rotary members in a lower position.
[0013] FIGS. 3A and 3B comprise a sectional view of the pump and gas separator of FIG. 1 , and showing the rotary members and drive shaft in an upper position.
[0014] FIG. 4 is a schematic sectional view illustrating a coupling between the rotor assembly and the gas separator drive shaft in accordance with this invention.
[0015] FIG. 5 is a view of the coupling of FIG. 4 , but showing the rotor disengaged from the coupling.
[0016] FIG. 6 is a sectional view of an alternate embodiment of a pump and gas separator in accordance with this invention.
[0017] FIG. 7 is an exploded sectional view of a portion of a drive shaft and hub sleeve of the gas separator of FIGS. 6A and 6B .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] Referring to FIG. 1 , progressing cavity pump 11 is conventional. Pump 11 has a stator 13 that has a tubular housing containing an elastomeric liner 15 . Liner 15 has a passage through it that has a double helical contour. Stator 13 is secured to the lower end of a string of production tubing 17 that extends into the well. Tubing 17 extends to the surface of the well for delivering well fluid. Tubing 17 may comprise sections of conventional well production tubing screwed together. Alternatively, tubing 17 could comprise a single continuous length of coiled tubing.
[0019] Pump 11 includes a rotor 19 that rotates within stator 13 . Rotor 19 is typically of metal and has a single helical contour. A string of drive rods 21 extends form the surface to rotor 19 for rotating rotor 19 . Drive rods 21 typically comprise sections of rods secured together by threads.
[0020] A bearing box 23 located at the surface is driven by a motor 25 , normally an electrical motor. Bearing box 23 engages the upper end of drive rods 21 for rotating drive rods 21 and rotor 19 .
[0021] Rotor 19 orbits or oscillates as it rotates, rather than remaining on a single concentric axis. A flex shaft 27 is secured to the lower end of rotor 19 , and for the purposes herein, may be considered to be a part of rotor 19 . Flex shaft 27 is typically a steel rod that has sufficient length to allow flexing. The lower end of flex shaft 27 is constrained about a single axis while the upper end of flex shaft 27 is free to orbit with the lower end of rotor 19 . Flex shaft 27 extends through a flex shaft housing 29 that contains bearings for supporting the lower end of flex shaft 27 . Flex shaft housing 29 does not have an elastomeric liner 15 within it, but could be integrally formed with the housing of stator 13 and may be considered a part of stator 13 .
[0022] A gas separator 31 is carried below flex shaft housing 29 . Gas separator 31 has a lower intake 35 for drawing well fluid into it and a gas discharge 37 near its upper end for discharging separated gas into the well. Gas separator 31 has a drive shaft 39 that is rotated by drive rods 29 , rotor 15 and flex shaft 27 . Referring to FIGS. 2A and 2B , gas separator 31 may be of a variety of rotary types. In this embodiment, gas separator 31 has a set of vanes 41 that rotate with drive shaft 39 to impart centrifugal force to the well fluid. Vanes 41 comprise a plurality of flat blade-like members, each being in a plane that is perpendicular to the axis of drive shaft 39 in this embodiment. The centrifugal force imparted by vanes 41 causes the heavier components to flow radially outward while the lighter components of the well fluid remain in the central area.
[0023] An inducer 43 optionally may be incorporated with gas separator 31 . Inducer 43 is a type of pump for inducing the flow of well fluid into gas separator 31 . In this embodiment, inducer 43 has a helical vane, similar to an auger for forcing well fluid upward into vanes 41 . Inducer 43 has a key, like vanes 41 , that causes it to rotate in unison with gas separator drive shaft 39 .
[0024] A crossover 45 is located at the upper end of gas separator housing 33 . Crossover member 45 has an inner passage 47 that leads to gas discharge port 37 . Crossover member 45 has an outer passage 49 that leads upward into flex shaft housing 29 . Crossover member 45 has an annular skirt 51 that depends downward and divides inner passage 47 from outer passage 49 at the entrance. A base member 53 secures to the lower end of gas separator housing 33 . Base member 53 may be used to connect gas separator 31 to other equipment, or it may have a cap 55 at the lower end. Base member 53 has an extension section 57 that extends downward below intake 35 . Drive shaft 39 has a lower end that extends into the extended section and is retained herein by a retaining ring 59 . Drive shaft 39 is movable between a lower position shown in FIG. 2B and an upper position shown in FIG. 3B . In the lower position, retaining ring 59 is located at the lower end of extension section 57 . In FIG. 3B , retaining ring 59 abuts a bushing or bearing member 61 located at the upper end of extension section 57 .
[0025] In this embodiment, vanes 41 and inducer 43 are secured to drive shaft 39 for axial movement as well as rotational movement. The length of housing 33 is greater than the axial length of the rotary components made up of vanes 41 and inducer 43 to accommodate this axial movement. In FIG. 2A , a substantial space exists between the upper edge of vanes 41 and skirt 51 . When in the upper position shown in FIG. 3A , the upper edge of vanes 41 engages skirt 51 . Drive shaft 39 may have a protective sleeve 63 or bushing surrounding it both in the lower section from inducer 43 to retaining ring 59 as well as in the upper section above vanes 41 .
[0026] In the embodiment of FIGS. 1-5 , drive shaft 39 is assembled with gas separator 31 at the surface and lowered into the well on tubing 17 . Rotor 19 and flex shaft 27 ( FIGS. 1A-1B ), are lowered through tubing 17 on drive rods 21 . A coupling 65 connects flex shaft 27 to drive shaft 39 when rotor 19 is fully inserted into stator 13 . Once engaged, coupling 65 will cause drive shaft 39 to rotate with flex shaft 27 and also will cause drive shaft 39 to move axially with flex shaft 27 and rotor 19 . Coupling 65 may be of a variety of types. In this embodiment, coupling 65 is secured to the upper end of drive shaft 39 , shown in FIG. 4 . Coupling 65 has a receptacle 67 on its upper end for receiving the lower end of flex shaft 27 . Receptacle 67 has a plurality of internal splines 69 . A latch ring 71 is mounted within receptacle 67 . Latch ring 71 is a split ring that is by standard for engaging an annular groove 73 ( FIG. 5 ) located on flex shaft 27 . Flex shaft 27 has a lower splined end 75 which mates with splines 69 .
[0027] In the operation of the embodiment of FIGS. 1-6 , the operator secures gas separator 31 to stator 13 . In this embodiment, this is accommodated by securing gas separator 33 to flex shaft housing 29 . Drive shaft 39 will be located within gas separator 33 . The operator lowers gas separator 33 on the string of tubing 17 .
[0028] The operator then connects flex shaft 27 to rotor 19 and lowers rotor 19 through tubing 17 on drive rods 21 . When rotor 19 reaches the lower end of stator 13 , flex shaft 27 will engage gas separator drive shaft 39 . Referring to FIG. 5 , lower end 75 of flex shaft 27 stabs into receptacle 67 , and latch ring 71 engages groove 73 . At this point, drive shaft 39 , vanes 41 and inducer 43 will be in the lower position shown in FIGS. 2A and 2B .
[0029] The operator then lifts drive rods 21 a measured distance to place rotor 19 with its upper end a selected distance above the upper end of stator liner 15 . Drive shaft 39 of gas separator 33 will move upward, bringing along with it vanes 41 and inducer 43 . This position will be located either at the uppermost position shown in FIGS. 3A and 3B , or some slightly lower position. The position will be selected to account for the stretch of rods 21 when tubing 17 is filled with liquid, and the amount of stretch will depend upon the length of rods 21 .
[0030] The operator then actuates motor 25 to rotate rods 21 , which in turn rotates rotor 19 and gas separator drive shaft 39 . Inducer 43 rotates to assist in drawing well fluid in through intake 35 . The well fluid flows through the rotating vanes 41 , which through centrifugal force forces the liquid to the outer side relative to the gaseous components which remain in the central area. The liquid flows up outer passage 49 and into stator 13 ( FIG. 1A ). The liquid is pumped by rotor 19 up tubing 17 to the surface. The gas flows through inner passage 47 ( FIG. 2A ) out gas discharge 37 into the well. The liquid within tubing 17 will gradually cause rods 21 to stretch. As rotor 19 and flex shaft 27 move downward, rotor drive shaft 39 also moves downward along with vanes 41 and inducer 43 . The amount of downward movement is pre-calculated so as to avoid vanes 41 and inducer 43 reaching the lowermost position shown in FIGS. 2A and 2B .
[0031] To retrieve rotor 19 , the operator exerts sufficient pull with drive rods 21 to over-pull latch ring 71 ( FIG. 4 ), causing it to release from coupling 65 , which remains downhole. In the embodiment of FIGS. 6 and 7 , gas separator 77 also has a rotary member which comprises vanes 79 and an optional inducer 81 . Vanes 79 and inducer 81 are linked together by an elongated hub sleeve 83 . Hub sleeve 83 has internal splines 85 within it, either continuous or in sections as shown in FIG. 7 . As shown in FIG. 6 , hub sleeve 83 extends downward into a lower bearing support 87 . The upper end of hub sleeve 83 preferably extends above crossover member 88 .
[0032] Drive shaft 89 is carried by rotor 19 ( FIG. 1A ) as rotor 19 is lowered through tubing 17 . Drive shaft 89 may comprise a portion of a flex shaft, or may be coupled to a flex shaft such as flex shaft 27 in the first embodiment. Drive shaft 89 has a section containing splines 91 that will mate with splines 85 in hub sleeve 83 . Drive shaft 89 may also have a pointed tip 93 , shown in FIG. 7 , to facilitate stabbing into hub sleeve 83 .
[0033] In the operation of the embodiment of FIGS. 6 and 7 , gas separator 77 is secured to tubing 17 and lowered into place in the same manner as in FIG. 1 , except that it does not contain a drive shaft. The operator then connects drive shaft 89 to the lower end of rotor 19 and lowers the assembly through tubing 17 . As rotor 19 reaches the lower end of stator 13 , drive shaft 89 will enter hub sleeve 83 and slide to the position shown in FIG. 6B . After reaching the lowermost position, the operator picks up drive rods 21 a selected distance to accommodate for stretch of drive rods 21 as in the first embodiment. The second embodiment operates in the same manner as in the first embodiment except vanes 79 and inducer 81 are not axially movable within gas separator 77 . Rather, only drive shaft 89 is axially movable in unison with rotor 19 ( FIG. 1A ).
[0034] The invention has significant advantages. The floating drive shaft of the gas separator allows for expansion and contraction of the rod string driving the unit. The floating shaft gas separator can be designed with varying axial movable links.
[0035] While the invention has been shown in only two of its forms, it should be apparent to those skilled in the art that it is not so limited but susceptible to various changes without departing from the scope of the invention.
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A progressing cavity pump is located within a well and has a gas separator for separating gas before reaching the pump. The pump has a rotor that is driven by a string of rods extending to the surface. A drive shaft for the gas separator is coupled to the rotor during pumping operation both for axial as well as rotational movement. The rotor assembly, when lowered through the tubing, stabs into engagement with the drive shaft of the gas separator in one version. In another version, the gas separator drive shaft is lowered through the tubing with the rotor and stabs into a hub sleeve in the gas separator.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a rotary connector for electrically connecting a pair of housing, which are coupled to each other in such a manner as to be relatively rotatable, through a flexible cable, and more particularly, to a rotary connector for use in connection of a plurality of circuits mounted on a steering wheel of a vehicle including an air bag circuit and other circuits, such as a horn circuit or an automatic cruise control circuit.
2. Description of the Related Art
Rotary connectors of the above-described type generally include a pair of housings coupled to each other in such a manner as to be relatively rotatable, and include a belt-like flexible cable accommodated in an annular space defined between the two housings. The two ends of the flexible cable are electrically connectable to an exterior of from the housings when the flexible cable is fixed to the two housings. The flexible cable has a plurality of parallel conductors. A connector is connected to the end of the portion of the flexible cable which extends externally from the housing. Such a connector is generally a special connector connected to the end of the portion of the flexible cable which extends externally from the housing over a predetermined length. An alternate connector connected to the end of the externally extended portion of the flexible cable is the direct coupling type connector disclosed in U.S. Pat. No. 5,230,713. This connector has a plurality of terminals provided on the housing and is connected to the conductors of the flexible cable.
The rotary connector arranged in the manner described above is assembled in a steering device of a vehicle and is used as electrical connection means between various circuits, such as an air bag circuit or a horn circuit. In that case, one of the housings of the rotary connector is connected to a steering column (a stator), while the other housing is connected to a steering wheel (a rotor). The special connectors or direct connectors connected to the two ends of the flexible cable are connected to external connectors mounted in an air bag inflator or a horn switch.
When a driver turns the steering wheel in either of the two directions while driving a vehicle, the housing mounted on the steering wheel turns in the same direction as that of the steering wheel, winding or unwinding the flexible cable in the rotary connector depending on the direction of turning of the steering wheel. In either state, electrical connection between the rotor and the stator is maintained by the flexible cable of the rotary connector.
When the rotary connector is assembled in the steering device of a vehicle, the flexible cable must be assembled in a state wherein it can be wound or unwound by almost the same amount from a reference position associated with the neutral turning position of the steering wheel.
Hence, the rotary connector is provided with a locking mechanism for maintaining the two housings at the neutral turning position until the rotary connector is assembled in a steering device. Such a rotary connector is designed such that free turning of the two housings is impeded, until the rotary connector is assembled in the steering device, by the locking member mounted relative to the two housings which have been positioned at the neutral turning position. The locking member is removed from the two housings when one of the housings is fixed the steering column.
In recent years, the number of circuit parts provided on the steering wheel of a vehicle have began to increase. That is, there is an increasing demand for providing, on the pad of a steering wheel, control switches for, for example, an automatic cruise control circuit or an air conditioner circuit, in addition to the air bag inflator and the horn switch. An increase in the number of circuits connected by the rotary connector inevitably increases the number of conductors of the flexible cable. However, the space near the steering device is limited, and an increase in the width of the flexible cable is thus restricted. As a result, the electrical insulation distance between the conductors is reduced, and this makes insulation of the conductor used for an air bag more important than the insulation for other conductors because a larger amount of current compared to that which flows in other conductors, flows in the air bag conductor to actuate the air bag inflator.
However, in the case of the aforementioned direct connector, since the terminals are connected directly to the conductors in the connector provided on the housing by, for example, spot welding or soldering, a decrease in the pitch between the conductors, caused by an increase in the number of conductors of the flexible cable, reduces the distance between the adjacent connecting portions, thus reducing the electrical insulation distance. Thus, the direct connector is not suited for connection of multiple circuits.
In view of the aforementioned problems of the prior art, an object of the present invention is to provide a rotary connector which is suitable for use in connection of multiple circuits.
U.S. Pat. No. 5,230,713 discloses the direct coupling type rotary connector in which connectors connected to the two ends of the flexible cable are provided on the housings so as to achieve direct connection with external devices, such as an air bag inflator. In such a rotary connector, since the connectors are formed integrally with the housings, electrical connection between the flexible cable and the external devices is obtained at the same time as the assembly of the rotary connector in the steering device, thus simplifying the connection process between the rotary connector and the external devices.
However, in the direct coupling type direct connector, since a plurality of terminals thereof are exposed from the housing, a provided member must be covered on the direct connector for the purpose of preventing deformation of these terminals and enhancing the dust prevention property. Accordingly, in the assembly process of the rotary connector, the aforementioned locking member and the cover member must be mounted separately, making the assembly operation complicated. Further, in the inspection process conducted after assembly of the rotary connector in the steering device to check whether or not the rotary connector has been accurately connected to the external devices, electrical characteristics are satisfied only if the cover member has been removed and the external devices have been connected to the direct connector. Thus, if the locking member is left unremoved, it is impossible in the inspection process to check whether or not the locking member has been improperly left connected to the rotary connector during assembly.
In view of the aforementioned problems of the prior art, a second object of the present invention is to provide a rotary connector which prevents accidental unremoval of a locking member.
SUMMARY OF THE INVENTION
To achieve the first object of the present invention, there is provided a rotary connector which comprises a pair of housings coupled to each other in such a manner as to be relatively rotatable, and a belt-like flexible cable wound in an annular space defined by the two housings, the flexible cable having a conductor for an air bag and another conductor parallel to the conductor. Two ends of each of the respective conductors of the flexible cable are electrically extended externally from the housings. At least one of the two externally extending ends of each of the connectors being connected to a corresponding terminal of a direct connector provided on the housing. The direct connector has a partitioning wall for separating a terminal connected to the conductor for the air bag from a terminal connected to the another conductor.
To achieve the first object of the present invention, there is further provided a rotary connector which comprises a pair of housings coupled to each other in such a manner as to be relatively rotatable, and a belt-like flexible cable wound in an annular space defined by the two housings, the flexible cable having conductors for an air bag and other conductors parallel to the conductors. Two ends of each of the respective conductors of the flexible cable being electrically connected to an external portion of the housings. At least one of the two externally extending ends of each of the conductors is connected to a corresponding terminal of a direct connector provided on the housing. The direct connector has a gap for separating terminals connected to the conductors for the air bag from terminals connected to the other conductors. A space of the gap is set to a value larger than a pitch at which the terminals connected to the other conductors are arranged.
To achieve the second object of the present invention, there is provided a rotary connector which comprises a pair of housings coupled to each other in such a manner as to be relatively rotatable, and a flexible cable wound in a space of the two housings, the flexible cable having a plurality of parallel conductors. Two ends of the flexible cable are electrically extended externally from the housings in such a state wherein the flexible cable is fixed to the housings. At least one of the two externally extending ends of the flexible cable is connected to an external device through a direct connector provided on the housing. A locking member for prohibiting free rotation of the two housings is removably mounted between the housings. A cover for covering the direct connector is formed integrally with the locking member.
According to a first aspect of the present invention provided to achieve the first object, the conductor of the flexible cable for the air bag and the other conductors thereof are connected to the corresponding terminals of the direct connector, respectively. The terminals of the direct connector, connected to the conductor for the air bag, and the terminals connected to the other conductors of the flexible cable are separated from each other by a partitioning wall or a gap.
According to a second aspect of the present invention provided to achieve the second object, since the locking member is mounted relative to the two housings which have been positioned at a neutral turning position in the rotary connector manufacturing process, the rotary connector which has been positioned at the neutral turning position can be assembled in a steering device in a state wherein free turning of the two housings is prohibited by the locking member. In that case, since the cover for covering the direct connector provided on the housing is formed integrally with the locking member, mounting of the locking member offers protection of the direct connector. Thus, separate process of covering the direct connector with a covering member is eliminated.
In the process of assembling the rotary connector in the steering device, when the locking member is removed from the two housings, the two housings are unlocked and at the same time the cover is removed from the direct connector, enabling the rotary connector to be electrically connected to external devices through the direct connector. In other words, the external devices can be connected to the direct connector only when the cover formed integrally with the locking member is removed. Thus, by inspecting electrical connection between the rotary connector with the external devices after the rotary connector has been assembled in the steering device, whether or not the locking member is removed can be determined, thus eliminating production of defective articles due to an accidental failure to remove the locking member.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical cross-sectional view of a first embodiment of a rotary connector according to the present invention;
FIG. 2 is a plan view of a flexible cable provided in the rotary connector of FIG. 1;
FIG. 3 is a perspective view of essential parts illustrating a connected state between a direct connector and the flexible cable provided in the rotary connector of FIG. 1;
FIG. 4 is a perspective view of essential parts illustrating a connected state between a direct connector and a flexible cable which are provided in a second embodiment of the rotary connector according to the present invention;
FIG. 5 is a perspective view of essential parts illustrating a connected state between a direct connector and a flexible cable which are provided in a third embodiment of the rotary connector according to the present invention;
FIG. 6 is a perspective view of essential parts illustrating a connected state between a direct connector and a flexible cable which are provided in a fourth embodiment of the rotary connector according to the present invention;
FIG. 7 is a perspective view of a fifth embodiment of the rotary connector according to the present invention;
FIG. 8 is a vertical cross-sectional view illustrating a state wherein a locking member is mounted on the rotary connector of FIG. 7;
FIG. 9 is a perspective view of essential parts of a sixth embodiment of the rotary connector according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the present invention will be described below with reference to the accompanying drawings.
FIG. 1 is a vertical cross-sectional view of a rotary connector according to a first embodiment of the present invention. FIG. 2 is a plan view of a flexible cable provided in the rotary connector shown in FIG. 1. FIG. 3 is a perspective view of essential parts illustrating a connected state of a direct connector provided in the rotary connector shown in FIG. 1 and the flexible cable.
Referring first to FIG. 1, a first housing 1 made of a synthetic resin has a disk-shaped bottom plate 2 and an outer cylindrical portion 3 connected to an outer peripheral edge of the bottom plate 2. The bottom plate 2 has a center hole 4 formed at a center thereof. A second housing 5, made of a synthetic resin, has a disk-shaped ceiling plate 6 and an inner cylindrical portion 7 connected to a central portion of the ceiling plate 6. The inner cylindrical portion 7 has a shaft insertion hole 8. The first and second housings 1 and 5 are coupled to each other in such a manner as to be rotatable relative to each other with the outer peripheral edge of the ceiling plate 6 being guided by the upper edge of the outer cylindrical portion 3 and the lower edge of the inner cylindrical portion 7 being guided by the inner edge of the bottom plate 2. A flexible cable 9 is housed in an annular space defined by the bottom plate 2 and outer cylindrical portion 3 of the first housing 1 and the ceiling plate 6 and the inner cylindrical portion 7 of the second housing 5. The flexible cable 9 is wound in a spiral fashion in the space. One end of the flexible cable 9 is led out from the first housing 1 in a state wherein it is fixed to the outer cylindrical portion 3. A special connector (not shown) is connected to a distal end of the portion of the flexible cable 9 which is led out from the first housing 1. The other end of the flexible cable 9 is led out of the second housing 5 through a direct connector 10.
As shown in FIG. 2, the flexible cable 9 is a belt-like flat cable in which a plurality of parallel conductor wires 11a through 11f are laminated by a pair of insulating films 12. The conductors 11a and 11b are used for connection with an air bag circuit. The conductor wires 11c to 11f are used for connection with a horn circuit, an automatic cruise control circuit or an air conditioner circuit. A current which flows through the air bag circuit is the largest, so the spacing between the air bag conductors 11a and 11b is larger than the pitch for the other conductor wires 11c to 11f. Further, very high connection reliability is required for the air bag circuit, so a noble metal plating, such as gold plating, is provided only on the surface of the portion of the air bag conductors which is exposed from the insulating films 12. A current which flows through the horn circuit is the second largest, so the conductor wire 11f located farthest from the air bag conductors 11a and 11b is used for the connection with the horn circuit. Further, a notch 9a is formed at one end portion of the flexible cable 9, whereby the flexible cable 9 is divided into the air bag conductors 11a and 11b and the other conductor wires 11c to 11f. The two parts are respectively folded at folding lines A and B which lie at 45 degrees with respect to the lateral direction of the flexible cable 9 so as to allow the flexible cable 9 to be directed toward the direct connector 10.
As shown in FIG. 3, the direct connector 10 includes a protruding casing 13 made of a synthetic resin and erected from the upper surface of the ceiling plate 6, a plurality of terminals 14a to 14f disposed in the protruding casing 13, and connecting plates 15 and 16 for connecting the terminals 14a to 14f with the conductor wires 11a to 11f. A partitioning wall 13a is formed integrally with the casing 13 at a central portion thereof to divide the terminals into the terminals 14a and 14b and the terminals 14c to 14f. The terminals 14a and 14b are also plated with a noble metal, such as gold. The terminals 14a and 14b are connected to the air bag conductors 11a and 11b within the one connecting plate 15 by means of, for example, soldering or spot welding. Similarly, the terminals 14c to 14f are connected to the conductor wires 11c to 11f within the other connecting plate 16 by means of, for example, soldering or spot welding. The connecting plates 15 and 16 are fixed in the protruding casing 13 by an adequate means, such as press fitting or snap-fastening.
The operation of the rotary connector according to the first aspect of the present invention will now be discussed. In the following description, the first housing 1 is used as a fixing member, while the second housing 5 is used as a movable member. In that case, the first housing 1 of the rotary connector is first fixed to a steering column. After a steering shaft is protruded from the shaft insertion hole 8 of the second housing 5, a steering hub is press-fitted with the steering shaft and a steering wheel formed integrally with the steering hub is fixed to the second housing 5. Thereafter, an external connector mounted on a car body is connected to the special connector led out from the first housing 1, and an external connector mounted on the steering wheel is connected to the direct connector 10 provided on the second housing 5, whereby an inflator for an air bag, a horn switch or control switches of an automatic cruise circuit or air conditioner circuit, mounted on the steering wheel, are connected to corresponding circuits mounted on the car body through the rotary connector.
In the above-described arrangement, when the steering wheel is rotated clockwise or counterclockwise, the rotational force of the steering wheel is transmitted to the second housing 5, rotating the second housing 5 in the same direction as that in which the steering wheel is rotated. For example, when the steering wheel is rotated counterclockwise from a neutral rotation position, the second housing 5 also rotates counterclockwise together with the steering wheel, making the flexible cable 9 wind toward the inner tube portion 7. Conversely, when the steering wheel is rotated clockwise, the second housing 5 also rotates clockwise together with the steering wheel, making the flexible cable 9 unwind toward the outer cylindrical portion 3. In either state, electrical connection between the housings 1 and 5 is maintained through the flexible cable 9.
In the above-described first embodiment, at the connection portion between the flexible cable 9 and the direct connector 10, the individual conductor wires 11a to 11f of the flexible cable 9 are divided into the air bag conductors 11a and 11b and the other conductor wires 11c to 11f, and the terminals 14a to 14f of the direct connector 10, respectively connected to the conductor wires 11a to 11f, are divided into the air bag terminals 14a and 14f and the other terminals 14c to 14f by the insulating partitioning wall 13a. Thus, the conductors and terminals for the air bag circuit, which require high connection reliability, can be reliably insulated electrically from the conductors and terminals of the other circuits. When electrical insulation of the conductors and terminals of the air bag circuit from the conductors and terminals of the other circuits can be conducted reliably, short-circuiting, which would occur between the other circuits due to the current which flows in the air bag circuit into the other circuits, can be prevented. Accordingly, the pitch at which the conductors 11c to 11f used for connection with the circuits other than the air bag circuit can be reduced, and even when the number of conductor wires 11c to 11f is increased, a great increase in the width of the flexible cable 9 can thus be avoided. Further, since the conductor wire 11f located farthest from the air bag conductors 11a and 11b is used for connection with the horn circuit, the insulation distance between the air bag circuit in which a largest amount of current flows and the horn circuit in which a second largest amount of current flows can be increased, thus enhancing electrical insulation of the air bag circuit. Further, since the flexible cable 9 is divided into the air bag conductors 11a and 11b and the conductor wires 11c to 11f for the circuits other than the air bag circuit at an end portion of the cable, the exposed ends of the air bag conductors 11a and 11b alone are dipped into a plating tank with the other conductor wires 11c to 11f on which expensive noble metal plating is conducted being not plated. Consequently, production cost can be reduced.
FIG. 4 is a perspective view of essential parts illustrating a connecting state between the direct connector and the flexible cable provided in the rotary connector according to a second embodiment of the present invention. Reference numerals in FIG. 4 identical to those in FIGS. 1 to 3 represent similar or identical elements.
The second embodiment differs from the first embodiment in that the first and second flexible cables 17a and 17b are employed and in that the air bag conductors 11a and 11b are provided on the first flexible cable 17a while the other conductor wires 11c to 11f are provided on the second flexible cable 17b. The other structure of the second embodiment is the same as that of the first embodiment. That is, the two flexible cables 17a and 17b are wound in the annular space in a state wherein they are placed on top of the other in the direction of thickness thereof over the entire length thereof. At least one end portions of the conductor wires 11a to 11f are connected to the corresponding terminals 14a to 14f of the direct connector 10.
In the second embodiment, since the air bag conductors 11a and 11b and the conductors 11c to 11f for the circuits other than the air bag circuit are allocated to the first and second flexible cables 17a and 17b placed on top of the other in the direction of thickness thereof, respectively, insulation between the air bag conductors 11a and 11b and the conductor wires 11c to 11f for the circuits other than the air bag circuit can be enhanced by the insulating films of the flexible cables 17a and 17b and the width of the flexible cables 17a and 17b can be narrowed. Thus, the second embodiment is suited to achieve a reduction in the thickness of the rotary connector in addition to the effects offered by the first embodiment.
FIG. 5 is a perspective view of essential parts illustrating a connected state between the direct connector and the flexible cables provided in the rotary connector according to a third embodiment of the present invention. Reference numerals in FIG. 5 identical to those in FIG. 4 represent similar or identical elements.
The third embodiment according to the present invention differs from the second embodiment in that the terminals of the direct connector 10 are divided into the air bag terminals 14a and 14b and the terminals 14c to 14f for the circuits other than the air bag circuit in the direction of thickness of the two flexible cables 17a and 17b through the partitioning wall 13a. The other structure is the same as that of the second embodiment.
FIG. 6 is a perspective view of essential parts illustrating a connected state between the direct connector and the flexible cable provided in the rotary connector according to a fourth embodiment of the present invention. Reference numerals in FIG. 6 identical to those in FIG. 4 represent similar or identical elements.
The fourth embodiment differs from the second embodiment in that the air bag terminals 14a and 14b are separated from the terminals 14c to 14f for the circuits other than the air bag circuit by a gap 18. The other structure of the fourth embodiment is basically the same as that of the second embodiment. The gap 18 is set to a value sufficiently large as compared with the pitch (spacing) between the air bag terminals 14a and 14b or the pitch between the other terminals 14c to 14f, and has the same function as that of the partitioning wall 13a which has been described in the first to third embodiments.
There is no limitation to the shape of the partitioning wall 13a employed in the first to third embodiments so long as the creepage distance for insulation between the air bag terminals 14a and 14b and the terminals 14c to 14f for the circuits other than the air bag circuit is long.
While the above embodiments are shown in FIGS. 1 to 6, wherein the first housing 1 is used as the fixing member and the second housing 5 is used as the movable member, other embodiments of the invention might include a rotary connector wherein the second housing 5 is used as the fixing member and the first housing 1 is used as the movable member.
Similarly, while the direct coupling type direct connector 10 is provided only on the second housing 5 while the special connector to be led out of the housing is provided on the first housing 1, alternate embodiments might contemplate a rotary connector in which the direct connector is provided only on the first housing while the special connector is provided on the second housing 5 and a rotary connector in which direct coupling type connectors are provided on both the housings 1 and 5.
A second aspect of the present invention will be described with reference to FIGS. 7-9.
FIG. 7 is a perspective view of a rotary connector according to a fifth embodiment of the present invention. FIG. 8 is a vertical cross-sectional view illustrating a state wherein a locking member is mounted on the rotary connector. In these figures, a first housing 101 made of a synthetic resin has a disk-shaped bottom plate 102 and an outer cylindrical portion 103 erected from an outer peripheral edge of the bottom plate 102. The bottom plate 102 has a center hole 104 formed at a center thereof. A second housing 105, made of a synthetic resin, has a disk-shaped ceiling plate 106 and an inner cylindrical portion 107 connected to a central portion of the ceiling plate 106. The inner cylindrical portion 107 has a shaft insertion hole 108. The first and second housings 101 and 105 are coupled to each other in such a manner as to be rotatable relative to each other with the outer peripheral edge of the ceiling plate 106 being guided by the upper edge of the outer cylindrical portion 103 while the lower edge of the inner cylindrical portion 107 being guided by the inner edge of the bottom plate 102. However, free rotation of the first and second housings 101 and 105 is prohibited by a locking member which will be described later. A flexible cable 109 is a belt-like flat cable in which a plurality of parallel conductor wires are laminated by a pair of insulating films. The flexible cable 109 is housed in an annular space defined by the bottom plate 102 and outer cylindrical portion 103 of the first housing 101 and the ceiling plate 106 and the inner cylindrical portion 107 of the second housing 105. The flexible cable 109 is wound in a spiral fashion in the space. One end of the flexible cable 109 is led out from the first housing 101 in a state wherein it is fixed to the outer cylindrical portion 103. A special connector 110 is connected to a distal end of the portion of the flexible cable 109 which is led out from the first housing 101. The other end of the flexible cable 109 is led out of the second housing 105 through a direct-coupling type connector 111 erected from the upper surface of the ceiling plate 106. The direct connector 111 includes a plurality of terminals 111a connected to the respective conductors of the flexible cable 109, and a protruding casing 111b for enclosing the terminals 111a. The terminals 111a are exposed through an upper opening of the protruding casing 111b.
A locking member 112 includes a box-shaped cover 112a which is open at an under surface thereof, a knob portion 112b protruding upward from the cover 112a, and an arm 112c extending horizontally from a side surface of the cover 112a. The locking member 112 is a one-unit member made of a synthetic resin or hard rubber. The cover 112a has an inner space large enough to cover the protruding casing 111b of the connector 111. A distal end portion of the arm 112c has a hole 112d. Corresponsive to the locking member 112, a protrusion 113 is formed integrally with the outer cylindrical portion 103 of the first housing 101 at an outer peripheral surface thereof. The protrusion 113 has a boss 114 on an upper surface thereof. In addition, thin portions 113a are formed at a connecting portion between the outer peripheral surface of the outer tube portion 103 and the protrusion 113. The thin portions 113a have the function of rupture portions when the protrusion 113 is removed from the first housing 101.
FIG. 7 illustrates a non-locked state wherein the locking member 112 is not yet mounted on the rotary connector. FIG. 8 illustrates a locked state wherein the locking member 112 is mounted on the rotary connector. In that locked state, the cover 112a of the locking member 112 is covered on the protruding casing 111b of the connector 111, and fixed to the protrusion 113 by heat caulking the hole 112d of the arm 112c to the boss 114.
The operation of the rotary connector according to the present invention will now be discussed. In the following description, the first housing 101 is used as a fixing member, while the second housing 105 is used as a movable member. In that case, the first housing 101 of the rotary connector is fixed to a steering column, and the second housing 105 is fixed to a steering wheel. Such a rotary member must be assembled in a steering device in such a manner that the second housing 105 serving as the movable member can be rotated by the same angle from the rotation neutral position of the steering wheel in two directions. To achieve this, in the manufacturing process of the rotary connector, after the first and second housings 101 and 105 are rotatably coupled to each other in a state wherein the flexible cable 109 is wound in the space, they are rendered to a neutral rotation state, as shown in FIG. 7. Thereafter, as shown in FIG. 8, the cover 112a of the locking member 112 is covered on the direct connector 111 of the second housing 105 and the hole 112d of the arm 112c is fitted with the boss 114. In that state, the boss 114 is heat caulked to fix the arm 112c to the protrusion 113 of the first housing 101. Thus, even if a rotational force is applied to the second housing 105, relative rotation of the first and second housings 101 and 105 could be prevented by the locking member 112 because the protruding casing 111b of the direct connector 111 abuts against a restriction wall of the cover 112a located in the direction of rotation of the protruding casing 111b. Consequently, even if vibrations act on the rotary connector during, for example, transportation, removal of the locking member 112 from the rotary connector would be prevented due to heat caulking of the boss 114. This enables the rotary connector to be assembled in the steering device in the neutral rotation state.
To assemble the rotary connector in the steering device (not shown), the first housing 101 of the rotary connector with the locking member 112 mounted thereon is fixed to the steering column, and a steering shaft is protruded from the shaft insertion hole 108 of the second housing 105. Next, the operator grips the knob portion 112b with a jig or his or her fingers and pulls up the locking member 112. In the pulling process, the thin portions 113a rupture and the protrusion 113 fixed to the arm 112c is separated from the first housing 101. Thus, removal of the locking member 112 from the rotary connector is facilitated, and at the same time, the cover 112a can be removed from the direct connector 111. Thereafter, a steering hub is press-fitted on the steering shaft, and a steering wheel provided integrally with the steering hub is fixed to the second housing 105, whereby the neutral rotation position of the rotary connector can be brought into coincidence with the neutral rotation position of the steering wheel. A connector 110 led out of the first housing 101 through the flexible cable 109 is connected to an external device, such as an air bag driving circuit or a horn circuit, mounted on the car body, and the connector 111 provided on the second housing 105 is connected to an external device, such as an air bag inflator or a horn switch, mounted on the steering wheel.
When assembly of the rotary connector in the steering device is completed, inspection is conducted to check whether or not the rotary connector is connected accurately to the external devices. In this inspection in which electrical connection between the corresponding external devices is checked, if electrical characteristics are satisfactory, electrical connection between the rotary connector and the external devices are determined as satisfactory and the locking member 112 are determined as removed from the rotary connector That is, since this embodiment is designed such that the external devices can be connected to the direct connector 111 only when the cover 112a formed integrally with the locking member 112 has been removed, whether or not the locking member 112 has been removed can be determined by inspecting electrical connection between the rotary connector and the external devices, and production of defective articles due to the locking member 112 being accidentally left on the rotary connector can thus be prevented.
In the above-described arrangement, when the steering wheel is rotated clockwise or counterclockwise, the rotational force of the steering wheel is transmitted to the second housing 105, rotating the second housing 105 in the same direction as that in which the steering wheel is rotated. For example, when the steering wheel is rotated counterclockwise from a rotation neutral position, the second housing 105 also rotates counterclockwise together with the steering wheel, making the flexible cable 109 wind toward the inner cylindrical portion 107. Conversely, when the steering wheel is rotated clockwise, the second housing 105 also rotates clockwise together with the steering wheel, making the flexible cable 199 unwind toward the outer cylindrical portion 103. In either state, electrical connection between the housings 101 and 105 is maintained through the flexible cable 109.
In the fifth embodiment of the invention, since the cover 112a for protecting the direct connector 111 of the second housing 105 is formed integrally with the locking member 112 for inhibiting free rotation of the housings 101 and 105, protection of the direct connector 111 can be achieved when the locking member 112 is mounted on the rotary connector. Thus, it is not necessary for the direct connector 111 to be covered with a covering member, facilitating the assembly operation. Furthermore, since the cover 112a has the restriction wall which abuts against the protruding casing 111b of the direct connector 111 in the direction of rotation thereof, that is, since the direct connector 111 constitutes part of the locking mechanism, it is not necessary for the second housing 105 to be provided with a rotation stopping member which is to abut against the locking member 112, simplifying the locking mechanism. Furthermore, since the locking member 112 is fixed to the protrusion 113 of the first housing 101 to prevent slip off of the locking member 112 from the rotary connector, it is not necessary for the cover 112a to be mounted tightly on the direct connector 111, thus simplifying mounting and removal of the cover 112a.
FIG. 9 is a perspective view of essential parts of the rotary connector according to a sixth embodiment of the present invention. Reference numerals in FIG. 9 identical to those in FIGS. 7 and 8 represent similar or identical elements.
The sixth embodiment of the invention differs from the fifth embodiment in that the cover 112a of the locking member 112 is shaped in the form of a flat plate and in that a pair of restricting pins 115 are erected on the second housing 105 as rotation stopping members of the locking member 112. The other structure of the sixth embodiment is the same as that of the fifth embodiment. In that case, although the cover 112a has only the protection function of covering the upper opening of the connector 111, since the arm 112c abuts against the restriction pins 115 in the direction of rotation of the second housing 105, relative rotation of the first and second housings 101 and 105 is prohibited by the locking member 112. In that case, the simple structure of the restriction pins 115 is enough to prevent relative rotation of the first and second housings 101 and 105.
While the fifth and sixth embodiments of the invention are substantially shown in FIGS. 7 to 9, wherein the first housing 101 acts as the fixing member while the second housing 105 serves as the movable member, alternate embodiments of the invention might include a rotary connector wherein the second housing 105 serves as the fixing member and the first housing 101 serves as the movable member.
Similarly, the direct coupling type direct connector 111 is shown in the fifth and sixth embodiment as being provided only on the second housing 105 with the externally extending connector 110 provided on the first housing 101, alternate embodiments might contemplate a rotary connector wherein the connectors which are to be provided on both the housings 101 and 105 are direct connectors and a rotary connector wherein one end of the locking member is fixed to the second housing 105 with the direct connector covered with a cover being provided on the first housing 101.
Similarly, while the locking member 112 is shown in the fifth and sixth embodiments as being fixed to the protrusion 113 by heat caulking the boss 114 which has been fitted with the hole 112d formed in the locking member 112, alternate embodiments might include the locking member 112 that is fixed to the protrusion 113 by merely press-fitting the boss 114 into the hole 112d to simplify the process and thereby facilitate the assembly operation. Alternatively, the locking member 112 may have a boss with the protrusion 113 having a hole, unlike the cases of the above-described embodiments. Similarly, while the thin portions 113a are shown in the fifth and sixth embodiments as being provided at the proximal end of the protrusion 113, alternate embodiments of the invention might include thin portions that are provided at a breaking point of the locking member 112 alone or that are provided on both the locking member 112 and the protrusion 13.
As will be understood from the foregoing description, in the present invention, even though the number of conductors of the flexible cable and the number of terminals of the direct connector which are connected to the respective conductors are increased, the air bag conductor and the terminal connected thereto are electrically insulated reliably from the other conductors and terminals, thus making the provision of a rotary connector suitable for use with multiple circuits possible.
Furthermore, in the present invention, since the locking member is mounted relative to the both housings which have been positioned to a rotation neutral position in the manufacturing process of the rotary connector, free rotation of the housings is locked and the direct connector provided on the housing is protected, thus simplifying the assembly operation. Further, when the locking member is removed from the two housings in the process of assembly of the rotary connector in a steering device, the two housings are unlocked while the cover is removed from the direct connector. Thus, whether or not the locking member has been removed can be determined by inspecting electrical connection between the rotary connector and external devices, and the locking member being accidentally left on the rotary connector can be reliably prevented.
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A rotary connector including a first housing rotatably connected to a second housing and forming an annular space therebetween, and a flexible cable wound within the annular spacing. According to a first aspect, the conductors of the flexible cable associated with an airbag circuit are spaced further apart than conductors for other circuits mounted on a steering wheel. A direct connector includes first terminals connected to the airbag conductors and second terminals connected to the other conductors. The first and second terminals are spaced apart and/or divided by a divider to prevent interference during assembly. In accordance with the second aspect, a locking member for preventing relative rotation of the first and second housings prior to assembly on a vehicle includes a cover portion for covering an open end of the direct connector.
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TECHNICAL FIELD
This invention relates to a method and apparatus for playing a video game among a plurality of players over a telephone network.
DESCRIPTION OF THE PRIOR ART
Today, there are many two-person video games available for machines such as Sega's Genesis, Nintendo's SNES, Atari's Jaguar, etc. However, if two persons want to play any of these games, they must be physically present at the same location and must engage the game with one game machine.
Imagine the situation that two persons have any existing but the exact same game machines (say, Sega's Genesis) and the exact same game software (cartridge or CD-ROM based) but these two persons are located at physically distant locations. Can they play the game over telephone network?
The primary problem of playing games over telephone network is keeping the game synchronized. There are two distinct ways to achieve the game synchronization; state synchronization and I/O synchronization. The state synchronization requires that the state of one machine's game space be transmitted to the rest of the machines, thus it requires hardware and software modifications to existing stand-alone game machines. The I/O synchronization, on the other hand shares players actions only, thus the game synchronization could be achieved by creating add-ons to existing stand-alone game machines. The article titled "Net-Play: A High-Energy Network Solution" by Andre LaMothe, published in Game Developer, June 1994 describes the above two synchronization approaches for networking games.
U.S. Pat. No. 4,570,930 to Thomas G. Matheson proposes new game machines which can be interconnected over the telephone line for networked games. This patent solves the video synchronization problem by one machine transmitting frame count information and position data to other machines. This solution is applicable to creation of new game machines only.
U.S. Pat. No. 5,292,125 to Peter A. Hochstein and Jeffrey Tenenbaum offers add-ons to any existing game machines for networking games, and is incorporated herein by reference. This patent claims that multi-party video games could be played over telephone network if local-payer's action-input is delayed to compensate the arrival delays experienced by the remote-player's actions. This delay insertion to local player's actions provide fairness to players. However, this solution does not guarantee that all game machines receive the players actions in same sequence. Thus, this invention may work in games where the sequence of actions entered by the players does not influence the progress of the game.
There is, therefore, a need for an apparatus and method of playing a video game over a telephone network where each video game machine receives the same sequence of player actions at the same speed. That is, the video game is played synchronously among the players.
SUMMARY OF THE INVENTION
It is, therefore, an object of this invention to insure that each of a number of video game machines receive at the same speed the same sequence of control signals representing actions of individual players playing the same video game with each other over a telephone network.
Accordingly, this invention provides a method and apparatus for playing a video game by a plurality of players at different locations from each other over a telephone network. With this invention, a video representation of the video game being played is stored at each of the locations. Control signals representing the actions of the players in playing the video game are transmitted over the telephone network to a selected one of the locations of the players. The control signals are then sequenced at this location and stored in a queue. The video game is then played at each of the locations synchronously by reading the sequence control signals from the queue at each of the locations and sending these signals to corresponding ports of a video game at each of the locations.
This patent creates an add-on unit to any existing game machine without requiring any modification to either the game machine or the game software. By connecting over a telephone network, two persons who are located at physically distant locations can play the game. The only requirement is that each person has the exact same game machine, the exact same game software and the add-on unit. Since the only information exchanged between game machines over telephone network are players actions and machine-clock related information, any deterministic (cf. random games) games based on cartridge and CD-ROMs could be played over the telephone network.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a standard video game machine.
FIG. 2 schematically illustrates the networking units used in this invention as well as the environment in which the invention is used.
FIG. 3 schematically illustrates the network unit of this invention operating in the "master" mode.
FIG. 4 schematically illustrates the networking unit operating in "slave" mode.
FIG. 5 schematically illustrates the action pacer, which insures synchronous delivery of the control signals representing player actions to each of the ports of the video games at the player locations.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 depicts a general functional view of a video game machine. A video game machine 100 usually has two control ports 101 and 102 for two players to which game control gears, Control Units 103 and 104, can be attached. This machine 100 also has a game port 105 to which a game 110 (usually in cartridge or CD-ROM form) can be attached. A game machine 100 has memory 106 to store a part of a game software 110, a scanner 107 which scans the ports 101 and 102 to determine the actions by players and a graphic/video rendering logic 108 which creates graphic images for a TV set 109.
FIG. 2 illustrates the conceptual view of Networking Units 201 and 202 as well as the connections between the TVs 109, video game machines 100, and Control Units 103 and 104. Networking Unit 201 (or 202) is placed between a video game machine 100 and a player's Control Unit 103 (or 104). It is also connected to a phone network 203 via modem. This figure assumes that the left hand side player's Networking Unit 201 is a "master", and the right hand side player's Networking Unit 202 is a "slave". Each Networking Unit 201 (or 202) has Action Queue 204 of queue length one or more. Networking Unit 201 on the "master" side is shown in detail (FIG. 4 shows Action Queue 407 of the "slave" machine 202). The use of actions sequenced in one Action Queue 204 by game machines 100 will guarantee that both machines will receive the players actions in the same order. "Slave" player's actions P2 will be transmitted to the "master" Networking Unit 201 which will merge "slave" player's and "master" player's actions P2 and P1 into Action Queue 204. These actions, stored in Action Queue 204, are fed into the "master" video game machine 100 and also sent to the "slave" Networking Unit 202 to feed the "slave" video game machine 100.
Assuming one-way networking delay of "d" msec, the "slave" player's actions will experience delays of d msec relative to the "master" player's actions. The "slave" player Player 2 experiences 2d msec delay between his action and the action being reflected on his TV screen 100. The delay, d, is expected to be about 5 msec for local connections and up to 30 msec for long distance connections within mainland USA. Sometimes this round trip delay 2d experienced by the "slave" side player Player 2 is considered unfair. In order to remedy this situation, an optional feature of inserting delays at appropriate places in the "master" Networking Unit can be considered. Referring to FIG. 3, delay 301 in front of Action Buffer 1 (304), and delays 302 and 303 after Action Queue 204 of the "master" Networking Unit 201, will eliminate the perceived unfairness. A simple way to compensate for the delay is to assume a fixed delay of 5 to 10 msec for d of the "master" Networking Unit 201. However, there is prior art in measuring the round trip delay 2d by looping the telephone network during setup. Once the delay has been measured, the delay values d at places 301, 302 and 303 in the "master" Networking Unit 201 can be set automatically.
To make the networked games more enjoyable, Networking Units 201 and 202 will support speaker phone or headset. Thus, the players can also converse while they are playing the game.
FIG. 3 illustrates the functional diagram of the networking unit when it is operated in the "master" mode with the phone connection ON. The mode of operation (Master Mode or Slave Mode) is agreed upon by the players when the players make connections over the telephone network. Networking Units 201 (and 202) comes with Master/Slave mode switch 320. FIG. 3 shows switches 321 and 322 and their connections when the master mode has been selected (FIG. 4 shows the same switches but labeled 421 and 422 and their connections when the slave mode has been selected). The "slave" side player actions are received through Mux/Demux 307 and Modem 308 and then S/P 309 (serial to parallel converter) to Action Buffer 2 (305). Scanner 311 scans Action Buffer 1 (304) and Action Buffer 2 (305) alternatively, sequences the players actions from both buffers, and stores them into one Action Queue 204. Each action stored in Action Queue 204 comes with identifier P1 or P2 so that each action can be associated with its corresponding player. Each action in Action Queue 204 is fed into the appropriate player ports 312 and 313, and to the P/S 318 (parallel to serial converter) which is connected through the Modem 308 to the telephone network 203, to feed the "slave" machine 202.
Game machines, even though they are exactly the same, often come with slightly different clocks, thus making frame generation and I/O polling different and eventually games become out of synchronization. To remedy this situation, this patent uses the concept of "action pacing" in which the faster machine inserts "null" actions to match the speed of the I/O polling of the slower machine. Referring to FIG. 3, Action Pacer 314 receives the I/O polling signal from the player port 312 and send it to the other machine via Modem 308. Action Pacer 314 also receives the I/O polling signal at the player port 412 of the other Networking Unit 202 via Modem 308. Action Pacer 314 then determines which game machines 210 or 220 (these machines 210 and 220 are identical to the machine 100, but numbered differently for ease of reference) is running faster. If its own machine 210 is faster, it will then send a signal to Pacer Switch 315 which will then get null actions from Null Action Queue 316, and sends them to P1/P2 Switch. The switching of Pacer Switch to Null Action Queue 316 lasts for twice of the game player port polling period and then it switches back to Action Queue 204. The switching position of P1/P2 SWITCH is controlled by P1 and P2 information fed by Action Queue 204 or by Null Action Queue 316.
FIG. 5 illustrates the functional diagram of Action Pacer 314 (or 414). Action Pacer 314 (or 414) receives the local game port polling signals from 312 (or 412) and updates Local Poll Counter 501. Action Pacer 314 (or 414) also receives the remote game port polling signals from Modem 308 (or 417) and updates Remote Poll Counter 502. Comparator/Subtractor 503 receives the counter information L from Local Poll Counter 501 and the counter information R from Remote Poll Counter, compares L and R and feeds the difference to Difference Counter 504. Comparator/Subtractor 503 also generates a control signal when L is greater than R and sends the signal to Comparator 506. Comparator 506 receives the counter value A from Difference Counter 504 and the counter value B from Null Action Counter 505, and compare the value A with the value B+1. If A is greater than B+1, Pacer Switch Controller 507 sends a signal to Pacer Switch 315 (or 408) as well as increments Null Action Counter 505 by one. All counters in Action Pacer 314 (or 414) must be reset at the starting time of a game play. Remote Poll Detector 508 detects the receipt of the first remote polling signal and then reset Local Poll Counter 501, Remote Poll Counter 502, Difference Counter 504 and Null Action Counter 505.
FIG. 4 illustrates the networking unit when it is operated in the "slave" mode and the phone connection is ON, and the connections of switches 421 and 422. The "slave" mode is set when the player depressed the slave side of the Master/Slave mode switch 420. The player's actions here are captured in its Action Buffer 1 (404), and then transmitted through P/S 415, Modem 417 and the telephone network 203 to the "master" game machine 201. This "slave" Networking Unit 202 will receive the sequenced players actions from the "master" Networking Unit 201, through the network 203, Mux/Demux 418, Modem 417, S/P 416 and into its Action Buffer 2 (405). Scanner 406 ignores Action Buffer 1 (404) in the Slave mode. Each action stored in Action Queue 407 is then used to feed the appropriate player ports 412 and 413. In the slave mode, the delays 401, 402 and 403 of Networking Unit 202 becomes "inactive".
Action Pacer 414 receives the I/O polling signals from the port 412 and sends them to Modem 417 so that the signals can be received by Action Pacer 314 of the "master" Networking Unit 201. Action Pacer 414 also receives the I/O polling signals at the player port 312 of the "master" Networking Unit 201 via Modem 417. It then determines which game machines 210 or 220 is running faster. If its own machine 220 which is attached to the "slave" Networking Unit 202 is running faster, it then determines when to insert null actions and instruct Pacer Switch 408 to scan in null actions from Null Action Queue 411. The function block diagram of Action Pacer 414 (or 314) is illustrated in FIG. 5.
Although it is not illustrated here, Networking Units 201 and 202 will come with an ON/OFF switch for telephone.
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A method and apparatus for playing the same video game by a number of players at remote locations over a telephone network. More specifically, a video representation of the game played by a number of video game players stored at each of the player locations. The control signals representing the actions of the players are then transmitted to a single one of the locations where the control signals are sequenced. The sequence control signals are then stored in a queue wherein the video game is played at each of the locations by synchronously reading the control signals from each queue at each of the locations and sending them to corresponding ports of each video game at each location.
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BACKGROUND OF THE INVENTION
The present invention relates to a vacuum panel manufacturing process, and in particular a process utilizing a powdered insulation material which is first evacuated of gases and subsequentially loaded and hermetically sealed into an impermeable barrier bag.
Vacuum insulation panels are useful in a variety of environments, and in particular in conjunction with refrigeration apparatus in which they are utilized as insulating panels in the walls of refrigerators and freezers.
Typically a vacuum insulation panel has some type of insulating material, generally microporous powders or microporous sheets of insulating material which are placed into a non-porous bag comprising flexible gas impermeable walls and, after evacuation of all gases, the bag is sealed. Such panels and a method for fabricating them are disclosed in U.S. Pat. No. 5,018,328, assigned to Whirlpool Corporation, the assignee of the present application, the disclosure of said patent being incorporated herein by reference, as well as in U.S. Pat. Nos. 5,076,984 and 4,683,702.
U.S. Pat. No. 4,554,041 discloses a vacuum insulated pipe in which the evacuated insulating space is filled with powder from an evacuated hopper. German Patent 40 40 144 discloses a method for filling a bag with dust-like material wherein the bag and the dust-like material are vacuum evacuated prior to and during filling of the bag.
SUMMARY OF THE INVENTION
The present invention provides a method for manufacturing vacuum panels in a significantly improved process over other presently known processes.
In an embodiment of the invention, the microporous powder is initially heated and dried and transferred, under a dry nitrogen or dry air blanket, to a hopper. In the hopper, the powder is evacuated of gases (preferably while the powder is hot) and then transferred to a metering hopper.
Separately, the barrier bags are moved into an air lock chamber where gases are evacuated and, subsequent to the evacuation, the bags are moved into a filling chamber. In the filling chamber the metering hoppers are actuated to cause the evacuated powder to be dispensed into the bags to fill the bags. Once the bags have been filled they are heat sealed closed. As an option, after the bags have been filled with the evacuated powder, and just prior to sealing of the bags, a small and specific amount of helium (preferably at a pressure of less than 1 mm Hg) can be injected into the bag which is then immediately sealed in order to allow for helium leak testing of the panel as disclosed in copending application Ser. No. 635,489, filed Dec. 28, 1990, the disclosure of which is incorporated herein by reference.
The panels are then formed into a final shape, after having been sealed, and then the panels are moved into an outfeed air lock chamber where the bags are reintroduced to atmospheric air pressure. The bags are then moved to a deposit area as completed panels.
Preferably a plurality of bags are formed into panels at the same time in the filling chamber in order to reduce the average cycle time per panel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart schematically illustrating an embodiment of the method of the present invention.
FIG. 2 is a schematic illustration of the equipment layout for the implementing.
FIG. 3 is a schematic plan view illustration of the equipment layout for implementing the present invention.
FIG. 4 is a side sectional view illustrating the bag filling apparatus utilized in the method of the present invention.
FIG. 5 is a side sectional view of the bag filling apparatus taken at 90° to that illustrated in FIG. 4.
FIG. 6 is a side sectional view of a heat sealing apparatus used to seal the vacuum panel.
FIG. 7 is a side sectional view of the heat sealing apparatus taken 90° to that illustrated in FIG. 6.
FIG. 8 is a plan view of the heat sealing apparatus in the operation.
FIG. 9 is a plan view of the heat sealing apparatus in the closed position.
FIG. 10 is a schematic plan view illustration of an alternative layout for implementing the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 there is illustrated an embodiment of a method for manufacturing a vacuum insulation panel. In this panel, a microporous powder is used as the insulating material. Step 20 shows a step of delivery of the powder from a delivery vehicle. The powder is delivered to a powder supply device, such as a storage hopper in step 22. The powder is then processed in step 24 such as by heating, drying and optionally subjecting it to a vacuum in order to remove moisture from the powder. The heating of the powder at this stage, to remove moisture, can occur at temperatures up to 400° F. (205° C.) or higher if desired. The dry powder is then transferred in step 26 to a storage hopper where it will be evacuated of gases (preferably while the powder is still hot) if that has not already been accomplished. From the storage hopper, the powder is transferred to a metering hopper as indicated in step 26.
The vacuum insulation panel is made with gas impervious barrier bags, preferably having multiple compartments within each bag. In a preferred embodiment, the bag consists of two compartments which are fabricated simultaneously by heat sealing three layers of plastic flexible barrier films (two vacuum metalized plastic films and one aluminum foil plastic laminate film) at one time. Three of the sides are sealed closed and the fourth side of the bag is left open in order to receive the powder. As indicated in step 28, the barrier bags are delivered and evacuated of gases.
Next, in step 30, the bags are moved into a filling chamber in which the powder from the metering hoppers is dispensed into the bags. This filling chamber is maintained under a vacuum so that the transfer of the powder into the bag occurs under vacuum as well.
After the bag compartments have been filled with powder, in a preferred embodiment, a small trace amount of helium (preferably below 1 mm Hg pressure) is injected into each of the compartments and then the bag is immediately sealed. Once the bags are sealed into panels, the panels are preferably pressed into a final shape in the form of a flat board-like panel and then the panels are reintroduced to atmospheric pressure.
If the panels have been injected with helium, a leak test as indicated in step 32 can be conducted on the panels to insure the vacuum integrity of the panels. The testing can be done in accordance with the teachings of copending application Ser. No. 635,489, filed Dec. 28, 1990, now abandoned, the disclosure of which is incorporated herein by reference. Upon completion of the leak test, the panels are completed as indicated in step 34 and are moved to a storage area.
FIGS. 2 and 3 illustrate a schematic equipment layout for an automated version of the process described in FIG. 1. The powder is transferred from bags 40 by means of a powder pickup wand 42 through a conduit 44 and a pneumatic transfer mechanism 46 to a dryer 48 (which may be an atmospheric dryer or a vacuum oven) to dry the powder. The dried powder is then transferred through a conduit 50 to one of two storage hoppers 52, 54, which can be supplied with a dry nitrogen or dry air internal atmosphere through conduit 56. Valves 58, 60 are used to selectively direct the powder to one of the two hoppers 52, 54. The powder supplied to each of the two hoppers 52, 54 may vary somewhat in that two compartments are provided in the vacuum insulation panels in the preferred embodiment. For example, different types of gettering material may be used in each of the two compartments as disclosed in U.S. Pat. No. 5,091,233, the disclosure of which is incorporated herein by reference. The hoppers 52 and 54 feed into metering hoppers 62, 64, all of which are maintained under vacuum by means of a hopper vacuum system 66 connected to the hoppers by a conduit 68. In a preferred embodiment, the evacuated pressure in the hopper is less than 2 mbars, preferably around 0.5 mbars.
Barrier bags 69 (FIG. 4) are stored in an area 70 (FIG. 3) and a selected number of bags are transported by an automatic conveyor 72 into an infeed air lock chamber 74.
The bags 69 are attached to a clamping device which includes a spread finger to hold a top end of the bag open. A spreading of each compartment to around 15 mm has been determined to be sufficient to fill the bag successfully (this might vary depending on the final thickness of the panel). Preferably two fixed fingers are used on one side and two separately attached spring loaded fingers are used on the other side. The spreading device is mounted on a carriage which preferably is designed to carry multiple bags 69 for the simultaneous production of multiple panels. The entire carriage is then moved into the chamber 74. Once a door 76 of the chamber 74 has been closed and the chamber has been evacuated by means of a vacuum pump 78, preferably to a pressure of approximately 0.5 mbar, a set of doors 80 are opened permitting the selected and now evacuated bags 69 to be moved into an evacuated filling chamber 82. The filling chamber 82 preferably is positioned directly below the powder storage hoppers 52, 54. Within the filling chamber 82 are a plurality of filling nozzles 84 (FIGS. 4 and 5) which can be inserted into the bags 69 for filling the bags. The nozzles 84 are preferably in the shape of funnels with a width at least 80% of the width of the bags 69. Each nozzle 84 has two internal passages 86, 88, one for feeding each of the two compartments 87, 89 of the bag. Each passage 86, 88 is supplied by a short transfer tube 90, 92 which in turn connects with an auger conveyor 94, 96 which communicates with the metering hoppers 64, 62. A lower end of each tube is positioned above a roof type flow deflector 98 to spread the flow of powder. The funnel nozzles 84 may be vibrated, for example at 100 Hz, to achieve even flow and reduce adhesion of powder on the nozzle wall.
The nozzles 84 are carried on extendable arms 100 (FIG. 5) which permit the nozzles to be extended down into the open mouth 102 of the bags. The bags 69 are held between rigid panels 104 which maintain the bags 69 in a substantially planar shape as they are being filled. Means may be provided for compacting the powder in the bags 69, such a means for vertically vibrating the bags as they are filling, or means for compressing the space between adjacent panels 104 to compact the powder in the interposing bags 69. For example, vibration of a 2 mm stroke at 20 Hz provides significant compaction. A crank shaft can be mounted below the carriage to provide the vertical vibration during filling.
After the bags have been filled and compacted, they are moved to a heat seal station which may be in a separate, evacuated chamber 106 from the filling chamber 82. At the heat seal station, if desired, a small trace amount of helium (preferably below 1 mm Hg pressure) can be injected into the bags by an appropriate nozzle 108 before they are sealed closed. In order to seal the bags, a plurality of impulse heated seal bars 120, 122 are carried on retractable rods 124, 126 operated by extendable actuators 128 which permit the heating bars to be moved toward and away from one another. The open ends of the bags are moved into a position between the spaced apart bars (FIG. 8), and then the bars are moved towards one another (FIG. 9), after the spreading fingers are removed from the mouths of the bags while at an elevated temperature to press the open edge of the bags together and to heat seal the open end.
After the bags have been sealed closed, they may be moved to an outfeed air lock chamber 140 (FIG. 3) where they are tested for leaks and then reintroduced to a normal atmospheric pressure. Alternatively the heat seal chamber 106 may act as the chamber for reintroducing the sealed bags to atmospheric pressure and subsequently the panels may be tested for leaks at a separate station. The bags are then transferred by an automatic conveyor 142 to a completed storage location 144.
An alternate embodiment of the manufacturing process is illustrated in FIG. 10. A selected number of barrier bags are transported by an automatic conveyor 72 directly into the filling chambers 82 which are initially at atmospheric pressure. Then the sliding doors 76 of the filling chambers 82 are closed and the filling chambers 82 are evacuated by means of vacuum pumps 66, preferably to a pressure of approximately 0.5 mbar. After the bags have been filled and compacted, they are moved to a heat seal station which may be in a separate, evacuated chamber 106 from the filling chamber 82. Once the bags have been sealed closed, the heat seal chamber 106 may act as the chamber for reintroducing the sealed bags to atmospheric pressure. The bags are then transferred by an automatic conveyor 142 to a completed storage location 144 for subsequent leak testing at a separate leak test station.
As is apparent from the foregoing specification, the invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceding specification and description. It should be understood that we wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of our contribution to the art.
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A method for manufacturing a vacuum insulation panel is provided which includes the steps of: drying a quantity of microporous powder; evacuating the powder of gases; evacuating a gas impermeable bag of gases; loading the powder into the gas impermeable bag while the bag and powder remain in an evacuated condition; and sealing the gas evacuated bag with the gas evacuated powder therein to form a vacuum insulation panel. The powder in the bag should be compacted before the bag is sealed and also a trace amount of helium may be injected into the bag prior to sealing to assist in leak detection of the sealed panel. The panel with injected helium has an internal pressure not exceeding 1 mm Hg.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a multi-layer, high-temperature corrosion protection coat for metallic surfaces.
2. Description of the Prior Art
Corrosion protection coatings for high operating temperatures are generally used in machine construction. The main field of application of such high-temperature protection coatings is found in the area of thermal fluid flow engines, particularly on components subject to high stress, such as gas turbine blades. These coatings serve the purpose of extending the life of the protected high-temperature materials.
The protective coatings known to the prior art are, in general, based on the protective effect of the oxides of chromium, aluminum and silicon, as well as alloying elements (yttrium), either individually or in combination (see for example, U.S. Pat. No. 3,676,085; U.S. Pat. No. 2,754,903; U.S. Pat. No. 3,542,530; German Pat. No. 2,520,192). Prior art coatings are also based on silicate layers based on Ni/Cr/Si/B alloys (see for example, Villat, M., Felix, P., "High-Temperature Corrosion Protection Coating for Gas Turbines", Technische Rundschau Sulzer 3, 1976, Pages 97 to 104).
The customary corrosion protection coatings for high-temperature applications are mostly specifically designed for resistance against certain corrosive agents. However, in the cases of corrosion by a multiplicity of agents, the anti-corrosive behavior of prior art coats is usually unsatisfactory. Thus, the protective coatings made from Cr, Al and Si have generally favorable characteristics in oxidizing atmospheres but fail in the presence of relatively high amounts of sulfur and fuel gases.
Because of their poor resistance to sulfidization, such prior art coatings require the use of relatively pure fuels, a fact which restricts their field of application. Additionally, such protective coatings are often deficient in chemical-physical compatibility with the base material to be protected, whereby the coatings tend to crack and peel. On the other hand, coatings on the basis of Ni/Cr/Si/B are generally quite compatible with the base material but do not have optimum corrosion behavior.
A need therefore continues to exist for a high-temperature corrosion protection coating with staggered protective effect for high operating temperatures which has increased sulfidization resistance with good oxidation resistance at high temperatures. Such a protective coating should have good physical-chemical compatibility with the base material which it covers and should be suitable for the production of solid solutions.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide a high-temperature corrosion protection coat for corrodible metallic surfaces.
A further object of the invention is to provide a corrosion coat which has high sulfidization resistance.
Still a further object of the invention is to provide a corrosion coat having good oxidation resistance at high temperatures.
These and other objects of the invention which will hereinafter become more readily apparent have been attained by providing a multi-layered high-temperature corrosion coat for a corrodible metallic surface which comprises:
(1) a first layer adjacent to said metallic surface comprising 1-15% zirconium, 10-30% chromium and remainder nickel; and
(2) a second layer adjacent to said first layer comprising at least 60% chromium and remainder selected from the group consisting of iron, iron plus nickel, and mixtures thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
FIG. 1 shows the cross-section through a protection coating after the first two layers are applied. Directly on top of the base material 1, which can for example, consist of a super-alloy, is first applied a thin first nickel intermediate coating 2, improving adhesiveness. On top of this thin first nickel intermediate coating 2, follows the coating, serving subsequently as the carrier for protective zone I. The protective zone I consists of a nickel matrix 3 into which finely dispersed zirconium particles 4 are embedded.
FIG. 2 shows the cross-section through a completed protective coating after the layers forming a second protective zone have been applied, wherein an additional structural layer of chromium 5, forms the protective zone II. Due to the pack-chroming effect at various temperatures, several diffusion zones have formed. Diffusion zone 6 between base material 1 and nickel matrix 3 has a relatively high nickel content, while the protective zone I in diffusion zone 7 beneath structural coating 5 of chromium (which is protective zone II) is essentially a nickel/chromium alloy of a variable composition. Diffusion areas or regions 8 of Zr/Ni alloy with a variable zirconium content exist around the zirconium particles 4, whereby the protective zone I, 7, is constituted therein.
FIG. 3 shows the cross-section through a protective coating after the first two layers are applied wherein the figure and reference symbols correspond exactly with the conditions of FIG. 1.
FIG. 4 shows the cross-section through a protective coating after a third layer has been applied, wherein the reference symbols and the zone structure correspond to FIG. 2. Diffusion zones 6 and 8 have come into existence through thermal treatment. The subsequent galvanic application of a chromium layer 5 does not yet result in a diffusion zone between said chromium layer 5 and nickel matrix 3.
FIG. 5 shows the cross-section through a protective coating after two additional layers are applied, wherein the galvanically applied iron layer 10 of the protective zone II is placed on a thin second nickel layer 9 improving the adhesiveness. The remaining reference symbols correspond to preceding FIG. 4.
FIG. 6 shows the cross-section through a completed protective coating comprising several zones wherein after an additional thermal treatment, additional diffusion zones have appeared. A layer 11 of the protective zone II contains predominantly chromium while iron/chromium alloy 12 on top of it delineates the protective zone II towards the surface. The remaining zones and reference symbols correspond to FIG. 2 or 5, respectively.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
It has been determined that very high values of corrosion resistance can be achieved with zirconium/chromium/nickel alloys which, if necessary, may contain other additions. This is generally applicable to alloys of the following composition:
1-15% Zr
10-30% Cr
Remainder Ni
In this context, up to 80 relative % of the zirconium can be replaced by titanium. Yttrium, lanthanum, rare earth and/or beryllium, in contents of 0.05 to 2% can be present in an advantageous manner as additional elements for further improvement of the anti-corrosive properties of the basic alloy. Depending on the process of production of the alloy, furthermore, sinter additions, such as silicon in contents of up to approximately 4% (preferably 3-4%) and boron up to approximately 2% (preferably 1.5-2%), can be included.
The Zr/Cr/Ni alloys of the invention can be favorably combined with pure Cr layers, or Cr/Fe layers, and/or Cr/Fe/Ni layers having a high Cr content to form multi-layer corrosion protection coatings with a favorable zone structure and long-time behavior. Such protective coatings, built in a staggered way, have a long life and a targeted specific anti-corrosion behavior which can be influenced with time. The zone structure of such protective coatings can be expediently controlled by means of intended diffusion processes during the production of the coats themselves (thermal treatment), as well as during operation.
A multi-layer coating can, for example, consist of a first zone on the basis of Zr/Cr/Ni as well as an additional zone on the basis of Cr. However, any suitable combination of customary types of coatings can, in principle, be prepared together with the Zr/Cr/Ni alloy of this invention.
In the initial stage of the corrosive attack, the outer zone first takes over the corrosion protection. Only when, due to the progressive corrosion or due to other influences, this outer zone is no longer effective, the corrision protection of the object is taken over by the subject zone below the outer one.
The production of multi-layer coatings can, in principle, be carried out by means of any combination of actually known process, such as plasma and flame spraying with sinters, galvanic processes, pack cementing, electrochemical separation from fused salt baths, separation from powder suspensions, physical or chemical separation from the gas phase, pyrolysis, plating, or the like.
Multi-layer protective coatings of a deviating composition can also be produced according to the described process. For example, a first protective zone I, can, quite generally, consist of a Zr/Cr/Ni alloy of a variable or approximately constant composition within the limits 1-15% Zr, 10-30% Cr and the remainder Ni. Further additive elements, such as beryllium, yttrium, rare earths, silicon and boron can be contained therein up to an approximate maximum of 5%. A second protective zone II, on the other hand, can in general be a Cr/Fe/Ni alloy which, however, should contain at least 60% chromium. Moreover, protective coatings can also be produced with other staggered sequences of layers. The practical variation possibilities are only limited by the compatibility of the layers with each other, such as by their expansion coefficients, and the like.
Said first layer or zone may have a thickness of 20-120μ and said second layer or zone have a thickness of 30-100μ.
Multi-layer systems and anti-corrosion mechanisms are created by the protective coatings according to the invention. The coatings have zone structures which permit the maximum utilization of the combined materials by their optimizable design targeted for each case of application, and guarantee in their cumulative effect a wide spectrum of anti-corrosive behavior and high operating temperatures. This is particularly shown by an increased corrosion resistance vis-a-vis sulfur-containing agents and in an extended life of the workpiece.
Multi-layer protective coatings can be used in an especially advantageous manner in machine and appliance construction, particularly for components of thermal engines under high thermal and corrosive stress. A preferred field of application is, in this context, represented by the gas turbine and its accessories whereby a wide field opens up for combustion chambers, entrance buckets, moving blades and the like.
Having now generally described this invention, a better understanding can be obtained by reference to certain specific examples which are included herein for purposes of illustration only and are not intended to be limiting unless otherwise specified.
EXAMPLE 1
This example represents the formation of a coating illustrated by FIGS. 1 and 2.
A gas turbine blade of a nickel super-alloy (trade name IN 738 LC) as base material 1 was first degreased and anodically pickled in 20% sulfuric acid. In order to improve the adhesion of the subsequent layer, the base material 1 was provided with a galvanically separated nickel intermediate layer 2 of a thickness of 3 to 4μ. The nickel bath provided for this purpose had the following composition:
300 g NiCl 2 /1 liter H 2 O
60 g HCl/1 liter H 2 O
The temperature during Ni deposition was 20° C., the current density was 3.6 A/dm 2 and the duration was 15 minutes. The blade nickeled in this manner was now placed into an additional nickel for the purpose of simultaneous galvanic separation of a nickel matrix 3, with zirconium particles of a maximum grain size of 5μ being held in suspension in said nickel bath by means of a mechanical stirrer. The nickel bath had the following composition:
600 g nickel sulfamate/1 liter H 2 O
5 g NiCl 2 /1 liter H 2 O
30 g B 2 O 3 /l liter H 2 O
500 g zirconium particles/1 liter H 2 O
The temperature was 20° C., the current density 5 A/dm 2 and the duration was 2 hours. The thickness of the separated layer forming a protective zone I amounted to approximately 120μ. Approximately 10 to 15% finely dispersed zirconium particles 4 were embedded into the nickel matrix 3. Subsequently, the blade was annealed at a temperature of 1040° C. for 1/2 hour in a hydrogen atmosphere. The subsequent step was the chroming after the packing process at a temperature of 1050° C. for 6 hours whereby a reaction chamber was used which, besides chromium-containing powders and ammonium chloride, also contained alumina as inert filler. During this process, a structural layer 5 of chromium develops outside having a thickness of approximately 30μ to 100μ which represents the main constituent element for protective zone II. Owing to the thermal treatment, diffusion zones 7 and 8 develop additionally. The diffusion zone 6 between the base material and nickel matrix 3 has, in general, a thickness of 5μ to 10μ while the diffusion zone 7 (protective zone I) under the chromium structural layer 5 has a thickness of approximately 40μ. At its bordering surface towards the chromium structural layer, its chromium content amounts to approximately 40 to 50% and decreases towards the inside successively to zero. Additionally, around each zirconium particle 4, a concentric, spherical "corona-like" diffusion area 8 is formed of a Zr/Ni alloy with a variable zirconium content by having a portion of the zirconium dissolved in the nickel matrix 3. The remainder is maintained in particle form in the plant for a possible later supply. As a last step in the process, a thermal treatment adapted to the base material 1 was performed. In the case of In 738 LC, it was a solution treatment effected at 1130° C. for 2 hours with subsequent precipitation at 850° C. for 24 hours. The principal zonal structure of the multi-layer protective coating was no longer substantially changed by this final thermal treatment even though certain shiftings in the concentration gradients of the diffusion zones may occur.
Principally, the multi-layer, high-temperature corrosion protection coating consists of the two protective zones I and II. In this connection, the zones enter, in general, into function in their effect successively in time or are in interaction with each other. The high chromium-containing zone II first takes over the protective function but acts at the same time, as the supplier for zone I. The latter has only its full effect when zone II is removed owing to progressive corrosion or erosion attacks or by means of other effects. By means of parallel diffusion processes, particularly on the part of the zironium and chromium, a constant recuperation of the protective coating is effected so that its effective thickness is at least maintained or can even increase during operation.
EXAMPLE 2
See FIGS. 3 to 6. A gas turbine blade of a nickel super-alloy (Trade Name IN 738 LC) as the base material 1 was, in the manner mentioned in Example 1, degreased, pickled and provided with a galvanically separated first nickel intermediate layer 2 and with an also galvanically applied nickel matrix 3 with dispersed zirconium particles 4. FIG. 3 shows the cross-section of this condition. Subsequently, the blade was annealed in hydrogen in accordance with Example 1. After the degreasing of the surface, the blade was additionally galvanically chromed. The chromium bath had the following composition:
240 g CrO 3 /1 liter H 2 O
(Make: SRHS HC 20 from M+D)
The temperature amounted to 40° C., the current density to 50 A/dm 2 and the duration was 3 hours. The thickness of this chromium layer 5 amounted to approximately 80μ. This condition is represented in FIG. 4 after this stage of the process in a cross-section on a schematic basis. Subsequently a second nickel intermediate layer 9, having a thickness of 3 to 4μ, was galvanically applied in the manner indicated in the preceding example whereby the bath conditions were identical to those of the first nickel intermediate layer. Finally, an iron layer 10 with a thickness of approximately 10μ was also galvanically separated. The iron bath had the following composition:
330 g ammonium iron sulfate/1 liter H 2 O.
The temperature amounted to 40° C., the current density to 2 A/dm 2 and the duration was 1/2 hour. FIG. 5 shows the multi-layer protective coating in this state. As a final phase of the process, the blade was exposed to the same thermal treatment (1130° C./2 hours; 850° C.=24 hours) as indicated in Example I. This led to a number of diffusion zones. The already existing zone 6 between basic material and nickel matrix 3 was somewhat broadened while, at the same time, the earlier described zone 7 under the chromium layer developed into the protective zone I with a variable chromium content. The same applies to the diffusion area 8 around the zirconium particles 4. The protective zone II consists now of the layer 11 containing mainly chromium and the outer layer which consists of an Fe/Cr alloy 12. At the border line between 7 and 11, a chromium content of approximately 40% develops after the described heat treatment which recedes to practically zero at a depth of about 30μ of the diffusion zone 7. The zirconium content dissolved in the nickel is still at the original points as finely dispersed particles 4. The protective zone I has, accordingly, a mean zirconium content of 15% corresponding to the initial layer (coating before the diffusion).
In principle, what has been said in Example I applies to the multi-layer coating. During operation, a re-supply of the chromium as well as the zirconium is effected so that the originally existing concentration differences are reduced. The corrosive behavior vis-a-vis pure chromium is further improved by the Fe/Cr alloy 12 and the adjustment to an optimum chromium content is facilitated in the protective zone II.
In order to obtain information on the corrosive resistance of the innermost protective zone alone, crucible corrosion tests and comparative tests were performed with corresponding alloys and with known materials. By doing so, the point of departure was always the Zr/Cr/Ni system and individual components were substituted in additional tests or the alloy was doped with other additives. In this way, the advantageous effect of such substitutions and dopings can be transferred, in an analogous manner, to the multi-layer coatings.
EXAMPLE 3
A Zr/Cr/Ni alloy was produced in a melting-metallurgical manner by weighing and melting the below listed components in a pure clay crucible:
Zr in the form of powder (purity 99.5%): 10 g
Cr in the form of powder (purity 99.5%): 20 g
Ni as pellets (purity 99.5%): 70 g
The melting-down was effected inductively in an argon atmosphere within a period of 10 minutes. The melted mass was maintained at a temperature of 1600° C. for approximately 2 minutes and, subsequently, poured into a copper mold with an inner diameter of 15 mm. The cold sample had the following composition:
10% Zr
20% Cr
70% Ni
Crucible corrosion tests were performed with this alloy in an aggressive fused salt bath at a temperature of 850° C. As a comparison, a parallel sample of the corrosion-resistant nickel super-alloy with the trade name IN 939, as applied to gas turbine blades, was used. The bath of the corrosive medium was composed of 2 parts "A" and "B" wherein "A" consisted in turn of 2 components. The following mass or mol relations existed:
______________________________________"A" = V.sub.2 O.sub.5 /Na.sub.2 SO.sub.4"B" = NaCl"A" :" B" = 2:1 (mass relation)V.sub.2 O.sub.5 :Na.sub. 2 SO.sub.4 = 1:1 (mol relation).______________________________________
Small plane-parallel plates of 10×7×5 mm were prepared from the mentioned samples by cutting and grinding. Nine of such small plates were placed into a firebrick provided with corresponding holes and approximately 0.3 g of the corrosive medium was strewn over it. The samples prepared in this way were subsequently exposed to a temperature of 850° C. in a resistance furnace, chilled in water to room temperature in intervals of 24 hours and, always after the chilling, again strewn with 0.3 g of the corrosive medium and put back into the furnace. The entire test period covered 300 hours. After the test, the samples were metallographically examined in their cross-ground section and the ratio of initial to remaining cross-section or the taken-down depth were determined. A slight taking-down of the depth represents a good corrosion resistance.
On an average, the comparison resulted in the following values for the taken-down depth:
______________________________________Zr/Cr/Ni alloy IN 9390.49 mm 1.5 mm______________________________________
The super-alloy IN 939 has the following composition:
______________________________________0.15% C0.15% Si0.16% Mn0.30% Fe0.07% Zr22.4% Cr19.1% Co3.7% Ti1.85% W1.9% Al1.0% Nb1.4% Ta0.009% BRemainder Ni______________________________________
Alloys of the following composition also proved to be favorable as coats:
______________________________________ 8 to 12% Zr18 to 22% Cr0.05 to 0.5% YRemainder Ni______________________________________
EXAMPLE 4
Zirconium can partially be replaced by titanium whereby additional very favorable alloy coats are obtained having the following composition:
______________________________________ 4 to 6% Zr4 to 6% Ti18 to 22% Cr0.05 to 0.5% Y______________________________________
The following alloy was obtained by melting using the above given process:
______________________________________ 5% Zr 5% Ti20% Cr70% Ni______________________________________
This alloy produced the following value for the taken-down depth, on the average, using the aforementioned crucible corrosion test:
0.30 mm.
EXAMPLE 5
To the Zr/Cr/Ni base alloy it is possible to add additional elements as doping agents. For this purpose it is appropriate to add certain alkaline earth metals and yttrium either in elemental or oxidized form. Following the description of Example 3, the following alloy was obtained by melting:
______________________________________ 10% Zr 20% Cr 0.5% Y.sub.2 O.sub.3 69.5% Ni______________________________________
The taken-down depth in the crucible test was:
0.43 mm
EXAMPLE 6
The element beryllium can also be added to the basic Zr/Cr/Ni alloy as a doping agent. The following alloy was obtained by melting using the above given process:
______________________________________ 10% Zr 20% Cr 1% Be 69% Ni______________________________________
The taken-down depth in the crucible test amounted to:
0.42 mm
EXAMPLE 7
Since the above investigated alloys are used as the innermost zone I of multi-layer coatings for components under high thermal and chemical stress, the possibility or even the necessity may arise under certain circumstances, depending on the process of application on the base material, of using additional elements for the basic alloy. The so called sinter additives represent an example. They are mostly used to obtain layers of a higher density when applying them through flame spraying, plasma spraying, etc. Known sinter additives are silicon and boron. In order to investigate their influence, the following alloy was prepared through melting:
______________________________________ 10% Zr 20% Cr 3% Si 1.8% B 65.2% Ni______________________________________
The taken-down depth in the crucible test amounted to:
0.48 mm.
This shows that the customary sinter additives have practically no effect on the high-temperature corrosion resistance of the basic alloy Zr/Cr/Ni.
EXAMPLE 8
A gas turbine blade of a nickel super-alloy (trade name IN 738 LC) was cleaned, degreased and subjected to a surface treatment by sand blasting. After the gas turbine blade, prepared in this manner, had been preheated to a temperature of 120° C., it was coated using the plasma application process in a protective gas atmosphere (argon) and by utilizing a metal powder mixture. The powder had a grain size from 40μ and 50μ and had the following composition:
______________________________________ 14% Zr 20% Cr 3% Si 2% B 61% Ni______________________________________
In this instance, the actually effective corrosion protection zone I is formed by the alloy consisting of the three substances Cr/Zr/Ni while the silicon and the boron mainly take over the function of sinter additives for the subsequent dense-sintering. The layer applied in the case under consideration had a thickness of 120μ. After the mechanical removal of the superfluous sprayed material, the primarily applied protective layer was dense-sintered under vacuum by the thermal treatment of the coated blade. The temperature amounted, in this case, to 1050° C. and the duration was 2 hours. Subsequently, the blade was subjected to a treatment by mud blasting in order to reduce the roughness of the surface. The corrosion protection zone I produced in this manner had the following composition and structure:
______________________________________Substances dissolved in the matrix: 20% Cr 3% Si 2% B 10% Zr 61% NiParticles finely dispersed in the matrix: 4% Zr______________________________________
Chroming according to the packing process as well as the thermal treatment according to Example 1 were the next steps used in the process.
Having now fully described this invention, it will apparent to one of ordinary skill in the art that many modifications and changes can be carried out without changing the spirit or scope of the invention thereof:
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Multi-layer, high-temperature corrosion protection coat for a corrodible metallic surface which comprises: (1) a first layer adjacent to the metallic surface comprising 1-15% zirconium, 10-30% chromium and remainder nickel; and (2) a second layer adjacent to said first layer comprising at least 60% chromium and remainder selected from the group consisting of iron, iron plus nickel and mixtures thereof. The protective coatings can be used in machine and appliance construction, particularly for components of thermal engines under high thermal and corrosive stress. They are resistant to sulfidization and oxidation.
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BACKGROUND OF THE INVENTION
The present invention relates to a method of operating an anti-lock automotive vehicle brake system for driving stability control and/or traction slip control, including a pneumatic brake power booster operable irrespective of the driver's wish and a master brake cylinder connected downstream of the brake power booster, the pressure chambers of the master brake cylinder being connected to wheel brakes associated with the individual vehicle wheels by way of an ABS hydraulic unit having a return pump.
German patent No. 42 08 496 discloses a brake system, wherein the brake power booster interacts with a solenoid valve to achieve automatically controlled braking operations along with a great deceleration of the vehicle. The solenoid valve permits an enhanced use of the braking pressure upon quick application of the brake pedal. A brake pedal position sensor, a brake light switch and a force sensor permitting detection of the driver's wish for deceleration are provided to achieve the above-mentioned braking pressure control concept. Further, the known brake system includes an anti-lock control system (ABS) which ensures a stable deceleration behavior of the vehicle during braking operations.
However, the patent referred to hereinabove does not provide any specific indications as to how the described brake system could be used for driving stability control.
German patent application No. 42 32 311 discloses a hydraulic vehicle brake system with an anti-lock control device having an auxiliary-pressure source for the improvement of the vehicle directional stability, in particular when cornering, by automatic braking. The auxiliary-pressure source is used to prefill the vehicle wheel brakes and to precharge the return pump. The auxiliary-pressure source, which is provided by parallel connection of an auxiliary pump, a throttle and an auxiliary-pressure limiting valve, is connected to an inlet port of one hydraulic cylinder each. The hydraulic cylinder is connected to the connection between the outlet of an actuating unit, comprised of a brake power booster and a master cylinder inserted downstream of the master cylinder, and the ABS hydraulic unit or the wheel brake. A second inlet of the cylinder is connected to the master brake cylinder, and a separating piston which can be acted upon by auxiliary pressure is guided in the cylinder. The separating piston accommodates a valve which is open in its inactive position and permits a connection between the master brake cylinder and the wheel brake. When the auxiliary pump is started, the separating piston is displaced, with the result that the valve closes the above-mentioned connection and the pressure fluid volume conducted by the separating piston causes prefilling of the wheel brakes and precharging of the return pump.
A disadvantage of this brake system is, however, the comparatively extensive technical effort and structure required to achieve the known method.
SUMMARY OF THE INVENTION
Therefore, an object of the present invention is to disclose a method of operating an anti-lock automotive vehicle brake system of the previously mentioned type which permits being achieved in a simple and low-cost manner by use of component parts which are already provided in the brake system.
A first objective achieved by the present invention involves the actuation of the brake power booster irrespective of the driver's wish upon commencement of the control to prefill the wheel brakes, and the further pressure increase in the wheel brakes is carried out by way of the return pump after completion of the prefilling action.
To measure the hydraulic pressure, introduced by the driver, by way of low-cost pressure sensors, it is favorable that after prefilling of the wheel brakes, the actuation of the brake power booster irrespective of the driver's wish (independent actuation) is deactivated.
In another aspect of the present invention, a favorable supply of the return pump with pressure fluid is achieved because the actuation of the brake power booster irrespective of the driver's wish (independent actuation) is maintained after the prefilling of the wheel brakes. It is advantageous, especially at low temperatures, that aspiration of the pressure fluid from the pressure fluid supply reservoir by way of open central valves, provided in the master brake cylinder, is not required.
In still another aspect of the present invention, the load on the return pump, which is caused during control operations due to the simultaneous actuation by the driver and the independent actuation of the brake power booster, is limited because the actuation of the brake power booster by the driver is sensed and the actuation irrespective of the driver's wish (independent actuation) is reduced accordingly.
To identify the hydraulic pressure introduced by the driver and/or the brake power booster, the hydraulic pressure introduced into the master brake cylinder is continuously determined according to the present invention. To achieve a redundant information about pressure values, the pressure is determined by pressure sensors connected to the pressure chambers of the master brake cylinder according to the present invention. The driver's wish for deceleration may be determined by these values, when the maximum output of the brake power booster is as known.
In a preferred aspect of the present invention, a reliable identification of the driver's wish for deceleration is ensured by sensing the actuating force which is introduced at a pedal actuating the brake power booster.
In another favorable aspect of the present invention, the output pressure of the return pump is limited, preferably to a value recommended for intervention by a car maker.
In still another favorable aspect of the present invention, adequate pressure fluid supply of the return pump is ensured in that the suction side of the return pump can be acted upon by the master brake cylinder pressure.
Further, it is required for the operation that the hydraulic connection between the master brake cylinder and the suction side of the return pump can be opened or closed at any master brake cylinder pressures desired. Preferably, the hydraulic connection is closed only until the pressure fluid volume, which is stored in a low-pressure accumulator connected to the suction side of the return pump, has been conducted to the pressure side of the return pump. It is ensured by this arrangement that the pressure fluid supply of the return pump is not interrupted when the low-pressure accumulator is evacuated.
The second objective achieved by the present invention involves using a volume of pressure fluid, which is stored in a pressure accumulator, for prefilling the wheel brakes upon the commencement of the control.
The dynamics of the above-mentioned pressure control is increased in particular in that the pressure accumulator is connected to the pressure side of the return pump by way of a shut-off valve when the delivery rate of the return pump is not sufficient to perform pressure control operations.
In still another aspect of the present invention, the pressure accumulator is charged when the delivery rate of the return pump is sufficient to simultaneously charge the pressure accumulator and perform the desired pressure control operation, or in the absence of a pressure increase period in any one of the connected wheel brakes. In this arrangement, the charging condition of the pressure accumulator may be monitored by a pressure sensor or a position sensor which determines the position of the pressure accumulator piston, for example.
The present invention will be explained in the following by way of two embodiments, making reference to the accompanying drawings.
BRIEF SUMMARY OF THE DRAWINGS
In the drawings,
FIG. 1 is a first embodiment of an anti-lock automotive vehicle brake system by which the first solution of the method of the present invention may be realized.
FIG. 2 is a second embodiment of an anti-lock automotive vehicle brake system by which the second solution of the method of the present invention may be realized.
DETAILED DESCRIPTION OF THE INVENTION
The brake system of the present invention to implement the method of the invention, as shown, includes two brake circuits I and II having a completely identical design. Thus, the following description of one brake circuit also applies to the other brake circuit. The brake system shown generally includes two braking pressure generators 1, 2 which are operable independently of each other and to which wheel brake cylinders 17, 18 are connectable by way of hydraulic lines (not referred to). Further, the brake system includes an electronic control unit with associated sensor means (not shown) The wheel brake cylinders 17, 18 of the individual brake circuits I, II are associated such that the first wheel brake cylinder 17 either is associated with a wheel of one vehicle axle and the other wheel brake cylinder 18 is associated with the diagonally opposite wheel of the other vehicle axle (diagonal split-up of the brake circuits), or both wheel brake cylinders 17 and 18 are associated with the same vehicle axle (black and white split-up of the brake circuits).
The first pressure generator 1 operable by the driver of the automotive vehicle by way of a brake pedal 6 includes a brake power booster 5, which may be a pneumatic booster, for example. A master brake cylinder, preferably a tandem master cylinder 3, is connected downstream of the brake power booster. The pressure chambers (not shown) of the tandem master cylinder are connectable to a pressure fluid supply reservoir 4. An actuating rod 27 is coupled to the brake pedal 6 permitting actuation of a control valve 8 (shown only schematically) which controls the increase of a pneumatic differential pressure in the housing of the vacuum brake power booster 5. A solenoid (not shown), operable by control signals of the electronic control unit, permits an independent actuation of the control valve 8 irrespective of an actuating force introduced at the brake pedal 6.
A brake light switch 14 which is operatively connected to the brake pedal 6 permits identifying the actuation of the brake power booster 5 by the driver or by an independent actuation. The brake pedal 6 is entrained and the brake light switch 14 is thereby reversed during independent actuation of the brake power booster 5. Actuation of the brake power booster 5 initiated by the driver can be detected by use of a release switch (not shown).
The second pressure generator 2 is configured as a motor-and-pump assembly which includes a hydraulic return pump 7 driven by an electric motor (not shown). The suction side of the return pump is connected to the first pressure chamber of the master brake cylinder 3 by a first non-return valve 24 and an electromagnetically operable switching valve 9. The pressure fluid flows from the pressure side of the return pump 7 to a hydraulic junction 21 by way of a second non-return valve 25 and a damping chamber (not shown). A line portion 38 leading to the first wheel brake cylinder 17 and a line portion 39 leading to the second wheel brake cylinder 18 are connected to junction 21. A hydraulic line 23 connects the pressure side of the return pump 7 to the tandem master cylinder 3. Further, a preferably electromagnetically operable separating valve 10 is interposed between the junction 21 and the master brake cylinder 3. A third non-return valve 31 and a pressure-limiting valve 28 are connected in parallel to the separating valve 10. A parallel connection of an inlet valve 11 with a fourth non-return valve 29 and an outlet valve 12 is used for the modulation of the pressure introduced into the first wheel brake cylinder 17. The mentioned parallel connection is provided in the line portion 38, and the outlet valve 12 permits a connection between the first wheel brake cylinder 17 and a low-pressure accumulator 13 for the reduction of the wheel braking pressure. The low-pressure accumulator 13 is connected to the suction side of the return pump 7 by way of a fifth non-return valve 30.
A second parallel connection of a second inlet valve 15 with a sixth non-return valve 40 and a second outlet valve 16 is provided to control the hydraulic pressure introduced into the second wheel brake cylinder 18 associated with the brake circuit at topic, which is similar to the wheel brake cylinder 17 referred to hereinabove. The mentioned parallel connection is arranged in the line portion 39, and the outlet valve 16 provides a connection between the second wheel brake cylinder 18 and the low-pressure accumulator 13 for the reduction of wheel braking pressure.
To identify pressure variations in the tandem master brake cylinder 3 initiated by the driver, a means to determine the master brake cylinder pressures is provided in both brake circuits I, II which, preferably, is configured as pressure sensors 32, 33 connected to the first and the second brake circuits I, II.
During normal braking operations, pressure increase and pressure reduction in the wheel brake cylinders 17, 18 can be effected by a corresponding operation of the first braking pressure generator 1 by way of the open separating valve 10 and the open inlet valves 11, 15.
The return pump 7 is started during ABS control operations in an imminent locked condition of the wheel associated with the wheel brake 17, for example. Both the switching valve 9 and the separating valve 10 remain non-actuated. The pressure is modulated by correspondingly switching the inlet and outlet valves 11 and 12, and the pressure fluid discharged into the low-pressure accumulator 13 is returned by the return pump 7 until the pressure level of the master brake cylinder is reached.
Upon commencement of each independently actuated braking operation, the brake power booster 5 is actuated irrespective of the driver's wish, during the starting period of the return pump 7, so that the wheel brakes 17, 18 are prefilled. The separating valve 10 is closed and the switching valve 9 is opened for further pressure increase. The result is that the return pump 7 generates a high pressure at the junction 21 which is limited by the pressure-limiting valve 28 to permit individual adjustment of the desired independent braking pressure in the wheel brake cylinders 17, 18 by switching the ABS inlet and outlet valves 11, 13 and 12, 16. After switch-over of the valves 9 and 10, actuation of the brake power booster 5 may be reduced to such an extent that the suction side of the return pump 7 is supplied with a still sufficient pressure fluid flow. The pressure prevailing in the master brake cylinder 3, which was adjusted due to simultaneous operation of the brake power booster 5 by the driver and the independent actuation, is monitored continuously by the pressure sensors 32, 33. It may also be expedient to monitor the actuating force introduced by the driver by way of a force sensor.
Pressure is increased by way of the open inlet valve 11. A period in which the pressure is maintained constant is achieved by switch-over of the inlet valve 11, while pressure is reduced by switch-over of the outlet valve 12, when the inlet valve 11 is still closed. The pressure variation required for the control is produced by pressure increase periods, pressure maintain-constant and pressure reduction periods. The pressure fluid discharged into the low-pressure accumulator 13 is returned by the return pump 7. This is done by the switching valve 9 which adopts its closed condition by way of separation of the suction side of the return pump 7 from the master brake cylinder 3 until the low-pressure accumulator 13 is emptied.
The brake power booster 5 is configured as a known vacuum brake power booster, which is operable only by the brake pedal 6, in the brake system shown in the embodiment of FIG. 2. The design of the brake system corresponds mainly to the brake system previously described with respect to the embodiment of FIG. 1. In the embodiment of FIG. 2, a hydraulic pressure accumulator 20 is connected to the hydraulic junction 21 by the intermediary of a shut-off valve 19. The charging condition of the pressure accumulator 20 is monitored by a pressure or travel sensor 34.
The wheel brakes 17, 18 in the brake system shown in FIG. 2 are prefilled during the starting period of the return pump 7 by opening the shut-off valve 19, with the result that the pressure fluid volume stored in the pressure accumulator 20 becomes available. When the electronic control unit (not shown) detects that the fluid flow through the shut-off valve 19 changes its direction to the effect of charging the pressure accumulator 20, the entire pump fluid volume is supplied for further pressure increase to the wheel brakes 17, 18 by closure of the shut-off valve 19.
As soon as the running return pump 7 has reached its nominal delivery rate, or in the absence of need of pressure increase in any one of the wheel brakes 17, 18, the shut-off valve 19 may be re-opened to permit recharge of the pressure accumulator 20.
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The present invention discloses a method of operating an anti-lock automotive vehicle brake system for driving stability control and/or traction slip control (DSC/TCS) including a brake power booster operable irrespective of the driver's wish. According to this method, the brake power booster is actuated irrespective of the driver's wish for prefilling the vehicle wheel brakes, and further pressure increase in the vehicle wheel brakes upon completion of the prefilling action is carried out by the ABS return pump.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application Ser. No. 61/487,086, filed on May 17, 2011, and entitled, “A System for Expanding High Density Non-Adherent Cells.” The disclosure of the above-identified application is hereby incorporated by reference in its entirety as if set forth herein in full for all that it teaches and for all purposes.
BACKGROUND
Cell expansion systems can be used to grow stem cells, as well as other types of cells, both adherent and non-adherent. Adherent cells require a surface for the cells to attach to before they will grow and divide. Non-adherent cells will grow and divide while floating in suspension.
Cell expansion systems provide nutrients to the growing cells and remove metabolites, as well as furnish a physiochemical environment conducive to cell growth. Cell expansion systems are known in the art.
As a component of a cell expansion system, a bioreactor, or cell growth chamber, plays an important role in providing an optimized environment for the expanding cells. There are many types of bioreactors known in the art. Bioreactor devices include culture flasks, roller bottles, shaker flasks, stirred-tank reactors, air-lift reactors, and hollow fiber bioreactors.
SUMMARY
Embodiments of the present disclosure generally relate to providing an environment conducive to high density non-adherent cell growth. Numerous factors may influence cell growth, including, for example, temperature, the geometries of the cells, etc. In particular, non-adherent cells expand based at least in part on the amount, or volume, of cell growth media available to them, in which increasing volumes of media promote increased cell growth. Cell density may affect not only the ability of cells to grow, but also the cell characteristics themselves. Therefore, if large amounts, or numbers, of non-adherent cells are desired, a large amount, or volume, of fluid should generally be available.
Aspects of particular embodiments provide for the expansion of high density non-adherent cells through the combined use of a cell growth chamber, a mass transfer device, or bioreactor, and a fluid circulation loop(s). Cell growth in the cell growth chamber is particularly promoted by using a cell growth chamber having a specialized shape and/or particular orientation that relies on the use of gravity to create a media-rich reservoir for cells to grow in. By vertically positioning the cell growth chamber, gravitational forces cause cells to accumulate in the lower portion of the cell growth chamber, in which such lower portion includes a media-rich reservoir for cell expansion.
According to embodiments of the present disclosure, the use of a cell growth chamber in conjunction with a mass transfer device and a fluid circulation loop creates efficiencies in cell expansion by relying on the cumulative and combined features of the devices. For example, in an embodiment, a majority of cells in the cell growth chamber are caused to settle to the bottom, or lower portion, of the cell growth chamber by gravitational forces. While some cells may exit the top portion of the cell growth chamber with the circulating media, most cells will settle into the media-rich reservoir of the lower portion of the cell growth chamber where cells can thrive and grow. Meanwhile, oxygen- and nutrient-depleted media, with some cells according to embodiments, exits the cell growth chamber. This circulating media enters the intracapillary space of the mass transfer device while fresh media, oxygenated by an oxygenator, enters the extracapillary space of the mass transfer device. The circulating media is replenished by nutrients and oxygen diffusing through the extracapillary space into the intracapillary space. Waste in the circulating media may also be diffused from the media into the extracapillary space. The replenished and cleaned media then flows through the outlet port of the mass transfer device to travel to the cell growth chamber to replenish its reservoir of media. Cells in the cell growth chamber are thus able to receive the nutrients they need for increasing expansion while remaining in the media-rich lower portion of the cell growth chamber.
Additional efficiencies are created in embodiments which rely on the cumulative and combined features of the devices. For example, the different characteristics and features of the cell growth chamber, mass transfer device, and fluid circulation loop allow for different cell types and/or sizes to flourish in environments conducive to handling their particular cell properties. In an embodiment, cells of a large diameter or weight, for example, tend to settle into the lower portion of the cell growth chamber at greater rates and at greater volumes than cells of a smaller diameter or weight.
The disclosure relates to a closed cell expansion system including a cell growth chamber, in which the cell growth chamber comprises two frustoconical shaped sections. The system also comprises a mass transfer device and a first fluid circulation loop fluidly associated with the cell growth chamber and the mass transfer device, in which non-adherent cells expand in at least two of the cell growth chamber, the mass transfer device, and the first fluid circulation loop. The non-adherent cells expand in a media that travels through the cell growth chamber, the mass transfer device, and the first fluid circulation loop.
In at least one embodiment, the two frustoconical shaped sections are joined at a maximum cross-sectional area. In at least one embodiment, the two frustoconical shaped sections taper in opposite directions toward an inlet and an outlet, in which the inlet and the outlet are disposed on opposite ends of the cell growth chamber.
In at least one embodiment, the inlet is positioned at a bottom portion of the cell growth chamber, and the cell growth chamber is oriented such that a direction of gravitational force is substantially from the outlet to the inlet. In at least one embodiment, a force of media flow from the inlet into the cell growth chamber is substantially equal to the gravitational force, in which the interaction of the force of the media flow and the gravitational force maintains the non-adherent cells in suspension in the cell growth chamber. In at least one embodiment, the cell growth chamber is formed from a unitary form. In at least one embodiment, the cell growth chamber is formed from a biocompatible polymeric material. In at least one embodiment, a semi-permeable material positioned substantially at the outlet of the cell growth chamber at least partially blocks the non-adherent cells from exiting the outlet.
In at least one embodiment, the mass transfer device comprises a housing having an intracapillary portion and an extracapillary portion. In at least one embodiment, the intracapillary portion is fluidly associated with the first fluid circulation loop. In at least one embodiment, the mass transfer device comprises an intracapillary inlet fluidly associated with an in-flow of the first circulation loop.
In at least one embodiment, the mass transfer device comprises a first end cap disposed at a first end of the housing and a second end cap disposed at a second end of the housing. In at least one embodiment, the mass transfer device comprises a plurality of hollow fibers potted to the first end cap and the second end cap. In at least one embodiment, the media flows through the plurality of the hollow fibers. In at least one embodiment, the plurality of the hollow fibers forms a membrane. In at least one embodiment, the plurality of the hollow fibers comprises a plurality of pores that allow small molecules to diffuse between the intracapillary portion and the extracapillary portion, in which the non-adherent cells are not small molecules. In at least one embodiment, the plurality of the hollow fibers is made from a biocompatible polymeric material. In at least one embodiment, the membrane allows for removal of metabolites from the media and replacement of nutrients in the media, in which the nutrients promote cell growth.
In at least one embodiment, the cell expansion system further comprises a second fluid circulation loop fluidly associated with the extracapillary portion of the mass transfer device, in which the second fluid circulation loop includes a second media that travels through the second fluid circulation loop. In at least one embodiment, the second fluid circulation loop comprises an oxygenator that adds at least a first gas to the second media. In at least one embodiment, a second gas purged from the system vents to the atmosphere via an exit port of the oxygenator. In at least one embodiment, a nutrient is introduced to the extracapillary portion of the mass transfer device through the second fluid circulation loop. In at least one embodiment, a first flow direction of the first fluid circulation loop and a second flow direction of the second fluid circulation loop are co-current.
The disclosure further relates to a closed cell expansion system, in which the system comprises a cell growth chamber having a first volume, wherein a first number of cells is grown in the first volume, and the cell growth chamber comprises two frustoconical shaped sections. The system also includes a mass transfer device comprising an intracapillary portion and an extracapillary portion, in which the intracapillary portion has a second volume, and wherein a second number of cells is grown in the second volume. The system also comprises a first fluid circulation loop fluidly associated with the cell growth chamber and the mass transfer device, in which cells expand in the cell growth chamber, the mass transfer device, and the first fluid circulation loop, and wherein the cells expand in a media that travels through the cell growth chamber, the mass transfer device, and the first fluid circulation loop, in which the first number of cells is greater than the second number of cells.
In at least one embodiment, the first and second volumes are different. In at least one embodiment, the cell growth chamber provides a reservoir of the media to promote high density cell growth. In at least one embodiment, the two frustoconical shaped sections are joined at a maximum cross-sectional area. In at least one embodiment, the two frustoconical shaped sections taper in opposite directions toward an inlet and an outlet, in which the inlet and the outlet are disposed on opposite ends of the cell growth chamber. In at least one embodiment, the inlet is positioned at a bottom portion of the cell growth chamber, in which the cell growth chamber is oriented such that a direction of gravitational force is substantially from the outlet to the inlet. In at least one embodiment, a force of media flow from the inlet into the cell growth chamber is substantially equal to the gravitational force, in which interaction of the force of the media flow and the gravitational force maintains the non-adherent cells in suspension in the cell growth chamber.
In at least one embodiment, the cell expansion system further comprises a second fluid circulation loop fluidly associated with the extracapillary portion of the mass transfer device, in which the second fluid circulation loop includes a second media that travels through the second fluid circulation loop. In at least one embodiment, the second fluid circulation loop comprises an oxygenator that adds at least one gas to the second media.
The disclosure further relates to a method of growing cells in a closed cell expansion system. The method includes the steps of providing a first volume of media in a cell growth chamber; growing a first number of cells in the first volume; fluidly associating the cell growth chamber with a mass transfer device and with a first fluid circulation loop; providing a second volume of media in an intracapillary portion of the mass transfer device; growing a second number of cells in the second volume; providing a third volume of media in the first fluid circulation loop; and growing a third number of cells in the third volume, in which the first, second, and third number of cells are different.
In at least one embodiment, the media flows through the cell growth chamber, the mass transfer device, and the first fluid circulation loop. In at least one embodiment, the method further comprises orienting the cell growth chamber such that a flow of the media is equal to and opposite in direction to a gravitational force on the cells in the cell growth chamber. In at least one embodiment, the media comprises one or more from the group consisting of: a fluid, a gas, a nutrient, a metabolite, an ion, and a lactate.
The disclosure further relates to a closed cell expansion system including a cell growth chamber, in which the cell growth chamber comprises an inlet and an outlet disposed on opposite ends of the cell growth chamber, the inlet being positioned at a bottom portion of the cell growth chamber, and the cell growth chamber being oriented such that a direction of gravitational force is substantially from the outlet to the inlet. The system further comprises a mass transfer device and a first fluid circulation loop fluidly associated with the cell growth chamber and the mass transfer device, in which non-adherent cells expand in at least two of the cell growth chamber, the mass transfer device, and the first fluid circulation loop, and wherein the non-adherent cells expand in a media that travels through the cell growth chamber, the mass transfer device, and the first fluid circulation loop.
In at least one embodiment, a force of media flow from the inlet into the cell growth chamber is substantially equal to the gravitational force, in which interaction of the force of the media flow and the gravitational force maintains the non-adherent cells in suspension in the cell growth chamber. In at least one embodiment, the cell growth chamber is formed from a biocompatible polymeric material. In at least one embodiment, a semi-permeable material positioned substantially at the outlet of the cell growth chamber partially blocks the non-adherent cells from exiting the outlet. In at least one embodiment, the mass transfer device comprises a housing having an intracapillary portion and an extracapillary portion. In at least one embodiment, the intracapillary portion is fluidly associated with the first circulation loop.
This Summary is included to provide a selection of concepts in a simplified form, in which such concepts are further described below in the Detailed Description. This Summary is not intended to be used in any way to limit the claimed subject matter's scope. Features, including equivalents and variations thereof, may be included in addition to those provided herein.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present disclosure may be described by referencing the accompanying figures. In the figures, like numerals refer to like items. Further, optional steps or components are illustrated in a dashed-line format.
FIG. 1 is a schematic illustration of the mass transfer device in accordance with embodiments of the present disclosure.
FIG. 2 is a schematic illustration of the cell growth chamber in accordance with embodiments of the present disclosure.
FIG. 3 is a schematic illustration of a high density cell expansion system in accordance with embodiments of the present disclosure.
FIG. 4 depicts a flow diagram showing the operational characteristics of a process for growing cells in a cell expansion system in accordance with embodiments of the present disclosure.
DETAILED DESCRIPTION
The following Detailed Description provides a discussion of illustrative embodiments with reference to the accompanying drawings. The inclusion of specific embodiments herein should not be construed as limiting or restricting the present disclosure. Further, while language specific to features, acts, and/or structures, for example, may be used in describing embodiments herein, the claims are not limited to the features, acts, and/or structures described. A person of skill in the art will understand other embodiments, including improvements, that are within the spirit and scope of the present disclosure.
Embodiments of the present disclosure are generally directed toward a closed system 200 (see FIG. 3 ) for continuous high density cell expansion, in particular, a system for expanding non-adherent cells. A closed system means that the contents of the system are closed, or not directly exposed, to the atmosphere. The system contains at least a cell growth chamber 12 (also referred to herein as a “cell expansion chamber”) and a mass transfer device 100 .
With reference to FIG. 1 , an example mass transfer device 100 which may be used with the present disclosure is shown in front side elevation view. Mass transfer device 100 has a longitudinal axis LA-LA and includes housing 104 . In at least one embodiment, mass transfer device housing 104 includes four openings or ports: intracapillary (IC) inlet port 108 , intracapillary (IC) outlet port 120 , extracapillary (EC) inlet port 128 , and extracapillary (EC) outlet port 132 .
A plurality of hollow fibers 116 are disposed within mass transfer device housing 104 . The material used to make the hollow fibers 116 may be any biocompatible polymeric material which is capable of being made into hollow fibers. The terms “hollow fiber,” “hollow fiber capillary,” and “capillary” are used interchangeably. A plurality of hollow fibers are collectively referred to as a “membrane.”
In embodiments, the ends of hollow fibers 116 are potted to the ends of the mass transfer device 100 by a connective material (also referred to herein as “potting” or “potting material”). The potting can be any suitable material for binding the hollow fibers 116 , provided that the flow or travel of culture media (and cells if desired) into the hollow fibers is not obstructed. Exemplary potting materials include, but are not limited to, polyurethane or other suitable binding or adhesive components. End caps 112 and 124 respectively, are disposed at each end of the mass transfer device. According to embodiments, the media includes one or more of the following, for example: a fluid, a gas, a nutrient, a metabolite, an ion, a lactate, and/or an oxygen atom, for example.
Small molecules (e.g., ions, water, oxygen, a metabolite, lactate, etc.) can diffuse through pores in the hollow fibers from the interior or IC space of the hollow fiber to the exterior or EC space, or from the EC space to the IC space, according to embodiments.
Use of a mass transfer device 100 , such as the one described, allows for the simultaneous and continuous removal of waste products from the cell growth media and the replacement of nutrients in the cell growth media throughout the cell expansion process.
In embodiments, the system 200 (see FIG. 3 ) also includes a cell growth or cell expansion chamber 12 . As shown in FIG. 2 , a schematic of a possible embodiment of a cell growth chamber which may be used with the present disclosure is depicted. In an embodiment, cell growth chamber 12 includes two frustoconical shaped sections 25 , 27 joined together at a maximum cross-sectional area 23 of the cell growth chamber 12 . The interior of the cell growth chamber 12 tapers (decreases in cross-section) from the maximum cross-sectional area 23 in opposite directions toward inlet 30 and outlet 32 . According to an embodiment, inlet 30 is positioned at the bottom, or a bottom portion, of the cell growth chamber.
The cell growth chamber 12 may be constructed from a unitary piece of plastic or from separate pieces joined together using a fixative or other sealing methods. It may be made of any biocompatible material capable of being assembled into the frustoconical shape, according to an embodiment.
The conical shape of the cell growth chamber 12 helps to keep the cells suspended within the chamber 12 . The flow of media, or force of media flow, along the walls of the cell growth chamber 12 from the inlet 30 of the chamber 12 through the interior to the outlet 32 is substantially equal and opposite to the gravitational pull, or gravitational force, on the cells. In an embodiment, the flow of media along the walls of the cell growth chamber 12 from the inlet 30 of the chamber 12 through the interior to the outlet 32 is constant. The interaction of the force of the media flow and the gravitational force helps to keep the cells suspended, i.e., maintains the non-adherent cells in suspension, within the cell growth chamber 12 .
The cells may be retained within the cell growth chamber 12 by blocking at least the outlet port 32 of the cell growth chamber 12 with some type of semi-permeable material which allows fluid to flow there through, yet retains cells within the chamber 12 .
For non-adherent cells, the rate limiting step for cell expansion is the amount, or volume, of cell growth media available to the cells, according to embodiments. Therefore, the cell expansion chamber 12 acts not only as a place for the cells to grow, but also as a media reservoir to encourage high density cell growth by providing as much media to the cells as possible. In an embodiment, for example, a greater number of cells grows in a larger volume of media. To achieve maximal growth, the chamber should be made as large as possible, including with respect to corresponding volume, for example, within the constraints of system 200 .
In embodiments, cells may additionally be grown inside the lumen or IC space of the hollow fibers of the mass transfer device 100 and also within the associated tubing of the first fluid circulation loop 202 (see FIG. 3 ). In such embodiments, cells are not only grown within the cell growth chamber 12 , but are also circulated throughout the first fluid circulation loop 202 in a volume of media, from the cell growth chamber 12 through the IC space of the mass transfer device 100 , and back to the cell growth chamber 12 . In embodiments, the volumes of media in the mass transfer device and in the first fluid circulation loop are different from the volume of media in the cell growth chamber. For example, the cell growth chamber may comprise a first volume of media, the mass transfer device may comprise a second volume of media, and the first fluid circulation loop may comprise a third volume of media. In an embodiment, the first, second and third volumes of media are different. In another embodiment, the first, second, and third volumes of media are the same.
A schematic of one possible embodiment of a cell expansion system 200 containing both the mass transfer device 100 and the cell growth chamber 12 as described above is shown in FIG. 3 .
First fluid flow path 206 is fluidly associated with mass transfer device 100 and cell growth chamber 12 to form first fluid circulation path 202 (also referred to herein as the “intracapillary loop” or “IC loop” or “first fluid circulation loop”). In an embodiment, a single mass transfer device 100 and cell growth chamber 12 are used. In another embodiment, multiple mass transfer devices and multiple cell growth chambers are used. Fluid flows or travels into mass transfer device 100 through inlet port 108 , and exits via outlet port 120 . The fluid path between the inlet port 108 and the outlet port 120 defines the intracapillary portion 126 of the mass transfer device (see FIG. 1 ). The intracapillary inlet 108 is fluidly associated with an in-flow of the first fluid circulation loop 202 . Fluid flows into cell growth chamber 12 through inlet port 30 and exits via outlet port 32 . It should be noted that the cell growth chamber may be located anywhere within the IC loop. Pressure gauge 210 measures the pressure of media leaving mass transfer device 100 and entering cell growth chamber 12 . IC circulation pump 212 controls the rate of media flow through first fluid circulation loop 202 . Media entering the IC loop may enter through valve 214 . As those skilled in the art will appreciate, additional valves and/or other devices can be placed at various locations to isolate and/or measure characteristics of the media along portions of the fluid paths. Accordingly, it is to be understood that the schematic shown represents one possible configuration for various elements of the cell expansion system, and modifications to the schematic shown are within the scope of embodiments of the present disclosure.
Samples of media can be obtained from a sample port 216 or a sample coil 218 during operation. Pressure/temperature gauge 220 allows measurement of media pressure and temperature during operation.
Cells grown/expanded in cell growth chamber 12 or in the entire IC loop 202 including mass transfer device 100 can be flushed out of the IC loop 202 into harvest bag 299 through valve 298 .
Fluid in second fluid circulation path 204 (also referred to herein as the “extracapillary loop” or “EC loop” or “second fluid circulation loop”) enters mass transfer device 100 via EC inlet port 128 , and leaves mass transfer device 100 via EC outlet port 132 . The fluid path between the EC inlet port 128 and the EC outlet port 132 defines the EC portion 136 of the mass transfer device 100 (see FIG. 1 ).
Pressure/temperature gauge 224 measures the pressure and temperature of the media before the media enters the EC space of the mass transfer device 100 . Pressure gauge 226 measures the pressure of media after it leaves the mass transfer device 100 . Samples of media can be obtained from sample port 230 or a sample coil (not shown) during operation, according to embodiments.
After leaving EC outlet port 132 of mass transfer device 100 , fluid in second fluid circulation path 204 passes through EC circulation pump 228 to oxygenator 232 . Media flows into oxygenator 232 via inlet port 234 , and exits oxygenator 232 via outlet port 236 . Oxygenator 232 adds oxygen and other gases, as desired, to the media. The oxygenator 232 can be any appropriately sized oxygenator known in the art. Gas flows into oxygenator 232 via inlet port 238 and out of oxygenator 232 through outlet port 240 . Filters (not shown) may be associated with ports 238 and 240 respectively to reduce or prevent contamination of oxygenator 232 and associated media. Air or gas purged from the system 200 can vent to the atmosphere via exit port 240 of oxygenator 232 .
In the configuration depicted in FIG. 3 , fluid media in first fluid circulation path 202 and second fluid circulation path 204 flows through mass transfer device 100 in the same direction (a co-current configuration). However, cell expansion system 200 can also be configured to flow fluid in an opposite or counter-current direction.
In an embodiment, cells (from bag 262 ) to be expanded and IC media from bag 246 are introduced to first fluid circulation path 202 via a valve(s). In an embodiment, valve 264 and/or valve 250 may be used, respectively, for example. Fluid containers 244 (reagent) and 246 (IC media) may be fluidly associated with either first fluid inlet path 242 via valves 248 and 250 , respectively, or second fluid inlet path 274 via valves 270 and 276 . First and second sterile sealable input priming paths 208 and 209 are provided. In embodiments, air removal chamber 256 is fluidly associated with first fluid circulation path 202 .
According to embodiments of the present disclosure, EC media (from bag 268 ) or wash solution ((if used) from bag 266 ) may be added to either the first or second fluid flow path. Fluid container 266 may be fluidly associated with valve 270 that is fluidly associated with first fluid circulation path 202 via distribution valve 272 and first fluid inlet path 242 . Alternatively, fluid container 266 can be fluidly associated with second fluid circulation path 204 via second fluid inlet path 274 and second fluid flow path 284 by opening valve 270 and closing distribution valve 272 . Likewise, fluid container 268 is fluidly associated with valve 276 that may be fluidly associated with first fluid circulation path 202 via first fluid inlet path 242 and distribution valve 272 . Alternatively, fluid container 268 may be fluidly associated with second fluid inlet path 274 by opening valve 276 and closing distribution valve 272 .
An optional heat exchanger 252 may be provided to warm media, reagent or wash solution.
In the IC loop 202 , fluid is initially advanced by the IC inlet pump 254 . In the EC loop 204 , fluid is initially advanced by the EC inlet pump 278 . An air detector 280 , such as an ultrasonic sensor, may also be associated with the EC inlet path 284 , according to embodiments.
First and second fluid circulation paths 202 and 204 are connected to waste line 288 . When valve 290 is opened, IC media can flow through waste line 288 to waste bag 286 . Likewise, when valve 292 is opened, EC media can flow through waste line 288 to waste bag 286 .
In accordance with embodiments of the present disclosure, expanded cells are harvested via cell harvest path 296 . Here, cells from cell expansion chamber 12 and, optionally, mass transfer device 100 and associated tubing can be harvested from the IC loop by pumping the IC media containing the cells through cell harvest path 296 and valve 298 to cell harvest bag 299 .
In embodiments, various components of the cell expansion system 200 are contained or housed within an incubator 300 , wherein the incubator maintains cells and media at a desirable temperature. The size of cell growth chamber 12 , and the volume of media it may contain, for example, is dependent upon the size of the incubator, according to embodiments. However, in other embodiments, the cell expansion system 200 may be placed in a larger temperature controlled space such as a warm room, in which case the size of the cell growth chamber 12 is not necessarily limited and may have a range of possible dimensions.
As consistent with FIGS. 1 , 2 , and 3 described above, FIG. 4 provides example operational steps 302 for growing cells in a cell expansion system, in accordance with embodiments of the present disclosure. START operation 304 is initiated, and process 302 proceeds to provide 306 a first volume of media in a cell growth chamber. In an embodiment, such first volume is controlled by the size of the cell growth chamber. In another embodiment, one or more pumps and/or one or more valves, as described above, may control the amount of the first volume of media. A first number of cells is then grown 308 in the first volume. Next, process 302 proceeds to fluidly associate 310 , 312 the cell growth chamber with a mass transfer device and a first fluid circulation loop, as described above according to embodiments.
Proceeding to operation 314 , a second volume of media is provided in the mass transfer device, according to embodiments described above. In an embodiment, such second volume is controlled by the size of the mass transfer device. In another embodiment, one or more pumps and/or one or more valves, as described above, may control the amount of the second volume of media. In an embodiment, such second volume of media is in an intracapillary portion of the mass transfer device, as shown by optional step 316 . Next, process 302 proceeds to operation 318 , in which a second number of cells is grown in the second volume.
In an embodiment, a third volume of media is provided 320 in the first fluid circulation loop, as described above in accordance with embodiments of the present disclosure. In an embodiment, such third volume is controlled by the size of the first circulation loop. In another embodiment, one or more pumps and/or one or more valves, as described above, may control the amount of the third volume of media. Next, a third number of cells is grown in the third volume of media 322 . In an embodiment, process 302 then terminates at END operation 324 .
With respect to the process illustrated in FIG. 4 , the operational steps depicted are offered for purposes of illustration and may be rearranged, combined into other steps, used in parallel with other steps, etc., according to embodiments of the present disclosure. Further, fewer or additional steps may be used in embodiments without departing from the spirit and scope of the present disclosure.
It will be apparent to those skilled in the art that various modifications may be made to the apparatus, systems, and methods described herein. Thus, it should be understood that the embodiments are not limited to the subject matter discussed in the Specification. Rather, the present disclosure is intended to cover modifications, variations, and/or equivalents. The acts, features, structures, and/or media are disclosed as illustrative embodiments for implementation of the claims. The invention is defined by the appended claims.
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Embodiments described herein generally relate to systems and methods for promoting the expansion of high density non-adherent cells through the use of a cell growth chamber, a mass transfer device, and a fluid circulation loop. Improved cell growth is achieved in the cell growth chamber by using a chamber having a particular orientation and shape, e.g., conical, to create a media-rich reservoir for growing cells. By placing the chamber in a vertical position, the force of media flow along the chamber walls is substantially equal and opposite to the gravitational force on the cells. The interaction of these forces maintains the non-adherent cells in suspension. The use of the cell growth chamber in conjunction with the mass transfer device and fluid circulation loop(s) creates efficiencies by relying on the cumulative and combined features of the devices.
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This application is a continuation of application Ser. No. 08/036,281, filed on Mar. 24, 1993, now abandoned.
BACKGROUND OF THE BACKGROUND
1. Field of the Invention
The present invention relates to an antifoaming agent for use in fermentation processes, a fermentation medium which incorporates the antifoaming agent, a method of producing L-amino acids in the presence of the agent, and a method of defoaming using the agent.
2. Description of the Background Art
In the fermentative production of useful substances by submerged aerobic culture, a great number of bubbles and foam occur causing various problems. For example, when a fermenter becomes filled with bubbles the culture capacity per unit volume is lowered, and the culture solution can overflow.
Attempts to suppress such bubbling have included the addition of an antifoaming agent to the fermentation medium Polyoxyalkylene polyhydric alcohol ethers, polyoxyalkylene alkyl ethers, polyoxyalkylene fatty acid esters, polyoxyalkylene alkyl ether fatty acid esters, etc. are antifoaming agents previously used (Japanese Patent Application Laid-Open Nos. 4282/1975, 121482/1975, 135298/1979, 169583/1981 and 35073/1990). These antifoaming agents for fermentation baths have not proven very satisfactory, however, due to an unacceptable antifoaming effect, an adverse affect on fermentative production (inhibition of growth of microorganisms, inhibition of formation of products, etc.), a long incubation time before developing an antifoaming effect, or the inability to retain an antifoaming effect over long periods of time.
Since the fermentative production of L-amino acids such as L-glutamic acid, L-lysine, L-glutamine, L-arginine, L-phenylalanine, L-threonine, L-isoleucine, L-histidine, L-proline, L-valine, L-serine, L-ornithine, L-citrulline, L-tyrosine, L-tryptophan and L-leucine is commercially important, is carried out on an industrial scale by the fermentation of microorganisms belonging to Brevibacterium, Corynebacterium, Microbacterium, Bacillus, Escherichia or the like and encounters problems due to foam and bubbles, it is desirable to provide an antifoaming agent that overcomes the above drawbacks.
Further, conventional L-amino acid fermentation processes are unsatisfactory with respect to yield. In order to increase the yield, specific surfactants have been added to the fermentation medium so as to allow for continuous fermentation while crystallizing out the L-amino acid product (Japanese Patent Application Laid-Open No. 288/1977). However, this process has proven unsatisfactory with respect to overall yield, although improvement as compared with conventionally-known processes is obtained.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an antifoaming agent for fermentation which has excellent antifoaming effects when added to a fermentative medium while improving the yield of the L-amino acid produced, and a process of producing L-amino acids using the medium containing the additive.
The present inventors have found that when a small amount of a product obtained by adding an alkylene oxide to a mixture of a fat and/or an oil with a polyhydric alcohol, or an acylation product of an (alkylene oxide-added) polyglycerol, is added to a fermentative medium, antifoaming is achieved quickly and for extended periods, and that the use of this antifoaming medium in the fermentation of L-amino acids improves the yield of L-amino acids significantly.
In one aspect of the present invention an antifoaming agent for fermentation is provided comprising, as active ingredient(s), either (a) at least one reaction product obtained by adding at least one alkylene oxide to a mixture of a fat and/or an oil with a trihydric or still higher polyhydric alcohol, or (b) at least one compound represented by the following general formula (1): ##STR2## wherein n stands for a number of 2-50, R 1 , and R 3 mean individually a hydrogen atom or an acyl group having 2-31 carbon atoms, X denotes an alkylene group having 2-4 carbon atoms, and m1, m2 and m3 are individually a number of 0-200, or (c) a mixture of (a) and (b).
In another aspect of the present invention, there is provided an L-amino acid-producing medium comprising water and, optionally a micororganism, nutrients and salts, and at least one of (a) the reaction product or (b) compound (1), or a mixture of (a) and (b).
In another aspect of the present invention, there is provided a process for the production of an L-amino acid comprising incubating L-amino acid-producing microorganisms in a medium containing at least one of (a) the reaction product or (b) compound (1), or both, and collecting the L-amino acid from the resulting cultured mixture.
Finally, the present invention provides a method of defoaming wherein at least one of (a), the reaction product or (b), a compound of formula (1), or both, are added to a medium which would be expected to foam or to a medium having foam already present.
The use of (a) the reaction product or (b) compound (1), or both, permits the quick, sure and durable suppression of bubbling during incubation. Therefore, the yield of the fermentation product intended per unit fermenter is improved.
In particular, when the above antifoaming agent is added to an L-amino acid-producing medium to produce an L-amino acid, the productivity of the L-amino acid is remarkably improved.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Component (a) useful in the practice of the present invention is the reaction product obtained by adding one or more alkylene oxides to a mixture of at least one fat and/or oil with at least one trihydric or still higher polyhydric alcohol. Examples of the fat or oil used as a raw material herein include vegetable oils such as coconut oil, palm oil, olive oil, soybean oil, rapeseed oil, linseed oil and castor oil; animal oils such as lard, beef tallow and bone oil; fish oils; and hardened oils and partially hydrogenated oils thereof, as well as recovered oils obtained in the purification process of these fats and oils.
Any generally-known alcohol containing three or more --OH groups may be used as the trihydric or still higher polyhydric alcohol. Among these, however, tri- to hexahydric alcohols having 3-15 carbon atoms, such as glycerol, sorbitol, glucose, trimethylolpropane, trimethylolethane, 1,2,4-butanetriol, 1,2,6-hexanetriol, 1,1,1-trimethylolhexane, pentaerythritol, erythrose, tetramethylolcyclohexanol, diglycerol and polyglycerol are preferred and may be used singly or in combination. Of these, glycerol is particularly preferred.
Examples of the alkylene oxide useful herein include ethylene oxide, propylene oxide and butylene oxide. These alkylene oxides may be added either singly or in any combination thereof. It is however preferred that two or more of these alkylene oxides should be added in combination. Examples of the combination of two or more alkylene oxides include ethylene oxide-propylene oxide, ethylene oxide-butylene oxide, and ethylene oxide-propylene oxide-butylene oxide. In the combination of ethylene oxide and propylene oxide or butylene oxide, it is desirable that the number of moles of the added propylene oxide or butylene oxide should be more than that of the added ethylene oxide. The addition of the alkylene oxides may be conducted either by adding them as a mixture (random addition) or by successively adding them (block addition). The total number of moles of the alkylene oxides added is preferably 1-100 moles, more preferably 5-100 moles, most preferably 5-50 moles per mole of the mixture of the fat and/or oil with the polyhydric alcohol. The mixing proportion of the fat or oil with the polyhydric alcohol is preferably 1:0.1-1:6, more preferably 1:0.3-1:3 by mole.
No particular limitation is imposed on the addition reaction of the alkylene oxide, fat and/or oil and polyhydric alcohol. The reaction may be conducted under the general conditions of addition reactions of an alkylene oxide to an active hydrogen-containing compound. More specifically, the reaction may be conducted by adding a catalytic amount of an alkaline substance to a mixture of the fat and/or oil with the polyhydric alcohol, which materials have been charged in the above-described molar ratio, and reacting 1-3 kg/cm 2 of the alkylene oxide with the charged mixture at about 100°-200° C.
Examples of component (b), i.e., the compound of formula (1), useful in the practice of the present invention include polyglycerol, mono-, di- and triacylated products of polyglycerol, adducts of polyglycerol with a polyoxyalkylene, and mono-, di- and triacylated products of adducts of polyglycerol with a polyoxyalkylene. Other preferred compounds are those where m1, m2 and m3 are from 0 to 100, n is from 2 to 10, R 1 , R 2 and R 3 are acyl groups having 4 to 24 carbon atoms, and x is alkylene of 2-4 carbons.
These compounds (1) can be produced by any method known in the art. An example of the production process of polyglycerol includes a process wherein glycerol is subjected to dehydrocondensation at an elevated temperature of 200°-300° C. in the presence of an alkali catalyst. Examples of the alkali catalyst used herein include NaOH, KOH, LiOH, Na 2 CO 3 , K 2 CO 3 , Li 2 CO 3 , CaO and MgO. The degree of polymerization of polyglycerol may be regulated by changing the reaction conditions. However, the resulting polyglycerol is not a single component, but a mixture having a certain molecular weight distribution. For example, the hydroxyl number of the commercialized polyglycerol referred to as hexaglycerol conforms with the calculated chemical formula thereof, but the polymer is in reality a mixture composed of polyglycerols of different polymerization degrees.
The polyglycerol obtained by the above-described method is a yellow or blackish brown liquid having a high viscosity. As its polymerization degree becomes higher, its hue becomes poorer, approaching blackish brown. Therefore, before use the colored polyglycerol is subjected to a decoloring treatment with an adsorbent like activated carbon or activated clay, or to removal of catalyst and decoloring treatment with an ion-exchange resin. Diglycerol, tetraglycerol, hexaglycerol and decaglycerol have been commercialized.
The present adduct of polyglycerol with a polyoxyalkylene may be produced by any known method including a well-known process wherein after adding an alkali catalyst, an alkylene oxide is added to, for example, the polyglycerol obtained in the above-described manner under pressure and heat. Examples of the alkylene oxide to be added include ethylene oxide, propylene oxide and butylene oxide, which have 2, 3 and 4 carbon atoms, respectively. These alkylene oxides may be added either singly, or in combination, as blocks or at random. They are added in an amount of preferably 1-200 moles, more preferably 1-50 moles on the average per mole basis of polyglycerol.
The mono-, di- or triacylated product of polyglycerol, and mono-, di- or triacylated product of an adduct of polyglycerol with a polyoxyalkylene (both products may be called polyglycerol fatty acid esters) can be generally produced by any direct esterification reaction. Various kinds of hydrophilic or lipophilic esters may be obtained by suitably combining polyglycerols of different polymerization degrees with each other and selecting the kind of a fatty acid to be used and the degree of esterification. Therefore, any ester having an HLB as measured by a Davis method of from 1 to 20, more preferably from 2 to 10 in the case of antifoaming agents, and from 10 to 18 in the case of improving the productivity of L-amino acids may be prepared and used.
The esterification reaction is generally conducted at a temperature not lower than 200° C. without using any catalyst or may be conducted in the presence of an alkali catalyst. Sulfite may be added during the reaction as may lipase, etc. Various products are provided by varying the degree of purification according to their end applications intended. The quality of the polyglycerol fatty acid esters produced depends in large part upon the quality of the polyglycerol starting material. This tendency becomes more pronounced as the polymerization degree of the polyglycerol increases.
A preferred material is a polyglycerol condensed-ricinoleic acid ester synthesized by dehydrating ricinoleic acid (castor oil fatty acid) under heat to precondense it for 3-6 minutes and esterifying polyglycerol with the thus-precondensed ricinoleic acid. The reaction conditions are generally the same as those described above for any polyglycerol fatty acid ester.
Reaction product (a) or compound (1) or their mixture may be used directly as an antifoaming agent for fermentation media and fermentation processes or for any other applications where defoaming is desired. However, they may also be mixed with known antifoaming agents before or after use. Reaction product (a) or compound (1) or their mixture may be added to a foaming medium in one to several portions before or after foaming begins. For fermentation media the agents can be added at the beginning of incubation or during incubation. The amount to be added is preferably 0.0001-5 wt. %, more preferably 0.001-2.5 wt. % based on the medium. It is preferable to add the antifoaming agent according to the present invention in an amount of 0.0001-2 wt. %, more preferably 0,001-1.0 wt. % where it is used to exert only an antifoaming effect, or in an amount of 0,001-5 wt. %, more preferably 0.01-5 wt. %, most preferably 0.05-2.5 wt. % where it is expected to improve the fermentative productivity of an L-amino acid in addition to exerting an antifoaming effect.
No particular limitation is imposed on fermentation culturing means to which the antifoaming agent according to the present invention is applied. Examples include aerobic culture, stirring culture, shaking culture and the like, all of which product a great number of bubbles. The fermentative production of an L-amino acid using the above-described components according to the present invention will hereinafter be described.
Upon production of an L-amino acid, at least one of the reaction products (a) or compound (1) or their mixture may be added either to a medium for seed culture or to a medium for principal fermentation. As a medium to which the at least one reaction product (a) and/or the compound (1) is to be added, media generally used in the incubation of L-amino acid-producing bacteria containing a carbon source, a nitrogen source, salts and other additives can be used. In the present invention, examples of the carbon source include carbohydrates such as glucose, dextrose, sucrose, fructose, maltose, crude sugar, fruit sugar, glucose, liquid sugar, cane molasses, beet sugar, blackstrap molasses, tapioca and starch-saccharified liquor; fatty acids such as acetic acid and propionic acid; organic acids such as pyruvic acid, citric acid, succinic acid and malic acid; and alcohols such as ethyl alcohol and butyl alcohol, all of which may be used either singly or in any combination thereof. As the nitrogen source, examples include ammonium salts such as ammonium sulfate, ammonium chloride and ammonium acetate, urea, aqueous ammonia, corn steep liquor, yeast extract, soybean hydrolyzate, peptone, polypeptone, meat extract, and the like. As the salts, phosphates, magnesium salts, calcium salts, potassium salts, sodium salts, iron salts, manganese salts, zinc salts, copper salts and the like may be used. Other metal salts may be further added as needed.
As described above, a surfactant other than (a) or (b) may be added to the fermentative medium to enhance the yield of the L-amino acid. Examples of such surfactants include anionic surfactants such as higher (C 6 -C 25 ) alcohols, sulfates, alkylbenzenesulfonates, alkyl phosphates and dialkyl sulfosuccinates; cationic surfactants such as alkylamines and quaternary ammonium salts; nonionic surfactants such as polyoxyethylene alkyl ethers, polyoxyethylene sorbitan fatty acid esters, sorbitan fatty acid esters, polyoxyethylene fatty acid esters, polyglycerol fatty acid esters, alkylglycosides and ester amides; and ampholytic surfactants such as imidazoline and betaine. Among these, alkylglycosides and ester amides are preferred. These surfactants may be used either singly or in any combination thereof, and are preferably added in an amount within the range of 0.01-2.5% by weight based on the weight of the medium.
Further, antibiotics, vitamins and the like may be added to the fermentative media as needed. Examples of the antibiotics include penicillin, chloramphenicol, erythromycin, streptomycin, kanamycin, oleandomycin, kasugamycin, tetracycline, mitomycin, actinomycin and cycloserine. Among these, penicillin is preferred. Examples of the vitamins include biotin, niacin and thiamin.
No specific limitation is imposed on the microorganisms added to the fermentative medium according to the present invention. Any one or combination of microorganisms may be used so long as they produce an L-amino acid. Specific examples thereof include the following microorganisms:
Corynebacterium:
Corynebacterium glutamicum, Corynebacterium acetoglutamicum, Corynebacterium acetoacidophilum;
Microbacterium:
Microbacterium amnoneaphilum;
Brevibacterium:
Brevibacterium acetoacidophilum, Brevibacterium flavum, Brevibacterium lactofermentum, Brevibacterium saccharolyticum, Brevibacterium roseum, Brevibacterium divaricatum;
Arthobacter:
Arthobacter citreus;
Bacillus:
Bacillus subtilis, Bacillus sphaericus.
Examples of L-amino acids obtained by incubating the above-mentioned microorganisms in the invention fermentation bath include L-glutomic acid, L-lysine, L-glutamine, L-arginine, L-phenylalanine, L-threonine, L-isoleucine, L-histidine, Lproline, L-valine, L-tyrosine, L-tryptophan, L-leucine, L-serine, L-ornithine and L-citrulline.
The conditions under which the medium according to the present invention is used to incubate L-amino acid-producing bacteria are the same as those used in general amino acid fermentation. Although the incubation temperature somewhat varies according to the L-amino acid intended and the strain to be used, it may be 20°-40° C. with 28°-37° C. being particularly preferred. Better results are obtained when pH is controlled near neutrality during the incubation. The incubation is generally conducted under aerobic conditions such as aeration, stirring or shaking culture. The incubation period is generally 1-7 days. However, incubation may be extended further by continuous culture or the like. The isolation of L-amino acids from the respective fermented solutions containing the L-amino acids is conducted by ion exchange treatment or any other method known in the art.
EXAMPLES
The present invention will hereinafter be described in more detail by the following examples. However, it should be borne in mind that this invention is not limited to or by these examples.
Example 1
100 ml of media (sterilized at 121° C. for 10 minutes, pH: 7.2) having the composition shown in Table 1 were inoculated with Brevibacterium flavum and separately placed in fermenters (500-ml graduated cylinder) and aerated at a rate of 5 l/min. When bubbles reached a marked line at 400 ml, reaction product (a) antifoaming agents shown in Table 2 were separately added little by little to the media which were then incubated at 30° C. for 2 hours. The amounts of the antifoaming agents required to suppress the bubble level at the marked line or lower are shown in Table 2 where the antifoaming agent ratios are by weight.
TABLE 1______________________________________Glucose 10% FeSO.sub.4.7H.sub.2 O 10 μg/lMeat extract 0.5% MnSO.sub.4.nH.sub.2 O 10 ng/lAmmonium sulfate 3% CuSO.sub.4.5H.sub.2 O 1 mg/lK.sub.2 HPO.sub.4 0.05% Urea 0.5%KH.sub.2 PO.sub.4 0.15% CaCO.sub.3 3%MgSO.sub.4.7H.sub.2 O 0.05% Thiamin hydrochloride 0.5 mg/l______________________________________
TABLE 2______________________________________ Amount of anti-foaming agent used Antifoaming agent (g)______________________________________Inventiveexamples:1 Beef tallow/glycerol/EO(5)/ 0.010 PO(15) = 1/0.3/5/152 Coconut oil/glycerol/EO(10)/ 0.013 PO(30) = 1/0.6/10/303 Soybean oil/glycerol/EO(15)/ 0.016 PO(25) = 1/1/15/254 Beef tallow/pentaerythritol/ 0.019 EO(10)/PO(45) = 1/0.5/10/45Comparativeexamples:5 Polypropylene glycol 1.2506 EO/PO/EO ("Pluronic", product 1.350 of Asahi Denka Kogyo K.K.7 Oleyl alcohol/EO/PO = 1/10/15 At least 2.58 Stearic acid/PO = 1/15 At least 2.5______________________________________ EO: Ethylene oxide; PO: Propylene oxide
As apparent from Table 2, the antifoaming agents according to the present invention exhibit an excellent antifoaming effect in extremely small amounts.
Example 2
A medium containing 10% (in terms of sugar) of blackstrap molasses, 0.5% of urea and 0.3% of corn steep liquor was inoculated with Corynebacterium glutamicum and incubated at 30° C. In the prophase of the logarithmic growth phase, 0.15% of polyoxyethylene monopalmitate was added to the medium and incubation conducted at 30° C. for 30 hours.
Thereafter, 15-ml portions of the resulting cultured mixtures were separately placed in 500-ml graduated cylinders. Air was introduced into the cylinders at a rate of 5 l/min. When bubbles reached a marked line at 400 ml, the antifoaming agents shown in Table 2 were added in amounts of 0.001 g to the respective medium portions. After aerating for 30 more minutes, the height (ml) of bubbles occurred in each graduated cylinder was measured. The results are shown in Table 3.
TABLE 3______________________________________Antifoaming agent No. Height of bubbles (ml)______________________________________1 1502 1703 1604 2005 At least 5006 4807 At least 5008 At least 500______________________________________ In the case of Antifoaming Agents Nos. 5, 7 and 8, bubbles overflowed the respective graduated cylinders.
Example 3
An L-lysine-producing medium was prepared as follows:
______________________________________Glucose 10%(NH.sub.4).sub.2 SO.sub.4 4.5%Thiamine hydrochloride 200 μg/lK.sub.2 HPO.sub.4 0.1%Peptone 1%Biotin 50 Mg/l______________________________________
where % is percent by weight. 100 ml-portions of a medium having the above composition were placed in 500-ml Sakaguchi flasks, sterilized at 120° C. for 15 minutes and then inoculated with the L-lysine-producing bacteria Brevibacterium SP. Thereafter, the antifoaming agents shown in Table 1 were separately added to the medium portions in amounts of 0.05% and 1.0% by weight based on each medium portion and incubation was further conducted at 30° C. for 30 hours. The amounts of L-lysine produced in the respective medium portions were then determined. The results are shown in Table 4.
TABLE 4______________________________________Antifoaming Amount Amount of L-lysine producedagent No. added (%) (g/l)______________________________________1 0.05 7.0 1.0 6.82 0.05 7.2 1.0 7.13 0.05 6.9 1.0 7.04 0.05 7.5 1.0 7.25 0.05 4.5 1.0 2.16 0.05 5.2 1.0 3.07 0.05 4.8 1.0 3.18 0.05 4.0 1.0 1.9______________________________________
As apparent from the results in Table 4, the antifoaming agents according to the present invention (Nos. 1-4) are excellent antifoaming agents each improving the production of L-lysine, a fermentation product.
Example 4
A medium composed of the following composition is prepared by weight.
______________________________________Blackstrap molasses 4%KH.sub.2 PO.sub.4 0.2%MgSO.sub.4 0.05%Urea 0.8%Biotin 5 μg/lWater Balance______________________________________
and adjusted to pH 7.2 with KOH, and a 30-ml portion thereof was placed in a 500-ml Sakaguchi flask and sterilized under heat. This medium portion was inoculated with Corynebacterium glutamicum grown on a glucose-peptone slant to conduct preliminary incubation at 30° C. for 18 hours.
Separately, 30-ml portions of a medium (pH: 7-8) having the following composition:
______________________________________Blackstrap molasses 10%Urea 1.0%KH.sub.2 PO.sub.4 0.1%MgSO.sub.4 0.05%Water Balance______________________________________
were placed in 500-ml Sakaguchi flasks and sterilized under heat. Medium samples were then prepared by separately adding to each of these 30-ml portions 0.3% by weight of reaction products (a) shown in Table 5, or 0.3% by weight of polyoxyethylene sorbitan monostearate and no additive in comparative examples. 500 μl portions of the preliminarily cultured mixture described above were added to these medium samples having the materials in Table 5 added thereto to conduct shaking culture at 30° C. for 48 hours. The amounts of L-glutamic acid produced in the respective media were then determined and the results are shown in Table 6.
TABLE 5______________________________________ Molar Alkylene oxideFat or Alcohol ratio Mole/oil (A) (B) (A/B) Compound A + B______________________________________Inventive 9 Coconut oil Glycerol 1/1 EO 2010 Beef tallow Glycerol 1/0.5 EO 5011 Palm oil Glycerol 1/0.5 EO/PO 20/5 (Block)12 Palm Pentaery- 1/2 EO/BO 30/10 kernel oil thritol (Block)13 Fish oil Glycerol 1/0.5 EO/PO 40/5 (Random)14 Beef tallow Pentaery- 1/1 EO 20/5 thritolComp.15 Polyoxyethylene sorbitan EO 20 monostearate16 Not added -- --______________________________________ EO: Ethylene oxide; PO: Propylene oxide; BO: Butylene oxide.
TABLE 6______________________________________Amount of L-glutamic acid (g/l)______________________________________9 45.010 38.911 37.912 41.313 37.614 39.515 17.616 1.3______________________________________
Example 5
The following media A and B were prepared by weight:
______________________________________Medium A:Blackstrap molasses 10% (in terms of glucose)(NH.sub.4).sub.2 SO.sub.4 4.5%KH.sub.2 PO.sub.4 0.1%Peptone 1%Water BalanceMedium B:Glucose 10%Biotin 50 μg/lThiamine hydrochloride 200 μg/l(NH.sub.4).sub.2 SO.sub.4 4.5%KH.sub.2 PO.sub.4 0.1%Peptone 1%Water Balance______________________________________
40-ml portions of each of the thus-prepared media were separately poured into two 500-ml Sakaguchi flasks and sterilized. The thus-sterilized portions were inoculated with L-lysine-producing bacteria, Brevibacterium SP and incubation was conducted at 30° C. for 18 hours. 400 μportions of the resulting cultured mixtures were then subcultured into the corresponding media A and B to conduct shaking culture at 30° C. for 8 hours. Thereafter, 0.15% by weight of reaction products (a) shown in Table 7 were separately added to the subcultured media A and B and shaking culture was continued for 24 hours. For the sake of comparison, portions of media A and B which contained 0.15% by weight of polyoxyethylene sorbitan monopalmitate and no additive therein, were incubated in the same manner as described above. The amounts of L-lysine in the cultured mixtures were then determined and the results are shown in Table 8.
TABLE 7______________________________________ Molar Alkylene oxideFat or Alcohol ratio Mole/oil (A) (B) (A/B) Compound A + B______________________________________Inventive17 Beef tallow Glycerol 1/0.5 EO 2018 Palm oil Glycerol 1/2 EO/PO 25/10 (Block)19 Fish oil Pentaery- 1/1 EO/PO 15/15 thritol (Block)20 Coconut oil Tri- 1/0.5 EO 20 methylol- propane21 Beef tallow Di- 1/1.0 EO/BO 30/15 glycerol (Block)Comp.22 Polyoxyethylene sorbitan EO 20 monopalmitate23 Not added -- --______________________________________
TABLE 8______________________________________ Amount of L-lysine (g/l) Medium A Medium B______________________________________17 7.2 6.518 6.9 6.219 6.5 5.920 7.8 7.021 6.7 6.022 3.5 3.223 1.6 1.4______________________________________
Example 6
A medium composed of the following composition by weight:
______________________________________Blackstrap molasses 4%KH.sub.2 PO.sub.4 0.1%MgSO.sub.4 0.05%Urea 0.8%Biotin 5 μg/lWater Balance______________________________________
was adjusted to pH 7.2 with KOH, and a 30-ml portion thereof was placed in a 500-ml Sakaguchi flask and sterilized under heat. This portion was inoculated with Corynebacterium glutamicum grown on a glucose-peptone slant to conduct incubation at 30° C. for 18 hours.
Separately, 30-ml portions of a medium (pH: 7-8) composed of the following composition:
______________________________________Blackstrap molasses 10% (in terms of sugar)Urea 1.0%K.sub.2 HPO.sub.4 0.1%MgSO.sub.4 0.05%Water Balance______________________________________
were placed in four 500-ml Sakaguchi flasks and sterilized under heat to prepare four media A, B, C and D. Then, 300 μl portions of the cultured mixture obtained above were separately subcultured into media A-D. Further, 0.2% of polyglycerol monolaurate and 0.2% of polyoxyethylene sorbitan monostearate were added to the medium A, 0.3% of polyglycerol monolaurate to the medium B, and 0.3% of polyoxyethylene sorbitan monostearate to the medium C. Medium D had no additive.
The media A-D were separately subjected to shaking culture at 30° C. for 48 hours to determine the amounts of L-glutamine in the respective media. The results are shown in Table 9.
TABLE 9______________________________________Medium Amount of L-glutamine (g/l)______________________________________Inventive:A 39.5B 34.0Comparative:C 18.0D 1.2______________________________________
Example 7
The following media A and B were prepared by weight:
______________________________________Medium A:Blackstrap molasses 10% (in terms of glucose)(NH.sub.4).sub.2 SO.sub.4 4.5%KH.sub.2 PO.sub.4 0.1%Peptone 1%Water BalanceMedium B:Glucose 10%Biotin 50 μg/lThiamine hydrochloride 200 mg/l(NH.sub.4).sub.2 SO.sub.4 4.5%KH.sub.2 PO.sub.4 0.1%Peptone 1%Water Balance______________________________________
40-ml portions of the thus-prepared media were separately poured into two 500-ml Sakaguchi flasks and sterilized. The thus-sterilized medium portions were inoculated with L-lysine-producing bacteria, Brevibacterium SP to conduct incubation at 30° C. for 18 hours. 400 μl of the resulting cultured mixtures were subcultured into their corresponding media A and B to conduct shaking culture at 30° C. for 8 hours. Thereafter, 0.15% of polyglycerol stearate was added to subcultured media A and B to continue the shaking culture further for 24 hours. For the sake of comparison, portions of media A and B, which contained no polyglycerol stearate therein, were incubated in the same manner as described above. The amounts of L-lysine produced in the respective cultured mixtures thus obtained are shown in Table 10.
TABLE 10______________________________________ Agent for improving Amount of L-lysineMedium the yield of amino acid (g/l)______________________________________A Added 7.2 Not added 1.8B Added 6.0 Not added 1.9______________________________________
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Disclosed herein are antifoaming agents for fermentation which include, as active ingredient at least one of (a) a reaction product obtained by adding at least one alkylene oxide to a mixture of a fat and/or oil with a trihydric or still higher polyhydric alcohol, or (b) a compound represented by the following general formula (1): ##STR1## wherein n stands for a number of 2-50, R 1 , R 2 and R 3 mean individually a hydrogen atom or an acyl group having 2-31 carbon atoms, x denotes an alkylene group having 2-4 carbon atoms, and m1, m2 and m3 are individually a number of 0-200, an L-amino acid-producing medium containing either one of these components, and a production process for L-amino acids making use of this medium. The use of this antifoaming agent permits the quick, sure and durable suppression of bubbling during incubation, and the overall production of the L-amino acid is significantly improved.
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TECHNICAL FIELD
[0001] The invention relates generally to charge controller and, more particularly, to a dying gasp charge controller.
BACKGROUND
[0002] In some power management systems, power down should be controlled enough so the system can gracefully shut down. An example of such an application is the digital subscriber line or xDSL modem standards compliant applications, which require manufacturers to allow for a “dying gasp” time when input power is disconnected. Typically, this “dying gasp” is on the order of about 60 ms. During this “dying gasp,” xDSL modems can communicate with the central computer about the shutdown and allow for better traffic handling.
[0003] Conventional solutions generally employ large external capacitors to store enough energy to operate the xDSL modem for the “dying gasp” period. These capacitors are generally on the order of 2000 μF to 8000 μF. Because these are large external capacitors, they are bulky and expensive, so it is desirable to reduce their size to produce a more economical xDSL modem.
[0004] Additionally, an example of conventional circuits is U.S. Pat. No. 7,098,557.
SUMMARY
[0005] A preferred embodiment of the present invention, accordingly, provides an apparatus. The apparatus comprising an input node; an internal capacitor that is coupled to the input node; an output node; and a dying gasp charge controller including: a dump circuit that is coupled to the input node and the output node, wherein the dump circuit provides charge to the output node from the input node on startup when the voltage on the output node is less than a precharge voltage, and wherein the dump circuit provides charge to the input node from the output node when the voltage on the input node falls below a gasp voltage; and a pump circuit that is coupled to the input node and the output node, wherein the pump circuit provides charge to the output node from the input node when the voltage on the output node is less than a charge voltage.
[0006] In accordance with a preferred embodiment of the present invention, the dump circuit further comprises a first transistor having a first passive electrode, a second passive electrode, and a control electrode, wherein the first passive electrode of the first transistor is coupled to the input node; a current limiter that is coupled to the input node and the control electrode of the first transistor; a second transistor having a first passive electrode, a second passive electrode, and a control electrode, wherein the first passive electrode of the first transistor is coupled to the second passive electrode of the first transistor, and wherein the second passive electrode of the second transistor is coupled to the output node; and an amplifier having a first input terminal, a second input terminal, and an output terminal, wherein the first input terminal of the amplifier is coupled to the input node, and wherein the second input terminal of the amplifier receives the gasp voltage, and wherein the output terminal of the amplifier is coupled to the control electrode of the second transistor.
[0007] In accordance with a preferred embodiment of the present invention, the first transistor is a PMOS transistor with the first passive electrode being the source, the second passive electrode being the drain, and the control electrode being the gate.
[0008] In accordance with a preferred embodiment of the present invention, the second transistor is a PMOS transistor with the first passive electrode being the drain, the second passive electrode being the source, and the control electrode being the gate.
[0009] In accordance with a preferred embodiment of the present invention, the pump circuit further comprises a low drop-out (LDO) regulator that is coupled to the input node; and a charge pump coupled between the LDO regulator and the output node.
[0010] In accordance with a preferred embodiment of the present invention, the pump circuit further comprises a charge pump.
[0011] In accordance with a preferred embodiment of the present invention, the pump circuit further comprises a boost converter.
[0012] In accordance with a preferred embodiment of the present invention, an apparatus is provided. The apparatus comprises an input node; a first capacitor that is coupled to the input node; an output node; a dying gasp charge controller including: a first PMOS transistor that is coupled to the input node at its source; a current limiter that is coupled to the input node and the gate of the first PMOS transistor; a second PMOS transistor that is coupled to the drain of the first PMOS transistor at its drain and the output node at its source; and an amplifier having a first input terminal, a second input terminal, and an output terminal, wherein the first input terminal of the amplifier is coupled to the input node, and wherein the second input terminal of the amplifier receives the gasp voltage, and wherein the output terminal of the amplifier is coupled to the gate of the second PMOS transistor; and a pump circuit that is coupled to the input node and the output node, wherein the dump circuit provides charge to the output node from the input node when the voltage on the output node is less than a charge voltage; and a second capacitor that is coupled to the output node.
[0013] In accordance with a preferred embodiment of the present invention, the LDO regulator further comprises: a third PMOS transistor that is coupled to the input node at its source; and a second amplifier having a first input terminal, a second input terminal, and an output terminal, wherein the first input terminal of the second amplifier receives the charge voltage, and wherein the second input terminal of the second amplifier is coupled to the output node, and wherein the output terminal of the second amplifier is coupled to the gate of the third PMOS transistor.
[0014] In accordance with a preferred embodiment of the present invention, the charge pump further comprises: a first diode that is coupled to the drain of the third PMOS transistor; a second diode coupled between the first diode and the output node; and a third capacitor that is coupled to a node between the first and second diodes and that is coupled to a switching node.
[0015] In accordance with a preferred embodiment of the present invention, the apparatus further comprises a buck converter having the switching node which is coupled to the third capacitor.
[0016] In accordance with a preferred embodiment of the present invention, an apparatus is provided. The apparatus comprises an input node; a first capacitor that is coupled to the input node; an output node; a buck converter having: a first NMOS transistor that coupled to the input node at its drain and a switching node at its source; a second NMOS transistor that is coupled to the switching node at its drain and ground at its source; a pulse width modulator (PWM) coupled to the gates of the first and second NMOS transistors; a dying gasp charge controller including: a first PMOS transistor that is coupled to the input node at its source; a current limiter that is coupled to the input node and the gate of the first PMOS transistor; a second PMOS transistor that is coupled to the drain of the first PMOS transistor at its drain and the output node at its source; a first amplifier having a first input terminal, a second input terminal, and an output terminal, wherein the first input terminal of the first amplifier is coupled to the input node, and wherein the second input terminal of the first amplifier receives the gasp voltage, and wherein the output terminal of the first amplifier is coupled to the gate of the second PMOS transistor; a third PMOS transistor that is coupled to the input node at its source and that is coupled to the output node at its source; a second amplifier having a first input terminal, a second input terminal, and an output terminal, wherein the first input terminal of the second amplifier receives the charge voltage, and wherein the second input terminal of the second amplifier is coupled to the output node, and wherein the output terminal of the second amplifier is coupled to the gate of the third PMOS transistor; a first diode that is coupled to the drain of the third PMOS transistor; a second diode coupled between the first diode and the output node; and a second capacitor that is coupled to a node between the first and second diodes and that is coupled to a switching node; and a third capacitor that is coupled to the output node.
[0017] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
[0019] FIG. 1 is a circuit diagram of a dying gasp charge controller in accordance with a preferred embodiment of the present invention;
[0020] FIG. 2 is a more detailed example of the dying gasp charge controller of FIG. 1 ; and
[0021] FIG. 3 is a state diagram for the dying gasp charge controller of FIG. 2 .
DETAILED DESCRIPTION
[0022] Refer now to the drawings wherein depicted elements are, for the sake of clarity, not necessarily shown to scale and wherein like or similar elements are designated by the same reference numeral through the several views.
[0023] Referring to FIG. 1 of the drawings, reference numeral 100 generally designates an example of a dying gasp charge controller in accordance with a preferred embodiment of the present invention. It is well known that the energy stored on a capacitor is ½CV 2 , where C is the capacitance of the capacitor and V is the voltage on the capacitor. Thus, to maintain substantially the same energy on two different size capacitors (having different capacitances), one would vary the voltage. Here, this principle is applied to the controller 100 , where an input large capacitor has been divided to an internal capacitor CIN and an external capacitor CEXT (which are coupled to the input node NIN and output node NOUT of the controller 100 , respectively) so that the voltage can be varied to have the same energy as a large capacitor. Each of capacitors CIN and CEXT are also about 100 μF and about 1000 μF, respectively.
[0024] To accomplish this, controller 100 employs a pump circuit 102 and a dump circuit 104 . The pump circuit 102 provides charge to the output node NOUT (and the external capacitor CEXT) from the input node NIN (which receives an input voltage VIN) on startup. In particular, dump circuit 104 charges the external or storage capacitor CEXT in a precharge mode when the voltage on the output node NOUT is less than a precharge voltage (typically about the input voltage VIN minus a voltage drop across a body diode). Following the precharge mode, the pump circuit 102 continues to charge the external capacitor CEXT by allowing charge to flow from the input node NIN to the output node NOUT until the voltage on the output node NOUT (and external capacitor CEXT) is greater than a charge voltage VMAX (which is typically about twice the input voltage VIN and which can be selectable by digital controls to generally ensure that the charge voltage VMAX does not exceed the voltage rating of the external capacitor CEXT). Controller 100 then continues to monitor the input voltage VIN (voltage on the input node NIN), and when the input voltage VIN (which is typical between about 9V and about 12V) falls below a gasp voltage VGASP (which is typically about 90% of the input voltage VIN), the external capacitor CEXT is discharged through the dump circuit 104 to the input node NIN.
[0025] There are several different implementation of the controller 100 that can be realized. For example, the pump circuit 102 can be implemented as a charge pump, a boost regulator, or a linear drop-out (LDO) regulator with a charge pump. Each of these different implementations provides a different set of benefits and drawback, but of the three enumerated implementations, the LDO regulator with a charge pump occupies the least amount of area.
[0026] Turning to FIGS. 2 and 3 of the drawings, an example of controller 100 (indicated by reference numeral 100 - 1 ) that employs an LDO regulator with a charge pump is shown along with its state diagram. In this configuration, controller 100 - 1 is coupled to internal capacitors CIN, C 1 , and C 2 , external capacitor CEXT, and buck converter 112 . The dump circuit 104 - 1 (which has the same general operation as dump circuit 104 of FIG. 1 ) is generally comprised of PMOS transistors Q 1 and Q 2 , current limiter 106 , and amplifier 108 . The pump circuit 102 - 1 (which has the same general operation as pump circuit 102 of FIG. 1 ) is generally comprised of amplifier 110 , PMOS (or NMOS) transistor Q 3 , diodes D 1 and D 2 , and capacitor C 2 . Additionally, buck converter 112 is generally comprised of a pulse width modulator 114 , an error amplifier 116 , voltage divider R 1 and R 2 , inductor L, capacitor C 3 , and NMOS transistors Q 4 and Q 5 . Buck converter 112 operates in the conventional manner by applying PWM signals (which are adjusted through the error amplifier 116 comparing the feedback voltage from voltage divider R 1 and R 2 to a reference voltage VREF) to the gates of transistors Q 4 and Q 5 . This allows the switching node NSW to switch between ground and input voltage VIN to drive inductor L and capacitor C 3 . Additionally, buck converter 112 can be replaced by another circuit that provides a switching node similar to that provided buck converter 112 .
[0027] In operation, controller 100 - 1 is able to charge and discharge the external capacitor CEXT in generally the same manner as controller 100 of FIG. 1 . During startup, the input voltage VIN rises to a desired level (for example, about 12V and typically above about 1.5V) of state 302 , and the controller 100 - 1 enters the precharge mode of state 304 . During the precharge mode of state 304 , amplifier 108 maintains transistor Q 2 in an “off” state so that it operates as a diode (using the inherent body diode of transistor Q 2 ), and current limiter 106 measures the current from the input node NIN to the output node NOUT so as to operate transistor Q 1 as a current-limited switch. The dump circuit 104 - 1 , then, continues to charge the external capacitor CEXT until the voltage on the output node (and capacitor CEXT) is greater than the precharge voltage (typically about the input voltage VIN minus a voltage drop across the body diode of transistor Q 3 ). Once the voltage on capacitor CEXT is greater than the precharge voltage, the controller 100 - 1 enters a charge mode of state 306 where the amplifier 110 actuates transistor Q 3 to allow charge to continue to flow from the input node NIN to the output node NOUT until the voltage on the output node NOUT (and capacitor CEXT) is greater than the charge voltage VMAX. Additionally, a stepping voltage (which is lower than the input voltage VIN) is applied to capacitor C 2 (which is coupled to a node between diodes D 1 and D 2 ) by a switching node (for example, from switching node NSW of buck converter 112 ) to provide additional charge control, operating as a charge pump.
[0028] Once capacitor CEXT is charged, amplifier 108 continues to monitor the input voltage VIN to determine whether it has fallen below the gasp voltage VGASP (indicating power loss). When this power loss is detected, controller 100 - 1 enters a dump mode of state 308 . In the dump mode of state 308 , amplifier 108 actuates transistor Q 2 , and the current limiter 106 does not limit any current flowing from output to input node during dump mode, allowing transistor Q 2 to act as a power field effect transistor (FET) of an LDO and allowing transistor Q 1 act as a switch. Current can then flow from the output node NOUT (and capacitor CEXT) to the input node NIN. Thus, the system can use the energy stored on capacitors CIN and CEXT to continue to power the system during a “dying gasp” period without the use of a bulky and expensive external capacitor. Additionally, because a large voltage is applied to capacitors CIN and CEXT, the energy storage capacity meets or exceeds that of conventional circuits.
[0029] Having thus described the present invention by reference to certain of its preferred embodiments, it is noted that the embodiments disclosed are illustrative rather than limiting in nature and that a wide range of variations, modifications, changes, and substitutions are contemplated in the foregoing disclosure and, in some instances, some features of the present invention may be employed without a corresponding use of the other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.
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In many applications, “dying gasp” periods following power down are used. Conventional circuits supply energy for the “dying gasp” periods generally by use of large external capacitors that are bulky and expensive. Here, a dying gasp charge controller is employed that allows for the use of smaller capacitors at higher voltages, which maintains or exceeds the energy storage capacities of conventional circuits.
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CROSS-REFERENCE
The present application is a section 371 of PCT/EP08/09701 filed 17 Nov. 2008, published 28 May 2009 as WO-2009-065539, claiming priority of German application DE 10 2007 057 099.8 filed 19 Nov. 2007, the disclosure of which is incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to a fan arrangement having a fan driven by an electric motor.
BACKGROUND
When a fan is driven by an electric motor, what results is a combination of the properties of the fan and the properties of the electric motor.
A variety of fan designs exist, e.g. radial fans, transverse-flow blowers, axial fans, and diagonal fans. Radial fans are divided into radial fans having backward-curved blades, and radial fans having forward-curved blades. There are likewise further sub-types in the case of the other designs.
The properties of a fan result from the so-called fan characteristic curve, which indicates the quantity of air per hour (m 3 /h) delivered by the fan at a particular static pressure, and from the motor characteristic curve, which indicates how much power the motor needs in order to deliver a specific quantity of air per hour.
The power requirement is further determined by the operating conditions of the fan. For example, when a fan is blowing air from outside into a room in which all the doors and windows are closed, the fan is operating at maximum static pressure. “Free outlet” blowing, conversely, means that the fan is located unrestrictedly in a space, and that no physical separation, and also no pressure difference, exists between its intake side and delivery side. This therefore means that a free outlet fan has a different power requirement than a fan that is delivering into a closed space.
An examination of the curve for a fan arrangement's power consumption plotted against generated volumetric air flow rate reveals that this power is highly dependent on the working point that is set, or on the pressure buildup in the fan. In the case of a radial fan, for example, maximum power is usually reached with free outlet, i.e. at a pressure elevation Δpf=0, whereas for an axial fan, it is reached at a maximum pressure elevation Δpf=maximum.
Radial fans are normally used at a higher static pressure. When they work without static pressure, i.e. in free-outlet fashion, they are being operated at their power limit, i.e. a radial fan must be designed for this operating point even though in practice it occurs seldom and in rather arbitrary fashion. This limits the power of such a fan under other operating conditions. Analogous considerations apply to other fan types.
SUMMARY OF THE INVENTION
It is an object of the invention to make available a novel fan arrangement.
This object is achieved by employing a controller which reduces any difference between operating electrical power P IST and desired electrical power P SOLL to thereby improve the air output characteristic curve.
Fan arrangements are normally designed so that the maximum permissible winding temperature of the electric motor is not exceeded at maximum electrical power consumption. This means that a fan arrangement of this kind is “understressed” for many applications, i.e. at most working points it is operating below its maximum permissible power level.
What is achieved, by means of the invention, is that a fan arrangement of this kind can be operated at its permissible power limit, i.e. an improved air output characteristic curve is obtained with the same fan. The approach in this context is to operate the fan arrangement always in the region of its maximum permissible power, i.e. at the power limit or close to it, and thereby to achieve a greater volumetric flow rate for the same counterpressure, i.e. to increase the air output without requiring a larger fan arrangement for that purpose. Different solutions may be produced in this context, depending on the type of fan arrangement.
BRIEF FIGURE DESCRIPTION
Further details and advantageous refinements of the invention are evident from the exemplifying embodiments, in no way to be understood as a limitation of the invention, that are described below and depicted in the drawings.
FIG. 1 shows an embodiment of an air output controller;
FIG. 2 shows the fan characteristic curve of a radial fan with and without the output controller of FIG. 1 ;
FIG. 3 depicts the fan power with and without an output controller;
FIG. 4 is a partial depiction of a radial fan wheel 100 whose fan blades 102 are “forward-curved”;
FIG. 5 depicts a radial fan wheel 104 whose fan blades 106 are “backward-curved”;
FIG. 6 shows measurement curves that were recorded using the motor according to FIG. 1 ; they show static pressure Δpf as a function of volumetric flow rate V/t at a constant low power and at a constant higher power;
FIG. 7 shows measurement curves for FIG. 1 ; they show rotation speed as a function of volumetric flow rate at a low constant power and at a higher constant power.
FIG. 8 shows motor current i MOT as a function of volumetric flow rate V/t at a constant low power and at a higher constant power; and
FIG. 9 shows the electrical power P (watts) consumed by motor 12 at a low constant power (curve 122 ) and at a higher constant power (curve 124 ); it is evident that the power during operation is held practically constant, so that the motor's power can be fully utilized.
DETAILED DESCRIPTION
FIG. 1 shows a preferred embodiment of a fan arrangement 20 having an electric motor 22 and a fan 24 driven thereby, which fan arrangement 20 operates with power control. Fan arrangement 20 is continuously operated with power control in order to achieve an increase in air output in the context of fan 24 , at least in portions of its fan characteristic curve, and thus to better utilize fan arrangement 20 .
Fan arrangement 20 can be, for example, a usual equipment fan whose motor 22 will usually be a collectorless DC motor since, in the case of the latter, the rotation speed can be more easily modified than in the case of an AC or three-phase motor. The use of an AC or three-phase motor is, however, also not excluded.
The users of such fans are accustomed to fan arrangements that work with a rotation speed control system, and in which the rotation speed can be adjusted. For this reason, the desired rotation speed n SOLL specified by the user is delivered to input 28 of a target value converter 26 , and converted there into a target power value P SOLL . This conversion is based, for example, on the rotation speed n assumed by fan arrangement 20 when a predetermined electrical power P is delivered to motor 22 , and fan 24 is blowing freely at its outlet 30 , e.g. into a room having open windows and doors. The inlet of fan 24 is labeled 32 , and in this case is unthrottled.
For example, if a rotation speed n SOLL of 1000 rpm is specified to target value converter 26 , target power P SOLL is then modified until fan arrangement 20 is running (with free outlet) at 1000 rpm, e.g. at 2.3 watts. The value pair 1000 rpm=2.3 W is then inputted into converter 26 . This is repeated for the entire value range that fan arrangement 20 can cover during operation, e.g. for 500, 600, 700, 1000, 2000 . . . rpm; interpolation between these values usually occurs.
Alternatively, it is also possible to determine a mathematical approximation formula with which the value for n SOLL can be converted directly into values for P SOLL .
Because the values are measured while fan 24 is blowing freely at its outlet 30 , the rotation speeds during actual operation are of course somewhat different from n SOLL but, in any case, the behavior obtained for fan arrangement 20 is similar to that of a speed-controlled fan.
Electrical power P IST consumed by motor 22 is ascertained, for example, by measuring voltage u MOT at motor 22 and motor current i MOT (e.g. at a measuring resistor 36 ). These values are delivered to a multiplier 38 , at whose output 40 a value is obtained for electrical power P IST consumed by motor 22 . This, along with value P SOLL from target value converter 26 , is delivered to a comparator 42 whose output signal is delivered to a controller 44 .
Depending on the speed and accuracy requirements, this latter can be, for example, a P controller, a PI controller, or a PID controller. Controller 44 has an output 45 at which a control input is obtained and is delivered to a limiter 46 . The latter limits the control input to a predetermined value, which can be different depending on the rotation direction.
The limited signal at output 47 of limiter 46 is delivered to a PWM module 48 and transformed there into a PWM signal 50 that is delivered to motor 22 and controls current i MOT therein.
In order to prevent motor 22 from overloading, its power is therefore limited to a maximum value, e.g. by limiting current i MOT .
FIGS. 2 and 3 show, by way of example, the effect of the invention on a radial fan whose fan blades are forward-curved, i.e. curved in the rotation direction. Fan blades of this kind are depicted by way of example in FIG. 4 .
FIG. 5 likewise shows a fan wheel whose fan blades are backward-curved and in which the invention can be used in the same fashion, although the curves that are obtained look somewhat different.
FIG. 2 shows, as an example, fan characteristic curve 49 without the invention, i.e. static pressure Δpf as a function of volumetric flow rate. For a radial fan, the maximum power is usually reached at a point 50 at which static pressure Δpf has a value of 0, i.e. at a point where fan 24 is blowing in free-outlet fashion, for example into a room having open windows and doors.
Moving from point 50 to the left, i.e. as the windows and doors are successively closed, the load on electric motor 22 decreases because static pressure Δpf increases. For curve 49 in FIG. 2 , for example, at a static pressure of 700 Pa air is no longer being delivered, i.e. no further cooling is occurring, and the electrical power necessary for motor 22 decreases (as shown in FIG. 3 ) in the range from 200 to 0 m 3 /h, as shown by curve 54 of FIG. 3 . Unutilized power reserves of fan arrangement 20 thus exist in this range.
Motor 22 is operated, for example, in a specific operating state with a target power value P SOLL of 100 W (see curve 56 of FIG. 3 ). When power P IST decreases here, as a result of the increasing static pressure, the rotation speed of fan 24 is increased, for example by raising the duty factor of PWM signal 50 , until the desired power P SOLL is reached. This results, according to FIG. 2 , in an improved fan characteristic curve 58 , in which air is still delivered up to a static pressure of approximately 1200 Pa. The power reserves of fan 24 are made usable in this fashion, and the cooling of a device cooled by fan 24 is improved. These mobilized power reserves are labeled 60 in FIG. 2 and are highlighted in gray.
The description above refers to a radial fan. Application is likewise possible, however, for transverse-flow blowers, axial fans, diagonal fans, etc. The influence on the air output characteristic curve is more or less pronounced depending on the fan type.
A motor 22 is designed, as standard, approximately so that it reaches the maximum required power P IST when operating voltage Ub corresponds to the rated voltage, and so that, if voltage Ub becomes too high, the power delivered to motor 22 is limited.
This is done by way of a corresponding reduction in motor current i MOT (by modifying the duty factor of signal 50 ). The arrangement according to FIG. 1 thereby automatically adapts to different values of voltage Ub that may occur during operation, and the risk of overloading motor 22 is ruled out.
FIGS. 6 to 9 show measured values for the power control system according to FIG. 1 , for an RER190 radial fan of the EBM-PAPST company and for two different power settings, namely a low power of approximately 135 W and a higher power of approximately 235 W.
FIG. 6 shows static pressure Δpf as a function of volumetric flow rate. Curve 110 shows the result at a constant power that was regulated to 135 W, and curve 112 shows the result at a constant power of approximately 235 W. The curves run approximately parallel to one another. The volumetric flow rate was modified in the usual way by means of a measurement nozzle.
FIG. 7 shows rotation speed n IST as a function of volumetric flow rate. The curve for 135 W is labeled 114 , and the curve for 235 W is labeled 116 . The volumetric flow rate was modified in the usual way by means of a measurement nozzle.
FIG. 8 shows motor current i MOT as a function of volumetric flow rate. Because DC voltage Ub (in this case 48 V) was held constant in FIG. 1 , current i MOT is held constant by output controller 98 . The curve for 135 W is labeled 118 , the resulting current having been approximately 2.8 A; and the curve for 235 W is labeled 120 , the current having been equal to about 5 A. Here as well, the volumetric flow was modified using a measurement nozzle (not depicted).
FIG. 9 shows electrical power P IST consumed by motor 22 as a function of volumetric flow. Curve 122 shows the result for a constant power of 135 W, and curve 124 shows the result for a constant power of 235 W. The volumetric flow rate was modified by means of a measurement nozzle (not depicted).
Many variants and modifications are of course possible in the context of the present invention.
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A fan arrangement ( 20 ) has a fan ( 24 ) driven by an electric motor ( 22 ), also an apparatus for detecting the electrical power (P IST ) consumed by the electric motor ( 22 ) during operation; an input apparatus ( 28 ) for inputting a desired rotation speed (n SOLL ) of said electric motor ( 22 ); a converter ( 26 ) for converting said desired rotation speed (n SOLL ) into a desired electrical power (P SOLL ); and a controller ( 44 ), which regulates the control input controlling the electric motor ( 22 ) in such a way that the difference between the electrical power (P IST ) consumed in operation and the desired electrical power (P SOLL ) is reduced, in order thereby to improve the air output characteristic curve ( 49, 58 ) of the fan arrangement ( 20 ) at least in a portion of the overall operating range.
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This application is a continuation in part of International Application Number PCT/RU96/00347, filed Dec. 16, 1996, which claims priority of application 95121508RU filed on Dec. 22, 1995.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to computer technology, particularly it concerns computer systems.
The invention has application in both engineering and technical calculations for space and aviation technologies, geodesy, hydrometeorology and other fields which require high performance computations.
2. Description of the Related Art
There is a known computer system which contains central input-output processors, a switch, a main memory unit, a control panel, peripheral memory devices with control blocks and data transmission processors (SU, A, 692400).
In this system Von Neumann's principle of data processing is used. Every central processor contains a conforming (conjugating) unit, a block for performing procedures, an indexing block, a block for value retrieving, a block for processing strings, an arithmetic-logical unit, a block of the basic registers, a unit for instructions forming, a control unit, a unit for the distribution of stack addresses, a buffering stack of operands, an associative memory unit, a unit for transformation of the mathematical addresses into the physical ones, a block of memory for buffering instructions, a block for analysis of interrupts.
The arithmetic-logical unit includes: blocks for multiplication, addition, division, code transformation and logical operation performing. These blocks work in parallel and independently from one another, providing parallel data processing within each processor and using the natural parallelism of the programs under execution.
However, implementation of this unit has shown that, in practice, the use of Von Neumann's principle of computation organization requires high unproductive expenditures of hardware and computing capacity to provide parallel work of several executive devices. These expenditures, first of all, are related to the fact that to form independent sequences of instructions from the program in execution it is necessary to do a preliminary survey of program segments (of the average length up to 30 instructions) and a dynamic planning of executing units loading with the help of special hardware means, which was described in detail (Babayan B.A. “Main results and perspective of development of the “Elbrus” architecture”, Applied Computer Science works collection, vol. 15, Moscow, Finance and Statistics, 1989, pp. 100-131).
Due to this fact the hardware becomes considerably more complicated, having simultaneously a low real increase of performance. Parallelism of program processing on several executive devices is restricted and does not spread on the whole program (the segments of parallel processing do not exceed 10-20 instructions). Moreover, the process of extraction of instructions from the program for parallel execution itself requires a large amount of additional hardware and working time of the processor. This is another factor of the decrease in performance.
There is a known device which contains units of common memory, units of central input-output processors, using Von Neumann's principle of computation processing and parallel work of several executive devices, being parts of central processors. This device achieves program processing parallelism by means of forming an extensive instruction which includes operations for the simultaneous start of several arithmetic units (SU, A, 1777148).
Formation of such an instruction is conducted by static operation planning during the program translation stage. Here, the number of operations of the instruction being executed in parallel is limited (it does not exceed 7).
However, this device does not achieve high performance based on the internal parallelism of the programs in execution because of limited parallelism of operations in execution in the device and a cessation of execution when all the operands necessary for a computation are not available. This problem arises from the restrictions set by the translator and also in the case when the variable position in memory depends on computation conditions. Also, this device has a complicated translator structure and a large amount of the hardware to conduct local parallelism of computation.
There is a known computer system which contains a switch and N processor units. In such a system the first control outputs and address outputs of the i-th processor unit (i=1, . . . ,N) are connected correspondingly with the i-th input of the first control input group and with the i-th input of the group of the address switch inputs. The first and second informational outputs of the i-th processor unit are connected with the corresponding i-th input of the group of informational switch inputs. The first informational, address, control and the second informational, address, control inputs of the i-th processor unit are connected with the first and second informational system inputs. The first control input of this system is connected with the control switch input and with the third control input of the i-th processor unit. The switch control output is connected with the fourth control input of the i-th processor unit. The third informational output of this unit is connected with the first informational output of the system. The computer system can have a second informational output and a third informational input (U.S. Pat. No. 4,814,978).
For computation organization this system uses the data flow principle, which provides effective loading for each processor unit and high total performance. This is achieved by means of parallel instruction execution in all sections of the program and is supported by a programmable computation organization. The program is mapped as a graph, each node of which is an instruction and arcs show the direction of data transmission. Each of the processor units, mutually connected through the switch, executes a local section of the program. The processor units work in parallel and the necessary synchronization between sections of the program is carried out by means of the data transmit through the switch. Parallelism is achieved by the partition of the program during translation into separate linked sections, which leads to a waste of time and adecrease in device performance. Thus, device performance depends greatly on the programming system capability to segregate sections (sub-programs), which are weakly linked to one another. in the original program and is quite time-consuming on the user (programmer) side.
These disadvantages do not allow the full internal parallelism of the programs in execution to be realized in this device and as a result do not achieve high performance based on this parallelism and the data flow principle.
SUMMARY OF THE INVENTION
The invention is based on the problem of creating a computer system which would achieve increased performance by means of simultaneous access of each processor unit to the entire program in execution and through automation of the process of computational means distribution.
The problem is solved this way. The computer system contains a switch, N processor units, a second informational output and a third informational input. The first control output and address output of the i-th processor unit (i=1 . . . N) are connected correspondingly with the i-th input of the first group of switch control inputs and with the i-th input of the group of switch address inputs. The first and second informational outputs of the i-th processor unit are connected with the corresponding input of the group of switch informational inputs. The first informational, address, and control inputs and the second informational, address, and control inputs of the i-th processor unit are connected with the first and second informational inputs of the system. The first control input of the system is connected with the control input of the switch and with third control input of the i-th processor unit. The control output of the switch 2 is connected with the fourth control input of the i-th processor unit. The third informational output of the i-th processor unit is connected with the first informational output of the system.
According to the invention,
1. The computer system contains an auxiliary switch, N modules of associative memory and a buffering block. The first control, first informational, second control and second informational outputs of the i-th group of exchange outputs of the auxiliary switch are connected correspondingly with the fifth control, third informational, sixth control and fourth informational inputs of the i-th processor unit. The first group of control outputs of the auxiliary switch is connected with the first group of control inputs of the buffering block. The second group of control outputs of the auxiliary switch is connected with the second group of control inputs of the buffering block. The control inputs of the auxiliary switch and of the buffering block and the first control input of each module of associative memory are connected with the control input of the system. The i-th inputs of the first and second groups of control inputs of the auxiliary switch are connected correspondingly with the second and third control outputs of the i-th processor unit. The seventh and eighth control inputs of the i-th processor unit are connected correspondingly with the i-th outputs of the first and second groups control outputs of the buffering block. The third group of control outputs and the first group of the informational outputs of the buffering block are connected correspondingly with the third group of control inputs and the first group of informational inputs of the auxiliary switch. The second group of informational outputs of the buffering block is connected with the second informational output of the system. The fourth group of control inputs of the auxiliary switch is connected with the fourth group of control outputs of the buffering block. The i-th input of the first group of informational inputs of the buffering block is connected with the fourth and fifth informational outputs of the i-th processor unit. The fourth control output of i-th processor unit is connected with the i-th input of the third group of control inputs of the buffering block. The third group of informational outputs of the buffering block is connected with the second group of informational inputs of the auxiliary switch. The first control output of the i-th module of associative memory is connected with the i-th input of the second group of control inputs of the switch. The i-th output of the group of informational outputs of the switch is connected with the informational input of the i-th module of associative memory. The informational and the second control outputs of the i-th module of associative memory are connected with the i-th inputs of the second group of informational inputs and the fourth group of control inputs of the buffering block. The third group of informational inputs of the buffering block is connected with the third informational input of the system. And, the i-th output of the group of control outputs of the switch is connected with the second control input of the i-th module of associative memory.
2. Each processor unit, according to the invention, may contain the first and second switches, the first and second control units, an executive device for instruction processing and an executive device for operand processing. The first and second control inputs of the first switch are connected with the first and second control outputs of the first control unit of control. The third control output of the first control unit is connected with the first control input of the executive device for instruction processing. The first and the second control outputs of the second control unit are connected with the first and second control inputs of the second switch. The first informational input of the second switch is connected with the address output of the executive device for instruction processing, the first informational output of the executive device for instruction processing is connected with the second informational input of the second switch and the first informational input of the first switch. The second informational output of the executive device for instruction processing is connected with the second informational input of the first switch and the third informational input of the second switch. The first control output of the executive device for instruction processing is connected with the first control input of the first control unit. The fourth control output of the first control unit is connected with the first control input of the executive device for operand processing. The first control output of the executive device for operand processing is connected with the second control input of the first control unit. The first control input of the second control unit is connected with the second control output of the executive device for operand processing. The second control output of the executive device for instruction processing is connected with the second control input of the second control unit. The second control input of the executive device for instruction processing is connected with the third control output of the second control unit. The fourth control output of the second control unit is connected with the second control input of the executive device for operand processing. The fourth informational input of the second switch is connected with the address output of the executive device for operand processing. The first informational output of the executive device for operand processing is connected with the fifth informational input of the second switch and the third informational input of the first switch. The second informational output of the executive device for operand processing is connected with the fourth informational input of the first switch and with the sixth informational input of the second switch. The first, second and third informational outputs of the second switch are the address output, the first informational output and second informational output of the processor unit respectively. The third informational outputs of the executive device for instruction processing and of the executive device for operand processing are connected with the third informational output of the processor unit. The fourth and fifth informational outputs of the processor unit are respectively the first and second informational outputs of the first switch. The fifth control output of the second control unit is connected with the first control output of the processor unit. The second and third control outputs of the processor unit are the third control outputs of the executive device for instruction processing and of the executive device for operand processing respectively. The fourth control output of the processor unit is connected with the fifth control output of the first control unit. The first informational, address and control inputs of the processor unit are the first informational, address and the third control inputs of the executive device for instruction processing respectively. The second informational, address and control inputs of the processor unit are connected correspondingly with the first informational, address and the third control inputs of the executive device for operand processing. The fourth control input of the executive device for operand processing and the fourth control input of the executive device for instruction processing are connected with the third control input of the processor unit. The fourth control input of the processor unit is connected with the third control input of the second control unit. The third informational input of the processor unit is the second informational input of the executive device for instruction processing. The fifth control input of the executive device for instruction processing is the fifth control input of the processor unit. The fourth informational and the sixth control inputs of the processor unit are connected with the second informational and the fifth control inputs of the executive device for operand processing respectively. And, the seventh and eighth control inputs of the processor unit are connected with the third and fourth control inputs of the first control unit respectively.
3. The auxiliary switch, according to the invention, may contain the first and second control units and the first and second switching units. The first groups of the control outputs of the first and second control units are connected with the first and second groups of the control outputs of the auxiliary switch respectively. The first and second control outputs of the i-th group of exchange outputs of the auxiliary switch are connected with the i-th outputs of the second group of the control outputs of the first and second control units respectively. The control inputs of the first and second control units are connected with the control input of the auxiliary switch. The first and second groups of the informational inputs of the auxiliary switch are connected with the groups of the informational inputs of the first and second switching units respectively. The i-th outputs of the group of the informational outputs of the first and second switching units are connected correspondingly with the first and second informational outputs of the i-th group of the exchange outputs of the auxiliary switch. The first and second groups of the control inputs of the auxiliary switch are connected with the first groups of the control inputs of the first and second control units respectively. The groups of the control outputs of the first and second switching units are connected correspondingly with the second groups of the control inputs of the first and the second control units. The third groups of the control inputs of the first and the second control units are connected correspondingly with the third and fourth groups of the control inputs of the auxiliary switch. And, the third groups of the control outputs of the first and second control units are connected with the first groups of the control inputs of the first and second switching units respectively. The second group of the control inputs of each of these units is connected correspondingly with the fourth group of the control outputs of the first and second control units.
4. The buffering block, according to the invention, may contain the group of buffering units. The first, second and third control outputs of the i-th buffering unit are connected with the i-th outputs of the first, second and third groups of the control outputs of the buffering block respectively. The i-th inputs of the first and second groups of the control inputs of the buffering block are connected with the first and second control inputs of the i-th buffering unit respectively. The fourth control output of the buffering unit is connected with the i-th output of the fourth group of the control outputs of the buffering block. The control input of the buffering block is connected with the third control input of each of the buffering units. The i-th inputs of the third and fourth groups of the control inputs of the buffering block are connected with the fourth and fifth control inputs of the i-th buffering unit respectively. The first, second and third informational outputs of the buffering units are connected correspondingly with the i-th outputs of the first, second and third groups of the informational outputs of the buffering block. The i-th inputs of the first, second and third groups of the informational inputs of the buffering block are connected with the first, second and third informational inputs of the i-th buffering unit respectively.
BRIEF DESCRIPTION OF THE FIGURES
Further on the invention is illustrated by an example of its application and attached drafts, where:
FIG. 1 represents the functional diagram of the computer system;
FIG. 2 represents the functional diagram of the computer system processor unit;
FIG. 3 represents the functional diagram of the control unit of the first switch of the processor unit;
FIG. 4 represents the functional diagram of the control unit of the second switch of the processor unit;
FIG. 5 represents the functional diagram of the executive device for instruction processing;
FIG. 6 represents the functional diagram of the control unit of the executive device for instruction processing of the processor unit;
FIG. 7 represents the functional diagram of the switching block of the executive device for instruction processing;
FIG. 8 represents the functional diagram of the control unit of the switching block of the executive device for instruction processing;
FIG. 9 represents the functional diagram of the input register unit of the executive device for instruction processing;
FIG. 10 represents the functional diagram of the instruction register unit of the executive device for instruction processing;
FIG. 11 represents the functional diagram of the executive device for operand processing of the processor unit;
FIG. 12 represents the functional diagram of the control unit of the executive device for operand processing;
FIG. 13 represents the functional diagram of the input register unit of the executive device for operand processing;
FIG. 14 represents the functional diagram of the output register unit of the executive device for operand processing;
FIG. 15 represents the functional diagram of the computer system auxiliary switch;
FIG. 16 represents the functional diagram of the auxiliary switch control unit;
FIG. 17 represents the functional diagram of the auxiliary switch switching unit;
FIG. 18 represents the functional diagram of the auxiliary switch query forming control unit;
FIG. 19 represents the functional diagram of the switching control block of the auxiliary switch control unit;
FIG. 20 represents the functional diagram of the switching priority control unit of the switching control block of the auxiliary switch control unit;
FIG. 21 represents the functional diagram of the input query unit of the switching control block of the auxiliary switch control unit;
FIG. 22 represents the functional diagram of the transforming-receiving unit of the auxiliary switch switching unit;
FIG. 23 represents the functional diagram of the transforming-transmitting unit of the auxiliary switch switching unit;
FIG. 24 represents the functional diagram of the computer system buffering block;
FIG. 25 represents the functional diagram of the buffering unit of the buffering block;
FIG. 26 represents the functional diagram of the buffering unit buffer;
FIG. 27 represents the functional diagram of the buffering control unit of the buffer unit;
FIG. 28 represents the functional diagram of the computer system associative memory module;
FIG. 29 represents the functional diagram of the computer system switch;
FIG. 30 represents the functional diagram of the computer system switch control unit;
FIG. 31 represents the functional diagram of the transmitting control unit of the computer system switch control unit;
FIG. 32 represents the functional diagram of the receiving control unit of the computer system switch control unit;
FIG. 33 represents the functional diagram of the switching control unit of the computer system switch control unit;
FIG. 34 represents the general appearance of computation graph;
FIG. 35 represents the informational package structure.
FIG. 36 is a schematic of the system of the invention.
DETAILED DESCRIPTION OF THE INVENTION
This application introduces a new architecture for a computing system which utilizes the principle of data flow processing.
The program scheme of a dataflow system is described as a graph consisting of nodes and archs connecting the nodes. The nodes represent operations and the archs represent the path of tokens through the system. The information represented by a node is assembled into packets.
Tokens of information are words which are subdivided into a number of fields. Fields may include an opcode field to represent the operation to be performed on the data, one data field to represent the information to be processed, one or two destination fields to represent the destination or node to which the results of processing are directed, and other fields to represent the context of program execution, tags or keys to be used for identification during processing, etc. Keys or tags are used to identify the iteration being performed, the individual tokens of a pair destined for the same node, etc.
Packets of information also are words which are subdivided into a number of fields. A packet may contain one or two data fields.
Thus, a program written according to a dataflow graph will indicate the direction in which the data is transferred during processing. Each node processes the input data and yields one or more results destined to a system output or to one or more other nodes.
Referring to FIG. 36, the system disclosed in this application comprises N processor units ( 1 -i) where N is a positive integer (i=1, . . . N), switch ( 2 ), auxiliary switch ( 3 ), buffering block ( 5 ), and M associative memory modules ( 4 -i) where M is a positive integer (i=1, . . . M).
Buffering block 5 is used to smooth peaks of the input queries on the inputs of the auxiliary switch 3 . The use of buffering block 5 in the starting process is its additional function.
In general, the system comprises at least one processor unit, at least one associative memory module at least one switch and at least one auxiliary switch. The functions of the buffering block my be carried out by separate buffering means, such as, for example, buffering block ( 5 ), or by buffering means incorporated in other units of the system, such as, for example, an auxiliary switch.
In a system with more than one processor unit, the design and configuration of each processor unit is preferrably the same as the design and configuration of every other processor unit. This affords certain advantages. For example, if one or several processors in a system fail, the system will still operate without need for adjustment by the user or programmer. Each processor unit comprises local or command instruction memory units, which may be subdivided into smaller subunits, which in turn may be dedicated to a particular executive device. A processor unit may comprise any number of executive devices. Preferrably, in a given processor unit, each executive device is best suited to processing a particular type of information. For example, each processor unit may comprise two executive devices and local command instruction memory subunits dedicated to each executive device, wherein one executive device is best suited to processing control instructions and the other executive unit is best suited to processing operands.
The entire command instruction set of the program being executed is loaded into each processor unit. Preferably, in a processor unit with more than one executive device and with a local memory subunit dedicated to each executive device, those instruction used only by a given executive device are loaded only into the memory subunit dedicated to that executive device.
Packets destined for processing in the processor units are directed through the buffering block to the auxiliary switch. The buffering block identifies each packet on the basis of the type of data contained in the packet. Identified packets are directed to the auxiliary switch, either immediately, or after storage in a buffer until later forwarding. For example, the buffering block may distinguish packets containing operands from packets containing control instructions. In another example, the buffering block may comprise at least one buffer dedicated to receiving operand packets and at least one buffer dedicated to receiving control instructions.
The auxiliary switch sequentially distributes each packet received to the next available processor unit. Preferably, each packet is directed not only to the next available processor unit but also is directed specifically to the executive device best adapted for the processing of the packet on the basis of packet type. Transmission from the auxiliary switch to a processor unit is determined by a “free address” switching regime. That is, control signals direct transmission of information from the auxiliary switch to a free processor unit. That is, the system comprises free address switching means to transmit information from an auxiliary switch to a free processor unit. For example, the transmission may be directed by the presence of a free register.
Packets received in an executive device are processed and the results of processing are obtained. If a result is a final result, that is, it is not destined for another node, the result is directed to an output of the system. If the result is a single input result, that is, it is destined to be the only input in a subsequent node, the result is sent directly to the buffering block for further processing. If the result is a double input result, that is, it is destined to be one of two inputs in a subsequent node, the result is sent indirectly to the buffering block, through the switch and the associative memory, for further processing.
Each token received by the switch must be matched with its pair for further processing. The switch utilizes a key on each token received to determine if the token's pair is already stored in associative memory. If the pair is found, the two tokens are paired together into a packet. Packets are directed to the buffering block, either immediately, or after storage in associative memory until later forwarding. If the received token's pair is not found, the token is directed to and stored in associative memory to await the arrival of its pair. The transmission of a token from a processor unit to an associative memory module is determined by a “fixed address” switching regime. That is, the system comprises fixed address switching means to transmit information from a processor unit to an associative memory module.
For example, an associative memory unit may comprise more than one module of associative memory. In this instance, a token is directed to a specific module or location of associative memory on the basis of a key encoded in the token. Each token of a pair is encoded with the same key in order to facillitate the pairing of tokens. Preferrably, the number of the module is determined from the key encoded on the token utilizing a hashing function. Also, preferrably, the hashing function is implemented in hardware and applied in the processor unit.
Preferrably, the auxiliary switch and/or the switch utilize an optical system, such as a dimensional or spatial optical system, to facilitate switching. That is, preferably, the system comprises at least one optical system to facilitate switching. For example, each switch comprises a dimensional optical system. The dimensional optical system comprises a first transforming-transmitting unit, a laser emitter, a photo-receiver, and a second transforming-transmitting unit. The optical system may also comprise a controlled deflector, a first group of lens rasters, a controlled optical transparency, and a second group of optical lens rasters. A packet or token is transmitted to an input register. Parallel code from the input register is transmitted to a first transforming-transmitting unit in which the parallel code is transformed to serial code which is transmitted to the laser emittter. A laser signal corresponding to the serial code is transmitted through an optical system to a photo-receiver, and from the photo-receiver to a second transforming-transmitting unit in which the serial code is transformed to a parallel code corresponding to the packet or token recieved at the input register.
The Best Way to Implement the Invention
The computer system (FIG. 1) contains a group of processor units 1 - 1 . . . 1 -N, a switch 2 , an auxiliary switch 3 , a group of associative memory modules 4 - 1 . . . 4 -N and a buffering block 5 .
The computer system also contains the first, second and third informational inputs 6 , 7 and 8 , control input 9 , the first and second informational outputs 10 - 11 and memory zeroizing input 12 .
Each processor unit 1 -i contains the first, second, third and fourth informational inputs 13 , 14 , 15 and 16 , the first and second address inputs 17 - 1 and 17 - 2 , the first to the eighth control inputs 18 - 1 . . . 18 - 8 respectively, the first to the fourth control outputs 19 - 1 . . . 19 - 4 , an address output 20 and the first to the fifth informational outputs 21 - 1 . . . 21 - 5 .
Auxiliary switch 3 contains control input 22 , the first to the fourth groups of control inputs 23 - 1 . . . 23 -N, 24 - 1 . . . 24 -N, 25 - 1 . . . 25 -N, 26 - 1 . . . 26 -N, the first and second groups of informational inputs 27 - 1 - 1 . . . 27 - 1 -N and 27 - 2 - 1 . . . 27 - 2 -N, the first and the second groups of control outputs 28 - 1 . . . 28 -N and 29 - 1 . . . 29 -N; N groups of exchange outputs, each of which includes the first control, first informational, the second control and the second informational outputs 30 - 1 -i, 30 - 2 -i, 30 - 3 -i, and 30 - 4 -i respectively.
Buffering block 5 contains control input 31 , the first and the second groups of control inputs 32 - 1 . . . 32 -N and 33 - 1 . . . 33 -N, the first group of informational inputs 34 - 1 . . . 34 -N, the third group of control inputs 35 - 1 . . . 35 -N, the second group of informational inputs 36 - 1 . . . 36 -N, the fourth group of control inputs 37 - 1 . . . 37 -N, and the third group of informational inputs 38 - 1 . . . 38 -N. Buffering block 5 also contains the first to the third groups of control outputs 39 - 1 . . . 39 -N, 40 - 1 . . . 40 -N, 41 - 1 . . . 41 -N, the first and the second groups of informational outputs 42 - 1 . . . 42 -N and 43 - 1 . . . 43 -N, the fourth group of control outputs 44 - 1 . . . 44 -N and the third group of informational outputs 45 - 1 . . . 45 -N.
Each associative memory module 4 -i contains first control input 46 , zeroizing input 47 , informational input 48 , second informational input 49 , first control output 50 , informational output 51 and second control output 52 .
Switch 2 contains control input 53 , the first group of control inputs 54 - 1 . . . 54 -N and the group of address inputs 55 - 1 . . . 55 -N. Switch 2 also contains the second group of control inputs 56 - 1 . . . 56 -N, the group of informational inputs 57 - 1 . . . 57 -N, control output 58 , the group of informational outputs 59 - 1 . . . 59 -N and the group of control outputs 60 - 1 . . . 60 -N. The synchronization and energy supply chains are not shown.
Each processor unit 1 -i (FIG. 2) includes the first and the second switches 61 and 62 , the first and the second switch control units 63 and 64 for the first and the second switches respectively, executive device for instruction processing 65 and executive device for operand processing 66 .
Switch 61 contains the first and the second control inputs 67 - 1 and 67 - 2 , the first to the fourth informational inputs 68 - 1 , 68 - 2 , 69 - 1 , 69 - 2 , and the first and the second informational outputs, connected with the outputs 21 - 4 and 21 - 5 of the processor unit.
Switch 62 contains the first and the second control inputs 70 - 1 and 70 - 2 , the first to the sixth informational inputs 71 - 1 , 71 - 2 , 71 - 3 , 72 - 1 , 72 - 2 , 72 - 3 , and the first to the third informational outputs, connected with the outputs 20 , 21 - 1 , 21 - 2 of the processor unit respectively.
First switch control unit 63 contains the first and the second control inputs 73 , 74 , the first to the fourth control outputs 75 - 1 , 75 - 2 , 76 - 1 , 76 - 2 , the third and the fourth control inputs which are connected with inputs 18 - 7 and 18 - 8 of the processor unit, and the fifth control output which is connected with output 19 - 4 of the processor unit.
Second switch control unit 64 contains the first and the second control inputs 77 and 78 , the first to the fourth control outputs 79 - 1 , 79 - 2 and 80 - 1 , 80 - 2 , the third control input which is connected with input 18 - 4 of the processor unit, and the fifth control output which is connected with output 19 - 1 of the processor unit.
Executive device for instruction processing 65 includes the first and the second control inputs 81 and 82 , the first and the second control outputs 83 and 84 , the third control output 85 , address output 86 , the first and the second informational outputs 87 and 88 , the third informational output which is connected with the output 21 - 3 of the processor unit, the first and the second informational inputs which are connected with inputs 13 and 15 of the processor unit respectively, the third to the fifth control inputs which are connected with inputs 18 - 1 , 18 - 3 , and 18 - 5 of the processor unit respectively, and an address input connected with input 17 - 1 of the processor unit.
Executive device for operand processing 66 contains the first and the second control inputs 89 and 90 , the first to the third control outputs 91 , 92 , 93 , address output 94 , the first and the second informational outputs 95 and 96 , the third informational output which is connected with the output 21 - 3 of the processor unit, the first and the second informational inputs which are connected with inputs 14 and 16 of the processor unit respectively, the third to the fifth control inputs which are connected with inputs 18 - 2 , 18 - 3 , and 18 - 6 of the processor unit respectively, and an address input connected to input 17 - 2 of the processor unit.
Each switch control unit 63 (FIG. 3) and 64 (FIG. 4) contains “AND” elements 97 and 98 , “OR” element 99 and priority coder 100 .
Executive device for instruction processing 65 (FIG. 5) contains control unit 101 , output switch 102 , switching block 103 , instruction register unit 104 , instruction memory 105 , arithmetic-logical unit (ALU) 106 , loading switch 107 and input register unit 108 .
Control unit 101 contains input 109 - 1 for zeroizing, the first and the second inputs 109 - 2 and 109 - 3 for control of result transmission, starting control input 109 - 4 , input 109 - 5 for instruction type bits, input 109 - 6 for memory readiness signal, input 109 - 7 for the ALU result significance signal, input 109 - 8 for the ALU readiness signal, input 109 - 9 for the instruction code, the first and the second outputs 110 - 1 and 110 - 2 for the data readiness signal, output 110 - 3 for the control of field switching, output 111 - 4 for the control of data reception, ALU starting control output 111 - 5 and output 111 - 6 for the control of instruction retrieval.
Output switch 102 contains the first and the second control inputs 112 - 1 and 112 - 2 , the first and the second informational inputs 112 - 3 and 112 - 4 and an informational output connected with the outputs 86 and 88 of the executive device 65 .
Switching block 103 contains control inputs 113 - 1 . . . 113 - 12 , informational inputs 114 - 1 . . . 114 - 10 and 115 - 1 . . . 115 - 4 , and informational outputs connected with the output 87 of executive device 65 and with inputs 112 - 3 and 112 - 4 of switch 102 .
Instruction register unit 104 contains informational input 116 - 1 , control input 116 - 2 , and informational outputs connected with the inputs 115 - 1 . . . 115 - 4 of block 103 .
The instruction memory 105 contains load control input 117 - 1 , informational input 117 - 2 , address input 117 - 3 , reading control input 117 - 4 , and informational and control outputs connected with the corresponding inputs 116 - 1 and 116 - 2 of the instruction register unit and with the corresponding inputs 109 - 5 and 109 - 6 of the control unit 101 .
Arithmetic-logical unit (ALU) 106 (made analogously to the device SU 1367012) contains instruction control input 118 - 1 , first and second operand inputs 118 - 2 and 118 - 3 , starting control input 118 - 4 , first and second informational outputs 119 - 1 and 119 - 2 , and control output 119 - 3 .
Loading switch 107 contains first and second informational inputs 120 - 1 and 120 - 2 , first and second control inputs 120 - 3 and 120 - 4 , and an informational output connected with address input 117 - 3 of instruction memory 105 .
Input register unit 108 contains control input 121 - 1 , informational outputs 122 - 1 . . . 122 - 11 .
Control unit 101 (FIG. 6) contains “AND” elements 123 and 124 , priority coder 125 , “AND” elements 126 . . . 133 , “OR” elements 134 . . . 136 , decoder 137 , “AND” elements 138 . . . 140 , “OR” elements 141 and 142 , “AND” elements 143 . . . 145 , control triggers 146 . . . 151 , “AND” elements 152 . . . 157 , “OR” element 158 , and “AND” elements 159 and 160 .
Switching block 103 (FIG. 7) contains registers 161 . . . 171 , control unit 172 , and switches 173 . . . 178 .
Control unit 172 (FIG. 8) contains “OR” elements 179 . . . 190 , control inputs 191 . . . 202 , and control outputs 203 . . . 222 .
Input register unit 108 (FIG. 9) contains status word register 223 , first data word register 224 and second data word register 225 .
Instruction register unit 104 (FIG. 10) contains first and second operation code registers 226 and 227 , and first and second instruction number registers 228 and 229 .
Executive device 66 (FIG. 11) contains control unit 230 , output switch 231 , output register unit 232 , instruction memory 233 , ALU 234 , loading switch 235 and input register unit 236 .
Control unit 230 contains zeroizing input 237 - 1 , first and second inputs for result transmission 237 - 2 and 237 - 3 , starting control input 237 - 4 , input for instruction type bits 237 - 5 , input for the memory readiness signal 237 - 6 , input 237 - 7 for the data significance signal, input 237 - 8 for the ALU readiness signal, first and second outputs for the control of output switching 238 - 1 and 238 - 2 , output for transmission control 238 - 3 , output for reception control 238 - 4 , output for starting control 238 - 5 , and the first to the third control outputs connected with the outputs 91 . . . 93 of the executive device 66 .
Output register unit 232 contains control inputs 239 - 1 , 239 - 2 and 239 - 3 , informational inputs 239 - 4 , 239 - 5 and 239 - 6 , and informational outputs 240 - 1 , 240 - 2 and 240 - 3 .
Switch 231 contains an informational output connected with outputs 94 and 96 of executive device 66 , first and second control inputs connected with outputs 238 - 1 and 238 - 2 of unit 230 , and first and second informational inputs connected with outputs 240 - 2 and 240 - 3 of output register unit 232 .
Instruction memory 233 , ALU 234 and loading switch 235 are analogous to the corresponding devices 105 , 106 and 107 in executive device 65 .
Input register unit 236 contains control and informational inputs 241 - 1 and 241 - 2 , and informational outputs 242 - 1 . . . 242 - 5 .
Control unit 230 (FIG. 12) contains “OR” elements 243 - 1 and 243 - 2 , “AND” elements 244 - 1 . . . 244 - 4 , “AND” elements 245 - 1 and 245 - 2 , “OR” element 246 , “AND” elements 247 - 1 and 247 - 2 , “OR” element 248 , priority coder 249 , “AND” elements 250 - 1 and 250 - 2 , “AND” element 251 , triggers 252 - 1 . . . 252 - 3 and 253 - 1 . . . 253 - 3 , “AND” elements 254 - 1 . . . 254 - 6 , “OR” element 255 , and “AND” element 256 .
Input register unit 236 (FIG. 13) contains registers 257 , 258 - 1 and 258 - 2 for the status word bits of the first and the second operands.
Output register unit 232 (FIG. 14) contains result register 259 , first and second registers of instruction number and operation code 260 - 1 and 260 - 2 , and status attribute register 261 .
Auxiliary switch 3 (FIG. 15) contains first and second control units 262 - 1 and 262 - 2 , and first and second switching units 263 - 1 and 263 - 2 .
Each control unit 262 - 1 and 262 - 2 contains control input 264 ; the first to the third groups of control inputs 265 - 1 . . . 265 -N, 266 - 1 . . . 266 -N, 267 - 1 . . . 267 -N respectively; and the first to the fourth groups of control outputs 268 - 1 . . . 268 -N, 269 - 1 . . . 269 -N, 270 - 1 - 1 . . . 270 -N-N and 271 - 1 . . . 271 -N.
Each switching unit 263 - 1 and 263 - 2 contains the first and the second groups of control inputs 272 - 1 - 1 . . . 272 -N-N and 273 - 1 . . . 273 -N, a group of informational inputs 274 - 1 . . . 274 -N, a group of informational outputs 275 - 1 . . . 275 -N, and a group of control outputs 276 - 1 . . . 276 -N.
Each control unit 262 - 1 and 262 - 2 (FIG. 16) contains a group of readiness signal formation triggers 277 - 1 . . . 277 -N, readiness set control unit 278 and switching control block 279 .
Readiness set control unit 278 contains N pairs of first and second control outputs 280 - 1 - 1 and 280 - 2 - 1 to 280 - 1 -N and 280 - 2 -N, zeroizing input 281 , the first to the third groups of control inputs 282 - 1 . . . 282 -N, 283 - 1 . . . 283 -N, and 284 - 1 . . . 284 -N, N groups of outputs 285 - 1 - 1 . . . 285 - 1 -N to 285 -N- 1 . . . 285 -N-N of bits for channel number switching, and N groups of inputs 286 - 1 - 1 . . . 286 - 1 -N to 286 -N- 1 . . . 286 -N-N of bits for channel number switching.
Switching control block 279 contains N groups of outputs 287 - 1 - 1 . . . 287 - 1 -N to 287 -N- 1 . . . 287 -N-N of the switching channel number set, the first and the second groups of control outputs 288 - 1 . . . 288 -N and 289 - 1 . . . 289 -N, zeroizing input 290 , N pairs of first and second control inputs 291 - 1 - 1 and 291 - 2 - 1 to 291 - 1 -N and 291 - 2 -N, a group of control inputs 292 - 1 . . . 292 -N, N groups of control outputs 293 - 1 - 1 . . . 293 - 1 -N to 293 -N- 1 . . . 293 -N-N of the switching elements, N groups of inputs 294 - 1 - 1 . . . 294 - 1 -N to 294 -N- 1 . . . 294 -N-N of the switching channel set, and the third group of control outputs 295 - 1 . . . 295 -N.
Each switching unit 263 - 1 ( 263 - 2 ) (FIG. 17) contains high frequency impulse generator 296 , a group of output registers 297 - 1 . . . 297 -N, a group of transforming-transmitting units 298 - 1 . . . 298 -N, a group of “OR” elements 299 - 1 . . . 299 -N, a group of photo-receivers 300 - 1 . . . 300 -N, the first group of the optical lens rasters 301 - 1 . . . 301 -N, controlled optical transparency 302 , the second group of optical lens rasters 303 - 1 . . . 303 -N, a group of deflectors 304 - 1 . . . 304 -N, a group of laser oscillators 305 - 1 . . . 305 -N, a group of transforming-transmitting units 306 - 1 . . . 306 -N, and a group of input registers 307 - 1 . . . 307 -N.
Each transforming-transmitting unit 298 -i contains control output 308 , informational outputs 308 - 1 . . . 308 -N of parallel code, first and second control inputs 309 - 1 and 309 - 2 , and informational input of serial code 309 - 3 .
Each transforming-transmitting unit 306 -i (FIG. 23) contains informational output of serial code 310 , control input 311 , a group of inputs of transforming control 311 - 1 . . . 311 -N and a group of informational inputs of parallel code 312 - 1 . . . 312 -N.
Readiness set control unit 278 (FIG. 18) contains first group of “OR” elements 313 - 1 . . . 313 -N, group of “AND” elements 314 - 1 . . . 314 -N, second group of “OR” elements 315 - 1 . . . 315 -N, a group of registers 316 - 1 . . . 316 -N, and third group of “OR” element 317 - 1 . . . 317 -N.
Switching control block 279 (FIG. 19) contains N groups of double-input “AND” elements 318 - 1 - 1 . . . 318 - 1 -N to 318 -N- 1 . . . 318 -N-N, N groups of N-input “AND” elements 319 - 1 - 1 . . . 319 - 1 -N to 319 -N- 1 . . . 319 -N-N, N groups of triggers 320 - 1 - 1 . . . 320 - 1 -N to 320 -N- 1 . . . 320 -N-N, priority control unit 321 and input query receiving unit 322 .
Priority control unit 321 contains zeroizing input unit 323 , the first to the fourth groups of control outputs 323 - 1 - 1 . . . 323 - 1 -N, 323 - 2 - 1 . . . 323 - 2 -N, 323 - 3 - 1 . . . 323 - 3 -N and 323 - 4 - 1 . . . 323 - 4 -N, N groups of inputs 324 - 1 - 1 . . . 324 - 1 -N to 324 -N- 1 . . . 324 -N-N of output channel sampling control, and the first to the third groups of control inputs 325 - 1 - 1 . . . 325 - 1 -N, 325 - 2 - 1 . . . 325 - 2 -N, 325 - 3 - 1 . . . 325 - 3 -N.
Priority control unit 321 (FIG. 20) contains the first and the second priority coders 326 and 327 , “OR” element 328 , the first and the second groups of status triggers 329 - 1 . . . 329 -N and 330 - 1 . . . 330 -N, the first group of “OR” elements 331 - 1 . . . 331 -N, a group of query triggers 332 - 1 . . . 332 -N, the first group of “AND” elements 333 - 1 . . . 333 -N, the second and the third groups of “OR” elements 334 - 1 . . . 334 -N and 335 - 1 . . . 335 -N, and the second group of “AND” elements 336 - 1 . . . 336 -N.
Input query receiving unit 322 (FIG. 21) contains a group of control inputs connected with inputs 291 - 2 - 1 . . . 291 - 2 -N of the switching control block 279 , N groups of inputs of output channel number bits connected with inputs 294 - 1 - 1 . . . 294 -N-N of the switching control block 279 , and a group of control outputs connected with inputs 325 - 1 - 1 . . . 325 - 1 -N of priority control unit 321 .
The unit 322 (FIG. 21) contains a group of switches 337 - 1 . . . 337 -N and a group of decoders 338 - 1 . . . 338 -N.
Each of the transforming-transmitting units 298 -i (FIG. 22) contains decoder 339 , counter 340 , “OR” element 341 and amplifier-former 342 . Each of the transforming-transmitting units 306 -i (FIG. 23) contains “OR” element 343 , amplifier-former 344 , coder 345 , counter 346 and “AND” element 347 .
Buffering block 5 (FIG. 24) contains group of buffering units 348 - 1 . . . 348 -N.
Each buffering unit 348 -i (FIG. 25) contains the first to the fourth control outputs 349 - 1 . . . 349 - 4 , the first to the third informational outputs 349 - 5 . . . 349 - 7 , the first and second control inputs connected with the corresponding inputs of the first and second groups of control inputs 32 - 1 . . . 32 -N and 33 - 1 . . . 33 -N, the third control input connected with control input 31 , the fourth and fifth control inputs connected with the corresponding inputs of the third and the fourth groups of control inputs 35 - 1 . . . 35 -N and 37 - 1 . . . 37 -N, and the first to the third informational inputs connected with the corresponding inputs of the first, the second and the third groups of informational inputs 34 - 1 . . . 34 -N, 36 - 1 . . . 36 -N and 38 - 1 . . . 38 -N.
Each buffering unit 348 -i contains the first and the second buffers 350 - 1 and 350 - 2 . Buffer 350 - 1 is used for temporary storage and transmission of instruction words, and buffer 350 - 2 is used for temporary storage and transmission of operand packets. Both buffers have the same structure and configuration, being different only in internal logic of means of identification of input packet type.
Each buffer 350 - 1 and 350 - 2 (FIG. 26) contains the first and the second control inputs 351 - 1 and 351 - 2 , the first and the second informational inputs 351 - 3 and 351 - 4 , the third and the fourth control inputs 351 - 5 and 351 - 6 , external exchange input 351 - 7 , the first and the second transmission control outputs 352 - 1 and 352 - 2 , informational output 352 - 3 , and external exchange output 352 - 4 .
Each buffer 350 - 1 and 350 - 2 contains output switch 353 , group of “OR” element 353 - 1 . . . 353 - 5 , group of “AND” elements 354 - 1 . . . 354 - 4 , the register memorizing unit (RMU) 355 and the corresponding control unit 356 - 1 ( 356 - 2 ), input switch 357 , and the first and the second input registers 358 - 1 and 358 - 2 .
Each control unit 356 - 1 and 356 - 2 contains control outputs 359 - 1 . . . 359 - 12 , zeroizing input 360 - 1 , the first input of packet code 360 - 2 , the first control input of receiving 360 - 3 , the second input of packet code 360 - 4 , the second and the third control inputs of receiving 360 - 5 and 360 - 6 , and the first to the fifth control inputs 361 - 1 . . . 361 - 5 .
Each of the control units 356 - 1 and 356 - 2 (FIG. 27) contains priority coder 362 , counters 362 - 1 and 362 - 2 , logical “AND” elements 363 - 1 . . . 363 - 4 , triggers 364 - 1 . . . 364 - 3 , logical “OR” element 365 , and the corresponding group of decoders 365 - 1 - 1 . . . 365 - 1 - 3 (or 365 - 2 - 1 . . . 365 - 2 - 3 ). The mentioned groups of decoders carry out the function of identification of input packet type and they are different only in the functioning of the inner logic: the group of decoders 365 - 1 - 1 . . . 365 - 1 - 3 is used for identification of instruction words packets, and the group of decoders 365 - 2 - 1 . . . 365 - 2 - 3 is used for identification of operand packets.
Each associative memory module 4 -i (FIG. 28) contains buffer register 366 and associative memorizing unit (AMU) 367 , built in analogy with the device (RU, 2035069).
AMU 367 contains the first and the second informational outputs 368 - 1 and 368 - 2 , the first and the second control outputs 369 and 370 , the first to the third control inputs 371 - 1 . . . 371 - 3 , and the first and the second informational inputs 372 - 1 and 372 - 2 .
Switch 2 (FIG. 29) contains control unit 373 and switching unit 374 , built in analogy with switching unit 263 - 1 ( 263 - 2 ) included in auxiliary switch 3 .
Control unit 373 contains exchange control output 375 , a group of control outputs 375 - 1 . . . 375 -N, N groups of control outputs 376 - 1 - 1 . . . 376 - 1 -N to 376 -N- 1 . . . 376 -N-N of channel switching, receiving control output 377 , zeroizing input 378 , and the first to the N-th groups of inputs. Each of the N groups of inputs contains control input 378 - 1 -i, address input 378 - 2 -i, and the first and the second groups of control inputs 379 - 1 . . . 379 -N and 380 - 1 . . . 380 -N.
Switching unit 374 contains a group of informational outputs 381 - 1 . . . 381 -N, a group of informational inputs 382 - 1 . . . 382 -N, N groups of inputs 383 - 1 - 1 . . . 383 - 1 -N to 383 -N- 1 . . . 383 -N-N of switching control, a group of control outputs 384 - 1 . . . 384 -N and a group of inputs 385 - 1 . . . 385 -N of receiving control.
Control unit 373 (FIG. 30) contains a group of output query forming triggers 386 - 1 . . . 386 -N, transmission control unit 387 , receiving control unit 388 , switching control unit 389 , a group of query receiving triggers 390 - 1 . . . 390 -N, a group of decoders 391 - 1 . . . 391 -N, a group of input registers 392 - 1 . . . 392 -N and a group of “AND” elements 393 - 1 . . . 393 -N.
Transmission control unit 387 contains N pairs of control outputs, each of which contains the first and the second query set outputs 394 - 1 - 1 to 394 - 1 -N and 394 - 2 - 1 to 394 - 2 -N, zeroizing input 395 , N groups of query control inputs 396 - 1 - 1 . . . 396 - 1 -N to 396 -N- 1 . . . 396 -N-N, the first and the second groups of control inputs 397 - 1 . . . 397 -N and 398 - 1 . . . 398 -N.
Receiving control unit 388 contains first control output 399 , a group of receiving control outputs 399 - 1 . . . 399 -N, second control output 400 , N pairs of inputs containing the first and the second inputs of status transmission 401 - 1 - 1 and 401 - 2 - 1 to 401 - 1 -N and 401 - 2 -N, a group of control inputs 402 - 1 . . . 402 -N, zeroizing input 403 , and N groups of resetting control inputs 404 - 1 - 1 . . . 404 - 1 -N to 404 -N- 1 . . . 404 -N-N.
Switching control unit 389 contains N groups of control outputs 405 - 1 - 1 . . . 405 - 1 -N to 405 -N- 1 . . . 405 -N-N, N groups of priority control inputs 406 - 1 - 1 . . . 406 - 1 -N to 406 -N- 1 . . . 406 -N-N, and a group of control inputs 407 - 1 . . . 407 -N.
Transmission control unit 387 (FIG. 31) contains the first group of “OR” elements 408 - 1 . . . 408 -N, a group of “AND” elements 409 - 1 . . . 409 -N, and the second group of “OR” elements 410 - 1 . . . 410 -N.
Receiving control unit 388 (FIG. 32) contains trigger 411 , a group of “OR” elements 411 - 1 . . . 411 -N, the first and the second “OR” elements 412 - 1 and 412 - 2 , N groups of “AND” elements 413 - 1 - 1 . . . 413 - 1 -N to 413 -N- 1 . . . 413 -N-N, and “AND” elements 414 , 415 - 1 and 415 - 2 .
Switching control unit 389 (FIG. 33) contains a group of priority coders 416 - 1 . . . 416 -N and N groups of “OR” elements 417 - 1 - 1 . . . 417 - 1 -N to 417 -N- 1 . . . 417 -N-N.
The principles of computational organization under data flow control assume that the algorithm of the problem solution is represented as a graph of the computation process. The graph consists of operations (instructions) on data (operands) and links (directions) by which the data (results) are transmitted from one instruction to another (FIG. 34 ).
Data processing according to the graph is carried out as the data prepared for processing appear at the instruction inputs. The completion of pairs of data related to a particular instruction is performed in memory, which seeks for them by a key. Generally, a key is a code consisting of instruction number bits, an index, an iteration and so on. The best operational realization of such memory, considering volume and speed, would be based on the utilization of optical elements, and considering an increase in performance, it would be optimal to break its whole volume into separate modules.
Each instruction has a number K-i which can be used to place it in the command memory, a code of operation (COP-i), and a “destination address” K-j to which the result of processing is related.
Furthermore, an instruction has attributes, determining the conditions of its processing or its type. An instruction can be double-input or single-input, depending on how many operands (one or two) it processes, which is determined by the operation code. An instruction can be double-address or single-address, depending on the number of destinations (to the input of how many instructions) to which its result is transmitted. For example, the instruction K- 1 (FIG. 34) is a single-input, double-address instruction; the instruction K- 4 is double-input, single-address instruction; and the instructions K 2 and K- 3 are single-address, single-input instructions.
Operations, determined by the COP of a given instruction, can be carried out with numeric data (operands) and with supplementary data (instruction words). The first functional group of instructions is performed by arithmetic operations (operand processing operations), and the second group by the instruction word processing operations.
In order to organize the graph processing, instructions and data are represented as informational objects consisting of multi-bit words, where the corresponding groups of bits form the fields with the necessary functional assignment (FIG. 35 ).
Information processing is carried out by executive devices of two different types, which receive the information in the form of operand packets and instruction words packets. Generally a packet includes a status word and two data words, which either are operands or contain supplementary data. A packet of a single-input instruction contains a status word and only one data word.
A status word contains the following basic groups of functional bits (fields):
COP—code of operation;
K—number of instruction;
G—number of generation;
T—number of iteration;
I—index.
The functional fields of a status word can de used in different ways. In particular, the key group of bits for data seeking in the associative memory modules is determined by the fields K, G, T, I. The field COP also may contain bits indicating the instruction type (single- or double-address, single- or double-input) and the packet type (packet of instruction words or packet of operands).
If an instruction has two outputs, then its processing result will be accompanied by two status words, which means two destinations for its transmission.
Bit groups of attributes, determining the type of destination instruction, are stored in command memory and are retrieved with its number and code of operation.
The computer system (FIG. 1) runs the program, which is loaded through the first and the second informational inputs 6 and 7 , and returns the result of processing through the second informational output 11 . The system realizes its own parallelism of the computational process, represented by the graph, by simultaneously processing all the prepared instructions. In the command memory 105 and 233 for the executive devices 65 and 66 of each of the processor units 1 -i, all the instructions of the program being executed are stored. Memory 105 contains all the instructions for instruction word processing, and memory 233 contains all the instructions for operand processing.
Instruction loading (FIGS. 5 and 11) is carried out through the first and the second informational inputs 13 and 14 and the loading switches 107 and 235 respectively, for the executive devices 65 and 66 .
The system is started by transmitting starting packets of instruction words and operands from an external (not shown on FIG. 1) system to the third input 8 .
The starting packets with the corresponding control signals are transmitted to the inputs of the third group of informational inputs 38 - 1 . . . 38 -N of buffering block 5 . The total number of inputs used will be determined by the starting conditions of a particular program.
Buffering block 5 is used to smooth peaks of the input queries on the inputs of the auxiliary switch 3 . The use of buffering block 5 in the starting process is its additional function.
Starting packet bits are transmitted to the informational input of the buffering unit 348 -i, which, in this case, conducts the starting functions, and further on to the external exchange input 351 - 7 of buffers 350 - 1 and 350 - 2 (FIG. 25 ). From the buffers 350 - 1 and 350 - 2 , the starting packets are transmitted to the fourth informational input of output switch 353 (FIG. 26 ). The switching in the output switch 353 is controlled through its fourth control input, to which the corresponding signal is transmitted from control output 359 - 12 of control unit 356 - 1 ( 356 - 2 ) through the “AND” element 354 - 4 . This control signal is formed (FIG. 27) at the output of the decoder 365 - 1 - 3 ( 365 - 2 - 3 ), to the input of which the coded bit group determining the type of the starting packet is transmitted. Depending on the type of starting packet, the switch 353 control signal will be formed either in buffer 350 - 1 (for instruction word receiving) or in buffer 350 - 2 (for operand receiving).
If the starting packet contains operands, then the bits of the packet from output 352 - 3 of buffer 350 - 2 are transmitted (through the second informational output of unit 348 -i and the i-th output of the third group of informational outputs 45 - 1 . . . 45 -N of buffering block 5 ) to the i-th input of the second group of informational inputs 27 - 2 - 1 . . . 27 - 2 -N of auxiliary switch 3 .
The information on the i-th output of the third group of informational outputs 45 - 1 . . . . 45 -N of buffering block 5 is accompanied by the strobe of transmission (signal of “significance” ), which is a control signal of an exchange query, and is transmitted from the i-th output of the fourth group of the control outputs 44 - 1 . . . 44 -N of buffering block 5 to the i-th input of the fourth group of control inputs 26 - 1 . . . 26 -N of auxiliary switch 3 .
The main function of the auxiliary switch is to distribute all received packets over its free outputs.
Transmission strobe and the bits of the operand packets, transmitted respectively to the i-th inputs of the fourth group of control inputs 26 - 1 . . . 26 -N and to the i-th inputs of the second group of the informational inputs 27 - 2 - 1 . . . 27 - 2 -N of the auxiliary switch, are transmitted respectively to the control inputs 265 -i of control unit 262 - 2 and the informational inputs 274 -i of switching unit 263 - 2 (FIG. 15, 16 , 17 ).
Operand packet bits, transmitted to input 274 -i of switching unit 263 - 2 , are received by input register 307 -i. The signal of receiving control is formed at output 271 -i of control unit 262 - 2 .
The switching, including the transmission of packet bits from input 264 -i of switching unit 263 - 2 to its informational output 275 -j, corresponding to the first free output register from the group 297 - 1 . . . 297 -N, is carried out with the help of a spatial optical system.
From the output of register 307 -i, the parallel code of the packet bits is transmitted to inputs 312 - 1 . . . 321 -N of transforming-transmitting unit 306 -i. Serial code, formed on output 310 , is transmitted to the laser emitter 305 -i. The laser signal corresponding to the serial code (through the optical system, which includes the controlled deflector 304 -i, a group of optical lens rasters 303 - 1 . . . 303 -N, controlled optical transparency 302 , and a group of optical lens rasters 301 - 1 . . . 303 -N) is transmitted to the input of photo-receiver 300 -j. From the output of photo-receiver 300 -j, the serial code of the input packet is transmitted to the informational input 309 - 3 of the transforming-transmitting unit 298 -j. A parallel code corresponding to the bit groups of the packet input at 274 -i of switching unit 263 - 2 is formed on the outputs of register 297 -j. And, a signal which determines the end of the formation of the output parallel code is formed on the output 308 of the unit 298 -j.
Switching unit 263 - 2 (FIG. 17) provides information transmission from any input 274 - 1 . . . 274 -N to any output 275 - 1 . . . 275 -N. The transmission is determined by a free register from the register group 297 - 1 . . . 297 -N, which means “free address” switching regime. Signals controlling the corresponding information transformation and switching of the spatial optical system are transmitted to inputs 272 - 1 - 1 . . . 272 -N-N of switching unit 263 - 2 from outputs 270 - 1 - 1 . . . 270 -N-N of control unit 262 - 2 (FIG. 15 ).
The formation of the signals mentioned (FIG. 16, 19 , 20 ) is carried out in switching control block 279 when the strobe of transmission is transmitted to input 292 -i from input 267 -i of control unit 262 - 2 . The strobe of packet transmission, which is formed at trigger 277 -j of the group of readiness signal forming triggers, is transmitted to output 269 -j of control unit 262 - 2 (FIG. 16 ).
Instruction word packet transmission is carried out in the same way with the use of identical functional structures of the buffering block 5 and the auxiliary switch 3 .
The strobe of transmission and the bits of the operand packet are transmitted, respectively, through outputs 30 - 3 -j and 30 - 4 -j of auxiliary switch 3 to inputs 18 - 6 and 16 of the processor unit 1 -j (FIG. 1) and to the corresponding inputs of the executive device 66 (FIG. 2 ).
The strobe of transmission is transmitted through the corresponding input of executive device 66 to input 237 - 4 of control unit 230 (FIG. 11) and the bits of the operand packet are transmitted to informational input 241 - 2 of input register unit 236 .
Functional fields of the operand packet (FIG. 13) are received by the status word register 257 and the operand registers 258 - 1 and 258 - 2 after the signal of receiving control is received at input 241 - 1 of input register unit 236 . The bits of the instruction number are transmitted from output 242 - 1 of input register unit 236 through the first informational input of loading switch 235 to the address input of command memory 233 . The starting control signal is transmitted from output 238 - 5 of control unit 230 to the retrieval control input of command memory 233 .
The operation code bits and the operand bits, accompanied by the starting control signal, are transmitted from outputs 242 - 2 , 242 - 3 and 242 - 4 of input register unit 236 to the corresponding inputs of the ALU 234 . The bits of the functional fields of G, T, I are transmitted to input 239 - 6 of output register unit 232 . The bits of functional fields containing the operation code and the instruction number for which the result of computations is destined are transmitted from the informational output of command memory 233 to input 239 - 5 of output register unit 232 . This result is transmitted to the input 239 - 4 of the unit 232 .
Inputs 239 - 1 , 239 - 2 and 239 - 3 of output register unit 232 receive the corresponding signals which control the reception of the ALU result to the register 259 , the bit fields K and COP of the subsequent instruction to the registers 260 - 1 and 260 - 2 , and the bit fields G, T, and I to the register 261 . The functional fields of the result of the current instruction processing (sub-packet) are formed on the outputs 240 - 1 , 240 - 2 and 240 - 3 of the output register unit 232 . These fields reflect the principles of computation represented by the computation graph and are transmitted respectively to the first informational input 95 of executive device 66 and to the informational inputs of output switch 231 . Control signals are transmitted from outputs 238 - 1 and 238 - 2 of control unit 230 to the control inputs of output switch 231 . The output of switch 231 is connected with address output 94 and the second informational output 96 of executive device 66 . The output 94 receives an informational field, corresponding to a group of lower bits of the instruction number, which is placed on the register 260 - 1 ( 260 - 2 ). This group of bits identifies the number of the associative memory module, from the group of modules 4 - 1 . . . 4 -N, allowing the sub-packets to be distributed evenly over the associative memory modules. The functions of the output switch 231 are determined by the presence of double-address instructions, i.e. the instructions, the processing result of which is the input operand for two following instructions having different number and operation codes. This condition is realized by having two output registers 260 - 1 and 260 - 2 of instructions, the content of which is sequentially transmitted through switch 231 to outputs 94 and 96 accompanying the result, which is transmitted to the output 95 .
The output switch 231 control signals are formed after the functional fields of the type of instruction and of the strobe of transmission are transmitted from the informational and control outputs of the command memory 233 to the inputs 237 - 5 and 237 - 6 of the control unit 230 respectively. The signal of significance of the result is transmitted from the informational output of the ALU to the input 237 - 7 .
The functional fields of the instruction type include the following attributes: 1A (single-address instruction), 2A (double-address instruction), 1B (single-input instruction), 2B (double-input instruction), which are transmitted (FIG. 12) to the triggers 254 - 2 . . . 254 - 5 . The status of the triggers influences the formation of the control signals on the outputs 238 - 1 and 238 - 2 of the control unit 230 . The transmission strobes, corresponding to the regimes of the single- or double-input instructions, are formed on the first and second control outputs 91 and 92 of the executive device 66 . And, corresponding to these regimes, bits of the functional fields of the sub-packet are formed on the first and the second informational outputs 95 and 96 .
In the single- and double-input instruction regimes, the bits of the sub-packet are transmitted from the outputs 95 and 96 to the outputs 21 - 4 , 21 - 5 and 21 - 1 and 21 - 2 of the j-th processor unit respectively through the switches 61 and 62 , which are controlled through the outputs 75 - 1 and 75 - 2 of the unit 63 and through the outputs 79 - 1 and 79 - 2 of the unit 64 . The control signals are formed after the input 74 of the unit 63 and input 77 of the unit 64 receive the strobes of transmission respectively from the outputs 91 and 92 of the executive device 66 . Information regarding the number of the associative memory module is transmitted from output 94 of the executive device 66 to the address output 20 of the processor unit only in the double-input instruction regime, since running a single-input instruction does not require searching for a second operand.
When the result (operand) output from the corresponding executive device is one for a double-input instruction, the search for the pair operand is conducted in an associative memory module. The number of the particular module (further on referred to as “address”) is determined by the bit group on the output 20 of the processor unit. Access to the group of associative memory modules 4 - 1 . . . 4 -N is realized by means of the switch 2 (FIG. 29 ).
Here, the j-th inputs of the first group of control inputs 54 - 1 . . . 54 -N, a group of address inputs 55 - 1 . . . 55 -N, and the second group of control inputs 57 - 1 . . . 57 -N of the switch 2 receive control signals, the number of the memory module and the functional fields of the sub-packet from the outputs 19 - 1 , 20 and 21 - 1 , 21 - 2 of the j-th processor unit respectively.
The switch 2 , which includes control unit 373 and switching unit 374 , provides data transmission, unlike the switch 3 , to a “fixed” address on the output as determined by the given number k of the associative memory module.
The switching conditions are realized in the control unit 373 (FIG. 30 ). Inputs 378 - 1 -j and 378 - 2 -j of control unit 373 receive the corresponding control information from inputs 54 -j and 55 -j of switch 2 . Then, the following operations are carried out: the address is received in register 392 -j, query trigger 390 -j is set, a position code corresponding to the k-th associative memory module is formed at the k-th output of the decoder 391 -j and these signals are transmitted to the inputs 407 - 1 . . . 407 -N and 406 - 1 - 1 . . . 406 -N-N of switching control unit 389 . Switching control signals are formed at outputs 405 - 1 - 1 . . . 405 -N-N of switching control unit 389 and are transmitted to outputs 376 - 1 - 1 . . . 376 -N-N of control unit 373 .
The mentioned signals are formed at the outputs of priority coders 416 - 1 . . . 416 -N (FIG. 33 ), which play the part of priority schemes, realizing the queuing of queries to each of the associative memory modules.
The control signals from the outputs 376 - 1 - 1 . . . 376 -N-N of the control unit 373 are transmitted to a group of switching control inputs 383 - 1 - 1 . . . 383 -N-N of the switching unit 374 The structure and functioning of switching unit 374 are fully similar to those of the switching units 263 - 1 and 263 - 2 of switch 3 . Here, input 383 -j-k of switching unit 374 receives a signal controlling the k-th input of the j-th deflector from the group 304 - 1 . . . 304 -N (FIG. 17 ), and the output 59 -k of switch 2 receives bit fields corresponding to those received at informational input 57 -j of switch 2 . The corresponding transmission strobe is formed at trigger 386 -k (FIG. 30) and is transmitted through output 375 -k of control unit 373 to output 60 -k of switch 2 .
Bits of the functional fields of the sub-packet and the transmission strobe are transmitted from the outputs 59 -k and 60 -k of the switch 2 to the inputs 48 and 49 of associative memory module 4 -k. The bit field of the status word (as a key for associative seeking),and the bit fields of the operand and the transmission strobe are transmitted respectively to inputs 372 - 1 , 372 - 2 and 371 - 3 of the associative memorizing unit (AMU) 367 . The bit field of the status word is also transmitted to the informational input of the buffering register 366 . The control input of the buffering register 366 receives the transmission strobe from the second control input 49 of the associative memory module.
A sub-packet which does not have a pair “stays” in memory.
When the AMU contains the corresponding pair operand, the bit fields of the first and the second operands are formed at outputs 368 - 1 and 368 - 2 . The bit fields of the first and the second operands, together with the bit field of the status word (at the output of register 366 ), are transmitted to the informational input of the associative memory module 4 -k. The second control output 92 of the associative memory module 4 -k receives the transmission strobe, formed at the first control output 369 of the AMU 367 .
Having been formed at the informational output 51 of the associative memory module k, the ensuing packet is transmitted to input 36 -k of buffering block 5 and then to the corresponding input of the buffering unit 348 -k. Input 37 -k of the buffering unit 348 -k receives the transmission strobe from the second control input 52 of the associative memory module 4 -k through the corresponding input of buffering block 5 .
If the received packet is an operand packet, its functional fields bits are received by the register 358 - 2 of the buffer 350 - 2 , and the corresponding receiving control signal is formed at output 359 - 9 of control unit 356 - 2 .
From the output of register 358 - 2 the bit fields of the packet are transmitted to the second informational input of switch 353 . The corresponding control input of switch 353 receives the signal of switching control from the output of “AND” element 354 - 1 . The signal of switching control is transmitted together with the bit fields of the packet to the first input of the switch 353 , which plays the part of transmission strobe, which is completed at the output of the “OR” element 353 - 1 .
If the corresponding input register 307 -k is free in switching unit 263 - 2 of switch 3 , then the input 27 - 2 -k of switch 3 receives a packet of operands from the first output of switch 353 through output 352 - 3 of buffer 350 - 2 , through output 349 - 6 of the buffering unit 348 -k and through output 45 -k of block 5 . Respectively, the transmission strobe is transmitted to input 26 -k of switch 3 from the output 44 -k of buffering block 5 and the ensuing processing cycle is run.
When reception by switch 3 is closed, in the case when register 307 -k is busy, a signal blocking transmission is transmitted from the switching unit to the input 33 -k of the buffering block 5 . The signal blocking transmission is transmitted through the corresponding input of the unit 348 -k to input 351 - 1 of buffer 350 - 2 and then to input 361 - 2 of control unit 356 - 2 and the input of “OR” element 353 - 5 . At the output of the “OR” element the control signal is formed. The control signal is transmitted to the fifth control input of switch 353 . Information transmitted through the second output of switch 353 is accompanied by the loading signal from the output 359 - 11 of the control unit 356 - 2 and is transmitted to an input of the RMU 355 . Information loading to RMU 355 will be carried out until the blocking signal is cleared from input 33 -k of buffering block 5 . When the signal is cleared and if there is no information at the registers 358 - 1 and 358 - 2 and at the fourth informational input of the switch 353 , the bits of the packet are transmitted from RMU 355 through the third informational input of switch 353 to output 352 - 3 of the buffer 350 - 2 and to the corresponding input 45 -k of buffering block 5 , and through the corresponding inputs and outputs of switch 3 to the fourth informational input 16 of the k-th processor unit.
If the result, obtained in executive device 66 , does not require a search for the corresponding pair, which is determined by the single-inputness of the instruction, then the result of processing and the corresponding strobe of transmission are transmitted from the corresponding outputs of the switch 61 and the control unit 63 (FIG. 2) to outputs 21 - 4 , 21 - 5 and 19 - 4 of the k-th processor unit respectively. The bit fields of the result and the corresponding control signals are formed similarly to the result of the double-input instruction. The sub-packet bits and the strobe of transmission are transmitted to the inputs 34 -k and 35 -k of buffering block 5 .
If the transmitted sub-packet is an instruction word, it is received by the register 358 - 1 of the buffer 350 - 1 . The corresponding control signal is formed at output 369 - 8 of control unit 356 - 1 . The bits of the sub-packet are transmitted from the output of register 358 - 1 to the informational input of switch 357 . From the first informational output of switch 357 , the bits of the sub-packet are transmitted to the first informational input of switch 353 . The corresponding signal of switching control is formed at the output of “AND” element 354 - 2 and is received by the first control input of switch 353 . A control signal is transmitted from output 359 - 4 of the control unit 356 - 1 to an input of the “AND” element 354 - 2 (FIG. 26, 27 ).
The second informational output of switch 357 is used for transmission of the computing result to the external controlling system. The corresponding control signal is formed at the first output of the decoder 365 - 1 . The input of decoder 365 - 1 receives the bits of the code determining the type of the sub-packet. Information from the second informational output of switch 357 together with the strobe of transmission from output 359 - 7 of control unit 356 - 1 is transmitted to output 352 - 4 of buffer 350 - 1 and through output 349 - 7 of the unit 348 -k and the output 43 -k of block 5 to the second informational output 11 of the system.
Processing of bit fields in executive device 65 , including the determination by the instruction system operations of the functional fields of the status word, are realized in the switching block 103 (FIG. 5 , 7 ). The corresponding control signals, which are formed at an output of decoder 137 are transmitted through output 111 - 3 of control unit 101 to inputs 113 - 1 . . . 113 - 12 of switching block 103 . In block 103 , the control signals of the switching group 173 . . . 178 are formed at outputs 203 . . . 222 of control unit 172 (FIG. 7 ). The informational inputs of switching block 103 receive the bits of the functional fields of the status word, transmitted from the outputs 122 - 2 . . . 122 - 11 of the input register unit 108 . The modified fields of the status and data words, formed on the registers 161 . . . 171 , are transmitted through the informational outputs of block 103 to the inputs 112 - 3 and 112 - 4 of the output switch 102 , and from the output of switch 102 to the address and the second informational outputs 86 and 88 of the executive device 65 .
In addition to the operations of modification of functional fields, executive device 65 also carries out the operations of relations determination (e.g., between the data values of two inputs of an instruction or between the values of separate functional bit groups). Such operations are run in ALU 106 .
As for the rest, the working of the functional units of the executive device 65 is similar to the working of the corresponding units of the executive device 66 . The corresponding control and informational outputs 19 - 4 , 21 - 4 and 21 - 5 , 19 - 1 , 21 - 1 and 21 - 2 of the k-th processor unit are the place for forming the transmission strobes and the bits of the result packet functional fields, which realize the beginning of the ensuing computing cycle. Each processor unit processes the instructions without mutual synchronization with any of the other (N-l) processor units.
Thus, the described computer system provides a high performance by means of increasing the load of the processor units and obtaining in this way a decrease of the working programs running time. Then, a high parallelism of the processor units' working is obtained automatically and there is no need to distribute the group parallel processes between separate computational structures (executive devices) inside every running program, or between programs, which is usually carried out by a person, who may become unable to cope with this problem when the number of parallel computing structures increases.
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A computing system for effecting scientific and technical calculations comprises at least a group of processor modules ( 1 - 1 . . . 1 -N), a switch ( 2 ), an auxiliary switch ( 3 ), a group of associative memory modules ( 4 - 1 . . . 4 -N), a buffering block ( 5 ). The computing system provides information processing without any inter-processor exchange, hence, decreasing the time for program processing.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the filing of U.S. Provisional Patent Application Ser. No. 60/543,615, entitled “Radio Frequency Jammer”, filed on Feb. 11, 2004 and the specification thereof is incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] The U.S. Government has a paid-up license in this invention and the right in limited circumstances to require the patent owner to license others on reasonable terms as provided for by the terms of Basic Ordering Agreement (BOA) No. W9124Q-04-G-0006 issued by the Army Contracting Agency, White Sands Missile Range, NM, which facilitated the award of Contract No. W9124Q-04-C-0103 by the Rapid Equipping Force, Fort Belvoir, Va.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention (Technical Field)
[0004] The present invention relates to Radio Frequency (RF) jamming devices. Particularly, the present invention relates to an RF jamming apparatus and method which preferably operates at the same frequencies as those used to remotely detonate explosives commonly referred to as Improvised Explosive Devices (IEDs).
[0005] 2. Description of Related Art
[0006] IEDs are explosive devices that are remotely detonated. These devices are used by military units, terrorist organizations, resistance groups, guerilla groups and the like, and are frequently employed to damage or destroy vehicles by remotely exploding an IED, by means of a radio frequency signal, when the vehicle comes within range of the IED. IED devices can also be employed against stationary targets, such as by having an IED in a vehicle that is parked in proximity to a target, and remotely detonating the IED. IEDs are a significant military challenge and threat. It is against this background that the present invention was developed.
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention is a radio frequency jamming device comprising an electromagnetic radiating device comprising an antenna and an electronics unit, said electronics unit comprising: one or more analog radio frequency modulator cards, each of said cards comprising one or more Voltage Controlled Oscillators, one or more analog modulations, one or more power amplifiers and a single 2-way combiner; and one or more processor cards, said processor cards comprising a Central Processing Unit, and a Gaussian Noise generator, wherein an output from said electronics unit is electrically connected to said electromagnetic radiating device.
[0008] The present invention is also a method for preventing the detonation of a radio frequency controlled explosive device, the method comprising the steps of: selecting a frequency range, said range comprising the operating frequency of a receiver of the explosive device; and transmitting electromagnetic waves comprising Gaussian noise at frequencies of the selected frequency range, wherein the transmitting step comprises transmitting electromagnetic waves having a power of at least 10 watts.
[0009] A primary object of the present invention is to provide a low cost method and apparatus which saves lives and property from the destructive effects of explosive devices which are remotely detonated using radio frequencies.
[0010] Another object of the present invention is to provide a jamming device which can be operated by untrained personnel in the field.
[0011] A primary advantage of the device of the present invention is that it can be easily programmed in response to changing threats.
[0012] Another advantage of the present invention is that multiple different threats, which use different frequencies or modulation modes, may be eliminated simultaneously.
[0013] A further advantage of the present invention is that a user can prevent the detonation of radio frequency controlled explosive devices regardless of whether the user is moving or stationary.
[0014] Other objects, advantages and novel features, and further scope of applicability of the present invention will be set forth in part in the detailed description to follow, taken in conjunction with the accompanying drawings, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0015] The accompanying drawings, which are incorporated into and form a part of the specification, illustrate one or more embodiments of the present invention and, together with the description, serve to explain the principles of the invention. The drawings are only for the purpose of illustrating one or more preferred embodiments of the invention and are not to be construed as limiting the invention. In the drawings:
[0016] FIG. 1 is a photograph depicting a preferred embodiment of the present invention;
[0017] FIG. 2 is a table showing various frequencies commonly used in explosive devices for various regions of the world, as well as the power typically employed;
[0018] FIG. 3 is an image showing a side view of an electronics unit of a preferred embodiment of the present invention;
[0019] FIG. 4 is a block diagram of an embodiment of the present invention;
[0020] FIG. 5 is an image showing an electromagnetic radiating device used in an embodiment of the present invention; and
[0021] FIGS. 6A, 6B and 6 C are charts depicting the elevation and azimuth patterns produced by the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The present invention is a low cost, portable, programmable jamming device for preventing detonation of remote controlled explosive devices.
[0023] The term “vehicle” as used throughout the specification and claims is used for the sake of simplicity and is intended to include any and all types of vehicles, including but not limited to those capable of traveling through the air, on the ground, across water, through water, or combinations thereof. While the term “vehicle” includes any device, apparatus, and/or structure capable of transporting people, the term “vehicle” is not limited to only those devices, apparatuses and/or structures capable of transporting people, but can also include devices, apparatuses, and/or structures capable of carrying cargo, including but not necessarily limited to the apparatus of the present invention. As such, the term “vehicle” can include a person carrying the apparatus of the present invention.
[0024] The present invention is directed to jamming Radio Frequency (RF) devices, particularly to jamming Improvised Explosive Devices (IEDs) as well as other remotely detonated explosives. While the present invention can of course be used in a stationary manner, such as, for example, in or near an encampment, building, or other structure having a geographic location which remains fixed for extended periods of time, the present invention is also capable of operating while traveling and thus can be used with virtually any type of vehicle.
[0025] The present invention preferably interferes with remote control devices which can be used to detonate IEDs. The present invention is capable of protecting vehicles by blocking RF signals within an effective radius of the IED, thus preventing RF detonated devices from exploding near the present invention. In one embodiment, the present invention is preferably mounted in or on a vehicle. Vehicles having the present invention mounted thereon or therein are thus able to prevent RF triggered IEDs from exploding near them and are thus protected therefrom. The apparatus of the present invention is highly effective, rugged, and can be produced in large quantities in a short period of time.
[0026] FIG. 1 shows an embodiment of RF jammer 10 of the present invention. As depicted therein, jammer 10 preferably comprises a plurality of electromagnetic radiating devices 12 and electronics unit 14 . FIG. 3 depicts a side view of electronics unit 14 disposed in a vehicle. For reference, FIG. 2 is included and shows the frequencies, regions, and power which can be used in accordance with the RF jammer of the present invention.
[0027] The present invention preferably produces simultaneous and continuous interfering electromagnetic waves, preferably comprising Gaussian noise, in one or more frequency ranges which correspond with and block those frequencies typically associated with an IED (20-1000 MHz). The actual frequencies, bandwidths, and power levels of the interfering electromagnetic waves produced by the present invention are preferably programmable and may be changed as the IEDs used are changed. The modulation mode used is also preferably programmable, and comprises one or modes known in the art, including but not limited to ΔP/ΔT, ΔF/ΔT, and frequency hop modes. The exact frequencies and bandwidths used in accordance with the present invention are preferably determined and programmed based on the most recent information available. With the ability to program jammer 10 , the ability to adapt to changing tactics used by those making and using IEDs is thus realized.
[0028] FIGS. 6A, 6B and 6 C depict the toroid-shaped pattern typically generated by a monopole radiator, and the pattern depicted in these figures is also preferably produced by electromagnetic radiating device 12 of jammer 10 of the present invention.
[0029] FIG. 4 is a block diagram of preferred control electronics for an embodiment of the present invention. As shown therein, electronics unit 14 of jammer 10 preferably comprises a plurality of analog radio frequency (RF) modulator cards. Each card preferably comprises two digital attenuators, two voltage controlled oscillators (VCO's), two analog modulation blocks, two power amplifiers and a single 2-way combiner. The processor card (see FIG. 4 ) preferably comprises a central processing unit (CPU), a Gaussian noise generator, and various digital logic control circuits that provide the necessary inputs to each RF modulator card. As depicted in FIG. 4 , the outputs from each of the analog modulator cards are preferably combined in a combiner before being passed to a wide-band antenna. A backplane for the antenna is preferably disposed as depicted in FIG. 3 .
[0030] By applying Gaussian noise from the Gaussian noise generator through the digital attenuators and the VCOs on each RF modulator card, the bandwidth is easily adjustable and programmable. The higher the attenuation is, the narrower the bandwidth. The bandwidth can preferably be varied from a narrow spike to about 40% of the center frequency.
[0031] Jammer 10 is preferably easily manufacturable using low cost components and modular to allow for the changing of major components, as well as for troubleshooting and repairing jammer 10 . The primary components of the jammer of the present invention preferably include: A wide band antenna, microprocessor card, high frequency (HF) RF card, a Very High Frequency (VHF1) RF Card, an Ultra-High Frequency (UHF1) RF Card, a second Ultra-High Frequency (UHF2) RF Card, and an L-Band RF card covering a lower end of frequencies. Each RF card preferably provides two frequencies in the appropriate frequency range.
[0032] While the power required to jam a RF device varies according to the particular device desired to be jammed, the present invention is preferably capable of transmitting at least about 10 watts of electromagnetic radiation from 25 MHz to 1000 MHz (continuous coverage). While an antenna of almost any size produces desirable results, it is preferable that electromagnetic radiating device 12 be less than or equal to about 32 inches high by about 4 inches in diameter. Electromagnetic radiating device 12 of the present invention also preferably has no active components. The antenna of electromagnetic radiating device 12 is preferably housed in a rugged radome capable of withstanding mechanical and environmental stresses and may be mounted externally or internally to any vehicle using a magnetic mount or other fastening element, system, or apparatus. Furthermore, electromagnetic radiating device 12 of the present invention is intended to appear to be part of the normal equipment commonly found on military vehicles, including but not limited to a Deep Water Fording kit.
[0033] Although reprogramming of the apparatus of the present invention can be accomplished in the field, it is preferable that such programming be performed by a depot level maintenance function. A more highly trained in theater military technician, a contractor in theater technician, or a technician at the contractor facility can preferably perform this function.
EXAMPLE 1
[0034] An RF jammer in accordance with the teachings of the present invention was constructed as follows:
[0035] First, the threat was evaluated. Based on the devices currently in use to remotely detonate improvised explosive devices (IEDs), the frequency range was found to be from 20 to 1000 MHz. The second step in this process was to establish which frequencies should not be interfered with. In this case, communications bands in use for HF satellite communications, VHF radio channels and UHF channels are designated as areas to avoid. The third step was to determine the power level and modulation required to interfere with the desired devices but to avoid frequency ranges of devices that should not be interfered with. An additional requirement was that the invention be highly cost effective, mass producible, programmable as the threats change, and be 100% effective.
[0036] Engineering challenges included the wide-band, electrically small and stealth appearing electromagnetic radiating device. The radiating device developed houses the BM-03-30, a biconnical monopole antenna. This antenna is a variant of the original biconnical monopole antenna developed by TMC Design Corporation in 1997 and extends the range and increases the gain of that original antenna to meet the needs of present invention.
[0037] The second major engineering challenge for the present invention was the development of an amplifier that was both cost effective and would have sufficient power output. The wide band amplifier developed has proven to be both with the added benefit of graceful degradation.
[0038] The third major engineering challenge was to allow the system to be effectively operated by non-trained operators. The operations and control methodology was therefore divided into three levels of control. The first level was the operator level, which is for the system operator requiring little or no intervention. For this level of control the operator turned the device on and checked for the operational status on operational indicators. The second level of operation was the maintenance mode, where the maintenance person assessed the operation of the device and repaired the unit by replacing cards. Additionally, the maintenance person was able to download threat database updates into the device. The threat database was generated at the third level of control for the system. The threat database was updated and changed based on the latest intelligence information concerning which remote devices were in use. In this way the jammer of the present invention was highly flexible and responded to changing threats but was still easy to operate by an untrained operator.
[0039] The final challenge was to transform the custom built jammer into one that is mass producible and can be supported in a field environment. The mechanical and electrical tolerances were adjusted to insure the final devices would perform properly, and assembly and automated test and tracking software and techniques were developed to allow the units to be assembled in large quantities while maintaining all operational specifications.
[0040] After the requirements were established, a prototype was fabricated and demonstrated. Based on the success of those tests, more elaborate electrical and thermal testing was performed to insure the electrical and mechanical design was sound. Simultaneously, the control and interface software was developed to allow control of this complicated device to appear simple. One final addition to the interface and control software was developed. This was in the form of a Windows-based program which allowed the user to update the threat database and load the new parameters directly into the electronics unit of the jammer.
[0041] The preceding example can be repeated with similar success by substituting the generically or specifically described operating conditions of this invention for those used in the preceding example.
[0042] Although the invention has been described in detail with particular reference to these preferred embodiments, other embodiments can achieve the same results. Variations and modifications of the present invention will be obvious to those skilled in the art and it is intended to cover in the appended claims all such modifications and equivalents. The entire disclosures of all references, applications, patents, and publications cited above and/or in the attachments, and of the corresponding application(s), are hereby incorporated by reference.
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A method and apparatus for broadcasting electromagnetic waves such that user-selected electromagnetic receivers are prevented from receiving an intended electromagnetic communication. Such device can be used to jam detonation of remote controlled explosive devices. The device can be portable or stationary, is preferably programmable, is low cost, and can be used by untrained personnel.
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CROSS REFERENCES TO RELATED APPLICATIONS
[0001] The present invention contains subject matter related to Japanese Patent Application JP 2006-047096 filed in the Japanese Patent Office on Feb. 23, 2006, the entire contents of which being incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an apparatus for and a method of processing data to generate bit sequence data, for use in the transmission of a serial digital video signal based on bit sequence data having a bit rate according to predetermined standards.
[0004] 2. Description of the Related Art
[0005] In the art of video signal processing, efforts have positively been made to employ digital video signals for the purpose of transmitting a variety of video information and achieving a high quality level of reproduced images. There has already been proposed a high-definition television (HDTV) system for handing digital video signals based on digital data representative of video signal information. According to the HDTV system, a digital video signal (hereinafter referred to as “HD signal”) is generated as a word sequence data according to a predetermined data format. HD signals available for the HDTV system include digital video signals in the YCbCr format and digital video signals in the RGB format. In the YCbCr format, Y represents a luma signal component and Cb and Cr chroma signal components. In the RGB format, R, G, B represent red, green, and blue primary signal components.
[0006] For transmitting an HD signal over a signal transmission path in the form of an optical signal transmission cable such as a coaxial cable or an optical fiber, for example, the HD signal should desirably be converted from word sequence data into bit sequence data (serial digital video signal) for transmission because the serial video signal transmission allows the signal transmission path to be simplified. For the serial transmission of HD signals, standards have been established by SMPTE (Society of Motion Picture and Television Engineers). HD signals are transmitted according to HD SDI (High-Definition Serial Digital Interface) standardized in the SMPTE 292M standard established by SMPTE (see SMPTE STANDARD for Television and Digital Cinema SMPTE 425M-200x).
[0007] For the transmission according to HD SDI, it has been specified by the standards that a serial digital video signal based on bit sequence data transmitted over a signal transmission path in the form of an optical signal transmission cable such as a coaxial cable or an optical fiber have a data rate (a bit rate) of 1.485 Gb/s or 1.485/1.001 Gb/s (according to the present invention, both bit rates will be referred to as 1.485 Gb/s). In other words, a serial digital video signal to be transmitted according to HD SDI (hereinafter referred to as “HD-SDI signal”) has a bit rate of 1.485 Gb/s.
SUMMARY OF THE INVENTION
[0008] At present, signal format and coaxial interface physical layer standards for multiplexing signals, which can be multiplexed and transmitted as two HD-SID signals, such as 1920×1080/50P, 60P/4:2:2/10 bits, 1920×1080/24P, 25P, 30P, 50I, 60I/4:4:4/10bits, 12 bits, prescribed under SMPTE 372M, at 2.97 Gb/s (3 Gb/s) and transmitting the multiplexed signal over a single coaxial cable, have been proposed according to SMPTE 425M. However, no standards for optical interfaces have been proposed.
[0009] Channel coding for the proposed coaxial physical layer standards is a scrambling process which is the same as with the present HD-SDI process, and tends to cause a pattern with many DC components or a pattern with many successions of 0s or 1s, which is known as a so-called pathological pattern.
[0010] Inexpensive optical devices such as semiconductor lasers and PIN photodiodes are not available for use in the 3 Gb/s band.
[0011] It is desirable to provide an apparatus for and a method of processing data to generate a serial signal having a bit rate necessary for optical interfaces, based on a plurality of input signals.
[0012] To achieve the above scope, there is provided in accordance with an embodiment of the present invention a data processing apparatus for processing a plurality of input signals to increase the number of bits thereof to disperse 0s and 1s therein and thereafter converting the input signals into a serial signal, including signal generating means for generating the serial signal having a second bit rate which is represented by the product of a first bit rate of the input signals, the number of the input signals, and a ratio of a bit length after the number of bits is increased to a bit length before the number of bits is increased.
[0013] According to another embodiment of the present invention, there is also provided a method of processing a plurality of input signals to increase the number of bits thereof to disperse 0s and 1s therein and thereafter converting the input signals into a serial signal, including the step of generating the serial signal having a second bit rate which is represented by the product of a first bit rate of the input signals, the number of the input signals, and a ratio of a bit length after the number of bits is increased to a bit length before the number of bits is increased.
[0014] With the arrangement of the present invention, the data processing apparatus and method are capable of generating a serial signal having a bit rate necessary for optical interfaces, based on a plurality of input signals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a block diagram of a communication system which incorporates a signal processing apparatus according to an embodiment of the present invention;
[0016] FIG. 2 is a block diagram of the signal processing apparatus shown in FIG. 1 ;
[0017] FIG. 3 is a diagram showing data formats by the signal processing apparatus shown in FIG. 1 while it is in operation;
[0018] FIG. 4 is a diagram showing data formats by the signal processing apparatus shown in FIG. 1 while it is in operation;
[0019] FIGS. 5A and 5B are diagrams showing formats of serial signals output from the signal processing apparatus shown in FIG. 1 ;
[0020] FIG. 6 is a block diagram of a signal processing apparatus according to a modification of the present invention; and
[0021] FIG. 7 is a format of a signal used by the signal processing apparatus shown in FIG. 6 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Embodiments of the present invention will be described below.
[0023] First, signals and standards used in the embodiments of the present invention will be described below.
<Signal Format>
[0024] Digital video data according to D 1 , D 2 , and HTDV are produced by quantizing a luma signal (Y) and chroma signals (CB/CR) with 10 bits (8 bits), and arranging the quantized data in a chronological sequence of a timing reference signal SAV (Start of Active Video), a digital effective line, timing reference signal EAV (End of Active Video), line number data, error detecting code data, and ancillary/undefined word data in the order of line numbers.
[0025] Of the four words of the timing reference signals SAV, EAV, the first three words (3FFh, 000h, 000h) are used to establish word synchronization and horizontal synchronization, and the last word (XYZh) is used to identify first and second fields of one frame and also to identify SAV and EAV.
[0026] The luma signal and the chroma signals are multiplexed in the order of “CB/CR, Y, CB/CR, Y, CB/CR, Y, CB/CR, Y, . . . ,” converted from the parallel format into the serial format, scrambled, and converted into an electric signal or an optical signal, which is then transmitted. The receiver inversely converts the received signal to reproduce the original signals. The scrambling process regards the input serial signal as a polynomial, divides it by a ninth-order primitive polynomial “X9+X4+1”, successively, and transmitting the quotient to statistically set the mark percentage (a proportion of 1s and 0s) of the transmitted data to ½ on the average. At the same time, the scrambling process performs encryption based on the primitive polynomial. The quotient is further divided by X+1 to produce polarity-free data (the data and its inverted data represent the same information), which is transmitted. The receiver multiplies the transmitted data by X+1, and then multiplies the product by the primitive polynomial “X9+X4+1” to reproduce the original data.
<1080/60P Signal>
[0027] The present HDTV system is a 1080/60I interlace system. A video signal used in the next-generation HDTV system is a 1080/60P progressive HDTV signal. A parallel signal format is determined by SMPTE 274M as follows:
[0028] (1) The number of active samples: 1920 samples/line;
[0029] (2) The number of active lines: 1080 lines/frame;
[0030] (3) Frame rate: 60 Hz, 60 Hz/1.001 (Progressive);
[0031] (4) Sampling frequency: 148.5 MHz or 148.5 MHz×1000/1001; and
[0032] (5) Quantization: 8 bits or 10 bits (or 12 bits).
[0033] The parallel interface is defined as:
[0034] (A1) RGB system: 8 bits×3=24 bits or 10 bits×2=20 bits; and
[0035] (A2) Y,CB/CR system: 8 bits×2=16 bits or 10 bits×2=20 bits.
[0036] Though the 10-bit quantization is popular at present, there are growing demands for the 12-bit quantization in view of higher image quality to be achieved in the future.
<D-Cinema Signal of 1080/24P·30P/4:4:4/10 bits, 12 bits>
[0037] D-Cinema (E-Cinema) stands for Digital-Cinema (Electric-Cinema).
[0038] A 24P system parallel signal format is determined by SMPTE 274M as follows:
[0039] (B1) The number of active samples: 1920 samples/line;
[0040] (B2) The number of active lines: 1080 lines/frame;
[0041] (B3) Frame rate: 24 Hz, 24 Hz/1.001, 30 Hz, 30 Hz/1.001 (Progressive);
[0042] (B4) Sampling frequency: 74.25 MHz or 74.25 MHz×1000/1001; and
[0043] (B5) Quantization: 8 bits or 10 bits.
[0044] The parallel interface is defined as:
[0045] (C1) RGB system: 8 bits×3=24 bits or 10 bits×3=30 bits; and
[0046] (C2) Y,CB/CR system: 8 bits×2=16 bits or 10 bits×2=20 bits.
[0047] The serial transmission of signals for the 4:2:2 (Y,CB/CR)/8 bits, 10bits system has been standardized using present HD SDI. However, a serial signal transmission process for a 12-bit quantization system and a 4:4:4 (R,G,B)/8 bits, 10bits, 12 bits, . . . system has not been standardized.
[0048] According to HD SDI, high-order four patterns and low-order four patterns, i.e., 000h through 003h and 3FFh through 3FCh, are inhibited codes. Since these patterns are used as flags of SAV, EAV, or ancillary data, they cannot be used as data. For the D-Cinema signal, however, there are strong demands to use all words without providing inhibited codes.
<Camera Transmission System>
[0049] Camera systems for use in broadcasting stations generally use a plurality of cameras to capture images of a subject. Video signals from the cameras are a Y,CB/CR signal or G,B,R signals according to the above signal format, and transmitted to a CCU (Camera Control Unit) (or VTR). In the Y,Pb/Pr system, a D 1 signal has a bit rate of 270 Mb/s, and an HD signal has a bit rate of 1.485 Gb/s. In order that the operator of a camera is able to know what scene another camera is capturing, the monitor screen of the camera displays the image from the other camera. The monitor image is called return video, and is transmitted from the CCU (or VTR) to the camera. Since return video may not necessarily be of high image quality, it is represented by an MPEG compressed signal and transmitted at a low bit rate of several Mb/s to several hundreds Mb/s. A prompter signal is also transmitted to display the script for an announcer. The prompter signal also has a low bit rate of about several Mb/s. The cameras are controlled by the CCU, and all the cameras, the CCR, and the VTR are operated in synchronism with the system clock.
<SMPTE 3 Gb/s Standards>
[0050] Signal multiplexing formats include SMPTE 425M and SMPTE 424M as coaxial interface physical layer standards. According to the signal multiplexing formats, signals, which can be multiplexed and transmitted as two HD-SID signals, such as 1920×1080/50P, 60P/4:2:2/10 bits, 1920 ×1080/24P, 25P, 30P, 50I, 60I/4:4:4/10bits, 12 bits, prescribed under SMPTE 372M, are multiplexed at 2.97 Gb/s (3 Gb/s) and transmitted over a signal coaxial cable. There are prescribed two signal multiplexing formats, i.e., a proposed direct mapping format unique to the G company and a multiplexing format that is compatible with SMPTE 372M. These formats are identified by Format IDs. Channel coding is a scrambling process which is the same as with the present HD-SDI process. The coaxial physical layer standards are similar to the coaxial standards of SMPTE 292M.
[0051] According to SMPTE 425M, 424M, no standards have been proposed for an optical interface. According to the present invention, a system for generating a serial signal having a bit rate of 3.7125 Gb/s or 4.25 Gb/s compatible with an optical interface is disclosed.
[0052] FIG. 1 shows in block form a communication system 1 which incorporates a signal processing apparatus according to an embodiment of the present invention.
[0053] As shown in FIG. 1 , the communication system 1 has a signal processing apparatus 3 and an optical transmission module 5 .
[0054] The signal processing apparatus 3 is supplied with HD-SDI signals DHS 1 , DHS 2 in channels n, each having a standardized bit rate of 1.485 Gb/s, and outputs a serial signal S 3 having a bit rate of 3.7125 Gb/s (or 4.25 Gb/s) based on the supplied HD-SDI signals DHS 1 , DHS 2 .
[0055] The optical transmission module 5 transmits the serial signal S 3 as an optical signal S 5 over an optical fiber.
[0056] According to the embodiment shown in FIG. 1 , HD-SDI signals DHS 1 , DHS 2 , . . . , DHSn in the channels n, each having a standardized bit rate of 1.485 Gb/s, are supplied as serial digital video signals in channels n, each in the form of bit sequence data having a standardized bit rate, to respective parallel data generators. Each of the HD-SDI signals DHS 1 , DHS 2 , DHSn in the channels n (n is an integer of 2 or greater) has a frame rate of 30 Hz, 25 Hz, or 24 Hz, for example. The number of effective lines in each frame and the number of effective words in each line are 1080 lines and 1920 words, respectively. The number of word bits (the number of quantized bits) is 10 bits, and the data format is the Y,CB/CR format. Each of these HD signals is supplied as a serial signal.
[0057] FIG. 2 shows in block form the signal processing apparatus 3 shown in FIG. 1 .
[0058] As shown in FIG. 2 , the signal processing apparatus 3 has a data processor 11 - 1 for processing the HD-SDI signal DHS 1 , a data processor 11 - 2 for processing the HD-SDI signal DHS 2 , and a P/S converter 40 .
[0059] The data processor 11 - 1 includes an S/P converter 21 - 1 , a synchronous detector 23 - 1 , an FIFO memory 25 - 1 , a K28.5·P.ID inserter 27 - 1 , an 8B/10B converter 29 - 1 , and a memory 31 - 1 .
[0060] The S/P converter 21 - 1 descrambles the HD-SDI signal DHS 1 input as a serial signal, converts the descrambled serial signal into a parallel signal S 21 - 1 , and outputs the parallel signal S 21 - 1 to the synchronous detector 23 - 1 .
[0061] The parallel signal S 21 - 1 includes word sequence data having a line-specific data structure shown in FIG. 3 , for example.
[0062] The line-specific data structure shown in FIG. 3 is made up of a Y data series including a video data part representative of luma signal information of a video signal and a line blanking part, and a CB/CR data series including a video data part representative of chroma signal information of the video signal and a line blanking part.
[0063] Each of the Y data series and the CB/CR data series has word data whose words bits are 10 bits. The Y data series and the CB/CR data series are parallel to each other in synchronism with each other, and provide 20-bit word sequence data as a whole. The Y data series and the CB/CR data series have a word rate of 74.25 Mb/s or 74.25/1.001 Mb/s (according to the present invention, both word rates will be referred to as 74.25 Mb/s).
[0064] Each of the line blanking parts of the Y data series and the CB/CR data series includes 4-word timing reference code data SAV (Start of Active Video) positioned immediately prior to the video data part and 4-word timing reference code data EAV (End of Active Video) positioned immediately subsequent to the video data part. The four words of each of the timing reference code data SAV, EAV are expressed as 3FF, 000,000, XYZ according to the hexadecimal notation. Each of 3FF and 000 is an inhibited code which is not used as a word in the video data part. The combination of 3FF, 000,000, XYZ does not appear in the video data part.
[0065] Each of the line blanking parts of the Y data series and the CB/CR data series includes ancillary data in addition to other data between the timing reference code data SAV and the timing reference code data EAV. The ancillary data in the line blanking part of the Y data series includes 4-word identification data: Payload ID which represents information about the video data of the HD signal.
[0066] The line-specific data structure shown in FIG. 3 is employed when the HD-SDI signal has a frame rate of 30 Hz. Therefore, each of the Y data series and the CB/CR data series has a line period of 2200 words, where the line blanking part includes 280 words and the video data part includes 1920 words.
[0067] The synchronous detector 23 - 1 detects the timing reference code data SAV, EAV contained in the parallel signal S 21 - 1 input from the S/P converter 21 - 1 , establishes bit synchronization and word synchronization based on the detected timing reference code data SAV, EAV (performs forward and backward protection), and detects the frame rate of the parallel signal S 21 - 1 .
[0068] The synchronous detector 23 - 1 writes 20 bits, at a time, of the parallel signal S 21 - 1 as word sequence data S 23 - 1 into the FIFO memory 25 - 1 based on a write clock signal QW 1 having a frequency of 74.25 MHz.
[0069] 40 bits, at a time, of the word sequence data S 23 - 1 written in the FIFO memory 25 - 1 are read therefrom based on a read clock signal QR 1 having a frequency of 74.25/2 MHz=37.125 MHz, and output to the K28.5·P.ID inserter 27 - 1 .
[0070] As shown in FIG. 4 , the K28.5·P.ID inserter 27 - 1 replaces a total of 40 bits of four words (3FF(C), 3FF(Y), 000(C), 000(Y)) out of the eight words (3FF(C), 3FF(Y), 000(C), 000(Y), 000(C), 000(Y), XYZ(C), XYZ(Y): (Y) indicates that the word is a word in the Y data series and (C) indicates that the word is a work in the CB/CR data series) of the timing reference code data SAV or EAV in each of the line blanking parts of the word sequence data S 23 - 1 , with two 8-bit word data DK and three 8-bit word data DP, thereby inserting the 8-bit word data DK, DP into the word sequence data S 23 - 1 .
[0071] When each of the two 8-bit K28.5·P.ID (word data) is subjected to 8B/10B conversion, it is converted into 10-bit word data (8-bit word data: HGFEDCBA=10111100) called a code name “K28.5” which is not used as word data representing video signal information.
[0072] When each of the three 8-bit word data DP is subjected to 8B/10B conversion, it is converted into data functioning as identification data: Payload ID which are three 10-bit word data corresponding to the first through third three words out of the four words of the identification data: Payload ID contained as ancillary data in the word sequence data Dh 1 .
[0073] The K28.5·P.ID inserter 27 - 1 delivers and outputs 40 bits, at a time, of word sequence data S 27 - 1 with the two 8-bit word data K28.5·P.ID and the three 8-bit word data DP inserted therein, to the 8B/10B converter 29 - 1 .
[0074] The 8B/10B converter 29 - 1 performs 8B/10B conversion on the word sequence data S 27 - 1 to convert 40 bits thereof into 50 bits at successive times, thereby generating word sequence data S 29 - 1 . Then, the 8B/10B converter 29 - 1 writes the word sequence data S 29 - 1 into the memory 31 - 1 .
[0075] The data processor 11 - 2 processes the HD-SDI signal DHS 2 in the same manner as the data processor 11 - 1 , and writes word sequence data S 29 - 2 into the memory 31 - 2 .
[0076] The P/S converter 40 reads the word sequence data S 29 - 1 , S 29 - 2 from the respective memories 31 - 1 , 31 - 2 , generates a serial signal S 3 having a bit rate of 3.7125 Gb/s or 4.25 Gb/s compatible with an optical interface, and outputs the serial signal S 3 to the optical transmission module 5 shown in FIG. 1 . If necessary, the P/S converter 40 adds additional data to each line to generate the serial signal S 3 of 3.7125 Gb/s or 4.25 Gb/s.
[0077] For the transmission of 1920×1080/60P/4:2:2/10 bits: 3.7125 Gb/s, the serial signal S 3 has a format shown in FIG. 5A . For the transmission of 1920×1080/60P/4:2:2/10 bits: 4.25 Gb/s, the serial signal S 3 has a format shown in FIG. 5B .
[0078] The optical transmission module 5 shown in FIG. 1 converts the serial signal S 3 input from the P/S converter 40 into an optical signal S 5 , and transmits the optical signal S 5 over an optical signal transmission cable or a coaxial cable including an optical fiber.
[0079] The optical transmission module 5 is of a 4.25 Gb/s Fiber Channel configuration. Since the optical transmission module 5 has only an electrical-to-optical converter (E/O) and an optical-to-electrical converter (O/E) and does not have a clock reproducing function, it can send and receive 8B/10B-converted signals having bit rates ranging from 1.0625 Gb/s to 4.25 Gb/s.
[0080] The optical transmission module 5 of the 4.25 Gb/s Fiber Channel configuration transmits optical signals having a wavelength of 850 nm. However, an optical transmission module for transmitting optical signals having a wavelength of 1300 nm is also feasible.
[0081] An optical transmission module that operates at a bit rate of 3.7125 Gb/s with a commercially available coaxial driver and equalizer may also be used for coaxial transmission of optical signals.
[0082] Operation of the signal processing apparatus 3 shown in FIG. 2 will be described below.
[0083] The HD-SDI signals DHS 1 , DHS 2 are input respectively to the data processors 11 - 1 , 11 - 2 . The S/P converter 21 - 1 of the data processor 11 - 1 descrambles the HD-SDI signal DHS 1 , converts the descrambled serial signal into the parallel signal S 21 - 1 , and outputs the parallel signal S 21 - 1 to the synchronous detector 23 - 1 .
[0084] The synchronous detector 23 - 1 detects the timing reference code data SAV, EAV contained in the parallel signal S 21 - 1 input from the S/P converter 21 - 1 , establishes bit synchronization and word synchronization based on the detected timing reference code data SAV, EAV (performs forward and backward protection), and detects the frame rate of the parallel signal S 21 - 1 .
[0085] The synchronous detector 23 - 1 writes 20 bits, at a time, of the parallel signal S 21 - 1 as word sequence data S 23 - 1 into the FIFO memory 25 - 1 based on the write clock signal QW 1 having a frequency of 74.25 MHz.
[0086] 40 bits, at a time, of the word sequence data S 23 - 1 written in the FIFO memory 25 - 1 are read therefrom based on the read clock signal QR 1 having a frequency of 74.25/2 MHz=37.125 MHz, and output to the K28.5·P.ID inserter 27 - 1 .
[0087] As shown in FIG. 4 , the K28.5·P.ID inserter 27 - 1 replaces a total of 40 bits of four words (3FF(C), 3FF(Y), 000(C), 000(Y)) out of the eight words (3FF(C), 3FF(Y), 000(C), 000(Y), 000(C), 000(Y), XYZ(C), XYZ(Y): (Y) indicates that the word is a word in the Y data series and (C) indicates that the word is a work in the CB/CR data series) of the timing reference code data SAV or EAV in each of the line blanking parts of the word sequence data S 23 - 1 , with two 8-bit word data DK and three 8-bit word data DP, thereby inserting the 8-bit word data DK, DP into the word sequence data S 23 - 1 .
[0088] The K28.5·P.ID inserter 27 - 1 delivers and outputs 40 bits, at a time, of word sequence data S 27 - 1 with the two 8-bit word data K28.5·P.ID and the three 8-bit word data DP inserted therein, to the 8B/10B converter 29 - 1 .
[0089] The 8B/10B converter 29 - 1 performs 8B/10B conversion on the word sequence data S 27 - 1 to convert 40 bits thereof into 50 bits at successive times, thereby generating word sequence data S 29 - 1 . Then, the 8B/10B converter 29 - 1 writes the word sequence data S 29 - 1 into the memory 31 - 1 .
[0090] At the same time that the data processor 11 - 1 processes the HD-SDI signal DHS 1 , the data processor 11 - 2 processes the HD-SDI signal DHS 2 , and writes word sequence data S 29 - 2 into the memory 31 - 2 .
[0091] The P/S converter 40 reads the word sequence data S 29 - 1 , S 29 - 2 from the respective memories 31 - 1 , 31 - 2 , generates a serial signal S 3 having a bit rate of 3.7125 Gb/s or 4.25 Gb/s compatible with an optical interface, and outputs the serial signal S 3 to the optical transmission module 5 shown in FIG. 1 . If necessary, the P/S converter 40 adds additional data to each line to generate the serial signal S 3 of 3.7125 Gb/s or 4.25 Gb/s.
[0092] The optical transmission module 5 shown in FIG. 1 converts the serial signal S 3 input from the P/S converter 40 into an optical signal S 5 , and transmits the optical signal S 5 over an optical signal transmission cable or a coaxial cable including an optical fiber.
[0093] As described above, the signal processing apparatus 3 of the communication system 1 generates a serial signal S 3 having a bit rate of 3.7125 Gb/s or 4.25 Gb/s which matches the optical interface standards for multiplexing the two HD-SDI signals DHS 1 , DHS 2 and transmitting the multiplexed signal through the optical interface. At the bit rate indicated above, inexpensive optical devices such as semiconductor lasers and PIN photodiodes can be used.
[0094] In the signal processing apparatus 3 , the 8B/10B converters 29 - 1 , 29 - 2 perform the 8B/10B conversion to produce error-resistant signals which tend to produce a pattern with many DC components or a pattern with many successions of 0s or 1s, which is known as a so-called pathological pattern.
[0095] More specifically, according to the present invention, there have been devised a process of constructing a synchronous-transmission 3 Gb/s serial interface circuit, a signal processing method, and a data structure, using a 4.25 Gb/s Fiber Channel optical transceiver module. Using the 3 Gb/s serial interface, the communication system can be operated as a synchronous system, which is the same as the present system, in future camera-VTR systems.
[0096] There have also been developed a 3 Gb/s serial interface circuit configuration and a data structure, using a 4.25 Gb/s Fiber Channel optical module and device. The 3 Gb/s serial interface allows HD-SDI signals in two channels to be transmitted according to SMPTE 372M, and makes it possible to realize a video signal real-time interface in a superwide frequency band which is twice HD signals, such as for D-Cinema (2k×1k/4:4:1/12 bits) signals.
[0097] Since the 4.25 Gb/s Fiber Channel optical module and device are expected to find widespread use and to become inexpensive, the period of time in which it is developed, the expenditures with which it is developed, and the cost of its products can be saved.
[0098] Since HD-SDI signals are input to and output from the 3 Gb/s serial interface, it is compatible with the present HD system. If an SD signal is to be transmitted, then it is multiplexed with an HD-SDI signal according to SMPTE 349M for the transmission using the 3 Gb/s serial interface.
[0099] According to the scrambling process, signals to be transmitted tend to cause a pattern that is unfavorable to the transmission, such as a pathological pattern. However, 8B/10B codes are stable as they do not produce transmission data such as a pathological pattern.
[0100] A receiver for receiving the optical signal S 5 transmitted by the communication system 1 has a signal processing IC for receiving a serial electrical signal having a bit rate of 3.7125 Gb/s or 4.25 Gb/s which has been reproduced by the 4.25 Gb/s Fiber Channel optical transceiver module.
[0101] The signal processing IC detects K28.5 for achieving byte alignment and also performing forward and backward protection.
[0102] Then, the signal processing IC performs 8B/10B decoding on the signal, replaces the K28.5 data with the original data, produces parallel HD signals, and outputs the parallel HD signals.
[0103] In the above embodiment, the signal processing apparatus 3 has the two data processors 11 - 1 , 11 - 2 . However, the signal processing apparatus may have three or more data processors.
[0104] A signal processing apparatus according to another embodiment of the present invention will be described below with reference to FIG. 6 .
[0105] FIG. 6 shows in block form a signal processing apparatus 103 according to the other embodiment of the present invention.
[0106] As shown in FIG. 6 , the signal processing apparatus 103 includes an S/P converter 21 - 1 , an S/P converter 21 - 2 , a synchronous detector 23 - 1 , a synchronous detector 23 - 2 , an FIFO memory 25 - 1 , an FIFO memory 25 - 2 , a byte multiplexer 126 , a K28.5·P.ID inserter 127 , an 8B/10B converter 129 , and a P/S converter 140 .
[0107] The S/P converter 21 - 1 , the synchronous detector 23 - 1 , and the FIFO memory 25 - 1 process the HD-SDI signal DHS 1 in the same manner as with the first embodiment.
[0108] Concurrently, the S/P converter 21 - 2 , the synchronous detector 23 - 2 , and the FIFO memory 25 - 2 process the HD-SDI signal DHS 2 in the same manner as with the first embodiment.
[0109] For transmitting a serial signal, the signal processing apparatus 103 converts the HD-SDI signals DHS 1 , DHS 2 in the two respective channels from serial signals into parallel signals and descrambles the parallel signals, using the S/P converter 21 - 1 , the S/P converter 21 - 2 , the synchronous detector 23 - 1 , the synchronous detector 23 - 2 , the FIFO memory 25 - 1 , and the FIFO memory 25 - 2 . Thereafter, the signal processing apparatus 103 brings the parallel signals into phase with each other using the FIFO memory 25 - 1 and the FIFO memory 25 - 2 , to generate 10-bit parallel signals S 23 - 1 , S 23 - 2 in the respective channels.
[0110] The byte multiplexer 126 multiplexes the 10-bit parallel signals S 23 - 1 , S 23 - 2 to generate a 10-bit multiplexed signal S 126 shown in FIG. 7 according to SMPTE 424M.
[0111] The K28.5·P.ID inserter 127 replaces five bytes, from the leading end of its SAV or EAV, of the multiplexed signal S 126 , with K28.52 bytes and P_ID 3 bytes for word synchronization of the 8B/10B code, thereby generating a multiplexed signal S 127 .
[0112] Then, the 8B/10B converter 129 performs 8B/10B conversion on the multiplexed signal S 127 to generate a serial signal S 129 having a bit rate of 3.7125 Gb/s. The P/S converter 140 converts the serial signal S 129 into a parallel signal, which is transmitted from the signal processing apparatus 103 .
[0113] A signal processing apparatus of a receiver for receiving the parallel signal transmitted by the communication system is supplied with a serial electrical signal having a bit rate of 3.7125 Gb/s (or 4.25 Gb/s) which has been reproduced by the 4.25 Gb/s Fiber Channel optical transceiver module.
[0114] The signal processing apparatus of the receiver detects K28.5 for achieving byte alignment and also performing forward and backward protection. Thereafter, the signal processing apparatus performs S/P conversion and 8B/10B decoding on the signal, replaces the K28.5 data with the original data, produces parallel HD signals in two channels, and outputs the parallel HD signals.
[0115] Although certain preferred embodiments of the present invention have been shown and described in detail, it should be understood that various changes and modifications may be made therein without departing from the scope of the appended claims.
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Disclosed herein is a data processing apparatus for processing a plurality of input signals to increase the number of bits thereof to disperse 0s and 1s therein and thereafter converting the input signals into a serial signal, including signal generating means for generating the serial signal having a second bit rate which is represented by the product of a first bit rate of the input signals, the number of the input signals, and a ratio of a bit length after the number of bits is increased to a bit length before the number of bits is increased.
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BACKGROUND OF THE INVENTION
A waste compactor is a hydraulically operated device which compresses waste in order to minimize the disposal costs thereof. Usually, a compactor has a container in which the waste is compacted and has a movable ram for transferring waste from a charge box into the container and for then compressing the waste therein. The charge box is usually at one end of the container and a door is at the opposite end and through which the compacted waste is removed when the container is full. Conventional operating procedure is to disconnect the compactor/container from the hydraulic unit and to haul the filled compactor/container to a refuse collection center where the container is emptied.
The waste container unit normally is transported by truck and the like between the waste receiving center and the compactor operating site. This transportation requires that the container and its related assemblies comply with applicable state and federal statutes and regulations with regard to highway transportation, among others. For example, there are regulations which control the width of a body transported on the highway by a vehicle.
A bustle gate is a door which is pivotally secured to the container to increase the amount of waste and the density of waste in the container. A bustle gate closes the waste-emptying opening of the container. The bustle gate has an arcuate portion facing into the container which causes the waste to be redirected during the compactor operation. The redirection is such that the waste is changed from flowing to the gate to flowing away from the gate. This redirection is effectuated by means of arcuate plates and the desirable benefit is that the density of the waste increased, thereby itating less frequent dumping, and the amount of waste is correspondingly increased.
Bustle gates have been used in the past on compactors. Typically, the gate has been pivotally connected along a top edge of the container and has been pivoted by means of a hydraulic mechanism. Such mechanisms can be complicated, necessitating a power supply and the like, and they also unnecessarily increase the height of the container and thereby limit passage under bridges and the like.
The compactor frequently contains a quantity of fluid waste requiring that the bustle gate be sealingly engaged with the container to prevent seepage of the waste. A typical side pivot assembly, such as provided by an hinge, has the undesirable effect of destroying the resilient rubber seal upon repeated operation of the gate. This is because the bustle gate has a rather substantial depth, as compared with a typicaI door, with the result that the resilient seal is progressively pushed from the hinge side to the latch side as the gate is pivoted into the closed position, with the result that the seal frequently tears. Such tearing may also occur with a conventional flat door.
In view of the above, there is a need for a bustle gate pivot mechanism which does not substantially increase the dimensions of the container. Furthermore, such a pivot mechanism should avoid the need for hydraulically operated mechanisms. Lastly, a good pivot mechanism should assure that the resilient seal is not torn upon repeated use of the gate. The disclosed invention meets these requirements by providing a pivot mechanism employing dual pivots for pivoting the gate on a first axis and then on a second parallel axis.
OBJECTS AND SUMMARY OF THE INVENTION
The primary object of the disclosed invention is to provide a bustle gate pivot mechanism which permits side pivoting of the bustle gate without requiring the use of hydraulic mechanisms or ratcheting hinge slide mechanisms and in a manner which maintains the integrity of the resilient seal throughout repeated use.
The disclosed invention is a bustle gate pivot mechanism for a multisided waste container. First seal means are disposed about a first end portion of the container and first means are connected to a first one of the sides. A first link extends from and is pivotally connected to the first means and a second means is connected to the first link means and is pivotal therewith and includes second link means extending therefrom and pivotally connected thereto. The bustle gate is connected to the second link means and is pivotal therewith. A second resilient seal is disposed about the gate whereby the gate is pivotal about the second means for selectively engaging and disengaging the first and second seal means and the gate and the first link means are pivotal about the first means for selectively positioning the gate proximate to and remote from the first end portion.
The waste container has an open discharge end opposite the charge box end and the bustle gate is pivotally connected along one vertical side to this open end. A ratchet latching mechanism is on the opposite side of the open end and selectively secures and releases the gate. The open end has a peripheral flange which is continuous thereabout and defines the first seal. A resilient seal is affixed to the gate about the lower half thereof and is engageable with the flange for making a liquid-tight connection therewith. The double axis pivot assembly is such that the gate first pivots 180° so as to be disposed parallel to the plane of the flange and then is pivoted 90° so as to be disposed generally transverse to the plane of the flange. The gate is closed by a reverse pivoting operation which minimizes the distortion of the seal because the seal approaches the flange generally transverse to the face thereof.
These and other objects and advantages of the invention will be readily apparent in view of the following description and drawings of the above described invention.
DESCRIPTION OF THE DRAWINGS
The above and other objects and advantages and novel features of the present invention will become apparent from the following detailed description of the preferred embodiment of the invention illustrated in the accompanying drawings, wherein:
FIG. 1 is a fragmentary top plan view partially in section disclosing the pivot mechanism of the invention and with pivoting indicated by broken lines;
FIG. 2 is a view similar to FIG. 1 with the gate pivoted 90° from the position of FIG. 1;
FIG. 3 is a front elevational view of the invention;
FIG. 4 is a fragmentary top plan view of the invention of FIG. 3;
FIG. 5 is a fragmentary side elevational view of the pivot mechanism of the invention;
FIG. 6 is a fragmentary side elevational view of the ratchet latching mechanism of the invention; and,
FIG. 7 is a fragmentary cross-sectional view through the bustle gate of the invention.
DESCRIPTION OF THE INVENTION
Waste container C, as best shown in FIG. 4, is, preferably, a steel container having a rectangular discharge opening, although the container body may be octagonal and which container has a charge box (not shown) at one end and a bustle gate G at the opposite end thereof. Bustle gate G, as best shown in FIG. 3, is pivotally connected to container C by first and second pivot mechanisms P1 and P2, respectively, as herein further explained. Ratchet latch mechamism R is disposed along a side of the container C opposite to the pivot mechanisms P1 and P2 and selectively releases and secures the gate G to the container C.
As best shown in FIG. 7, container C has a first open discharge end 10 through which waste is removed when the container C is full. A box beam 12 extends along the top of container C and has a forward face 14 aligned with the end of the container. A similar box beam 16 extends along the bottom of container C and has a corresponding forward face 18. As best shown in FIG. 4, correspondingly similar and aligned box beams 20 and 22 are disposed upon opposite sides, of the container C and the beams 20 and 22 are secured, to the beams 12 and 16. The beams 20 and 22 likewise have corresponding forward faces 24 and 26, respectively, which lie on the same common plane as the forward faces 14 and 18 of the box beams 12 and 16, respectively. The box beams 12, 16, 20 and 22 are secured together, by welding and the like, so that the forward faces 14, 18, 24 and 26 thereof provide a continuous and uninterrupted flange which is a sealing surface, for reasons to be explained further.
Bustle gate G includes a top box beam 28 as well as a bottom box beam 30, eaCh of which is in alignment with the adjacent beam 12 and 16, respectively, Similar box beams 32 and 34 extend along the sides of the gate G and are likewise in alignment with the box beams 20 and 22, respectively. The box beams 28, 30, 32 and 34 have corresponding rear faces 36, 38, 40 and 42, respectively. The faces 36, 38, 40 and 42 are in spatial alignment with the faces 14, 18, 24 and 26 respectively. FIG. 7 discloses longitudinally extending plates 44 and 46 to which the beams 28 and 30 are secured, respectively, by welding and the like. It can be noted that the plates 44 and 46 have a length exceeding the length of the respective beams 28 and 30. Lengthwise, the beams are longer. Widthwise, the plates are wider.
Arcuate plate 48 is secured to the plates 44 and 46, as well as to the corresponding side beams 32 and 34, as best shown in FIG. 7. The plate 48 has a curvature which is rather flat and the center thereof is directed forwardly into or beyond the container C. The result is that waste moved into the container C by the compactor ram is directed along deflector plate 49 and from there onto the plate 48 and is therewith caused to follow along the plate 48 upwardly and subsequently to be redirected back into the container C by the upper portion of the plate 48. The plate 49 in the floor of container C starts the waste moving upwardly. The result is that the waste achieves a greater compacted density than can be achieved with a conventional door. Because of the greater density, then more waste can be received in the container C without necessitating dumping.
FIG. 7 also discloses the resilient rubber seal 50 which is secured to the rear faces 36, 38 and 40 of the gate G and which sealingly engages with the forward faces 18, 24 and 26 of the container C. The seal 50 is, preferably, manufactured from a high compression styrene butadiene which resists oil and chemicals. The seal 50 extends in continuous and uninterrupted fashion about the lower half of gate G and thereby avoids broken spots which could cause the leak of fluid from the container. Certainly, the seal 50 could extend around the entirety of gate G.
As previously noted the resilient door seal of a conventional door, particularly a deep door, which corresponds with seal 50 of the bustle gate G, is subjected to relatively high lateral forces during closing. These lateral forces result from the fact that the seal extending along the door nearest the pivot assemblies is first engaged with the container seal surface and progressively moves along in side-wise manner as the door is closed. The result is that the resilient seal adjacent the hinge mechanism is frequently subjected to such strong forces that the seal may be distorted, torn or otherwise cease to function.
The pivot mechanisms P1 and P2, as illustrated in FIGS. 3 and 5, are uniquely designed to minimize the lateral closing forces on the seal 50 and thereby extend the operational life of the seal 50 of the bustle gate G.
As best shown in FIG. 3, fixed tubes 52 and 54 are secured to the bustle gate G in spaced apart coaxial relation. A pivot tube 56 is positioned between the fixed tubes 52 and 54 and pintle 58 extends through the aligned apertures of the tubes 52, 54 and 56 so that tube 56, and thereby gate G, may pivot relative to tubes 52 and 54. Similarly, fixed tubes 60 and 62 are disposed in spaced apart coaxial relation at the bottom of gate G. A pivot tube 64 is disposed between and is in coaxial alignment with the fixed tubes 60 and 62. Pintle 66 extends through the apertures of the tubes 60, 62 and 64. The pintles 58 and 66 are coaxial and thereby define a pivot axis about which the bustle gate G rotates for causing the seal 50 to be selectively engaged and disengaged from the forward faces 18, 24 and 26.
Fixed tubes 88 and 70 are secured to the container C along a first side thereof in spaced apart coaxial relation, preferably in alignment with the fixed tubes 52 and 54 respectively, as best shown in FIG. 5. A pivot tube 72 is disposed between the fixed tubes 68 and 70 and pintle 74 extends through the aligned apertures of the tubes 68, 70 and 72. Similarly, fixed tubes 76 and 78 are disposed in spaced apart coaxial relation and are secured to the container C at the bottom thereof. A pivot tube 80 is disposed between the tubes 76 and 78 and pintle 82 extends through the aligned apertures of the tubes 76, 78 and 80. The pintles 74 and 82 are in coaxial alignment and define another pivot axis. Therefore the pintles 74 and 82 define a first pivot axis while the pintles 58 and 66 define a second parallel pivot axis.
A first rectangular bar or link 84 is secured to and extends between the pivot tubes 72 and 56. A similar bar 86 is secured to and extends between the pivot tubes 80 and 84. Preferably, the bars 84 and 86 are disposed in the same plane. The bars 84 and 86 connect the bustle gate G with the container C with the result that the gate G is free to pivot about the first pivot axis and to then subsequently pivot about the second pivot axis, as will be further explained.
As best shown in FIG. 1, first link or support 88 is secured to the fixed tube 68 and to the box beam 20 for maintaining the fixed tube 68 in proper alignment. Those skilled in the art will appreciate that similar links 88 are provided for each of the tubes 70, 76 and 78 and serve to secure the fixed tubes relative to the beam 20. A corresonding link 90 is secured to the fixed tube 58 and to the beam 32, for like reason. Similarly, corresponding links 90 secure each of the tubes 54, 60 and 62 to the gate G. In this way, the gate G and the container C are operably interconnected by the pivot mechanisms P1 and P2. It can also be noted in FIG. 1 that the tubes 68 and 52 are disposed at the opposite ends of the rectangular bar 84 which extend therebetween.
Tubes or pipes 92, 94, 96 and 98, as best shown in FIGS. 3 and 6, extend outwardly from gate G in spaced parallel relation. The tubes 92, 94, 96 and 98 extend outwardly from box beam 34 adjacent a second side of container C.
Links 100, 104 and 106 are pivotally connected to beam 20 and rotate about pivot points 108, 112 and 114, respectively. Hooks 116, 120 and 122 extend from the links 100, 104 and 106, respectively, and are engageable with the tubes 92, 98 and 98, respectively. Vertical riser 124 is connected to each of the links 100, 104 and 106 and is pivotal therewith about pivot points 126, 130 and 132, respectively. Consequently, upward movement of riser 124 causes the links 100, 104 and 106 to pivot so that the hooks 116, 120 and 122, respectively, disengage from the tubes 92, 96 and 98, respectively. Likewise, downward movement of riser 124 causes the hooks to engage the respective tubes and thereby secure and seal the gate G to the container C. Those skilled in the art will understand that the pipe 94 serves as a guide pin for gate G and is received within the opening of guide plate 102.
Ratchet 134 has a first end pivotally connected at 136 to link 106 and a second end connected at 138 to container C. The ratchet 134 operates such that movement of handle 140 cause the link 106 to be associatively pivoted with the result that the riser 124 is selectively vertically moved in response to movement of handle 140. In this way, movement of handle 140 causes the hooks 116, 120 and 122 and the guide plate 102 to be selectively engaged and disengaged from the respective tubes 92, 96, 98 and 94.
As best shown in FIG. 2, chain 142 is secured to gate G at a first end thereof. A second end thereof is engaged with hook 144 secured to container C. The chain 142 when engaged with the hook 144 thereby prevents the gate G from pivoting from the fully open position disclosed in FIG. 2. Those skilled in the art will understand that the chain 142 and hook 144 are positioned toward one side of gate G to permit convenient access.
Those skilled in the art will appreciate that the container C has longitudinally extending sides, to one of which the pivot mechanisms P1 and P2 are operably associated and to an opposite one of which the ratchet mechanism R is associated. The gate G is, in the closed position of FIG. 3, disposed generally transverse to the sides of the container C. When the container C must be emptied, then the gate G is pivoted by pivot mechanisms P1 and P2 on the first and second pivot axes so as to extend parallel to these sides, as best shown in FIG. 2.
OPERATION OF PIVOT MECHANISMS
The bustle gate G of the invention is side hinged and therefore has no inherent or gravitational movement capability. This is to be contrasted with the top hinged gates of other container assemblies and avoids a potential safety problem of sudden unexpected movement. The bustle gate G of the invention will remain in one position after being moved there by the operator and does not require any hydraulic or similar mechanical assistance to accomplish the pivoting. Likewise, the ratchet mechanism R is hand-operated and avoids the needs for hydraulic assemblies and the like.
Pivoting of the bustle gate G by an angular amount of 270° Can be accomplished simply and without difficulty because of the pivot mechanisms P1 and P2, each of which has the aligned first and second pivot axes defined by the respective pintles. Opening of the gate G from its sealing closed position with the container C first requires that the hooks 116, 120 and 122 be disengaged from the respective tubes 92, 96 and 98. The gate G may then be pivoted about the first pivot axis defined by the pintles 58 and 66 so that the pipe 94 disengages from plate 102 with the result that the gate G rotates 180° into the position shown in FIG. 1. It can be noted in FIG. 1 that the gate G extends generally transverse to the longitudinal sides of the container C. The gate G may then be pivoted about the second axis defined by the pintles 74 and 82 and then disposed in the fully opened position shown in FIG. 2. In this position, the gate G extends parallel to the sides of the container C. It can also be noted in FIG. 2 that the bar 84 has also pivoted with the gate G because of the interconnection of the pivot tubes 56 and 72.
Closing of the gate G is likewise accomplished in straightforward manner. The chain 142 is removed from the hook 144 and the gate G and the bars 84 and 86 may then be pivoted about the second axis into the position shown in dark lines in FIG. 1. It can be noted in FIG. 1 that the bar 84 extends parallel to the sides of the container C. The gate G may then be pivoted 180° about the first pivot axis from the position shown in dark lines in FIG. 1 to the position shown in phantom lines wherein pipe 94 is located in the opening of plate 102. At that point, the ratchet mechanism 134 may be operated to cause the hooks to engage the respective tubes and thereby secure the bustle gate G to the container C.
The double pivot mechanism of the invention minimizes the lateral forces exerted on the seal 50 by the closing of the gate G. This is because the seal 50 adjacent the first pivot axis of the pivot mechanisms P1 and P2 engages the face 24 only shortly before the seal 50 engages the face 26. This is due to the fact that the gate G pivots about the first pivot axis such that the seal 50 moves essentially transverse to the forward faces of the box beams just before engagement therewith.
Those skilled in the art understand that the bustle gate G is deeper than the usual tailgate which oloses a container C. The double pivot mechanism of the invention provides the important function of allowing the relatively deep tailgate G to open 270° and also to lie flat against the container side when opened. The geometric location of the pivots defined by the first and second pivot axes allows the seal 50 to be compressed when the ratchet R is tightened while also allowing the tailgate G to be repeatedly opened and closed without damaging the seal 50. The pivot mechanisms P1 and P2 are very compact and therefore permit the container C to have more usable width than would be expected with a bustle gate having side hinges.
The first pivot axis must be located close to the seal 50 for the preferred seal contact to occur with the forward faces of the box beams. The length of the bars 84 and 86 and the location of the second pivot axis are determined by the length that the bustle gate G extends beyond the first pivot axis.
While this invention has been described as having a preferred design, it is understood that it is capable of further modifications, uses and/or adaptations of the invention following in general the principle of the invention and including such departures from the present disclosure has come within known or customary practice in the art to which the invention pertains, and as may be applied to the central features hereinbefore set forth, and fall within the scope of the invention of the limits of the appended claims.
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A bustle gate pivot mechanism includes a multisided container. A first seal is disposed about a first end portion of the container. A first pivot mechanism is connected to a first one of the sides and includes a first link extending therefrom and pivotally connected thereto. A second pivot mechanism is connected to the first link at a distance from the first pivot mechanism and is pivotal therewith and includes a second link extending therefrom and pivotally connected thereto. A bustle gate is connected to the second link at a distance from the second pivot mechanism and is pivotal therewith. A second seal is disposed about the gate. The gate is pivotal about the second pivot mechanism for selectingly engaging and disengaging the first and second seals. The gate and the first link are furthermore pivotal about the first pivot mechanism for selectively positioning the gate proximate to and remote from the first end portion.
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