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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to cement compositions comprised of cement and an addition copolymer of (a) an adduct of a polyether polyol and an ethylenically unsaturated isocyanate with (b) an ethylenically unsaturated carboxylic acid.
2. Description of the Prior Art
Various additives have been proposed to increase the fluidity of hydraulic cement compositions. U.S. Pat. No. 4,814,014, for example, proposes the use of certain graft copolymers comprised of a polyether backbone having attached side chain polymers formed by polymerization of ethylenically unsaturated monomers as such additives. Illustrative additives are formed of acrylic acid and an oxyethylene/oxypropylene copolymer.
See also U.S. Pat. No. 4,946,904 which proposes cement additives comprising a copolymer of a polyoxyalkylene derivative and maleic anhydride.
U.S. Pat. No. 5,478,521 proposes cement compositions which contain a polymer additive which functions as a dispersant and super plasticizer and which comprises a polymeric backbone moiety and a polymeric side chain moiety, one of which is a polyether moiety and the other is a non-polyether moiety formed by polymerization of ethylenically unsaturated monomers. Polyether backbone moieties are described as are side chain moieties formed by acrylic acid polymerization.
U.S. Pat. No. 4,390,645 describes the addition copolymerization of (a) an adduct of a polyether polyol and an ethylenically unsaturated isocyanate with (b) an ethylenically unsaturated monomer such as styrene or a mixture of styrene and acrylonitrile. These materials are described as useful in the production of a wide variety of polyurethane products. Included among the myriad of possible ethylenically unsaturated monomers are styrene, acrylic acid, maleic anhydride, vinyl esters, vinyl ethers, and the like; only styrene and styrene plus acrylonitrile are exemplified.
BRIEF DESCRIPTION OF THE INVENTION
In accordance with the present invention, cement compositions are provided comprised of hydraulic cement and as a fluidity improving additive an addition copolymer of (a) an adduct of a polyether polyol and an ethylenically unsaturated isocyanate with (b) an ethylenically unsaturated carboxylic acid.
DETAILED DESCRIPTION
In accordance with the invention, a prepolymer is formed by the reaction of a polyether polyol and an ethylenically unsaturated isocyanate.
The polyoxyalkylene polyols most suitable for use in the preparation of the additives used in this invention are the polymerization products of an alkylene oxide or a mixture of alkylene oxides. The functionality of the polyol should be at least about one, but can be varied as desired by changing the structure of the active hydrogen containing initiator or by any other means known in the art. Diols and triols are particularly preferred. Suitable alkylene oxides include, but are not limited to, ethylene oxide, propylene oxide, 1,2-butylene oxide, and the like. Propylene oxide polyols and propylene oxide/ethylene oxide copolyols (either random or endcapped) are most preferred. The polyoxyalkylene polyether polyols may be prepared by any of the methods well-known to those skilled in the art and may contain small amounts of unsaturation. Polyoxyalkylene polyols in which the terminal hydroxyl groups have been replaced with primary or secondary amine groups or with other active hydrogen moieties are also suitable for use in this invention. The number average molecular weight of the polyoxyalkylene polyol is preferably between about 1000 and 10,000 and most preferably is from about 2000 to 7000.
In accordance with the invention, a prepolymer is formed by the reaction of a polyether polyol and an ethylenically unsaturated isocyanate.
The isocyanate vinyl monomer may be any monomer containing at least one vinyl functional group (i.e., a carbon-carbon double bond capable of polymerizing in a free radical manner) and at least one isocyanate functional group.
Suitable isocyanate vinyl monomers may have the following general structure(1): ##STR1## wherein R is a divalent hydrocarbon radical, R 1 is hydrogen or methyl, and R 2 and R 3 separately represent a monovalent hydrocarbon radical. For example, R may be an aromatic ring or an aliphatic chain. The aromatic ring or aliphatic chain may bear additional substituents, as long as such substituents do not interfere with the desired reactivity of the vinyl or isocyanate groups. R 2 and R 3 , may be methyl, ethyl, phenyl, the like.
(1,1-Dialkyl-1-isocyanatomethyl) vinyl aromatic monomers, are one class of isocyanate vinyl monomers particularly suitable for use in this invention. Shown below is (1,1-dimethyl-1-isocyanatomethyl)-m-isopropanol benzene (also known as TMI), a preferred isocyanate vinyl monomer since it is available commercially. ##STR2##
Aromatic isocyanate monomers of Structure 2 are also useful in this invention, where R 1 , R 2 , and R 3 have the same meaning as in Structure 1. ##STR3##
The adduct formed of the polyether polyol and ethylenically unsaturated isocyanate is formed in accordance with known procedures as shown, for example, in U.S. Pat. No. 5,194,493, the disclosure of which is incorporated herein by reference.
The addition copolymer used in practice of the invention can be formed by the general procedures described in U.S. Pat. No. 4,390,645, the disclosure of which is incorporated herein by reference. The ethylenically unsaturated carboxylic acid used in the copolymerization is preferably acrylic acid or methacrylic acid.
The copolymerization is readily carried out by simultaneously adding at a steady or constant rate the carboxylic acid monomer and a free radical catalyst to a mixture of the adduct and the polyether polyol under conditions sufficient to cause free radical addition polymerization. The temperature of the copolymerization is dependent upon the initiator and is preferably in the range from about 25° to about 190° C., most preferably from about 110° to about 130° C., when peroxy-type catalysts are used. Alternatively, the free radical catalyst may be dispersed in a portion of the polyether polyol and thereafter added along with monomer to the remaining portion of the polyether polyol containing the mono-adduct. Other polymerization processes, both continuous and batch, may be suitably employed.
The cements in which the fluidity improving additives are used include ordinary, quick-hardening, and moderate-heat portland cements, alumina cement, blast-furnace slag cement, and flash cement. Of these, Portland cements of the ordinary and quick-hardening types are particularly desirable.
The quantity of additive used may vary with various factors. The quantity of the fluidity improving additive to be used in accordance with the invention is usually in the range of 0.001-5%, preferably 0.01-1%, based on the weight of cement. If the quantity is less than 0.001% by weight, the additive will give only a small fluidity improving effect. If the quantity exceeds 5 wt %, costs of the additive are excessive. The quantity of water to be used for setting the cement can vary; generally weight ratios of water to cement in the range 0.25:1 to 0.7:1, preferably 0.3:1 to 0.5:1, are satisfactory. Where necessary, an aggregate such as pebble, gravel, sand, pumice, or fired perlite may be employed in conventional amounts. The quantity of the fluidity improving additive is usually 0.001-5%, based on the weight of the cement, or usually 0.0003-2% on the basis of the total weight of the cement, additive, water and aggregate combined.
Various other conventional ingredients may also be used. Among the optionally employable ingredients are: conventional hardening accelerators, e.g. metal chlorides such as calcium chloride and sodium chloride, metal sulfates, such as sodium sulfate, and organic amines such as triethanolamine; ordinary hardening retarders, e.g. alcohols, sugars, starch and cellulose; reinforcing-steel corrosion inhibitors such as sodium nitrate and calcium nitrite; water reducing agents and high-range water reducers such as lignosulfonic acids and their salts, and derivatives, hydroxylated carboxylic acids and their salts, condensation products of naphthalenesulfonic acids and formalin, sulfonated melamine polycondensation products, amines and their derivatives, alkanolamines, and inorganic salts such as borates, phosphates, chlorides and nitrates; air entrainers; super plasticizers; shrinkage reducing agents; and the like. The quantity of such an optional ingredient or ingredients is usually 0.01-6% by weight of the cement.
The manner of adding the fluidity improving additive to the cement may be the same as with ordinary cement admixtures. For example, the additive can be admixed with a suitable proportion of water and then this composition mixed with cement and aggregate. As an alternative, a suitable amount of the combination may be added when cement, aggregate and water are mixed.
The concrete and the like incorporating the fluidity-improving agent combination according to the invention may be applied in conventional ways. For example, it may be trowelled, filled in forms, applied by spraying, or injected by means of a caulking gun. Hardening or curing of the concrete and the like may be by any of the air drying, wet air, water and heat-assisted (steam, autoclave, etc.) curing techniques. If desired, two or more such techniques may be combined. The respective curing conditions may be the same as in the past.
The addition to cement of the copolymer in accordance with the invention markedly improves the fluidity of the resulting composition.
The following example illustrate the invention:
EXAMPLE 1
(Preparation of urethane prepolymer)
500 g of a monofunctional polyether, MP1, having a number average molecular weight of about 2000, corresponding to a hydroxyl number of 28 mg KOH/g, made by reacting methanol with ethylene oxide and propylene oxide (70:30 weight ratio) in the presence of an alkali metal hydroxide catalyst was heated to 80° C. in a reaction flask and a mixture of 50 g TMI, dimethyl-m-isopropanol benzyl isocyanate supplied by Cytec Industries, and 0.2 g Coscat83, an organobismuth compound supplied by CosChem Inc., was added slowly and the mixture was then heated for 2 hours at 80° C.
EXAMPLE 2
100 g of the monofunctional polyether, MP1, described in Example 1, was heated to 145° C. in a reaction flask. A mixture of 20 g of the urethane prepolymer from Example 1, 30 g acrylic acid and 1.5 g t-butylperoxybenzoate was added to the reactor over 1 hour at 145° C. Any volatiles remaining at the end of the reaction time were removed by flash evaporation in vacuo.
EXAMPLE 3
50 g of the monofunctional polyether, MP1, described in Example 1, was heated to 145° C. in a reaction flask. A mixture of 70 g of the urethane prepolymer from Example 1, 30 g acrylic acid and 1.5 g t-butylperoxybenzoate was added to the reactor over 1 hour at 145° C. Any volatiles remaining at the end of the reaction were removed by vacuum flash.
EXAMPLE 4
(Comparative)
237 g of the monofunctional polyether, MP1, described in example 1 was heated in a reaction flask. A mixture of 60 g acrylic acid and 3 g t-butyl peroxybenzoate was added dropwise over 1 hour. Remaining volatiles were removed by vacuum flash.
EXAMPLE 5
The reaction products of Examples 1 through 4 were tested in mortar mixes. Slump was measured using a half-size slump cone; air content was determined by ASTM method C185. In a typical preparation, the additive under test was added to the required amount of water; 2700 g sand (ASTM C778 graded) was then added to the mixture followed by 1200 g cement. The procedures of ASTM C305 were used for mixing. Typically the ingredients were mixed for 8 minutes at slow speed with the Hobart mixer. Results are summarized in the Table. As needed, a defoamer such as tri-n-butyl phosphate was added to the mixture so that each batch had an air content comparable to that of the control. Performance of the prepolymer from example 1 was the same as that for the control which had no additive and showed no fluidity-improving properties. The product from comparative example 4 showed some water reduction, as described in U.S. Pat. No. 4,814,014, but, at a given dosage, the product from examples 2 and 3 showed much better water reduction. At 0.2% dosage, for example, water reduction doubled to 14% for example 3 compared to only 7% for example 4. At 0.3% dosage, water reduction was 19% for example 2 compared to 11% for example 4.
For example 2, the additive was converted to the sodium salt and used as a 25% aqueous solution. For example 3, the additive was used as made.
TABLE__________________________________________________________________________ wt % additive Slump % water DefoamerAdditive Water/Cement on dry cement mm % Air red (% of additive)__________________________________________________________________________none 0.52 -- 102 2 -- nonenone 0.50 -- 83 4 -- nonenone 0.48 -- 59 5 -- nonenone 0.45 -- 44 6 -- nonenone 0.42 -- 24 8 -- noneExample 1* 0.42 0.2 22 7 none TBP (3%)Example 2 0.42 0.1 84 6 16 TBP (11%)Example 2 0.42 0.2 84 10 ≠ noneExample 2 0.42 0.3 100 5 19 TBP (4%)Example 3 0.42 0.2 70 5 14 TBP (4%)Example 4* 0.42 0.2 44 5 7 TBP (4%)Example 4* 0.42 0.3 60 5 11 TBP (2%)__________________________________________________________________________ *Comparative ≠cannot be compared to other data because air content is much highe | There is provided a cement composition having improved fluidity comprising cement and an addition copolymer of (a) an adduct of a polyether polyol and an ethylenically unsaturated isocyanate with (b) an ethylenically unsaturated carboxylic acid. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional application Nos. 61/097,406 filed Sep. 16, 2008 and 61/095,216 filed Sep. 8, 2008, and U.S. non-provisional application Ser. No. 12/555,369 filed Sep. 8, 2009, the entireties of which are herein incorporated by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] This invention was made with United States government support awarded by the following agency:
[0003] NSF 0520152
[0004] The United States government has certain rights in this invention.
BACKGROUND OF THE INVENTION
[0005] The present invention relates to security systems for computer networks and, in particular, to a security system for networks employing wireless communication links.
[0006] Providing security for data transmitted electronically over a computer network is important to prevent the theft of data or services, preserve privacy, and prevent the introduction of malware such as viruses. One common method of ensuring network security uses a “white list” of authorized users and checks the identity of network users against this list at the time the users enter the network and/or periodically during their connection.
[0007] Reliably determining the identity of a user connecting to the network is not a simple matter. One method is through the use of a personal identification number (PIN), password, or encryption key known only to the user. But such keys are often lost or stolen.
[0008] Additional security may be had by combining a user entered key, a machine identifier such as the MAC address of a network interface card, and a unique serial number assigned to each network interface card chip. Unfortunately, it is relatively easy to forge a MAC address. For this reason, more sophisticated machine/user identifiers may be used such as hardware fobs generating a series of pseudorandom numbers in parallel with similar hardware at a network gateway. All of these authenticating techniques, which allow the authentication to be implemented through data transmitted over the network, will be termed “network data implemented authenticators” because the authenticating information is conveyed using the data transmitting qualities of the network.
[0009] For highly secure networks, “network data implemented authenticators” may be supplemented with techniques that do not rely on the data conveyed by the network, for example limiting connection to the network to physically secure network jacks within a building. These measures are resistant to the loss or theft of passwords or hardware password devices.
[0010] This latter type of supplemental identification of the user is far more difficult with a wireless network which anticipates that users may be mobile and where it is difficult to contain the wireless signal within a building or controlled environment.
SUMMARY OF THE INVENTION
[0011] The present invention provides a system that extracts a nearly unique “fingerprint” of the wireless device from imperfections in its radio transmitter circuitry and then uses such fingerprints to identify the physical transmitting device for security-related purposes. The present invention operates primarily in the “modulation domain,” i.e. at the last stages of conversion of analog signal to digital data in contrast to some radio transmitter identifications systems which represent device identity in the “waveform domain”, i.e., based on information gathered in early stages of signal acquisition that do not take advantage of the signal properties due to modulation. A test of the present invention with off-the-shelf wireless network cards indicates that sufficient variation exists even with mass-produced wireless network cards to reliably differentiate cards from each other in a typical wireless environment subject to noise, multipath effects, and channel distortion.
[0012] Importantly, the exploited imperfections in the radio transmitters used for this identification are a product of the underlying difficulty and cost of controlling these imperfections, making the creation of a “mimic” for any particular transmitter card disproportionately expensive to someone who would breach the security of the network.
[0013] Significantly, too, all network communication over the wireless card must reveal the data necessary to extract the modulation domain fingerprint making this technique inescapable. At the same time, implementation of the invention does not require any modifications to the mobile wireless devices, making it easy to deploy in existing environments.
[0014] As an additional benefit, the modulation domain parameters that make up the fingerprint are extracted using a process very similar to that already used in existing transceivers, making implementation of the invention relatively simple and inexpensive.
[0015] In detail, then, the present invention provides a secure network transceiver system for communicating network data with a plurality of mobile transceivers, each mobile transceiver having a digital signal portion communicating with an analog radio portion. The secure network includes at least one base transceiver having: (1) an analog radio portion exchanging radio signals with the mobile transceivers, the analog radio portion providing modulation domain outputs reading modulation domain qualities of received radio signals from the mobile transceivers; (2) a digital signal portion communicating digital data with the analog radio portion related to encoded content of the radio signals; and (3) an electronic computer including a processor and a memory, the electronic computer exchanging network data related to the digital data with the digital signal portion and receiving modulation domain outputs from the analog radio portion.
[0016] The electronic computer executes a stored program contained in memory to: (1) execute an authentication process with mobile transceivers through the exchange of network data, the authentication process employing a network data authenticator; (2) characterize received radio signals of mobile transceivers according to the modulation domain qualities indicated by the modulation domain outputs; (3) compare the characterized radio signals to pre-established characterizations of authorized mobile transceivers; and (d) generate an output indicating a possible security violation when the characterized radio signals do not match pre-established characterizations to within a predetermined threshold.
[0017] It is thus an object of the invention to provide a method of uniquely identifying a wireless transmitter that is difficult to forge and that is inescapably revealed in network communications. It is another object of the invention to provide a method that does not require special modification of the wireless transmitters of mobile devices and thus is scalable at low cost.
[0018] The electronic computer may further execute the stored program to revoke authorization of mobile transmitters whose characterized radio signals do not match pre-established characterizations to within a predetermined threshold.
[0019] It is thus an object of the invention to provide a system that may automatically and rapidly stop security breaches.
[0020] The modulation domain qualities may be selected from the group consisting of measurements related to trajectory of a received signal's phasor in the modulation domain. Including, but not limited to symbol phase error, symbol magnitude error, and symbol error vector magnitude. Alternatively or in addition, measurements may be related to overall modulation-domain characteristics of a received signal including, but not limited to carrier frequency offset, symbol clock offset, SYNC correlation. It is thus an object of the invention to use fundamental characteristics of analog transmitter circuitry revealed in a radio signal that provide sufficient variation to serve as transmitter identification.
[0021] The comparison may provide a multidimensional comparison using multiple different modulation domain qualities.
[0022] Thus it is an object of the invention to produce a “fingerprint” that is extremely difficult to forge requiring the simultaneous control of multiple parameters of a radio transmitter that are normally electrically inter-dependent.
[0023] The network may include multiple base transceivers, and each of the base transceivers may use different pre-established characterizations each unique to one base transceiver receiver or the multiple base transceivers may share pre-established characterizations.
[0024] It is thus an object of the invention to provide a flexible trade-off between a simple commissioning process in which a set of measurements at one base station serve all base stations, and extremely precise radiometric characterization wherein each base transceiver creates a fingerprint unique to its own receiver characteristics.
[0025] The comparison of the characterized radio signals may employ comparison algorithms selected from the group consisting of: k-nearest-neighbor, support vector machines, decision trees, neural networks, Bayesian-based algorithms, polynomial classifiers, regression fitting, hidden Markov models, Gaussian mixture models, radial basis functions, classifier boosting, classifier ensembles.
[0026] Thus it is an object of the invention to provide high accuracy by using a sophisticated multidimensional comparison algorithm.
[0027] The electronic computer may further execute the stored program contained in memory to change a pre-established characterization fear a mobile transceiver on a periodic basis using recent transmissions when the characterization of the recent transmissions match existing characterizations to within a second predetermined threshold or when the characterization of the recent transmissions matches an original characterization to within a second predetermined threshold.
[0028] It is thus an object of the invention to permit tighter characterizations of mobile transceivers by accommodating slow evolution of transceiver parameters.
[0029] These particular objects and advantages may apply to only some embodiments falling within the claims, and thus do not define the scope of the invention.
DETAILED DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is a representation of a simple wireless network having three multiple mobile users communicating with two base stations, the latter connected on a network with a central server;
[0031] FIG. 2 is a block diagram of a transceiver of the type used by the mobile users and base stations also showing a modification used in the base stations only;
[0032] FIG. 3 is a block diagram of the central server of FIG. 1 such as may contain the radiometric identification program of the present invention, radiometric information, and network data authenticators for use by the invention;
[0033] FIG. 4 is a flow chart of a program executed by the server of FIG. 3 during the commissioning of new mobile wireless device;
[0034] FIG. 5 is a flow chart of a program executed by the server of FIG. 3 during a typical authorization of a pre-commissioned mobile wireless device;
[0035] FIG. 6 is a constellation diagram of one type of quadrature modulation suitable for use with the present invention showing the radiometric information used by the present invention;
[0036] FIG. 7 is a simplified representation of a nearest neighbor classification algorithm;
[0037] FIG. 8 is a simplified representation of a support vector machine algorithm suitable for use with the present invention;
[0038] FIG. 9 is a detailed fragmentary view of one quadrant of quadrature constellation of FIG. 7 showing a possible strategy for heuristic modification of the radiometric fingerprints; and
[0039] FIG. 10 an example of a possible phasor trajectory.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
General Description of the Network
[0040] Referring now to FIG. 1 , an example network 10 suitable for use with the present invention employs multiple mobile devices 12 , for example, laptop computers having wireless adapters 14 such as those employing the IEEE 802.11 wireless standard well known in the art. The present invention however is not limited to the IEEE 802.11 standard.
[0041] When connected in a network, the mobile devices 12 may communicate by radio waves over a wireless communication channel with one of two base stations 16 (typically stationary) that may in turn communicate on a wire or optical carrier medium 18 with a central server 20 . The central server 20 may have additional connections, for example, to a secure institutional network 22 . In this way the mobile devices 12 may flexibly connect to the secure institutional network 22 .
Transceiver
[0042] Referring now to FIG. 2 , each of the wireless adapters 14 and base stations 16 may include a transceiver 24 . Generally, similar transceivers 24 are used in both the network adapters and base stations 16 ; however, a receiver portion of the transceiver 24 is modified slightly for the base station 16 only, as will be described below. The depicted transceiver 24 is simplified and is one of many possible designs that can work with the present invention as will be understood from the following description to those of ordinary skill in the art.
[0043] Referring still to FIG. 2 , during transmission, the transceiver 24 may receive data from a processor 26 communicating with a memory 28 and executing a stored program in the memory 28 to produce a data stream 30 to be transmitted over the wireless communication channel. This data stream 30 , for example, may be data exchanged between the base stations 16 and the mobile devices 12 as part of standard network communication and may include network data authenticators for authorizing the user. When the transceiver 24 is in the base station 16 , the processor 26 may operate simply to exchange data with the server 20 and is connected to a network card 72 connecting it to the earlier medium 18 . When the transceiver 24 is in the mobile devices 12 , the processor 26 may be the microprocessor of a laptop or other mobile device such as a cell phone, portable digital assistant, camera, music player or the like and the network card 72 is not required.
[0044] As is understood in the art, data of the data stream 30 will typically be organized in a frame including a data packet encoded by the data link layer for digital transmission to a node (either the base station 16 or mobile device 12 ). A frame will typically include a header synchronization section, a payload of network data, and a trailer, for example, of error correction codes or the like.
[0045] Within the transceiver 24 , the data stream 30 will be received by a symbol encoder 32 which accepts sets of bits of each data packet in sequence and encodes them according to the particular encoding scheme used by the transceiver 24 . In this example, it will be assumed that the transceiver 24 uses QPSK modulation (quadrature phase-shift keying) in which data is encoded in the phase of quadrature subcarriers of the transmitter radiowave. These quadrature subcarriers will be termed the in-phase subcarrier (I) and the quadrature-phase subcarrier (Q) and are separated in phase by 90°. While this modulation technique is assumed in the following example, it should be emphasized that the present invention can be used with a variety of other modulation systems including but not limited to 16-QAM, and 256 QAM.
[0046] In general, a transmitter encodes discrete data onto a carder signal by continuously varying, or modulating in time some analog, that is to say, continuous property of the carrier signal. The receiver measures those variations and reconstructs signal's data payload according to the communication standard in use. Practitioners in the art use the term. “phasor” to describe an instantaneous value of those modulated properties (state of the signal) at a given point in time (see FIG. 10 ). The exact relationship between phasor value and physical properties of a signal is defined by the communication protocol in use. Therefore, as time passes and signal's properties are changed by the transmitter, the phasor value changes accordingly. As instantaneous value of a phasor is most commonly described using two independent components known as I (in-phase component) and Q (quadrature component). In the art, a physical radio wave is then equivalent to the trajectory of the phasor in an abstract two-dimensional space commonly called I/Q or modulation domain. In fact, information may be encoded in higher-dimensional space, as is the case, for example, with MIMO (multiple input and multiple output) technology. Handling such cases would require only minor changes to the overall procedure, since, as long as the modulation format's number of symbols is finite, they can be mapped onto a two-dimensional space or multiple two-dimensional spaces.
[0047] The relationship between the dimensions of the modulation domain representation and waveform characteristics is determined by the communication protocol. For example, the I-dimension could correspond to the amplitude or the I-subcarrier at a point in time, and Q-dimension could be related to the phase of the Q-subcarrier. The exact relationships between waveform-domain representation and modulation-domain representation for the purposes of this invention are irrelevant, as long as they are known.
[0048] Therefore, we can treat phasor trajectory as the entity encoding information. However, keeping accurate track of phasor's trajectory is resource-intensive. Instead, practical systems periodically measure phasor's position at times dictated by the communication standard, and generally disregard phasor's intermediate transitions. Phasor values at these critical points in time form a “constellation” that serves as basis for analog-to-digital conversion, and a basis for representing identity in this invention.
[0049] One contributions of some embodiments of this invention is to base the notion of the transmitter's identity on the persistent device-specific properties of phasor trajectory of its signals that persistently manifest themselves regardless of the information encoded in the signal. Specifically, a signature, or a fingerprint of a specific device is based on some notion of difference between the phasor trajectory observed at the receiver and the phasor trajectory of the “ideal signal”, i.e. theoretical signal generated by conceptual model of a perfect transmitter, unaffected by hardware impairments or channel distortion. The notion of the ideal reference signal is inevitably defined by the communication protocol in use, as part of the procedure for decoding of received signals.
[0050] Consumer-grade transceivers typically do not keep precise track of phasor trajectory, as doing so would require higher sampling rates and more capable hardware than what is minimally necessary to communicate in typical environments. Instead, phasor trajectory is periodically sampled at frequency determined by the communication standard, effectively producing a single position of the phasor corresponding to every elementary quantum of information encoded in the signal. Therefore, the most economical embodiment of the invention will represent phasor trajectory as a single point per quantum of information encoded in the signal, thereby leveraging capabilities of existing hardware.
[0051] In our implementation even such concise trajectory representation allowed degree of accuracy suitable for many applications. However, since in such embodiment most information about phasor trajectory is discarded, an embodiment designed to deliver maximal accuracy can benefit from a more enhanced and consequently costly receiver that is required strictly for data communication alone. Referring momentarily to FIG. 7 , the QPSK modulation system provides a modulation “constellation” admitting four different encoding states or “symbols” represented by points 34 a (with the I and Q phases positive), points 34 b (with the I phase positive and the Q phase negative), points 34 c, (with the I and Q phases negative), and points 34 d (with the I phase negative and the Q phase positive). These four encoding points 34 permit the encoding of two bits per symbol with point 34 a encoding bits 00 , point 34 d encoding bits 01 , point 34 b encoding bits 10 , and point 34 c encoding bits 11 . Symbol encoder 32 thus takes pairs of bits and encodes them into I and Q phases represented, for example, as two voltages indicating positive or negative I and Q phase shifts.
[0052] The I and Q phases produced by the symbol encoder 32 may be subject to a baseband filter 36 band limiting the transmission of data (for example by metering the symbol values appropriately). The output of the baseband filter 36 may then be received by digital-to-analog converter 38 for conversion to analog I and Q values.
[0053] These phase values from the digital-to-analog converter 38 are received by a mixer 40 multiplying these values by appropriate quadrature carriers produced by a carrier oscillator 42 according to standard modulation techniques. The vector sum of the modulated phase values is then provided to an IF (intermediate frequency) filter 44 removing the out-of-band signal and then up-converted at up-converter 46 by a phase-locked, up-convening signal also from the carrier oscillator 42 (of different frequency than that provided to mixer 40 ). The output of the up-converter 46 is amplified by amplifier 48 and transmitted over antenna 50 .
[0054] The transceivers 24 may also receive a modulated signal through the antenna 50 . This signal is amplified by amplifier 52 and provided to down-converter 54 receiving a down converting signal from carrier oscillator 57 (possibly the same oscillator structure used for oscillator 42 ). The oscillator 57 must be closely phase (and frequency) locked to the incoming signal for phase detection and thus may employ phase and frequency lock circuit naturally providing a carrier frequency output signal which will be used as described below.
[0055] The output of down-converter 54 is received by IF filter 56 removing out-of-band signals and then demodulated by demodulator 58 receiving a quadrature demodulation signal from carrier oscillator 57 (typically a different frequency than that provided to the down converter 54 ). The output of the demodulator 58 is received by an analog-to-digital converter 60 (for example, a threshold detector) providing digital I and Q signals to a symbol decoder 62 . The symbol decoder 62 matching the phase of the digital and Q signals per FIG. 7 then provides network data 63 to the processor 26 .
[0056] The described circuitry of the transceiver 24 may be generally divided into an analog section 64 and a digital section 66 . The analog section 64 holds the mixer 40 , oscillators 42 and 57 , the up converter 46 and down converter 54 , IF filters 44 and 56 , the demodulator 58 , and amplifiers 48 and 52 . The digital section 66 holds the symbol encoder 32 , the symbol decoder 62 , and the baseband filter 36 . Digital-to-analog converter 38 and analog-to-digital converter 60 form bridges between the analog section 64 and the digital section 66 .
[0057] Analog circuitry deals generally with continuous voltage and current ranges as understood in the art. Generally, the signals manipulated by the analog section 64 will vary continuously and slightly with slight changes in values of the analog components. Further minor changes in the signals in one section of the analog circuitry will cause additional changes in those signals in later sections of the analog circuitry as a result of the continuous functions implemented by typical analog circuitry. Within normal manufacturing tolerances and the tolerances imposed by standards such as IEEE 802.11, measurable differences in the resulting transmitted signal will be produced in the analog sections of different transceivers 24 for identical digital signals being modulated by different network cards. These differences manifest themselves as, for example, phase and amplitude variations that provide for the radiometric fingerprint used by the present invention.
[0058] Digital circuitry deals generally with discontinuous voltages providing discrete binary levels. For this reason, minor variations in the component values within normal manufacturing tolerances and the requirements of standards such as IEEE 8802.11 do not provide significant differences in the digital signals conveyed by the digital section 66 . Further, minor changes in the digital signal in one part of the digital circuitry will normally not be propagated through the digital circuitry.
[0059] Referring still to FIG. 2 , the transceiver 24 , and in particular the receiver portion of the transceiver 24 in the base stations 16 only, is modified to measure modulation parameters of the received signals by the addition of a monitoring block 70 . The monitoring block 70 captures naturally occurring signals in the analog section 64 of the receiver and digitizes them as radiometric information 71 , sending them to the processor 26 . Because the monitoring block 70 may make use of circuitry already present in the receiver, the monitoring block represents a relatively minor modification of the transceiver 24 of the base station 16 and may be readily implemented. Further, this modification is not required of the transceivers 24 of the mobile devices 12 allowing the present invention to scale well with additional users.
[0060] The monitoring block 70 may first capture frequency data 59 from the demodulation oscillator 57 and is phase locked to the frequency of the incoming signal from antenna 50 . This frequency data 59 characterizes minor frequency shifts in the carrier signal of the received signal. In addition, the monitoring block 70 may receive one or more of the raw I and Q phase values per symbol from the demodulator 58 to detect minor variations in phase and amplitude of the carrier before digitization by the analog-to-digital converter 60 . This radiometric information 71 from the monitoring block 70 is digitized, and provided to the processor 26 to be conveyed in the base stations by a network card 72 to the server 20 .
[0061] Referring now to FIG. 3 , the server 20 may include a network interface card 74 connecting it to the carrier medium 18 for receiving network data 63 and radiometric data 71 . The network interface card 74 may communicate with a microprocessor 76 , the latter of which connects via an internal bus with an electronic memory 78 , for example, composed of hard disk and solid-state memory elements. The memory 78 may hold a network data authentication program 80 (employing network data authenticators) and a radiometric identification program 82 (employing modulation domain data) as will be described and which operate jointly to ensure network security. The memory 78 may also include NDA (network data authenticator) table 84 holding passwords or secure keys of the type known in the art and one or more radiometric identification tables 86 holding radiometric templates used for radiometric comparison as will be described.
Secure Operation of the Network
Commissioning a Mobile Device
[0062] Referring now to FIGS. 1, 3 and 4 , the authentication program 80 and radiometric identification program 82 may work together as indicated by process block 90 to commission a new mobile device 12 . This process involves assigning a network data authenticator (e.g. a password or encryption key) to the user of the mobile devices 12 as will be required for entry onto the network 22 . This network data authenticator may be assigned by a network administrator or may be generated in part by the user according to well-known techniques. The resulting authenticator is then stored in the NDA table 84 providing a “white list” of authorized network users. This authentication process may accept or transmit the authenticator data over the network itself or may use a more secure or different channel including but not limited to person-to-person transfer, mail or voice telephone communication.
[0063] At process block 92 , the particular mobile device 12 being commissioned is operated for a period of time either in a controlled environment or during an initial login by the user required to exchange authenticator data. During this operation, radiometric data is collected from transmissions from the mobile device 12 . This radiometric data may be collected by monitoring of arbitrary transmissions from the mobile device 12 or may use a special teaching transmission set intended to expose various modulation domain properties.
[0064] Referring momentarily to FIG. 6 , modulation domain properties are generally those that make measurements of modulated qualities of the radiowave including, for example, those related to the frequency or phase. Many such measurements require modulation circuitry for detection and are not apparent in conventional time domain monitoring tools such as, for example, oscilloscopes. In a preferred embodiment of the invention, the radiometric data collected may include any of the modulation domain information provided in the following Table I.
[0000]
TABLE I
Radiometric Data Type
Short description
Symbol phase error
The angle between the ideal and measured
phasors
Average (peak) phase error
The average (or peak) value of symbol
phase errors within a single frame
Symbol magnitude error
The difference in the scalar magnitude
between the ideal and measured phasors
Average (peak) magnitude
The average (or peak) value of symbol
error
magnitude errors within a single frame
Symbol error vector
The magnitude of the vector difference
magnitude
between the measured and ideal phasors
Average (peak) error vector
The average (or peak) magnitude of the
magnitude
vector difference between measured and
ideal phasors of a frame
Frame I/Q origin offset
The distance between the constellation
origin (0, 0) and the average of measured
I/Q values of a frame
Frame frequency error
The difference between ideal and observed
carrier frequencies
Frame SYNC correlation
Normalized cross correlation of the
observed and the ideal SYNC preambles.
This is the SYNC correlation of a frame.
The larger the value, the higher the
modulation quality.
[0065] Each of these radiometric quantities may be derived from the analog section 64 used to convert digital data into transmittable radio signals by modulation, filtering, and up or down converting. These measurements may be distinguished from measurements such as signal transients, which are time domain measurements. The modulation domain outputs are characteristics of the radio transmitter and largely indifferent to the underlying data being transmitted or the network protocol.
[0066] Referring again to FIG. 6 , these different radiometric measurements may be further explained by considering the point 34 a as a point defined by the tip of an ideal phasor (vector) 94 leading from the origin 96 of the constellation diagram and representing the de-modulated phase of the transmitted signal. This ideal vector 94 shown, represents a perfectly modulated quadrature carrier having positive I and positive Q phases. It will be understood that similar ideal vectors 94 exist for each of the points 34 b - d.
[0067] As a signal is received by the transceiver 24 , an actual vector 102 may be measured representing an actual measured point 34 a ′ of the transmitted signal. This vector 102 may be extracted before the analog-to-digital converter 60 by the monitoring block 70 and deviates from the ideal vector 94 defined by point 34 a to be defined instead by a point 34 a ′ that nevertheless remains within an acceptable boundary 100 for the particular modulation standard (for example 802.11). This actual vector 102 will have a different length from vector 94 and thus can be used to generate a scalar magnitude difference 104 with respect to ideal vector 94 (being their difference in length). This magnitude difference 104 is the symbol magnitude error described above and may be used also to calculate the average (peak) magnitude errors described above.
[0068] A difference vector 106 can also be defined between point 34 a and 34 a ′. The magnitude (lanes) of this vector 106 provides the symbol error vector magnitude described above.
[0069] Vectors 94 and 102 have an angular phase difference 108 . This angular phase difference 108 provides the symbol phase error and the average (peak) phase errors described above.
[0070] It will be understood that similar metrics can be derived for the other quadrants of the constellation and used for the average or peak measurements.
[0071] When multiple actual points 34 ′ are averaged (in an average that includes equal numbers of symbols from each quadrant) they provide an average value 110 offset from the origin by an amount 112 . This is the frame I/Q origin offset.
[0072] The frame frequency error is the difference between the carrier frequency and the ideal carrier frequency described with respect to oscillator 57 above and extractable from the phase frequency lock circuitry used in the receiver.
[0073] The frame SYNC correlation correlates an ideal frame SYNC signal with that actually detected and serves as a measurement of modulation quality. Normally each of these last three errors will be evaluated over multiple bits in a given transmission frame.
[0074] Referring again to FIGS. 1, 3 and 4 , after radiometric information has been collected for the mobile device 12 to be commissioned, the collected radiometric information is stored as a radiometric template associated with a particular mobile device 12 and a network data authenticator (e.g., password) as indicated by process block 114 .
[0075] In one embodiment, a single copy of these radiometric templates is stored in the radiometric identification tables 86 described above at the server 20 to be shared by both base stations 16 . Alternatively, each base station 16 may provide its own radiometric identification table 86 reflecting the coloring of the modulation data of received signals as affected by the receiver of that base station 16 . In this case, the commissioning process requires sequential data collection at each of the base stations 16 for the purpose of generating the radiometric templates. Alternatively, the receiver path of each base station 16 may be pre-characterized allowing radiometric data collected by a single base station 16 to be modified for use by the individual base stations 16 to create base station unique radiometric templates.
Authentication of a Commissioned Wireless Device
[0076] Referring now to FIGS. 1, 3 and 5 , after the mobile devices 12 have been commissioned and radiometric templates established for their transceivers 24 , the authentication program 80 and radiometric identification program 82 may work in conjunction to permit mobile devices 12 to log on to the network 22 and be authenticated for communication with the network 22 . The beginning of this authentication process, as indicated by process block 116 , uses the network data authenticators described above, such as a password or secure key or network fob or MAC address. This step relies on the transfer of digital data conventionally conveyed by wireless communication. In this authentication, the user provides an identification that is compared against the identifications in table 84 and used to identify the appropriate radiometric templates from table 66 associated with the user who is logging in.
[0077] At process block 118 , radiometric data from the user logging in is collected either through a special authorization sequence executed by the mobile device 12 as prompted by the base stations 16 or by simply monitoring the communication of frames during process block 114 .
[0078] At process block 120 , the collected radiometric data is compared with the radiometric templates stored in table 86 (collected per process block 114 in the commissioning process) to detect possible impostors.
[0079] Referring now to FIGS. 1, 3, 5 and 7 , this comparison process may use a variety of techniques and the present invention is not limited to any particular one of these comparison techniques. In the preferred embodiments, the comparison is made through individual ones or combinations of the known comparison techniques or their equivalents including: k-nearest-neighbor, support vector machines, decision trees, neural networks, Bayesian-based algorithms, polynomial classifiers, regression fitting, hidden Markov models, Gaussian mixture models, radial basis functions, classifier boosting, classifier ensembles The techniques of a “k-nearest neighbor” comparison or a “system vector machine” (SVM) comparison are described briefly below.
[0080] In the k-nearest neighbor approach, the radiometric templates stored in table 86 represent individual point 122 in an n-dimensional space where n equals the number of different radiometric parameters from Table I that will be used in a comparison process and which are embodied in the radiometric templates. In a preferred version of this embodiment of the present invention, frame frequency error, SYNC correlation, frame I/Q offset, frame magnitude error, and frame phasor error are used in that order of importance. It will be understood that variations in these subsets are also possible.
[0081] Each template point 122 , in this case, is constructed by monitoring frames during process block 92 of the commissioning process, described above, and discarding half of the collected frames for each parameter furthest from their average in the n-dimensional space. The remaining frames are then averaged to produce a single n-dimensional point 122 stored in table 86 and indexed to the user identification obtained in process block 116 .
[0082] The comparison of process block 120 , in this case, analyzes the distance 124 from an average of the collected data 126 at process block 118 to the template point 122 .
[0083] If that distance 124 is greater than a certain amount, then at decision block 128 , the authorization of the mobile device 12 is rejected and the program proceeds to process block 130 . At process block 130 , the program may generate an output signal indicating a mismatched output to a system operator or a log entry. As noted, optionally at process block 134 , the authorization of the mobile device 12 may be revoked either temporarily or until a reauthorization process per FIG. 5 maybe completed again. This revocation may be effected by removing or flagging the data in table 84 .
[0084] On the other hand, if the average of the collected data 126 is within a predetermined distance of the indicated template point 122 , then network connection is authorized and the program proceeds to process block 132 allowing the mobile device 12 access to the network 22 .
[0085] Referring to FIGS. 1, 3, 5 and 8 , in a second embodiment, the comparison process of process block 120 uses a support vector machine algorithm. In this embodiment, data points 131 , obtained in process block 114 , are collected into clusters identified to a particular mobile device 12 according to table 84 and stored as the radiometric templates. Data points 126 collected during the authentication process are compared to the cluster using a support vector machine algorithm which provides a confidence value indicating whether the collected data point 126 belongs to that cluster. This confidence value may be used like the threshold value above to determine the presence of an impostor if the confidence value is below a certain value. Again, depending on the confidence value at decision block 128 , the program will branch to process block 130 or 132 .
[0086] It will be understood that the sensitivity of the present invention may be varied by simply adjusting the threshold or confidence levels of the comparison process of process block 120 to either increase or decrease the security of the network. The present invention is intended to work together with an identifier, for example, secure key or password and to provide an augmentation of security or to increase security of an otherwise insecure system.
[0087] Referring now to FIGS. 1, 3 and 9 , a trade-off between high levels of security and high levels of false negatives in the system may be implemented by allowing the evolution of the template stored in table 86 over a pre-established time period, for example, a given session being the time between logging in and logging out. In such a system, an initial template point 140 may be replaced with a later template point 141 so that the template value may evolve over time. Restraints on this process may be had by limiting the increment of evolution 142 per given time or session and providing a limit on the maximum evolution 144 until reauthorization. It will be understood that points 140 and 141 are points in n-dimensional space similar to that described with respect to FIGS. 8 and 9 .
[0088] As described, the program for radiometric identification of the present invention is located in a server 20 shared among base stations 16 ; however, it will be recognized that the base stations 16 themselves may provide for this functionality and, in fact, there is no particular significance to how the authentication program is distributed among hardware components, this being a matter of engineering choice to the extent that it does not affect security
EXAMPLE I
[0089] The present invention was applied to differentiating among 138 identical IEEE 802.11 network interface cards and provided accuracy in excess of 99.99%. The optimal feature set for differentiation of network interface cards in order of positive effect on performance for SVM comparison was (1) frequency error, (2) SYNC correlation, (3) I/Q offset, (4) magnitude, and phase errors. For k-nearest neighbor comparison, the optimal feature set for differentiation of network interface cards in order of positive effect on performance was: (1) frequency error, (2) SYNC correlation, (3) I/Q offset. Interestingly, the set of network cards most susceptible to false rejections with SVM, were different from the set of network cards most susceptible to false rejections with k-nearest neighbor, so improved performance may be obtained by a combination of approaches to reduce false rejection rates. Details of the methodology of this experiment are provided in the attached appendix.
[0090] The present invention may also find use in identifying illegal transmitters based on fingerprints extracted from their illegal transmissions.
Alternative Embodiments
[0091] As noted, the present invention may base device identity of some notion of difference between the ideal and the observed phasor trajectories. The present inventors have determined that good performance is possible when the trajectory is represented by a single measurement per symbol. This approach has the advantage of minimizing the necessary modifications to the existing hardware designs.
[0092] However, in an alternative embodiment, performance can be improved further by collecting more fine-grained information about the phasor trajectory (this is a mathematical fact; informally, the more data the less chance of a mistake). Such optimization may require a more capable receiver but will allow to capture each symbol's signal state as a curve rather than a point, thus allowing use of additional metrics of deviation from the ideal signal. For example, in addition to analyses described here, curves could be represented using splines and wavelets, which are well-known in the art. Such mathematical entities can be defined as a set of numeric parameters. The difference in the corresponding parameters between the ideal and observed signal could serve as a basis for a new dimension of analysis.
[0093] In a further embodiment, further optimization can be derived from the fact that modulation fidelity of adjacent symbols is not independent. The correlation can be due to environmental factors as well as the fundamental properties of the transmitter hardware. In either case correlations between modulation errors of groups of symbols can be used to detect outliers or generate new ways to compare signals.
[0094] Analog transmissions of the same digital data by different transmitters differ, in part, due to relative reference-level differences between them. For example, one transmitter may be biased toward positive carrier frequency offset, while another to a negative offset. This happen while neither of them is aware of the inaccuracy nor has reliable means of measuring it. A further embodiment may focus on measuring such inaccuracies at the base station. However, a natural extension to the scheme would be for a sufficiently capable base station to alter characteristics of its outgoing signals based on the intended receiver to determine the point at which the receiver is unable to demodulate the signal, and use this information as an additional dimension of transceiver's signature.
[0095] For example, a receiver that is biased toward positive carrier frequency offset will fail to demodulate a signal whose carrier frequency offset is higher than some critical number. This critical number will be even higher for another receiver with a negative carrier frequency bias. The transmitter can use the difference between these critical values as another way of differentiating the receivers. Similar technique can be applied to other modulation accuracy metrics discussed here.
Advantages Over Prior Art
[0096] The main challenge of transmitter identification based on characteristics of its transmissions is dealing with noise and distortion. Performing signature extraction and comparison in the modulation domain is superior to prior approaches because it leverages existing signal processing facilities whose purpose is, essentially, to de-noise the signal for the purposes of data recovery.
[0097] For example, approaches based on signal transients during power-on ramps (waveform domain techniques) are necessarily performed at the lowest layer of measurement because transients are unstructured and it is difficult to tell which properties of the transient are due to the transmitter's hardware and which are due to noise. In contrast, the present invention leverages structural knowledge of the modulation scheme being used to separate intentional (due to transmitter) and unintentional (due to noise) features of the signal. In a sense, this approach operates at the last analog stage of the communication process where continuous (I/Q) values falling in certain ranges are mapped to discrete values, as specified by the modulation format.
[0098] The theoretical downside of this approach is that it requires knowledge of the modulation scheme being used (unlike transient-based approaches). However, this is a nonissue in the context of network security, where all necessary information is always available.
[0099] Moreover, knowledge of the signal's structure allows the invention to collect at least as many measurements as there are symbols in a signal (and more in practice), further improving resilience to noise since there is enough data to perform outlier removal, for example, by considering the middle quartile of measurements. In contrast, there is only one short transient per transmission, meaning that misclassifications need to be averaged out across entire transmissions, not symbols.
[0100] It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein, but include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the following claims. | A network security system for wireless devices derives a fingerprint from the modulation imperfections of the analog circuitry of the wireless transceivers. These fingerprints may be compared to templates obtained when the wireless devices are initially commissioned in a secure setting and used to augment passwords or other security tools in detecting intruders on the network. | 8 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This invention is an improvement on the circuit of application Ser. No. 079,072 filed Sept. 26, 1979 entitled "Circuit and Apparatus for Controlling A Water Softener" in which the inventors are Stanley F. Rak and Donald P. DeVale.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates in general to water softeners and in particular to a novel circuit for a water softener.
2. Description of the Prior Art
Probes to indicate resistance changes in ion exchange material in water softeners are shown in issued U.S. Pat. No. 3,373,351 to Stanley F. Rak and resistance sensing probe systems are disclosed in U.S. Pat. No. 3,159,573 to H. D. Ritchie. These systems of the prior art are designed to immediately rejuvenate and recondition the ion exchange resin which can occur at times when it is desirable that water be supplied from the system.
Thus, in the prior art various systems have been known for causing regeneration of the resin bed of a water softener such as manual regeneration, or regeneration based on a control device which initiates regeneration at fixed given intervals of time. The problem with these two systems is that the regeneration may occur before it is needed or, alternatively, it may not occur quickly enough and the water may not be properly softened toward the end of the interval. A third system for water softening is based on a control which causes water softening when the condition of the output water and/or the resin bed indicates that regeneration should occur. The problem with this type of system is that regeneration can occur at periods when there is a high demand for soft water and during regeneration generally the soft water is not available and the unsoftened is bypassed by the water softener.
Other known systems have utilized a pair of water softening or water conditioning apparatuses each having separate control units and in which the units are interconnected with interlocking devices to prevent both units from being in the regenerating condition at the same time and an example of this type of system is disclosed in U.S. Pat. No. 3,675,041. This type of system is expensive in that two complete systems are required. Copending application Ser. No. 079,072 referenced above discloses an improved system.
SUMMARY OF THE INVENTION
The present invention relates to a water softener system and control wherein a resistance sensing probe including two pairs of spaced electrodes are mounted in the ion exchange bed of the granular material carrying water softening ions to detect the condition of the ion exchange bed and when the condition is such that rejuvenation should occur a control circuit is placed in a latched condition to command rejuvenation. The control remains in the latched condition and rejuvenation does not occur until a preset time so that normal usage of water is not interrupted during the daytime. After the rejuvenation has occured the circuit is reset ready to again detect the condition which requires rejuvenation. In this invention a bridge circuit with reference and sensing electrodes is used and the bridge circuit provides a signal to the control circuit.
Other objects, features and advantages of the invention will be readily apparent from the following description of certain preferred embodiments thereof taken in conjunction with the accompanying drawings although variations and modifications may be effected without departing from the spirit and scope of the novel concepts of the disclosure and in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a water softening system with certain portions cut away; and
FIG. 2 is an electrical schematic of the control system of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a water conditioning or softening apparatus or device generally indicated as 10 which has a control unit 11.
The water conditioning apparatus 10 includes a tank 12 containing a bed 13 of suitable ion exchange resin. So as to provide water to the tank, a water supply line 14 is connected to the valve housing 16 which passes the water through a pipe 17 which extends to the tank 12. The water passes down through the bed 13 and is removed by a pipe 18 through the valve housing 16 to a line 19 which supplies the softened water to the water system. A conduit 21 extends from the valve control to a brine tank 22 which contains salt for forming the brine. A drain conduit 23 is also connected to the valve housing 16 and is connected to a suitable drain.
The control valve structure 16 may be on conventional type as, for example, described in U.S. Pat. No. 3,926,071 and may be either the two or five cycle type which systems are well known to those skilled in the art. The recycling control 24 controls the recycling and might be, for example, such as described in U.S. Pat. No. 3,926,071 and in the present invention comprises an electronic control 26 which assures that the recycling does not occur except at predetermined times as, for example, between 2:00 and 6:00 A.M. so that rejuvenation does not occur at other times when is desired to obtain softened water.
The electronic control 26 of the present invention detects when rejuvenation of the resin bed should occur by the use of two pairs of vertically mounted electrodes R s and R r which are mounted in a suitable holding probe unit 27 which extends down into the tank 12 and are vertically spaced relative to each other for detecting the resistivity so as to determine when rejuvenation should occur for energizing a latching circuit. However, in the present invention rejuvenation of the resin bed is not immediately commenced when the condition is detected which indicates rejuvenation should occur, but rather the circuit of the invention remains in a latched condition until a time which has been preset at which time rejuvenation will occur and the detecting circuit will be reset after rejuvenation until rejuvenation is again required. In other words, in the present invention as soon as the resistivity difference between the detecting electrodes R s and R r is such that rejuvenation should occur then the circuit of the invention is placed in a latched condition and will remain in such latched condition until the resin is rejuvenated. However, the rejuvenation will not be initiated until the preset period as, for example, between 2:00 to 6:00 A.M. so that rejuvenation doesn't occur at those periods when there is a demand for softened water.
A pair of 60 cycle input power terminals 27 and 28 are connected to the primary 29 of a transformer T1 which has secondary windings 31 and 32. A bridge circuit 33 includes a pair of resistors R1 and R2 and a reference cell R r and a sensing cell R s connected in a bridge configuration. The junction point between resistors R1 and R2 is connected to one end of the secondary 32 and the other end of the secondary 32 is connected to the junction point between the sensing and reference cells R s and R r .
A comparator A1 has its plus input V1 connected to lead 36 which is connected to the junction point between resistors R s and R 2 . The negative input to the comparator A1 is designated V2 and is connected by lead 34 to the junction point between resistor R1 and the impedance R r of the bridge 33. The output of the comparator A1 designated V3 is connected through a diode D3 to a resistor R4 which is connected to the plus input of a second comparator A2. The other input to the comparator A2 designated V6 is connected to lead 41 which is connected to the output of a voltage regulator 58. A resistor R5 is connected between the output of the comparator A2 and the plus input V4. A third comparator A3 has its plus input V5 connected to the output of the comparator A2. The negative input to the comparator A3 is connected to lead 41. The output of the comparator A3 is connected to a resistor R8 and then through a reset switch S2 to the junction point between the diode D3 and the resistor R4. One end of the secondary 32 is connected by lead 39 to an output of the voltage regulator 58. An extra regeneration switch S1 is connected between lead 38 and the junction point between diode D3 and resistor R4. A capacitor C1 and resistor R6 are connected in parallel with the switch S1 as shown. A capacitor C2 is connected between lead 38 and lead 37 which is also connected to a third input of the regulator 58. A relay coil RY1 is connected from lead 60 to a resistor R7 which has its other side connected to the plus input of the comparator A3. A diode D4 is connected in parallel with the relay coil RY1. A diode D2 is connected from one side of the secondary 31 which connects to lead 37 and its other side is connected to lead 60. A diode D1 is connected from lead 37 to a resistor R3 which has its other side connected to the output of the comparator A1. A clock motor 51 receives power on input terminals 56 and 57 and has an output shaft which carries cams 53 and 43. The cam 53 has a high portion 54 which is engageable with a switch S2 to open it for resetting the circuit after regeneration has occurred. The cam 43 has a high portion 40 which engages a switch 44 to close it so it makes contact with a terminal 46. Contact 46 is connected to switch 47 which is controlled by the relay RY1 such that when the relay RY1 is energized and switch 47 is closed by the armature 49 of the relay so that lead 48 will be connected to contact 46. The lead 48 connects to a recycling control 42 such that when switches 47 and 44 are closed, regeneration of the ion exchange bed of the water softener will occur.
When the bridge circuit 33 is unbalanced such that R s is greater than R r the bridge will be unbalanced to produce an AC voltage V1 which is applied to the comparator A1. The voltage V1 will be in phase with the voltage V3 at the output of the comparator. The comparator A1 with a regulated voltage V2 applied and a variable voltage V1 applied due to variation in the resistance R s such that when V1 is less than V2 will cause the positive half cycle of the voltage V3 to charge the capacitor C1 through resistor R3 and the diode D3.
The comparator A2 which receives the applied voltage V4 which is essentially the voltage across the capacitor C1 as well as the voltage V6 which is a regulated voltage of approximately 5 volts such that when voltage V4 is greater than voltage V6 the relay RY7 will not be energized.
The comparator A3 which receives an applied voltage of V5 which is high about 14 volts when the relay is not energized as well as the voltage V6 which is from the regulator 58 and which is approximately 5 volts. When V5 is greater than V6, no clamping action occurs at V4 which is the input to the comparator A2.
The diode D2 and the capacitor C2 provide rectification and filtering.
When the sensor resistance R s increases, the bridge circuit 33 becomes unbalanced such that the positive half cycles of voltage V1 exceed the set level voltage V2 and the comparator A1 will clamp voltage V3 during the positive half cycles of V1. Since V1 and V3 are in phase, and the positive half cycles of voltage V3 charge the capacitor C1 through diode D3, then the voltage V3 will be clamped by the comparator A1 during the positive half cycles of V3 which would normally keep capacitor C1 charged.
The voltage across the capacitor C1 (V4) will start to decay since C1 is discharging through the resistor R6 to ground and resistor R4 through the input of the comparator A2. When the voltage V4 becomes less than the voltage V6 the comparator A2 will clamp the relay RY1 to ground (V5 equals 0) thereby energizing the relay.
At this time, V5 will be lower than voltage V6 and comparator A3 will clamp C1 to ground thereby maintaining the relay in the energized position. The relay closes switch 47 and the clock motor 51 and portion 40 of cam 43 will close switch 44 at the appropriate time to provide regeneration of the ion bed. The cam 53 has a high point 54 which will open switch S2 to reset the circuit so that the relay RY1 will be de-energized at a time when R s equals R r by momentarily opening switch S2.
The discharge time of capacitor C1 is set by resistor R6 to a value of about 30 seconds so as to prevent premature or false lockups.
It is to be noted that if the bridge 33 is unbalanced in the reverse direction such that R r is greater than R s nothing happens because the voltages V1 and V2 will then be out of phase.
Resistor R8 protects comparator A3 from a high in-rush current but is low enough in value to maintain the voltage V4 below the voltage V6.
In a particular circuit construction according to the invention, the components had the following values:
______________________________________Reference Description______________________________________T1 120V/12V/2.5VR1 200 OHM 1% M.F.R2 215 OHM 1% M.F.R3 4.7K 5% C.F.R4 4.7K 5% C.F.R5 10M 5% C.F.R6 1M 5% C.F.R7 680 OHM 5% C.F.R8 4.7K 5% C.F.Rr Probe Reference CellRs Probe Sensing CellC1 22 μfd 35VC2 100 μfd 25VD1 1N4001D2 1N4001D3 1N4001D4 1N4001A1 1/4 CA 339GA2 1/4 CA 339GA3 1/4 CA 339GVr 78L05A Voltage RegulatorS1 SPST (Extra Regeneration)S2 SPST (Reset)RY1 Electrol R7310-1 Relay______________________________________
The circuit of the invention is simpler than the circuit of copending application Ser. No. 079,072 and a reference potentiometer is not required for establishing a reference voltage for the comparator A1. In the present invention, the reference is applied from lead 36 from the bridge circuit 33.
Although the invention has been described with respect to preferred embodiments, it is not to be so limited as changes and modifications can be made which are within the full intended scope of the invention as defined by the appended claims. | A novel electronic control circuit which utilizes an improved and greatly simplified arrangement for producing the reference voltage and which includes a probe which includes two pairs of spaced electrodes which are connected in a bridge circuit so that both a reference signal and a control signal is obtained for closing an energizing circuit and latch it until it is time for regeneration and in which the regeneration will occur only at preset times so as to not interfere with normal use. | 1 |
[0001] This application is a divisional of application Ser. No. 10/972,592, filed Oct. 25, 2004, which is a continuation-in-part of application Ser. No. 10/162,965, filed Jun. 5, 2002, now U.S. Pat. No. 6,916,414, which is a continuation-in-part of application Ser. No. 10/033,554, filed Oct. 19, 2001, now abandoned, which is a continuation-in-part of application Ser. No. 09/968,023, filed Oct. 2, 2001, now abandoned, each of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to the anodization of aluminum and aluminum alloy workpieces to provide coatings comprising titanium and/or zirconium oxides, and the subsequent coating of the anodized workpiece with coatings, e.g. non-stick coatings comprising polytetrafluoroethylene (hereinafter referred to as “PTFE”) or silicone. The invention is especially useful for forming longer life PTFE or silicone non-stick coatings on aluminum substrates.
BACKGROUND OF THE INVENTION
[0003] Aluminum and its alloys have found a variety of industrial applications. However, because of the reactivity of aluminum and its alloys, and their tendency toward corrosion and environmental degradation, it is necessary to provide the exposed surfaces of these metals with an adequate corrosion-resistant and protective coating. Further, such coatings should resist abrasion so that the coatings remain intact during use, where the metal article may be subjected to repeated contact with other surfaces, particulate matter and the like. Where the appearance of articles fabricated is considered important, the protective coating applied thereto should additionally be uniform and decorative.
[0004] In order to provide an effective and permanent protective coating on aluminum and its alloys, such metals have been anodized in a variety of electrolyte solutions, such as sulfuric acid, oxalic acid and chromic acid, which produce an alumina coating on the substrate. While anodization of aluminum and its alloys is capable of forming a more effective coating than painting or enameling, the resulting coated metals have still not been entirely satisfactory for their intended uses. The coatings frequently lack one or more of the desired degree of flexibility, hardness, smoothness, durability, adherence, heat resistance, resistance to acid and alkali attack, corrosion resistance, and/or imperviousness required to meet the most demanding needs of industry.
[0005] Heat resistance is a very desirable feature of a protective coating for aluminum and its alloys. In the cookware industry, for instance, aluminum is a material of choice due to its light weight and rapid heat conduction properties. However, bare aluminum is subject to corrosion and discoloration, particularly when exposed to ordinary food acids such as lemon juice and vinegar, as well as alkali, such as dishwasher soap. PTFE or silicone containing paints are a common heat resistant coating for aluminum, which provide resistance to corrosion, discoloration and give a “non-stick” cooking surface. However, PTFE containing paints have the drawback of insufficient adherence to the substrate to resist peeling when subjected to abrasion. To improve adherence of PTFE coatings, manufacturers generally must provide three coats of paint on the aluminum substrate: a primer, a midlayer and finally a topcoat containing PTFE. This three-step process is costly and does not solve the problem of insufficient abrasion resistance and the problem of subsequent corrosion of the underlying aluminum when the protective paint, in particular the PTFE coating wears off. Likewise, the non-stick silicone coatings eventually wear away and the underlying aluminum is exposed to acid, alkali and corrosive attack.
[0006] To improve toughness and abrasion resistance, it is known in the cookware industry to anodize aluminum to deposit a coating of aluminum oxide, using a strongly acidic bath (pH<1), and to thereafter apply a non-stick seal coating containing PTFE. A drawback of this method is the nature of the anodized coating produced. The aluminum oxide coating is not as impervious to acid and alkali as oxides of titanium and/or zirconium. Articles coated using this known process lose their PTFE coatings with repeated exposure to typical dishwasher cycles of hot water and alkaline cleaning agents.
[0007] So called, hard anodizing aluminum results in a harder coating of aluminum oxide, deposited by anodic coating at pH<1 and temperatures of less than 3° C., which generates an alpha phase alumina crystalline structure that still lacks sufficient resistance to corrosion and alkali attack.
[0008] In another known attempt to provide a corrosion-, heat- and abrasion-resistant coating to support adherence of PTFE to aluminum, an aluminum alloy was thermally sprayed with titanium dioxide to generate a film that is physically adhered to the underlying aluminum. This film had some adherence to the aluminum article, but showed voids in the coating that are undesirable.
[0009] Thus, there is still considerable need to develop alternative anodization processes for aluminum and its alloys which do not have any of the aforementioned shortcomings and yet still furnish adherent, corrosion-, heat- and abrasion-resistant protective coatings of high quality and pleasing appearance.
SUMMARY OF THE INVENTION
[0010] Applicant has developed a process whereby articles of aluminum or aluminum alloy may be rapidly anodized to form protective coatings that are resistant to corrosion and abrasion using anodizing solutions containing complex fluorides and/or complex oxyfluorides. The anodizing solution is aqueous and comprises one or more components selected from water-soluble and water-dispersible complex fluorides and oxyfluorides of elements selected from the group consisting of Ti, Zr, Hf, Sn, Al, Ge and B. The use of the term “solution” herein is not meant to imply that every component present is necessarily fully dissolved and/or dispersed. Some anodizing solutions of the invention comprise a precipitate or develop a small amount of sludge in the bath during use, which does not adversely affect performance. In especially preferred embodiments of the invention, the anodizing solution comprises one or more components selected from the group consisting of the following:
a) water-soluble and/or water-dispersible phosphorus oxysalts, wherein the phosphorus concentration in the anodizing solution is at least 0.01M; b) water-soluble and/or water-dispersible complex fluorides of elements selected from the group consisting of Ti, Zr, Hf, Sn, Al, Ge and B; c) water-soluble and/or water-dispersible zirconium oxysalts; d) water-soluble and/or water-dispersible vanadium oxysalts; e) water-soluble and/or water-dispersible titanium oxysalts; f) water-soluble and/or water-dispersible alkali metal fluorides; g) water-soluble and/or water-dispersible niobium salts; h) water-soluble and/or water-dispersible molybdenum salts; i) water-soluble and/or water-dispersible manganese salts; j) water-soluble and/or water-dispersible tungsten salts; and k) water-soluble and/or water-dispersible alkali metal hydroxides.
[0022] In one embodiment of the invention, niobium, molybdenum, manganese, and/or tungsten salts are co-deposited in a ceramic oxide film of zirconium and/or titanium.
[0023] The method of the invention comprises providing a cathode in contact with the anodizing solution, placing the article as an anode in the anodizing solution, and passing a current through the anodizing solution at a voltage and for a time effective to form the protective coating on the surface of the article. Pulsed direct current or alternating current is generally preferred. Non-pulsed direct current may also be used. When using pulsed current, the average voltage is preferably not more than 250 volts, more preferably, not more than 200 volts, or, most preferably, not more than 175 volts, depending on the composition of the anodizing solution selected. The peak voltage, when pulsed current is being used, is preferably not more than 600, most preferably 500 volts. In one embodiment, the peak voltage for pulsed current is not more than, in increasing order of preference 600, 575, 550, 525, 500 volts and independently not less than 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400 volts. When alternating current is being used, the voltage may range from about 200 to about 600 volts. In another alternating current embodiment, the voltage is, in increasing order of preference 600, 575, 550, 525, 500 volts and independently not less than 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400 volts. In the presence of phosphorus containing components, non-pulsed direct current, also known as straight direct current, may be used at voltages from about 200 to about 600 volts. The non-pulsed direct current desirably has a voltage of, in increasing order of preference 600, 575, 550, 525, 500 volts and independently not less than 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400 volts.
[0024] It is an object of the invention to provide a method of forming a protective coating on a surface of a metal article comprising aluminum or aluminum alloy, the method comprising: providing an anodizing solution comprised of water and one or more additional components selected from the group consisting of water-soluble complex fluorides, water-soluble complex oxyfluorides, water-dispersible complex fluorides, and water-dispersible complex oxyfluorides of elements selected from the group consisting of Ti, Zr, Hf, Sn, Al, Ge and B and mixtures thereof; providing a cathode in contact with the anodizing solution; placing a metal article comprising aluminum or aluminum alloy as an anode in the anodizing solution; passing a current between the anode and cathode through the anodizing solution for a time effective to form a first protective coating on the surface of the metal article; removing the metal article having a first protective coating from the anodizing solution and drying the article; and applying one or more layers of paint to the metal article having a first protective coating, at least one of the layers comprising PTFE or silicone, to form a second protective coating.
[0025] It is a further object of the invention to provide a method wherein the first protective coating comprises titanium dioxide and/or zirconium oxide. It is a yet further object of the invention to provide a method wherein the first protective coating is comprised of titanium dioxide and the current is direct current.
[0026] It is a further object of the invention to provide a method wherein the anodizing solution is maintained at a temperature of from 0° C. to 90° C. It is also a further object of the invention to provide a method wherein the current is pulsed direct current having an average voltage of not more than 200 volts. It is a further object of the invention to provide a method wherein the metal article is aluminum and the current is direct current or alternating current. It is a further object of the invention to provide a method wherein the current is pulsed direct current.
[0027] It is a further object of the invention to provide a method wherein the protective coating is formed at a rate of at least 1 micron thickness per minute.
[0028] It is a further object of the invention to provide a method wherein the second protective coating comprises a non-stick topcoat comprising PTFE or silicone and at least one additional paint layer between the topcoat and the first protective coating.
[0029] It is a further object of the invention to provide a method wherein the anodizing solution is prepared using a complex fluoride selected from the group consisting of H 2 TiF 6 , H 2 ZrF 6 , H 2 HfF 6 , H 2 SnF 6 , H 2 GeF 6 , H 3 AlF 6 , HBF 4 and salts and mixtures thereof and optionally comprises HF or a salt thereof
[0030] It is a further object of the invention to provide a method wherein the anodizing solution is additionally comprised of a phosphorus containing acid and/or salt, and/or a chelating agent. Preferably, the phosphorus containing acid and/or salt comprises one or more of a phosphoric acid, a phosphoric acid salt, a phosphorous acid and a phosphorous acid salt. It is a further object of the invention to provide a method wherein pH of the anodizing solution is adjusted using ammonia, an amine, an alkali metal hydroxide or a mixture thereof.
[0031] It is an object of the invention to provide a method of forming a protective coating on a surface of a metallic article comprised predominantly of aluminum, the method comprising: providing an anodizing solution comprised of water, a phosphorus containing acid and/or salt, and one or more additional components selected from the group consisting of water-soluble and water-dispersible complex fluorides and mixtures thereof, the fluorides comprising elements selected from the group consisting of Ti, Zr, and combinations thereof; providing a cathode in contact with the anodizing solution; placing a metallic article comprised predominantly of aluminum as an anode in the anodizing solution; passing a direct current or an alternating current between the anode and the cathode for a time effective to form a first protective coating on the surface of the metal article; removing the metal article having a first protective coating from the anodizing solution and drying the article; and applying one or more layers of paint to the metal article having a first protective coating, at least one of the layers comprising PTFE or silicone, to form a second protective coating.
[0032] It is a further object of the invention to provide a method wherein the anodizing solution is prepared using a complex fluoride comprising an anion comprising at least 4 fluorine atoms and at least one atom selected from the group consisting of Ti, Zr, and combinations thereof.
[0033] It is a further object of the invention to provide a method wherein the anodizing solution is prepared using a complex fluoride selected from the group consisting of H 2 TiF 6 , H 2 ZrF 6 , salts of H 2 TiF 6 , salts of H 2 ZrF 6 , and mixtures thereof.
[0034] It is a further object of the invention to provide a method wherein the complex fluoride is introduced into the anodizing solution at a concentration of at least 0.05M.
[0035] It is a further object of the invention to provide a method wherein the direct current has an average voltage of not more than 250 volts.
[0036] It is a further object of the invention to provide a method wherein the anodizing solution is additionally comprised of a chelating agent.
[0037] It is a further object of the invention to provide a method wherein the anodizing solution is comprised of at least one complex oxyfluoride prepared by combining at least one complex fluoride of at least one element selected from the group consisting of Ti, Zr, and at least one compound which is an oxide, hydroxide, carbonate or alkoxide of at least one element selected from the group consisting of Ti, Zr, Hf, Sn, B, Al and Ge.
[0038] It is a further object of the invention to provide a method wherein the anodizing solution has a pH of from about 2 to about 6.
[0039] It is an object of the invention to provide a method of forming a protective coating on an article having a metallic surface comprised of aluminum or aluminum alloy, the method comprising: providing an anodizing solution, the anodizing solution having been prepared by dissolving a water-soluble complex fluoride and/or oxyfluoride of an element selected from the group consisting of Ti, Zr, Hf, Sn, Ge, B and combinations thereof and an inorganic acid or salt thereof that contains phosphorus in water; providing a cathode in contact with the anodizing solution; placing an article comprising at least one metallic surface comprised of aluminum or aluminum alloy as an anode in the anodizing solution; passing a direct current or an alternating current between the anode and the cathode for a time effective to form a first protective coating on the at least one metallic surface; removing the article comprising at least one metallic surface having a first protective coating from the anodizing solution and drying the article; and applying one or more layers of paint to the first protective coating, at least one of the layers comprising PTFE or silicone, to form a second protective coating.
[0040] It is a further object of the invention to provide a method wherein pH of the anodizing solution is adjusted using ammonia, an amine, an alkali metal hydroxide or a mixture thereof.
[0041] It is a further object of the invention to provide a method wherein the current is pulsed direct current having an average voltage of not more than 150 volts.
[0042] It is a further object of the invention to provide a method wherein at least one compound which is an oxide, hydroxide, carbonate or alkoxide of at least one element selected from the group consisting of Ti, Zr, Hf, Sn, B, Al and Ge is additionally used to prepare the anodizing solution.
[0043] It is an object of the invention to provide a method of forming a protective coating on a surface of an article comprised of aluminum, the method comprising: providing an anodizing solution, the anodizing solution having been prepared by combining one or more water-soluble complex fluorides of titanium and/or zirconium or salts thereof, a phosphorus containing oxy acid and/or salt and optionally, an oxide, hydroxide, carbonate or alkoxide of zirconium; providing a cathode in contact with the anodizing solution; placing an article comprised of aluminum as an anode in the anodizing solution; and passing a direct current or an alternating current between the anode and the cathode for a time effective to form the protective coating on a surface of the article; removing the article having a first protective coating from the anodizing solution and drying the article; and applying one or more layers of paint to the article having a first protective coating, at least one of the layers comprising PTFE or silicone, to form a second protective coating.
[0044] It is a further object of the invention to provide a method wherein one or more of H 2 TiF 6 , salts of H 2 TiF 6 , H 2 ZrF 6 , and salts of H 2 ZrF 6 is used to prepare the anodizing solution. It is a further object of the invention to provide a method wherein zirconium basic carbonate is also used to prepare the anodizing solution. It is a further object of the invention to provide a method wherein the one or more water-soluble complex fluorides is a complex fluoride of titanium or zirconium and the current is direct current, pulsed or non-pulsed.
DETAILED DESCRIPTION OF THE INVENTION
[0045] Except in the claims and the operating examples, or where otherwise expressly indicated, all numerical quantities in this description indicating amounts of material or conditions of reaction and/or use are to be understood as modified by the word “about” in describing the scope of the invention. Practice within the numerical limits stated is generally preferred, however. Also, throughout the description, unless expressly stated to the contrary: percent, “parts of”, and ratio values are by weight or mass; the description of a group or class of materials as suitable or preferred for a given purpose in connection with the invention implies that mixtures of any two or more of the members of the group or class are equally suitable or preferred; description of constituents in chemical terms refers to the constituents at the time of addition to any combination specified in the description or of generation in situ within the composition by chemical reaction(s) between one or more newly added constituents and one or more constituents already present in the composition when the other constituents are added; specification of constituents in ionic form additionally implies the presence of sufficient counterions to produce electrical neutrality for the composition as a whole and for any substance added to the composition; any counterions thus implicitly specified preferably are selected from among other constituents explicitly specified in ionic form, to the extent possible; otherwise, such counterions may be freely selected, except for avoiding counterions that act adversely to an object of the invention, the term “paint” and its grammatical variations includes any more specialized types of protective exterior coatings that are also known as, for example, lacquer, electropaint, shellac, porcelain enamel, top coat, mid coat, base coat, color coat, and the like; the word “mole” means “gram mole”, and the word itself and all of its grammatical variations may be used for any chemical species defined by all of the types and numbers of atoms present in it, irrespective of whether the species is ionic, neutral, unstable, hypothetical or in fact a stable neutral substance with well defined molecules; and the terms “solution”, “soluble”, “homogeneous”, and the like are to be understood as including not only true equilibrium solutions or homogeneity but also dispersions.
[0046] There is no specific limitation on the aluminum or aluminum alloy article to be subjected to anodization in accordance with the present invention. It is desirable that at least a portion of the article is fabricated from a metal that contains not less than 50% by weight, more preferably not less than 70% by weight aluminum. Preferably, the article is fabricated from a metal that contains not less than, in increasing order of preference, 30, 40, 50, 60, 70, 80, 90, 100% by weight aluminum.
[0047] In carrying out the anodization of a workpiece, an anodizing solution is employed which is preferably maintained at a temperature between about 0° C. and about 90° C. It is desirable that the temperature be at least about, in increasing order of preference 5, 10, 15, 20, 25, 30, 40, 50° C. and not more than 90, 88, 86, 84, 82, 80, 75, 70, 65° C.
[0048] The anodization process comprises immersing at least a portion of the workpiece in the anodizing solution, which is preferably contained within a bath, tank or other such container. The article (workpiece) functions as the anode. A second metal article that is cathodic relative to the workpiece is also placed in the anodizing solution. Alternatively, the anodizing solution is placed in a container which is itself cathodic relative to the workpiece (anode). When using pulsed current, an average voltage potential not in excess of in increasing order of preference 250 volts, 200 volts, 175 volts, 150 volts, 125 volts is then applied across the electrodes until a coating of the desired thickness is formed on the surface of the aluminum article in contact with the anodizing solution. When certain anodizing solution compositions are used, good results may be obtained even at average voltages not in excess of 100 volts. It has been observed that the formation of a corrosion- and abrasion-resistant protective coating is often associated with anodization conditions which are effective to cause a visible light-emitting discharge (sometimes referred to herein as a “plasma”, although the use of this term is not meant to imply that a true plasma exists) to be generated (either on a continuous or intermittent or periodic basis) on the surface of the aluminum article.
[0049] In one embodiment, direct current (DC) is used at 10-400 Amps/square foot and 200 to 600 volts. In another embodiment, the current is pulsed or pulsing current. Non-pulsed direct current is desirably used in the range of 200-600 volts; preferably the voltage is at least, in increasing order of preference 200, 250, 300, 350, 400 and at least for the sake of economy, not more than in increasing order of preference 700, 650, 600, 550. Direct current is preferably used, although alternating current may also be utilized (under some conditions, however, the rate of coating formation may be lower using AC). The frequency of the current may range from 10 to 10,000 Hertz; higher frequencies may be used. In embodiments where AC power is used, 300 to 600 volts is the preferred voltage level.
[0050] In a preferred embodiment, the pulsed signal may have an “off” time between each consecutive voltage pulse preferably lasting between about 10% as long as the voltage pulse and about 1000% as long as the voltage pulse. During the “off” period, the voltage need not be dropped to zero (i.e., the voltage may be cycled between a relatively low baseline voltage and a relatively high ceiling voltage). The baseline voltage thus may be adjusted to a voltage that is from 0% to 99.9% of the peak applied ceiling voltage. Low baseline voltages (e.g., less than 30% of the peak ceiling voltage) tend to favor the generation of a periodic or intermittent visible light-emitting discharge, while higher baseline voltages (e.g., more than 60% of the peak ceiling voltage) tend to result in continuous plasma anodization (relative to the human eye frame refresh rate of 0.1-0.2 seconds). The current can be pulsed with either electronic or mechanical switches activated by a frequency generator. The average amperage per square foot is at least in increasing order of preference 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 105, 110, 115, and not more than at least for economic considerations in increasing order of preference 300, 275, 250, 225, 200, 180, 170, 160, 150, 140, 130, 125. More complex waveforms may also be employed, such as, for example, a DC signal having an AC component. Alternating current may also be used, with voltages desirably between about 200 and about 600 volts. The higher the concentration of the electrolyte in the anodizing solution, the lower the voltage can be while still depositing satisfactory coatings.
[0051] A number of different types of anodizing solutions may be successfully used in the process of this invention, as will be described in more detail hereinafter. However, it is believed that a wide variety of water-soluble or water-dispersible anionic species containing metal, metalloid, and/or non-metal elements are suitable for use as components of the anodizing solution. Suitable elements include, for example, phosphorus, titanium, zirconium, hafnium, tin, germanium, boron, vanadium, fluoride, zinc, niobium, molybdenum, manganese, tungsten and the like (including combinations of such elements). In a preferred embodiment of the invention, the components of the anodizing solution are titanium and/or zirconium.
[0052] Without wishing to be bound by theory, it is thought that the anodization of aluminum and aluminum alloy articles in the presence of complex fluoride or oxyfluoride species to be described subsequently in more detail leads to the formation of surface films comprised of metal/metalloid oxide ceramics (including partially hydrolyzed glasses containing O, OH and/or F ligands) or metal/non-metal compounds wherein the metal comprising the surface film includes metals from the complex fluoride or oxyfluoride species and some metals from the article. The plasma or sparking which often occurs during anodization in accordance with the present invention is believed to destabilize the anionic species, causing certain ligands or substituents on such species to be hydrolyzed or displaced by O and/or OH or metal-organic bonds to be replaced by metal-O or metal-OH bonds. Such hydrolysis and displacement reactions render the species less water-soluble or water-dispersible, thereby driving the formation of the surface coating.
[0053] A pH adjuster may be present in the anodizing solution; suitable pH adjusters include, by way of nonlimiting example, ammonia, amine or other base. The amount of pH adjuster is limited to the amount required to achieve a pH of 2-11, preferably 2-8 and most preferably 3-6; and is dependent upon the type of electrolyte used in the anodizing bath. In a preferred embodiment, the amount of pH adjuster is less than 1% w/v.
[0054] In certain embodiments of the invention, the anodizing solution is essentially (more preferably, entirely) free of chromium, permanganate, borate, sulfate, free fluoride and/or free chloride.
[0055] The anodizing solution used preferably comprises water and at least one complex fluoride or oxyfluoride of an element selected from the group consisting of Ti, Zr, Hf, Sn, Al, Ge and B (preferably, Ti and/or Zr). The complex fluoride or oxyfluoride should be water-soluble or water-dispersible and preferably comprises an anion comprising at least 1 fluorine atom and at least one atom of an element selected from the group consisting of Ti, Zr, Hf, Sn, Al, Ge or B. The complex fluorides and oxyfluorides (sometimes referred to by workers in the field as “fluorometallates”) preferably are substances with molecules having the following general empirical formula (I):
[0000] H p T q F r O s (I)
[0000] wherein: each of p, q, r, and s represents a non-negative integer; T represents a chemical atomic symbol selected from the group consisting of Ti, Zr, Hf, Sn, Al, Ge, and B; r is at least 1; q is at least 1; and, unless T represents B, (r+s) is at least 6. One or more of the H atoms may be replaced by suitable cations such as ammonium, metal, alkaline earth metal or alkali metal cations (e.g., the complex fluoride may be in the form of a salt, provided such salt is water-soluble or water-dispersible).
[0056] Illustrative examples of suitable complex fluorides include, but are not limited to, H 2 TiF 6 , H 2 ZrF 6 , H 2 HfF 6 , H 2 SnF 6 , H 2 GeF 6 , H 3 AlF 6 , HBF 4 , and salts (fully as well as partially neutralized) and mixtures thereof. Examples of suitable complex fluoride salts include SrZrF 6 , MgZrF 6 , Na 2 ZrF 6 , Li 2 ZrF 6 , SrTiF 6 , MgTiF 8 , Na 2 TiFe and Li 2 TiF 6 .
[0057] The total concentration of complex fluoride and complex oxyfluoride in the anodizing solution preferably is at least about 0.005 M. Generally, there is no preferred upper concentration limit, except of course for any solubility constraints. It is desirable that the total concentration of complex fluoride and complex oxyfluoride in the anodizing solution be at least 0.005, 0.010, 0.020, 0.030, 0.040, 0.050, 0.060, 0.070, 0.080, 0.090, 0.10, 0.20, 0.30, 0.40, 0.50, 0.60 M, and if only for the sake of economy be not more than, in increasing order of preference 2.0, 1.5, 1.0, 0.80 M.
[0058] To improve the solubility of the complex fluoride or oxyfluoride, especially at higher pH, it may be desirable to include an inorganic acid (or salt thereof) that contains fluorine but does not contain any of the elements Ti, Zr, Hf, Sn, Al, Ge or B in the electrolyte composition. Hydrofluoric acid or a salt of hydrofluoric acid such as ammonium bifluoride is preferably used as the inorganic acid. The inorganic acid is believed to prevent or hinder premature polymerization or condensation of the complex fluoride or oxyfluoride, which otherwise (particularly in the case of complex fluorides having an atomic ratio of fluorine to “T” of 6) may be susceptible to slow spontaneous decomposition to form a water-insoluble oxide. Certain commercial sources of hexafluorotitanic acid and hexafluorozirconic acid are supplied with an inorganic acid or salt thereof, but it may be desirable in certain embodiments of the invention to add still more inorganic acid or inorganic salt.
[0059] A chelating agent, especially a chelating agent containing two or more carboxylic acid groups per molecule such as nitrilotriacetic acid, ethylene diamine tetraacetic acid, N-hydroxyethyl-ethylenediamine triacetic acid, or diethylene-triamine pentaacetic acid or salts thereof, may also be included in the anodizing solution. Other Group IV compounds may be used, such as, by way of non-limiting example, Ti and/or Zr oxaiates and/or acetates, as well as other stabilizing ligands, such as acetylacetonate, known in the art that do not interfere with the anodic deposition of the anodizing solution and normal bath lifespan. In particular, it is necessary to avoid organic materials that either decompose or undesirably polymerize in the energized anodizing solution.
[0060] Suitable complex oxyfluorides may be prepared by combining at least one complex fluoride with at least one compound which is an oxide, hydroxide, carbonate, carboxylate or alkoxide of at least one element selected from the group consisting of Ti, Zr, Hf, Sn, B, Al, or Ge. Examples of suitable compounds of this type that may be used to prepare the anodizing solutions of the present invention include, without limitation, zirconium basic carbonate, zirconium acetate and zirconium hydroxide. The preparation of complex oxyfluorides suitable for use in the present invention is described in U.S. Pat. No. 5,281,282, incorporated herein by reference in its entirety. The concentration of this compound used to make up the anodizing solution is preferably at least, in increasing preference in the order given, 0.0001, 0.001 or 0.005 moles/kg (calculated based on the moles of the element(s) Ti, Zr, Hf, Sn, B, Al and/or Ge present in the compound used). Independently, the ratio of the concentration of moles/kg of complex fluoride to the concentration in moles/kg of the oxide, hydroxide, carbonate or alkoxide compound preferably is at least, with increasing preference in the order given, 0.05:1, 0.1:1, or 1:1. In general, it will be preferred to maintain the pH of the anodizing solution in this embodiment of the invention in the range of from about 2 to about 11, more preferably 2-8, and in one embodiment a pH of 2-6.5 is desirable. A base such as ammonia, amine or alkali metal hydroxide may be used, for example, to adjust the pH of the anodizing solution to the desired value.
[0061] Rapid coating formation is generally observed at average voltages of 150 volts or less (preferably 100 or less), using pulsed DC. It is desirable that the average voltage be of sufficient magnitude to generate coatings of the invention at a rate of at least about 1 micron thickness per minute, preferably at least 3-8 microns in 3 minutes. If only for the sake of economy, it is desirable that the average voltage be less than, in increasing order of preference, 150, 140, 130, 125, 120, 115, 110, 100, 90 volts. The time required to deposit a coating of a selected thickness is inversely proportional to the concentration of the anodizing bath and the amount of current Amps/square foot used. By way of non-limiting example, parts may be coated with an 8 micron thick metal oxide layer in as little as 10-15 seconds at concentrations cited in the Examples by increasing the Amps/square foot to 300-2000 amps/square foot. The determination of correct concentrations and current amounts for optimum part coating in a given period of time can be made by one of skill in the art based on the teachings herein with minimal experimentation.
[0062] Coatings of the invention are typically fine-grained and desirably are at least 1 micron thick, preferred embodiments have coating thicknesses from 1-20 microns. Thinner or thicker coatings may be applied, although thinner coatings may not provide the desired coverage of the article. Without being bound by a single theory, it is believed that, particularly for insulating oxide films, as the coating thickness increases the film deposition rate is eventually reduced to a rate that approaches zero asymptotically. Add-on mass of coatings of the invention ranges from approximately 5-200 g/m 2 or more and is a function of the coating thickness and the composition of the coating. It is desirable that the add-on mass of coatings be at least, in increasing order of preference, 5, 10, 11, 12, 14, 16, 18, 20, 25, 30, 35, 40, 45, 50 g/m 2 .
[0063] An anodizing solution for use in forming a white protective coating on an aluminum or aluminum alloy substrate may be prepared using the following components:
[0000] Zirconium Basic Carbonate 0.01 to 1 wt. % H 2 ZrF 6 0.1 to 10 wt. % Water Balance to 100%
pH adjusted to the range of 2 to 5 using ammonia, amine or other base.
[0064] In a preferred embodiment utilizing zirconium basic carbonate and H 2 ZrF 6 , it is desirable that the anodizing solution comprise zirconium basic carbonate in an amount of at least, in increasing order of preference 0.05, 0.10, 0.15, 0.20, 0.25, 0.30, 0.35, 0.40, 0.45, 0.50, 0.55, 0.60 wt. % and not more than, in increasing order of preference 1.0, 0.97, 0.95, 0.92, 0.90, 0.87, 0.85, 0.82, 0.80, 0.77 wt. %. In this embodiment, it is desirable that the anodizing solution comprises H 2 ZrF 6 in an amount of at least, in increasing order of preference 0.2, 0.4, 0.6, 0.8. 1.0, 1.2, 1.3, 1.4, 1.5, 2.0, 2.5, 3.0, 3.5, wt. % and not more than, in increasing order of preference 10, 9.75, 9.5, 9.25, 9.0, 8.75, 8.5, 8.25, 8.0, 7.75 4.0, 4.5, 5.0, 5.5, 6.0 wt. %.
[0065] In a particularly preferred embodiment the amount of zirconium basic carbonate ranges from about 0.75 to 0.25 wt. %, the H 2 ZrF 6 ranges from 6.0 to 9.5 wt %; a base such as ammonia is used to adjust the pH to ranges from 3 to 5.
[0066] It is believed that the zirconium basic carbonate and the hexafluorozirconic acid combine to at least some extent to form one or more complex oxyfluoride species. The resulting anodizing solution permits rapid anodization of aluminum-containing articles using pulsed direct current having an average voltage of not more than 175 volts. In this particular embodiment of the invention, better coatings are generally obtained when the anodizing solution is maintained at a relatively high temperature during anodization (e.g., 40 degrees C. to 80 degrees C.). Alternatively, alternating current preferably having a voltage of from 300 to 600 volts may be used. The solution has the further advantage of forming protective coatings that are white in color, thereby eliminating the need to paint the anodized surface if a white decorative finish is desired. The anodized coatings produced in accordance with this embodiment of the invention typically have L values of at least 80, high hiding power at coating thicknesses of 4 to 8 microns, and excellent acid, alkali and corrosion resistance. To the best of the inventor's knowledge, no anodization technologies being commercially practiced today are capable of producing coatings having this desirable combination of properties.
[0067] In another particularly preferred embodiment of the invention, the anodizing solution used comprises water, a water-soluble or water-dispersible phosphorus containing acid or salt, such as a phosphorus oxyacid or salt, preferably an acid or salt containing phosphate anion; and at least one of H 2 TiF 6 and H 2 ZrF 8 . It is desirable that the pH of the anodizing solution is neutral to acid, 6.5 to 1, more preferably, 6 to 2, most preferably 5-3.
[0068] It was surprisingly found that the combination of a phosphorus containing acid and/or salt and the complex fluoride in the anodizing solution produced a different type of anodically deposited coating. The oxide coatings deposited comprised predominantly oxides of anions present in the anodizing solution prior to any dissolution of the anode. That is, this process results in coatings that result predominantly from deposition of substances that are not drawn from the body of the anode, resulting in less change to the substrate of the article being anodized.
[0069] In this embodiment, it is desirable that the anodizing solution comprise the at least one complex fluoride, e.g. H 2 TiF 6 and/or H 2 ZrF 6 in an amount of at least, in increasing order of preference 0.2, 0.4, 0.6, 0.8. 1.0, 1.2, 1.3, 1.4, 1.5, 2.0, 2.5, 3.0, 3.5 wt. % and not more than, in increasing order of preference 10, 9.5, 9.0, 8.5, 8.0, 7.5, 7.0, 6.5, 6.0, 5.5, 5.0, 4.5. 4.0 wt. %. The at least one complex fluoride may be supplied from any suitable source such as, for example, various aqueous solutions known in the art. For H 2 TiF 6 commercially available solutions typically range in concentration from 50-60 wt %; while for H 2 ZrF 6 such solutions range in concentration between 20-50%.
[0070] The phosphorus oxysalt may be supplied from any suitable source such as, for example, ortho-phosphoric acid, pyro-phosphoric acid, tri-phosphoric acid, meta-phosphoric acid, polyphosphoric acid and other combined forms of phosphoric acid, as well as phosphorous acids, and hypo-phosphorous acids, and may be present in the anodizing solution in partially or fully neutralized form (e.g., as a salt, wherein the counter ion(s) are alkali metal cations, ammonium or other such species that render the phosphorus oxysalt water-soluble). Organophosphates such as phosphonates and the like may also be used (for example, the various phosphonates available from Rhodia Inc. and Solutia Inc.) provided that the organic component does not interfere with the anodic deposition.
[0071] Particularly preferred is the use of a phosphorus oxysalt in acid form. The phosphorus concentration in the anodizing solution is at least 0.01 M. It is preferred that the concentration of phosphorus in the anodizing solution be at least, in increasing order of preference, 0.01M, 0.015, 0.02, 0.03, 0.04, 0.05, 0.07, 0.09, 0.10, 0.12, 0.14, 0.16. In embodiments where the pH of the anodizing solution is acidic (pH<7), the phosphorus concentration can be 0.2 M, 0.3 M or more and preferably, at least for economy is not more than 1.0, 0.9, 0.8, 0.7, 0.6 M. In embodiments where the pH is neutral to basic, the concentration of phosphorus in the anodizing solution is not more than, in increasing order of preference 0.40, 0.30, 0.25, 0.20 M.
[0072] A preferred anodizing solution for use in forming a protective ceramic coating according to this embodiment on an aluminum or aluminum alloy substrate may be prepared using the following components:
[0000] H 2 TiF 6 0.05 to 10 wt. % H 3 PO 4 0.1 to 0.6 wt. % Water Balance to 100%
The pH is adjusted to the range of 2 to 6 using ammonia, amine or other base.
[0073] With the aforedescribed anodizing solutions, the generation of a sustained “plasma” (visible light emitting discharge) during anodization is generally attained using pulsed DC having an average voltage of no more than 150 volts. In preferred operation, the average voltage does not exceed 100 volts.
[0074] The anodized coatings produced in accordance with the invention typically range in color from blue-grey and light grey to charcoal grey depending upon the coating thickness and relative amounts of Ti and Zr oxides in the coatings. The coatings exhibit high hiding power at coating thicknesses of 2-10 microns, and excellent acid, alkali and corrosion resistance. A test panel of a 400 series aluminum alloy anodically coated according to a process of the invention had an 8-micron thick layer of adherent ceramic predominantly comprising titanium dioxide. This coated test panel was scratched down to bare metal prior to salt fog testing. Despite being subjected to 1000 hours of salt fog testing according to ASTM B-117-03, there was no corrosion extending from the scribed line.
[0075] A commercially available bare aluminum wheel was cut into pieces and the test specimen was anodically coated according to a process of the invention with a 10-micron thick layer of ceramic predominantly comprising titanium dioxide. Without being bound to a single theory, the darker grey coating is attributed to the greater thickness of the coating. The coating completely covered the surfaces of the aluminum wheel including the design edges. The coated aluminum wheel portion had a line scratched into the coating down to bare metal prior to salt fog testing. Despite being subjected to 1000 hours of salt fog according to ASTM B-117-03, there is no corrosion extending from the scribed line and no corrosion at the design edges. References to “design edges” will be understood to include the cut edges as well as shoulders or indentations in the article which have or create external corners at the intersection of lines generated by the intersection of two planes. The excellent protection of the design edges is an improvement over conversion coatings, including chrome containing conversion coatings, which show corrosion at the design edges after similar testing.
[0076] In another aspect of the invention, Applicant surprisingly discovered that titanium containing substrates and aluminum containing substrates can be coated simultaneously in the anodizing process of the invention. A titanium clamp was used to hold an aluminum test panel during anodization according to the invention and both substrates, the clamp and the panel, were coated simultaneously according to the process of the invention. Although the substrates do not have the same composition, the coating on the surface appeared uniform and monochromatic. The substrates were anodically coated according to a process of the invention with a 7-micron thick layer of ceramic predominantly comprising titanium dioxide. The coating was a light grey in color, and provided good hiding power.
[0077] Before being subjected to anodic treatment in accordance with the invention, the aluminiferous metal article preferably is subjected to a cleaning and/or degreasing step. For example, the article may be chemically degreased by exposure to an alkaline cleaner such as, for example, a diluted solution of PARCO Cleaner 305 (a product of the Henkel Surface Technologies division of Henkel Corporation, Madison Heights, Mich.). After cleaning, the article preferably is rinsed with water. Cleaning may then, if desired, be followed by etching with an acidic deoxidixer/desmutter such as SC592, commercially available from Henkel Corporation, or other deoxidizing solution, followed by additional rinsing prior to anodization. Such pre-anodization treatments are well known in the art.
[0078] After anodization, the protective ceramic coatings produced on the surface of the workpiece are subjected to a further treatment comprising PTFE or silicone paint applied to the anodized surface, typically at a film build (thickness) of from about 3 to about 30 microns to form a non-stick layer. Suitable PTFE topcoats are known in the industry and typically comprise PTFE particles dispersed with surfactant, solvent and other adjuvants in water. Prior art PTFE-coated aluminiferous articles, require a primer and midcoat to be applied prior to a topcoat containing PTFE. Primers, midcoats and PTFE-containing topcoats, as well as silicone-containing paints, are known in the art and providing such non-stick coatings that are suitable for use in the invention is within the knowledge of those skilled in the art.
[0079] Articles having the first protective coating of the invention may be coated with PTFE coating systems known in the art, but do not require a three-step coating process to adhere PTFE. In embodiments having a zirconium oxide protective coating of the invention, Applicant surprisingly found that PTFE topcoat may be applied directly onto the zirconium oxide layer in the absence of any intermediate coating. In a preferred embodiment, the PTFE topcoat is applied to the zirconium oxide layer in the absence of a primer or midcoat or both. Similarly, embodiments having a titanium oxide protective coating of the invention, show good adhesion of the PTFE topcoat without application of a midcoat, thus eliminating one processing step and its attendant costs. In a preferred embodiment, the PTFE topcoat is applied to the titanium oxide layer having a primer thereon and in the absence of a midcoat, resulting in non-stick coating. Applicant also discovered that a silicone containing paint can be applied directly to zirconium and titanium coatings of the invention with good adherence resulting in non-stick coating.
[0080] The invention will now be further described with reference to a number of specific examples, which are to be regarded solely as illustrative and not as restricting the scope of the invention.
EXAMPLES
Example 1
[0081] An anodizing solution was prepared using the following components:
[0000]
Parts per 1000 grams
Zirconium Basic Carbonate
5.24
Fluozirconic Acid (20% solution)
80.24
Deionized Water
914.5
[0082] The pH was adjusted to 3.9 using ammonia. An aluminum-containing article was subjected to anodization for 120 seconds in the anodizing solution using pulsed direct current having a peak ceiling voltage of 450 volts (approximate average voltage=75 volts). The “on” time was 10 milliseconds, the “off” time was 30 milliseconds (with the “off” or baseline voltage being 0% of the peak ceiling voltage). A uniform white coating 6.3 microns in thickness was formed on the surface of the aluminum-containing article. A periodic to continuous plasma (rapid flashing just visible to the unaided human eye) was generated during anodization. The test panels of Example 1 were analyzed using energy dispersive spectroscopy and found to comprise a coating comprised predominantly of zirconium and oxygen.
Example 2
[0083] An aluminum alloy article was cleaned in a diluted solution of PARCO Cleaner 305, an alkaline cleaner, and an alkaline etch cleaner, Aluminum Etchant 34, both commercially available from Henkel Corporation. The aluminum alloy article was then desmutted in SC592, an iron based acidic deoxidizer commercially available from Henkel Corporation.
[0084] The aluminum alloy article was then coated, using the anodizing solution of Example 1, by being subjected to anodization for 3 minutes in the anodizing solution using pulsed direct current having a peak ceiling voltage of 500 volts (approximate average voltage=130 volts). The “on” time was 10 milliseconds, the “off” time was 30 milliseconds (with the “off” or baseline voltage being 0% of the peak ceiling voltage). Ceramic coatings of 3-6 microns in thickness were formed on the surface of the aluminum alloy article. The coatings had a uniform white appearance.
Example 3
[0085] A ceramic coated aluminum alloy article from Example 2 (said article hereinafter referred to as Example 3) was subjected to testing for adherence of PTFE and compared to a similar aluminum alloy article that had been subjected to the cleaning, etching and desmutting stages of Example 2 and then directly coated with PTFE as described below (Comparative Example 1).
[0086] Comparative Example 1 and Example 3 were rinsed in deionized water and dried. A standard PTFE-containing topcoat, commercially available from Dupont under the name 852-201, was spray applied as directed by the manufacturer. The PTFE coating on Comparative Example 1 and Example 3 were cured at 725° F. for 30 minutes and then immersed in cold water to cool to room temperature. The PTFE film thickness was 12-15 microns.
[0087] The films were crosshatched and subjected to adhesion tests wherein commercially available 898 tape was firmly adhered to each film and then pulled off at a 90° angle to the surface. Comparative Example 1 had 100% delamination of the PTFE coating in the cross-hatch area. No loss of adhesion was observed in the PTFE coating adhered to the ceramic-coated article from Example 3.
[0088] To assess hot/cold cycling stability, Example 3 was heated to 824° F. for two hours and immediately subjected to 10 cold-water dips. The film was again cross-hatched and no delamination of the PTFE coating was observed. The underlying ceramic coating showed no visual changes in appearance.
Example 4
[0089] An aluminum alloy substrate in the shape of a cookware pan was the test article for Example 4. The article was cleaned in a diluted solution of PARCO Cleaner 305, an alkaline cleaner, and an alkaline etch cleaner, such as Aluminum Etchant 34, both commercially available from Henkel Corporation. The aluminum alloy article was then desmutted in SC0592, an iron based acidic deoxidizer commercially available from Henkel Corporation.
[0090] The aluminum alloy article was then coated, using an anodizing solution prepared using the following components:
[0000]
H 2 TiF 6
12.0 g/L
H 3 PO 4
3.0 g/L
[0091] The pH was adjusted to 2.1 using ammonia. The test article was subjected to anodization for 6 minutes in the anodizing solution using pulsed direct current having a peak ceiling voltage of 500 volts (approximate average voltage=140 volts). The “on” time was 10 milliseconds, the “off” time was 30 milliseconds (with the “off” or baseline voltage being 0% of the peak ceiling voltage). A uniform blue-grey coating 10 microns in thickness was formed on the surface of the test article. The test article was analyzed using energy dispersive spectroscopy and found to have a coating predominantly of titanium and oxygen, with trace amounts of phosphorus, estimated at less than 10 wt %. The titanium dioxide ceramic-coated test article of Example 4 was subjected to acid stability testing by heating lemon juice (citric acid) of pH 2 and boiling to dryness in the article. No change in the oxide layer was noted.
Example 5
[0092] An aluminum alloy test panel of 400 series aluminum alloy was coated according to the procedure of Example 4. A scribe line was scratched into the test panel down to bare metal prior to salt fog testing. Despite being subjected to 1000 hours of salt fog testing according to ASTM B-117-03, there was no corrosion extending from the scribed line.
Example 6
[0093] An aluminum alloy wheel was the test article for Example 6. The substrate was treated as in Example 4, except that the anodizing treatment was as follows:
[0094] The aluminum alloy article was coated, using an anodizing solution prepared using the following components.
[0000]
H 2 TiF 6 (60%)
20.0 g/L
H 3 PO 4
4.0 g/L
[0095] The pH was adjusted to 2.2 using aqueous ammonia. The article was subjected to anodization for 3 minutes in the anodizing solution using pulsed direct current having a peak ceiling voltage of 450 volts (approximate average voltage=130 volts) at 90° F. The “on” time was 10 milliseconds, the “off” time was 30 milliseconds (with the “off” or baseline voltage being 0% of the peak ceiling voltage). The average current density was 40 amps/ft2. A uniform coating, 8 microns in thickness, was formed on the surface of the aluminum-containing article. The article was analyzed using qualitative energy dispersive spectroscopy and found to have a coating predominantly of titanium, oxygen and a trace of phosphorus.
[0096] A line was scribed into the coated article down to bare metal and the article was subjected to the following testing: 1000 hours of salt fog per ASTM B-117-03. The article showed no signs of corrosion along the scribe line or along the design edges.
Example 7
[0097] An aluminum alloy test panel was treated as in Example 4. The test panel was submerged in the anodizing solution using a titanium alloy clamp. A uniform blue-grey coating, 7 microns in thickness, was formed on the surface of the predominantly aluminum test panel. A similar blue-grey coating, 7 microns, in thickness was formed on the surface of the predominantly titanium clamp. Both the test panel and the clamp were analyzed using qualitative energy dispersive spectroscopy and found to have a coating predominantly of titanium, oxygen and a trace of phosphorus.
Example 8
[0098] Aluminum alloy test panels of 6063 aluminum were treated according to the procedure of Example 4, except that the anodizing treatment was as follows:
[0099] The aluminum alloy articles were coated, using an anodizing solution containing phosphorous acid in place of phosphoric acid:
[0000]
H 2 TiF 6 (60%)
20.0 g/L
H 3 PO 3 (70%)
8.0 g/L
[0100] The aluminum alloy articles were subjected to anodization for 2 minutes in the anodizing solution. Panel A was subjected to 300 to 500 volts applied voltage as direct current. Panel B was subjected to the same peak voltage but as pulsed direct current. A uniform grey coating 5 microns in thickness was formed on the surface of both Panel A and Panel B.
Example 9
[0101] The test article of Example 4, now having a coating of titanium dioxide ceramic, was the subject of Example 9. Example 9 was rinsed in deionized water and dried. The inside of the article was overcoated with Dupont Teflon® primer and topcoat paints, available from Dupont as 857-101 and 852-201, respectively, spray applied as directed by the manufacturer. The primer and topcoat on Example 9 were cured at 725° F. for 30 minutes and then immersed in cold water to cool to room temperature. The PTFE film thickness was 5-15 microns.
[0102] Comparative Example 2 was a commercially available aluminum pan having a non-stick seal over a hard-coat anodized coating of aluminum oxide on the inner and outer pan surfaces.
[0103] Table 1 shows the results of repeated exposure to typical dishwasher cycles of hot water and alkaline cleaning agents.
[0000]
TABLE 1
Example
Outside of Pan
Inside of Pan
Comparative Example 2
Non-stick seal removed within
Non-stick seal removed within
6 washes and hardcoat is
6 washes and hardcoat is
attacked at surface - part
attacked at surface - part is
develops white discoloration
covered with white
discoloration
Example 9 - Titanium Dioxide
Ceramic coating unaffected
Teflon ® coating unaffected
after 18 wash cycles
after 18 wash cycles
[0104] Although the invention has been described with particular reference to specific examples, it is understood that modifications are contemplated. Variations and additional embodiments of the invention described herein will be apparent to those skilled in the art without departing from the scope of the invention as defined in the claims to follow. The scope of the invention is limited only by the breadth of the appended claims. | An article of manufacture and a process for making the article by the anodization of aluminum and aluminum alloy workpieces to provide corrosion-, heat- and abrasion-resistant ceramic coatings comprising titanium and/or zirconium oxides, and the subsequent coating of the anodized workpiece with polytetrafluoroethylene (“PTFE”) or silicone containing coatings. The invention is especially useful for forming longer life PTFE coatings on aluminum substrates by pre-coating the substrate with an anodized layer of titanium and/or zirconium oxide that provides excellent corrosion-, heat- and abrasion-resistance in a hard yet flexible film. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 61/693,931, filed Aug. 28, 2012, which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] Embedded data systems are commonly used in avionics and elsewhere in an aircraft, such as in a flight data recorder, where massive amounts of data are stored for later retrieval. Processing the data from the large data base in a meaningful and efficient manner is typically done in a ground based system, rather than in an airborne aircraft, because of the greater processing power typically required. Nonetheless, the data base on the aircraft normally requires mapping the data to the particular storage medium so particular data can be located later during processing. It is known to use relational databases in embedded systems to enable later processing of the stored data, but relational databases often cannot run effectively on low power systems, or low memory systems, or task-specific systems such as might be found on an aircraft.
[0003] Ground based systems are often coded with the particular mapping of a particular storage medium in an aircraft that enables effective processing of data from the storage medium, but the necessary requirements for hardware, software and networking make such systems costly and cumbersome. A distributed file system such as Apache's Hadoop®, an open source framework for data-intensive applications, may provide a means to process the large data bases of an aircraft embedded system, but it does not relate well to embedded systems, nor does it address selecting an individual data sample very well.
BRIEF DESCRIPTION OF THE INVENTION
[0004] A method of storing data, in a variety of structured formats, in an indexable way on low cost and low power systems. One embodiment of the present invention includes reading data sampled from sensors or calculated data stored as an object within the embedded system; splitting identifier information from an object; indexing identifier information in association with a particular object, or portion thereof, in an index; and storing the index. Depending on the needs of the system for retrieval, the data values are stored in row or column based formats, and indexes a variety of identifiers, alert indicators, or timestamps.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] In the drawings:
[0006] FIG. 1 is a schematic diagram illustrating one embodiment of an index according to the invention.
[0007] FIG. 2 is a schematic diagram illustrating another embodiment of an index according to the invention.
[0008] FIG. 3 is a schematic diagram depicting one embodiment of a method of storing identifiers in an index wherein the index and data objects reside on the same system.
[0009] FIG. 4 is a schematic diagram depicting another embodiment of a method of storing identifiers in an index wherein the index and data objects reside on different systems.
[0010] FIG. 5 is a block diagram of an index stored in the same system as the data objects according to one embodiment.
[0011] FIG. 6 is a block diagram of an index stored on different systems as the data objects according to another embodiment.
DETAILED DESCRIPTION
[0012] In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the technology described herein. It will be evident to one skilled in the art, however, that the exemplary embodiments may be practiced without these specific details. In other instances, structures and devices are shown in diagram form in order to facilitate description of the exemplary embodiments.
[0013] The exemplary embodiments are described below with reference to the drawings. These drawings illustrate certain details of specific embodiments that implement the module, method, and computer program product described herein. However, the drawings should not be construed as imposing any limitations that may be present in the drawings. The method and computer program product may be provided on any machine-readable media for accomplishing their operations. The embodiments may be implemented using an existing computer processor, or by a special purpose computer processor incorporated for this or another purpose, or by a hardwired system.
[0014] As noted above, embodiments described herein include a computer program product comprising machine-readable media for carrying or having machine-executable instructions or data structures stored thereon. Such machine-readable media can be any available media, which can be accessed by a general purpose or special purpose computer or other machine with a processor. By way of example, such machine-readable media can comprise RAM, ROM, EPROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to carry or store desired program code in the form of machine-executable instructions or data structures and that can be accessed by a general purpose or special purpose computer or other machine with a processor. When information is transferred or provided over a network 18 or another communication connection (either hardwired, wireless, or a combination of hardwired or wireless) to a machine, the machine properly views the connection as a machine-readable medium. Thus, any such a connection is properly termed a machine-readable medium. Combinations of the above are also included within the scope of machine-readable media. Machine-executable instructions comprise, for example, instructions and data, which cause a general purpose computer, special purpose computer, or special purpose processing machines to perform a certain function or group of functions.
[0015] Embodiments will be described in the general context of method steps that may be implemented in one embodiment by a program product including machine-executable instructions, such as program code, for example, in the form of program modules executed by machines in networked environments. Generally, program modules include routines, programs, objects, components, data structures, etc. that have the technical effect of performing particular tasks or implement particular abstract data types. Machine-executable instructions, associated data structures, and program modules represent examples of program code for executing steps of the method disclosed herein. The particular sequence of such executable instructions or associated data structures represent examples of corresponding acts for implementing the functions described in such steps.
[0016] Embodiments may be practiced in a networked environment using logical connections to one or more remote computers having processors. Logical connections may include a local area network (LAN) and a wide area network (WAN) that are presented here by way of example and not limitation. Such networking environments are commonplace in office-wide or enterprise-wide computer networks, intranets and the internet and may use a wide variety of different communication protocols. Those skilled in the art will appreciate that such network computing environments will typically encompass many types of computer system configuration, including personal computers, hand-held devices, multiprocessor systems, microprocessor-based or programmable consumer electronics, network PCs, minicomputers, mainframe computers, and the like.
[0017] Embodiments may also be practiced in distributed computing environments where tasks are performed by local and remote processing devices that are linked (either by hardwired links, wireless links, or by a combination of hardwired or wireless links) through a communication network. In a distributed computing environment, program modules may be located in both local and remote memory storage devices.
[0018] An exemplary system for implementing the overall or portions of the exemplary embodiments might include an embedded computing device found on aircrafts in the form of a dedicated computer, including a processing unit, a system memory, and a system bus, that couples various system components including the system memory to the processing unit. The system memory may include read only memory (ROM) and random access memory (RAM). Alternatively, a system for implementing portions of the embodiments might include a general purpose computing device in the form of a computer, including a processing unit, a system memory, and a system bus, that couples various system components including the system memory to the processing unit. A system may also include a magnetic hard disk drive for reading from and writing to a magnetic hard disk, a magnetic disk drive for reading from or writing to a removable magnetic disk, and an optical disk drive for reading from or writing to a removable optical disk such as a CD-ROM or other optical media. The drives and their associated machine-readable media provide nonvolatile storage of machine-executable instructions, data structures, program modules and other data for the system.
[0019] Technical effects of the method disclosed in the embodiments include avoiding use of relational databases for data storage on low-powered, low-memory or task specific embedded systems. For larger computer platforms, most of the data can be stored on regular commodity data storage devices, thus reducing the storage and memory requirements for relational databases and providing an ability to off-load the data access task to other systems. Data processing can be targeted at a system that is physically close to the data store, thereby reducing network requirements. Particular advantages are found in embedded aircraft systems.
[0020] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
[0021] For the convenience of the reader, the discussion that follows begins with a description of an index according to the invention ( FIGS. 1 and 2 ), then a method ( FIG. 3 and FIG. 4 ), followed by a discussion of the operation of various components in the system ( FIG. 5 and FIG. 6 ).
[0022] As described by FIG. 1 , an index 14 used in embodiments of the system and method according to the invention contains stored identifiers 9 from data objects 5 . The index 14 can be a separately stored file, apart from the objects 16 . Depending on the needs for retrieval, index identifier values 3 can be stored in a row or column based array. In one example, as shown in FIG. 1 , the index 14 is serialized into one or more columns 1 wherein object identifiers 2 are stored in independent arrays. In a second example, shown in FIG. 2 , the index 14 is organized in a row-based structure 4 wherein each object 5 is represented by a single row, and columns are identified based on the identifiers 2 collected. In either embodiment, the arrays can be structured by an undefined size, wherein new identifier data is appended to the index 14 , or by a predefined size, calculated by the number of known object 15 entries and identifiers 9 per object 5 , wherein new identifier 9 data overwrites the allocated memory or media.
[0023] The index 14 is a separately indexable file. If using a file system that is capable, the index 14 is stored with a particular filename known to those skilled in the art, thus avoiding the indexing steps. For low power systems, the index 14 may be stored in the basic format described herein. For larger computing platforms, the indexes could be stored in relational databases on which queries may be performed to get a resource location of the stored data object 15 .
[0024] In the first embodiment, the index 14 is stored in the same system 13 as the data objects. In the second embodiment, the index is stored in a remotely networked system 16 away from the data objects system 15 . In this respect, the network 18 may be, for example, the Internet, intranets, wide area networks (WANs), local area networks, wireless networks, or other suitable networks, etc., or any combination of two or more such networks.
[0025] A method routine, show in FIG. 3 , is conducted within an embedded system 13 by a controller or processor wherein the routine looks for triggering events 7 to conduct the method. These triggering events 7 may include, but are not limited to: continual query for data objects that were not present in the previous query; system-controlled alerts to new data creation; or any other indicator of new or existing data object presence in the data object storage system 13 .
[0026] In an embedded system 13 of an aircraft, new data objects 5 are created from sensors, calculated data, or other processes 6 . The process of how the system registers data object input 6 is controlled via known system processes. The system processes serialize the data objects 5 into a particular format for storage as defined by the system. Ideally, this particular format is based on OSACBM, in either binary or XML format, but any format may be used.
[0027] Upon a triggering event 7 , system processes identify a new data object 5 and read the data and data header 9 . The method extracts 8 identifiers 3 from the data and data header 9 as defined by the retrieval needs, from the local data object storage system 13 . Examples of identifiers 3 include, but are not limited to: dataID, time stamp, and alert status. The method extracts 8 at least one identifier 3 for each data object 5 . Each extracted identifier 3 points to a location of the associated data object in the local storage system 13 .
[0028] The method then duplicates 10 said identifier or identifiers 3 to the locally stored index 14 corresponding to the defined array arrangement. The index 14 is then stored 11 in the local data storage system 13 for additional method indexing or retrieval. The method then continues to operate depending on the needs of the system for retrieval 12 .
[0029] In a method routine, shown in FIG. 4 , in an embedded system 17 of an aircraft, new data objects 5 are created from sensors, calculated data, or other processes 6 . The process of how system registers this data object input is controlled via known system processes. The system processes serialize the data object into a particular format for storage as defined by the system 17 . Ideally, this particular format is based on OSACBM, in either binary or XML format, but any format may be used.
[0030] A method routine is conducted within an embedded system 17 by a controller or processor wherein the routine looks for triggering events 7 to conduct the method. These triggering events 7 may include, but are not limited to: continual query for data objects that were not present in the previous query; system-controlled alerts to new data creation; or any other indicator of new or existing data object presence in the data object storage system.
[0031] Upon a triggering event 7 of the method routine, system processes identify the new data 5 object in the data object storage system 17 and read the data and data header 9 . The method extracts 8 identifiers 3 from the data and data header 9 as defined by the retrieval needs, from the networked data object storage system 17 . Examples of identifiers 3 include, but are not limited to: dataID, time stamp, and alert status. The method extracts at least one identifier 3 for each data object 5 . The extracted identifier 3 points to a location of the associated data object 5 in the networked data storage system 17 .
[0032] The method then connects via network 18 to the remote index storage system 16 and duplicates 10 said identifier or identifiers 3 to the networked stored index 14 corresponding to the defined array arrangement. The index 14 is then stored 11 in the remote index storage system 16 for additional method indexing or retrieval. The method then continues to operate depending on the needs of the system for retrieval 12 .
[0033] With reference to FIG. 5 , shown is a block diagram of an index 14 stored in the same system 13 as the data objects 15 according to the first embodiment of the present method. The environment includes, for example, an input device 6 for the new data object 5 , and a system 13 including a medium holding the index 14 and data objects 15 as described above. In this respect, the input device 6 is coupled to the system 13 . Alternatively, the input device 6 may be coupled to a network 18 and may communicate with the system 13 , also coupled to a network 18 , through the network 18 . The system 13 herein may be an embedded system or an alternative system where the referenced data objects 15 and index 14 might have been transferred for processing.
[0034] With reference to FIG. 6 , shown is a block diagram of an index 14 stored in a remotely networked system 16 away from the data objects 15 according to the second embodiment of the present method. The networked environment includes, for example, an input device 6 for the new data object 5 , a system 16 including the remote index storage medium, and system 17 including a data object storage medium. The systems 16 and 17 herein may be embedded systems or alternative systems where the referenced data objects 15 and index 14 might have been transferred for processing. In this respect, the input device 6 might be coupled to a data object storage medium system 17 . The system 17 including the data object storages 15 is coupled to a network 18 . Alternatively, the input device 6 may be coupled to a network 18 and may communicate with the system 17 through the network 18 . The remote index storage medium system 16 is coupled to a network 18 and may communicate with the data object storage medium system 17 though the network. | A system and method for storing and accessing data in an embedded system of an aircraft extracts identifiers from headers in stored data, and stores the identifiers in a separately indexable array. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit under 35 U.S.C. §119(e) of U.S. Patent Application No. 62/014,453, titled MATERIAL DEPOSITION SYSTEMS WITH FOUR OR MORE AXES, filed Jun. 19, 2014. The disclosure of the above application is incorporated herein by reference in its entirety.
BACKGROUND
[0002] This specification relates to three dimensional (3D) printing or additive manufacturing, such as fused deposition modeling (FDM).
[0003] FDM using extruded polymer filament has evolved rapidly and is useful for creating reasonably accurate three dimensional objects quickly. Current FDM printing is typically accomplished by forcing a solid plastic feedstock through a heated nozzle with smaller diameter than the original feedstock. The filament is liquefied before or as it passes through the constriction in the nozzle, and the feed pressure causes material to be extruded with a cross section approximately equal to the nozzle exit. Other 3D printing techniques referred to in this application include selective laser sintering (SLS), stereolithography (SLA), direct metal laser sintering (DMLS) and material jetting processes such as ObJet.
SUMMARY
[0004] This specification relates to 3D printing or additive manufacturing, such as FDM.
[0005] According to one aspect, a system for fabricating an object includes: an extruder for one or more deposition materials, the extruder including at least one nozzle and a movable support for the nozzle, wherein the nozzle has a nozzle axis and is rotatably attached to the movable support via a connector that is actuatable relative to the movable support to change an angular orientation of the nozzle axis relative to the movable support so as to vary an angle between the nozzle axis and a deposition surface during deposition of a deposition material; and a controller coupled with the extruder, the controller configured and arranged to apply a correction factor calculated for a path of the nozzle based on the angle formed between the nozzle axis and the deposition surface being an acute angle, the correction factor for the nozzle moving toward the acute angle being different from the correction factor for the nozzle moving away from the acute angle. The correction factor removes differences in thickness of the deposited material caused by variations in the angle formed between the nozzle axis and the deposition surface.
[0006] Implementations according to this aspect may include one or more of the following features. For example, the connector can be configured to be actuated with at least two degrees of freedom for the nozzle relative to the movable support. The extruder can include a softening zone positioned upstream of an actuation point of the connector, the softening zone being configured to increase flexibility of a feedstock material passing through the softening zone. The softening zone can be configured to apply heat to the feedstock material passing therethrough. The extruder can include forming rollers that are configured to flatten the feedstock material passing therethrough. The nozzle can include the connector. The system can be configured to move the movable support and the nozzle relative to the object being fabricated along three orthogonal axes to thereby provide three degrees of freedom relative to the object, the nozzle being rotatably attached to the movable support via the connector to rotate about a first axis that is transverse to the nozzle axis to thereby provide a fourth degree of freedom relative to the object, and the system can include a rotatable base on which the object being fabricated is placed, the controller being configured to rotate the base during deposition to thereby provide a fifth degree of freedom between the nozzle and the object. In some cases, the system can be configured to move the movable support and the nozzle relative to the object being fabricated along three orthogonal axes to thereby provide three degrees of freedom relative to the object, the nozzle being rotatably attached to the movable support via the connector to rotate about a first axis that is transverse to the nozzle axis to thereby provide a fourth degree of freedom relative to the object, and the connector can be rotatably connected to the movable support to allow the connector and the nozzle to rotate about the nozzle axis to thereby provide a fifth degree of freedom relative to the object. In some cases, the system can be configured to move the nozzle relative to the object being fabricated along three orthogonal axes to thereby provide three degrees of freedom relative to the object, and the connector can include a multi-link coupler that is rotatably attached to the movable support to rotate about a first axis that is transverse to the nozzle axis, the nozzle being rotatably attached to the multi-link coupler to rotate about a second axis that is transverse to the first axis to thereby provide two additional degrees freedom relative to the object. The correction factor can cause the path of the nozzle to become farther from the surface of the object when the nozzle is moving away from the acute angle. The correction factor can cause the path of the nozzle to become closer to the surface of the object when the nozzle is moving toward the acute angle. Based on the nozzle moving away from the acute angle, the controller can be apply the correction factor that causes the path of the nozzle to become farther from the surface of the object, and based on the nozzle moving toward the acute angle, the controller can apply the correction factor that causes the path of the nozzle to become closer to the surface of the object. Based on determining that the nozzle makes contact with any portion of the system or the object, the controller can cause the angular orientation of the nozzle to change to avoid making contact. The extruder can include a feedstock channel through which a feedstock material passes during deposition, the feedstock channel providing a curved path between the extruder and the rotated nozzle, and wherein the controller is configured to change a volume flow rate of the feedstock material according to a curvature of the feedstock channel.
[0007] According to another aspect, a non-transitory computer-readable medium storing software includes instructions executable by one or more computers, which, upon such execution, cause the one or more computers to perform operations for controlling a 3D printer to create a 3D object, the 3D printer including an extruder for one or more deposition materials, the extruder including at least one nozzle and a movable support for the nozzle, wherein the nozzle has a nozzle axis and is rotatably attached to the movable support via a connector that is actuatable relative to the movable support to change an angular orientation of the nozzle axis relative to the movable support so as to vary an angle between the nozzle axis and a deposition surface during deposition of a deposition material. The operations include applying a correction factor calculated for a path of the nozzle based on the angle formed between the nozzle axis and the deposition surface being an acute angle, the correction factor for the nozzle moving toward the acute angle being different from the correction factor for the nozzle moving away from the acute angle, and causing movement of the nozzle along the path to deposit material to form the object, wherein the correction factor removes differences in thickness of the deposited material caused by variations in the angle formed between the nozzle axis and the deposition surface.
[0008] According to yet another aspect, a process for additively fabricating components with improved resistance to delamination includes using a material deposition system and depositing one or more first material segments of a first material with at least one first locking portion and one or more secondary material segments of a second material with at least one second locking portion. The second locking portions have a shape that is defined by the shape of the first locking portions such that the second locking portions form an interlock with the first locking portions. The first and second material segments can each include a continuous material. Components can be fabricated from such continuous materials to have comparable resistance to delamination or breakage in all directions.
[0009] Implementations according to this aspect may include one or more of the following features. For example, the first and/or second materials can include continuous fibers. The materials can include composite materials such as fibers and a matrix material. The matrix material can be a thermoplastic. The fibers can have a range of lengths, and the matrix material can be, for example, concrete or another cement-like or similar hardening mineral compound. In some cases, the matrix material can be a thermoset. The first and second materials can be deposited through a nozzle having an orifice. In some cases, the first and second materials can be made from the same material. The first material segments and second material segments can be formed from a continuous material (i.e. forming the second material segment after the first material segment without cutting the material so they are connected and continuous). Avoiding cutting fibers and restarting the deposition process can have several benefits including improving speed and reliability of the process as well as part strength. The first interlocking portions can include gaps, and second interlocking portions can include tabs. Here, the tabs can be formed by forcing the second material into the gaps. In some cases, the gaps can include a narrow region and a wider region, and the second material can be forced through the narrow region into the wider region to form a physical interlock between the second interlocking portion and the first interlocking portion. The first material segments can take the form of one or more first material layers, and the secondary material segments take the form of one or more secondary material layers. The interlock can prevent delamination of the second material layers from the first material layers. The material layers can be curved or non-planar. The material deposition system can control at least two translational and one rotational degrees of freedom (i.e. axes of motion) between the component being built and the material deposition system.
[0010] The details of one or more implementations of the subject matter described in this specification are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the invention will become apparent from the description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 shows an example FDM 3D printing system.
[0012] FIGS. 2 a and 2 b show a fixed angle nozzle depositing material on a sloped surface.
[0013] FIGS. 3 a - 3 f show an example variable angle nozzle depositing material on a sloped surface according to an implementation of this disclosure.
[0014] FIG. 4 shows a cross section view of a sample part made using a 5-axis FDM system.
[0015] FIG. 5 shows a cross section of a sample part with interlocking layers made using a 5-axis FDM system.
[0016] FIGS. 6 a - 6 b show side cross section views of an example implementation of an articulating material dispensing system.
[0017] FIGS. 7 a - 7 b show side cross section and isometric views of another example implementation of an articulating material dispensing system.
[0018] FIGS. 8 a - 8 d show various views of an example material guide system.
[0019] FIG. 9 shows an isometric view of another example implementation of an articulating material dispensing system.
[0020] FIGS. 10 a - 10 c show example implementations of a roller-based feeding system.
[0021] FIGS. 11 a - 11 b show an example implementation of an articulating material dispensing system having drive dogs.
[0022] FIG. 12 shows an isometric view of an example implementation of an articulating material dispensing system having a rotating base.
[0023] FIGS. 13 a - 13 b show side and front cross sections views of another example implementation of an articulating material dispensing system.
[0024] FIGS. 14 a - 14 b show side cross section views of another example implementation of an articulating material dispensing system.
[0025] FIGS. 15 a - 15 e show various views of another example implementation of an articulating material dispensing system.
[0026] FIG. 16 shows a side view of another example implementation of an articulating material dispensing system.
[0027] FIGS. 17 a - 17 c show isometric, top, and front views of an example deposited element having an interlocking feature.
[0028] FIG. 18 shows multiple elements from FIGS. 17 a - 17 c deposited next to each other.
[0029] FIGS. 19 a - 19 c show isometric, top, and front views of another example deposited element having an interlocking features.
[0030] FIG. 20 shows multiple elements from FIGS. 19 a - 19 c deposited next to each other.
[0031] FIGS. 21 a - 21 b show front and isometric views of an example two-layer interlocking structure.
[0032] FIGS. 22 a - 22 b show front and isometric views of an example three-layer interlocking structure.
[0033] FIGS. 23 a - 23 b show front and isometric views of an example four-layer interlocking structure.
[0034] FIGS. 24 a - 24 b show front and isometric views of an example twelve-layer interlocking structure.
[0035] Like reference numbers and designations in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0036] Referring to FIG. 1 , an example FDM 3D printing system 100 includes an extruder or 3D printer 102 , a controller 104 , and a communication link 106 that links the extruder 102 to the controller 104 . The 3D printer 102 includes an extruder nozzle 108 . The FDM system 100 can produce 3D products such as item 120 . The controller 104 can include one or more processors, memory, hard drive, solid-state drive, and/or input devices such as touch screen, mouse, or voice input capability. In some cases, the controller 104 can be an internet server or some other device, computer, processor, phone, or tablet. In some cases, the controller 104 and extruder 102 are integrated into a single 3D printing device.
[0037] Referring now to FIG. 2 a , a nozzle 200 , for example from an FDM system such as system 100 , is shown depositing material 202 on a sloped part surface 204 with a motion of travel in a downward sloping direction along part surface 204 . The nozzle 200 can be a nozzle tip designed for use with an FDM system or it can be from a different material deposition system such as a welding tip or electrode, syringe, adhesive material deposition system, material solidification system, material curing system or material pump, or combinations thereof. As shown the nozzle 200 is constrained to maintain its vertically oriented position. In other words, the nozzle 200 can move along, for example, the x, y, and z coordinates during deposition but will not be able to further change the angle at which it deposits material. Accordingly, the system depicted in FIG. 2 a may be referred to as a 3-axis FDM system. Implementations of the 3-axis FDM system are further described in related U.S. patent application Ser. No. 14/663,393, filed Mar. 19, 2015, titled SYSTEMS AND METHODS FOR IMPROVED 3D PRINTING, hereby incorporated by reference in its entirety.
[0038] FIG. 2 b shows the nozzle 200 , likewise constrained to the vertical orientation, depositing material 202 on the sloped part surface 204 with a motion of travel in an upward direction along the part surface 204 . Here, the nozzle 200 is shown moving uphill relative to the part surface 204 instead of downhill as in FIG. 2 a . The nozzle 200 can be a nozzle designed for use with an FDM system or it can be from a material deposition system such as a welding tip or electrode, syringe, adhesive material deposition system, material solidification system, material curing system or material pump or combinations thereof.
[0039] As shown in FIGS. 2 a and 2 b , the distance between the nozzle 200 and the part surface 204 can be varied depending on whether the nozzle 200 is moving downward or upward to thereby ensure that the resulting deposited material thickness can be similar or the same when the nozzle travels downhill or uphill or horizontally.
[0040] For example, in one method of correcting the position or path of the nozzle 200 , corrections can be made in the following way: a first nominal path or set of positions for the nozzle 200 is computed independent of the direction of travel of the nozzle 200 or the slope of the path of the nozzle 200 . Then a second path can be created by adjusting vertical position values by an amount dependent on the slope of the path of the nozzle 200 . The slope of the path may be defined as vertical distance moved over an interval divided by horizontal distance moved over the same interval, or as rate of instantaneous vertical motion divided by rate of instantaneous horizontal motion.
[0041] FIGS. 3 a , 3 b , and 3 c show material deposition on a sloped surface by an FDM system with a nozzle that is not constrained to be vertical. This can be for example an FDM system with additional axes to allow rotation of the nozzle, which is discussed in further detail below.
[0042] Referring to FIG. 3 a , a nozzle 300 is shown depositing material 302 along a surface with the nozzle axis perpendicular to a local surface 304 . In this case, the nozzle 300 can deposit the material 302 to have the same thickness while traveling in either direction along a given path. That is, the path can be the same for a nozzle moving in either direction to deposit material of a desired thickness.
[0043] Referring to FIG. 3 b , the nozzle 300 is shown depositing the material 302 along a sloped surface in an orientation such that the nozzle axis is not perpendicular to the local surface 304 . The nozzle 300 shown in FIG. 3 b can have one or more movable angle motion degrees of freedom or actuation so that the angle of a nozzle axis 306 with respect to vertical can be changed or can change along a path. The nozzle 300 in FIG. 3 b can have an acute angle 308 between its axis and the surface on one side (the “acute angle side”). The nozzle 300 in FIG. 3 b is shown traveling toward the side that forms the acute angle side as it deposits material that is left behind on the local surface 304 .
[0044] Referring to FIG. 3 c , the nozzle 300 is shown in a similar configuration as in FIG. 3 b , that is, in the same orientation as in FIG. 3 b while depositing material along the same sloped surface, but is instead shown moving away from the side that forms the acute angle. In order to deposit material of a given desired thickness, the nozzle 300 must follow a different path while moving toward the acute angle side as in FIG. 3 b as compared to moving away from the acute angle side as in FIG. 3 c . The path that the nozzle 300 follows can be closer to the surface 304 when the nozzle moves toward the acute angle as in FIG. 3 b and the path can be farther away from the surface 304 when the nozzle 300 moves away from the acute angle as in FIG. 3 c in order to deposit material of the same thickness in both cases.
[0045] Generally, a nominal path may be a path that a nozzle with axis perpendicular to the local surface should follow to deposit material of a given thickness in either direction. A nominal path may be adjusted to accommodate a non-perpendicular angle between the nozzle and the local surface while still depositing material of the same thickness by adjusting the path away from the local surface in areas where the nozzle moves away from the acute angle between the nozzle axis and the surface and adjusting the path to be closer to the surface in areas where the nozzle moves toward the acute angle.
[0046] Referring now to FIG. 3 d , a nozzle 310 with an orientation angle Φ 1 between a nozzle axis 312 and a part surface 314 . The angle between the surface 314 and a plane perpendicular to the nozzle axis can be defined as angle Φ 2 . Φ 2 can therefore represent the angle of the nozzle tip to the part surface at a specific location. As shown, the nozzle has a tip outer diameter D o and a tip inner diameter D i . Nozzle tip inner diameter D i can represent a nozzle exit orifice. A nominal path for the nozzle to follow can be represented by a series of position points, such that at each point along the nominal path there can be a distance, h o , between the local surface and the center of the nozzle exit orifice, where h o can be measured perpendicular to the local surface.
[0047] FIG. 3 e shows the nozzle 310 of FIG. 3 d traveling toward the side that forms the acute angle Φ 1 . The angle Φ 2 is similarly shown as in FIG. 3 d . In order for the nozzle 310 with angle Φ 1 to deposit material having the same thickness as a nozzle that is perpendicular to the local surface (for example, see FIG. 3 a ), an adjustment can be made to the path of travel such that a new distance between the surface and the center of the nozzle exit orifice, h 1 , is less than h o . One example way to accomplish this adjustment can be by making the following calculation: adjustment′=(D i /2)*sin(Φ 2 ). The new path point can be found as: h 1 =h o −adjustment 1 . Corresponding x,y,z coordinates or other suitable coordinates can be calculated with knowledge of Φ 2 , h o , and h 1 . The path in this case can be closer to the surface than the nominal path because the inside edge of the nozzle orifice largely determines the resulting material thickness.
[0048] FIG. 3 f shows the nozzle 310 of FIG. 3 d traveling in a direction away from acute angle Φ 1 . Again, Φ 2 is defined the same as in in FIG. 3 d . In order for the nozzle 310 with angle Φ 1 to deposit material in the same thickness as a nozzle that is perpendicular to the local surface (not shown here, but see FIG. 3 a ), an adjustment can be made to the path of travel such that a new distance between the surface and the center of the nozzle exit orifice, h 2 , is greater than h o . One example way to accomplish this adjustment can be by making the following calculation: adjustment 2 =(D o /2)*sin(Φ 2 ). The new path point can be found as: h 1 =h o +adjustment 2 . Corresponding x,y,z coordinates or other suitable coordinates can be calculated with knowledge of Φ 2 , h o , and h 2 . The path in this case can be farther from the surface than the nominal path because the outside edge of the nozzle tip largely determines the resulting material thickness.
[0049] Other calculations can be used to make corresponding adjustments based on Φ 2 , h o , and h 1 . In some cases, one or more of nozzle geometry, type of material being deposited, surface properties, etc. can be used to determine the necessary adjustments.
[0050] Referring now to FIG. 4 , a cross-section of an example part 400 is shown. The part 400 may be made by using a 5-axis FDM system or other material deposition system with a nozzle that can change angular orientation relative to the part. Part 400 is made of multiple layers 402 of deposited material that may be non-planar. In some cases, such layers 402 of deposited material may have a tendency to split or delaminate at layer interfaces.
[0051] FIG. 5 shows a cross section of a part 500 that is similar to the part 400 of FIG. 4 , except that layers 502 shown in FIG. 5 are locked together so that they are prevented or mitigated from splitting or delaminating at layer interfaces. Layers 502 can be made up of structural members 506 which are deposited as material from a nozzle 504 that then solidifies. Structural members 506 can be formed in several types with different features which combine to create an interlocking effect.
[0052] For example, layers can be deposited starting with the innermost layers and proceeding to the outermost layers. An n th layer can be deposited with one or more gaps of a first width. Then, a next layer (n+1 layer) can be deposited with gaps of a second width which can be narrower than the first width and which can be aligned with the gap(s) of the n th layer. A subsequent layer (n+2 layer) can be deposited over or outside of the n+1 layer with sufficient material and deposition speed or pressure that the material of the n+2 layer flows through the gap in then n+1 layer and into the gap in the n th layer. The n+2 layer material can partially or completely fill the gap(s) in the n th and n+1 layers. If the gap(s) in the n th layer are larger than the gap(s) in the n+1 layer, the N+2 layer material can form a physical interlock with the material of the other layers. The n+2 layer material that flows into the gaps in the other layers can be a locking feature 508 . Each layer can alternately have gaps of different widths at different locations as well as locking features so that all or nearly all of the layers can be sequentially interlocked. This construction can be effective at eliminating layer separation or delamination. The part 500 , formed in this or other similar manner, can include one or more of flat, concave, and convex portions.
[0053] In some cases, it can be possible to create useful layer interlocking with different layers having gaps of the same width or with combinations of just single gap-layers plus layers with locking features (i.e., without the stacking of multiple layers with aligned gaps). The layers 502 and associated gaps as well as locking features can be formed with the nozzle 504 being in various orientations. In some cases, the nozzle (and its corresponding nozzle axis) can remain vertical during material deposition, as in the case of a conventional 3-axis (x,y,z) FDM system. In some cases, the nozzle can be kept perpendicular to the local part surface during the deposition process. In some cases, the nozzle can have a variable angle with respect to the local part surface in order to facilitate certain features such as forming the base of a vertical wall next to a baseplate. For example, FIG. 5 shows the nozzle 504 completing a section of vertical wall next to a baseplate and shows the nozzle 504 at a non-perpendicular angle to the part surface to avoid crashing into the baseplate or other portions of the FDM system. Additionally, or alternatively, the angular orientation of the nozzle may be changed from a perpendicular angle to a non-perpendicular angle, or in some cases from a first non-perpendicular angle to a second non-perpendicular angle different from the first, to avoid making contact with an already deposited portion of the object being fabricated. In some cases, by changing the angular orientation of the nozzle to avoid making contact with parts of the FDM system or the object being fabricated, the possible coverage area of the nozzle may be increased. In other words, the nozzle, by changing its angular orientation to avoid making contact, could deposit materials into tighter spaces than would be otherwise possible without making such angle re-adjustments. Referring to FIG. 5 , as an example, the nozzle 504 can, by rotating in a clockwise direction to avoid hitting the base, deposit material closer to the intersection between the object and the base.
[0054] Locking features can be formed with the nozzle perpendicular to the local part surface or with the nozzle angled off of perpendicular to the local part surface. Layers and structural members can also be formed with overhangs 510 adjacent to locking features of other layers in order to create an interlocking structure. In some cases, interference members 512 can be deposited to help further improve interlocking between layers.
[0055] For a 5-axis FDM system or other material deposition system with a nozzle that can change angular orientation relative to the part, a compact, angularly variable distal end can help the nozzle reach into tight spaces. To achieve this, it is generally desired to have one of the angular articulation axes as close to the “tip”—or point where material is dispensed—as possible. However, based on conventional feedstock dispensing systems, it can be challenging to get a solid feedstock filament to go around such a sharp bend at the end before being pushed out of the tip.
[0056] Referring to FIGS. 6 a and 6 b , an articulating material dispensing system 600 is shown, with FIG. 6 a showing the articulating material dispensing system 600 in a nominal (vertical) configuration and FIG. 6 b showing the articulating material dispensing system 600 in an articulated (flexed) configuration.
[0057] As shown, the material dispensing system 600 can include flexible strips 602 which form the sides of a material channel 604 . There can be multiple flexible strips 602 in a leaf-spring structure that enables the width of the material channel 604 to be maintained throughout the range of articulation. A nozzle 606 can be employed at the distal end of the material dispensing system 600 to create a specific exit orifice size and control the flow of material. Cables 608 , as well as pushrods or other types of actuators, can be used to pull and/or push on the material dispensing system to cause controllable articulation. In some cases, a flexible sleeve can be used to hold the flexible strips 602 in place. Heating elements 610 can be used to heat the material flowing through the flexible portion of the system or can be used to heat the nozzle itself. Heating material flowing through the flexible portion of the system can help liquefy or soften the material which may allow the material to more easily flow around a corner when the system 600 is articulated. The flexible strips 602 can be used to shift in the nozzle axial direction (or along the length of the curve) to enable articulation (see FIG. 6 b ). Because creating the curvature, as indicated by the changing lengths of the flexible strips 602 , may require more feedstock material to ensure a continuous flow of material, the volume flow of material per distance, or extrusion ratio, may need to be increased in cases where there are curvatures in the feedstock channel.
[0058] In some cases, a material drive system such as a drive wheel can be located proximal to the articulating section. Alternatively, or additionally, a material drive system such as the drive wheel can be located distal to the articulating section. In cases where the feedstock material is softened or liquefied for improved passage through the articulating section, the feedstock material can be cooled, for example via a cooling zone, prior to being driven by the driven wheel.
[0059] The position of the exit orifice with respect to the degree of articulation or direction of articulation may be characterized so that for a given articulation amount (i.e. amount of bending) the position of the nozzle exit orifice can be known with little error.
[0060] Referring to FIGS. 7 a and 7 b , an articulating material dispensing system 700 , an alternative implementation, is shown. The system 700 shown in FIGS. 7 a and 7 b is similar to that of FIGS. 6 a and 6 b except that the material dispensing channel can be lined with or defined by a coil spring or set of material rings 702 in the articulating portion of the system. A coil spring can be used to define the material dispensing channel and can enable the channel size to stay relatively constant during articulation. A flexible sleeve 704 can surround the coil spring and further guide it or constrain its shape. Cables 706 , as well as pushrods, linkages, hydraulic actuators, inflatable bladders, muscle wires, or the like, can be used to control the degree of articulation of the system 700 .
[0061] In the example shown in FIG. 7 b , the system 700 is shown with 4 cables for articulation (one is hidden behind other components). This way, the system 700 can be articulated in multiple directions (i.e. can have multiple degrees of freedom). When combined with a 3-axis gantry system, a net system with 5 (five) axes of motion can be created (in addition to motion of the dispensed material). Additional translation and rotation axes are also possible to create 6, 7, 8, or more axes of motion and to allow the fabrication of a wide range of part shapes.
[0062] A nozzle 708 is shown at the distal end of the system 700 to control material flow and create an exit orifice. Heating elements 710 are shown in the nozzle 708 , but they can also or alternately be in the articulating section or proximal to (i.e. above) the articulating section. FIG. 7 a also shows drive wheels 712 (or a drive wheel and an idler wheel) that are shown proximal to the articulating section, though they can also be located at the articulating section or distal to it, for example in the nozzle 708 .
[0063] Referring to FIGS. 8 a - 8 d , a material guide system 800 can be used in an articulating material dispensing system such as that of FIGS. 7 a and 7 b to help guide the feedstock material. FIG. 8 a shows a cross section of a plain coil spring 802 . FIG. 8 b shows a cross section of the same coil spring 802 with the addition of contoured rollers 804 which can be threaded onto the spring and which can individually rotate about the spring such that material passing axially through the center of the spring might contact the rollers and might experience low resistance to axial motion due to the ability of the rollers to rotate.
[0064] FIG. 8 c shows a top view of the material guide system 800 of FIG. 8 b , and FIG. 8 d shows an isometric view of the same. The material guide system 800 as shown in FIGS. 8 a - 8 d can allow a material dispensing system to articulate (bend) while adding minimum resistance to feed motion of the material.
[0065] Referring to FIG. 9 , a material dispensing system 900 having two rotational degrees of freedom is shown. As shown, the first rotational degree of freedom allows the system to rotate about an axis that can be aligned with the entering feedstock—i.e. a vertical axis in the orientation of the system shown in FIG. 9 . The second rotational degree of freedom allows a nozzle to rotate about an axis that can be perpendicular to the axis of the first rotational degree of freedom. Continuous rotation of the first rotational degree of freedom can be possible if “winding up” of the feedstock can be eliminated. One or both of the heating zone and a cooling zone can be included. The heating zone 902 can help soften the feedstock to the point that it alleviates wind-up of the material (i.e. it allows arbitrary angular dislocation of the distal portion of the feedstock relative to the proximal portion). As material is continually fed through, any adverse effects of the local twisting of the material can be alleviated as that material is passed out of the nozzle and fresh feedstock material arrives to be heated so it can take up any further twisting of the system. A cooling zone 904 can help enable the material to solidify again before it is fed into the nozzle. A final drive wheel 906 can be used to provide the necessary driving force to controllably feed the feedstock into the nozzle. The material can be re-heated and softened or liquefied in the nozzle. An initial drive wheel 908 can be included to help drive the feedstock into the heating zone 902 .
[0066] In some cases, the feedstock material can be pinched and/or formed into flattened and/or ridged sections to help facilitate going around corners. For example, referring now to FIGS. 10 a - 10 c , a material deposition system 1000 changes the cross section shape of the feedstock so that the feedstock can more easily turn a tight corner.
[0067] FIG. 10 a shows a cylindrical feedstock 1002 being fed through rollers 1004 which can squeeze it and transform the fed-through portion to a ribbon section 1006 to have a thin rectangle or other cross-sectional shape with one thin dimension so that the feedstock can bend around a corner more easily or with lower force. A nozzle 1008 can provide an exit orifice 1010 . The nozzle 1008 can have an opening 1012 shaped correspondingly to accept the reshaped feedstock, for example it can have a rectangular opening. The shape of the exit orifice 1010 can be any required shape, for example it can have a circular shape. The feedstock can be heated before entering the feed rollers so that it is softened and its cross section shape can be more easily changed. The feedstock can be cooled as it passes between the rollers or it can be cooled after it passes through the rollers so that it solidifies and its shape is stable before it enters the nozzle. Additional elements of the material dispensing system 1000 , for example guides, can further be provided to improve operation.
[0068] FIG. 10 b shows rollers 1014 , which is another version of the forming rollers 1004 of FIG. 10 a , that has roller shapes that create a resulting material shape that has positive drive features. For example, the resulting reshaped feedstock can have a constant cross section area along its length so that a constant motion of the feedstock should result in a constant material flow rate out of a nozzle. A heating zone 1016 can be positioned at an upstream position relative to the rollers 1014 to soften the feedstock material for improved formability. FIG. 10 c shows another possible reshaped feedstock shape with positive drive features.
[0069] In some cases, additional features, such as reciprocating linear feed dogs, can be used to help drive the feedstock. FIGS. 11 a and 11 b show aspects of an articulating material dispensing system 1100 that is based on the reciprocating linear feed dog mechanism.
[0070] Referring to FIG. 11 a , the articulating material dispensing system 1100 has a bendable portion that creates articulation. The system includes reciprocating drive dogs 1102 which can be flexible members with asymmetric teeth that drive material feedstock when the feed dogs are moved in one direction (toward the distal nozzle end) and which can slide back along the feedstock without inducing motion in the feedstock to effect the reverse portion of the reciprocation motion. The feed dog teeth 1104 can bite into the feedstock to create a positive interlock during the forward portion of the reciprocation. Alternatively, the teeth 1104 can interlock with pre-existing serrations, indentations or other features on the feedstock.
[0071] The reciprocation motion can have a continuous speed or it can have different speeds for the forward and reverse portions of the motion, for example the reverse portion can happen much faster than the forward portion so that more than one feed dog can be pushing forward on the feedstock at any given time. There can be more than two feed dogs 1102 , for example there can be pairs or groups of feed dogs on each side of the feedstock so that there is always at least one feed dog on each side of the feedstock pushing forward at any given time. The motion of the various feed dogs can be coordinated so that while the motion of each individual feed dog can be reciprocal, the net motion imparted to the feed stock can be continuous forward motion or any desired motion profile. Different reverse feed dogs can be employed to effect reverse motion of the feed stock when needed. Or all feed dogs can be pulled backward at the same time which may create reverse feedstock motion.
[0072] Even though FIG. 11 a shows an articulating material dispensing system, the linear or reciprocating feed dog system described here may also be used in a non-articulating (i.e. straight) material dispensing system and may have advantages such as increased drive force and more consistent feed drive ratio with less variation of feedrate or feed ratio between different types of material feedstocks.
[0073] FIG. 11 b shows one possible construction of a flexible feed dog 1102 that can be used in a system such as that shown in FIG. 11 a . Here, an isometric view of a part of a feed dog made of sheet metal is shown. The feed dog includes flexible teeth formed in the sheet metal. Flexible teeth can be helpful in that they can positively grab the feedstock when moving forward and can slide relative to the feedstock when moving in reverse. A feed dog made of thin, flexible sheet metal can be used to drive the feedstock around a bend as in the system of FIG. 11 a.
[0074] FIG. 12 shows a different way to create a 5 (or more) axis material deposition system. The alternative system 1200 shown in FIG. 12 can include three linear motion axes, for example X, Y and Z. The system 1200 can include movement about a first rotational axis, such as α, allows angular articulation of a nozzle very close to the exit orifice. Having a non-vertical rotation axis (in this case a horizontal axis) located close to the exit orifice, can allow the nozzle to fit into tight spaces while still articulating, for example to deposit material on the inside of cavities in parts. Moreover, a part 1202 that is being formed can be rotated about a second rotational axis, such as θ. This can be achieved, for example, by placing the part 1202 on a rotatable base 1204 that can be rotated during deposition. The combination of the X,Y,Z, α and θ movements, then, as shown in FIG. 12 , enables full 5-axis motion without some of the complications that may be associated with articulating a nozzle with two rotational axes.
[0075] Referring now to FIGS. 13 a and 13 b , a material dispensing system 1300 with a nozzle mounted on a rotational axis is shown. Here, feedstock within a feedstock channel 1302 can be softened or liquefied in a liquefaction zone 1304 before it reaches the nozzle rotation axis. A drive wheel 1306 can be used to drive the feedstock through. Feedstock material can then flow sideways through a jog that is coincident with the nozzle rotation axis and then flows out through the nozzle. The jog coincident with the nozzle rotation axis can allow the nozzle to articulate through a range of motion while still providing a continuous, leak-free flow path for the feedstock material.
[0076] Referring to FIGS. 14 a and 14 b , a material dispensing system 1400 with a nozzle 1402 configured to rotate about two rotational axes is shown. The system 1400 also includes a material drive system (e.g. 1404 a - c ) that accommodates the range of motion of the nozzle rotation. An optional first rotation axis 1406 is shown with a vertical orientation. The nozzle can rotate about this vertical axis if this degree of freedom is present. A second rotational axis 1408 can be perpendicular to the first rotational axis 1406 (shown as horizontal, in/out of the page). Feedstock material 1410 is fed by a drive wheel 1404 c to the nozzle 1402 having an exit orifice. FIG. 14 a shows a side view of the system 1400 in a fully articulated position, and FIG. 14 b shows a side view of the system 1400 in a non-articulated (vertical) position.
[0077] Here, the feedstock 1410 follows a path that is off to the side so that it can wrap around the drive wheel 1404 c , and so that the drive wheel 1404 c can be centered on the second rotational axis 1408 . Having the drive wheel centered on the second rotational axis enables the drive wheel to stay in the same location as the nozzle rotates about the second axis. Having the drive wheel stay in the same position means that it can be driven by a belt 1404 a from above. Additionally, having the feedstock wrap around the drive wheel can facilitate bending the feedstock around the corner when the nozzle is in an articulated position. The radius of curvature can be larger in this configuration than it would be if the feedstock had to travel axially along the nozzle and the upper portion of the dispensing system. The feedstock material can exit the nozzle in-line with the nozzle axis because the feedstock path through the nozzle can guide it from being non-axial to becoming aligned with the nozzle axis just before it exits. An idler bearing can maintain pressure between the feedstock and the drive wheel. The idler bearing 1412 can be spring loaded so that it applies a relatively constant force to pinch the feedstock between itself and the drive wheel. The idler bearing can be affixed to the nozzle portion of the dispensing system so that when the nozzle rotates about the second axis, the idler bearing rotates with it so that it is always pinching the feedstock to the drive wheel just at the point before the feedstock enters the body of the nozzle, which can help in getting the feedstock to travel around the bend. The drive wheel can be actuated by a drive belt that can be driven by a motor or other actuator that is proximal of the drive wheel. In some cases, an additional set of drive belt and pulley can be used to control the articulation of the nozzle 1402 about the second rotation axis. The drive wheel motion can be coordinated with the rotation of the nozzle about the second axis so that the feedstock is not inadvertently fed or retracted when the nozzle rotates about the second axis.
[0078] FIGS. 15 a - 15 e show another implementation of the multi axis material deposition system. Referring to FIG. 15 a , an isometric view of a multi-axis material deposition system 14002 is shown. A material deposition nozzle 14004 is rotatable with respect to a base 14006 about a rotation axis 14022 . A material 14008 which can be a filament can be fed through nozzle 14004 . The base 14006 can move along, for example, the x, y, z axes and may be referred to as a movable support relative to which the nozzle 14004 can rotate. A feed drive belt 14010 can be used to transfer feed forces in order to feed material 14008 . A nozzle positioning drive belt 14012 can be used to transfer positioning forces in order to rotate nozzle 14004 .
[0079] Referring to FIG. 15 b , a path of material 14008 through nozzle 14004 is visible. Hatching has been omitted for clarity. A material drive wheel 14014 can drive material 14008 with the aid of a pinch roller 14016 . Positioning drive belt 14012 can drive a positioning pulley 14018 .
[0080] FIG. 15 c shows an isometric section view of system 14002 with the section plane passing through nozzle rotation axis 14022 . As shown, a positioning pulley 14018 is driven by positioning drive belt 14012 and is connected to nozzle 14004 so that when positioning drive belt 14012 moves, it results in rotation of nozzle 14004 about axis 14022 . Drive wheel 14014 is connected to a material drive pulley 14020 which is driven by belt 14010 so that when belt 14010 moves, material 14018 (see FIG. 15 b ) is fed through nozzle 14004 .
[0081] FIG. 15 d shows a front view of system 14002 in which nozzle 14004 is in a rotated position with respect to base 14006 . FIG. 15 e shows an isometric view of system 14002 with base 14006 removed for clarity to show the other components.
[0082] Referring now to FIG. 16 , another version of a material dispensing system 1600 having multiple rotational degrees of freedom is shown. Here, a center coupler 1602 couples a main body 1604 and a nozzle 1606 . Additional linkage parts between the coupler and the main body and the coupler and the nozzle can be used but are not shown here for sake of clarity.
[0083] As shown, there are four rotation axes: two parallel rotation axes that are horizontal in the plane of the page; and another two parallel horizontal rotation axes that are projecting in and out of the plane of the page. Using multiple parallel axes means that rotation at each axis can be limited, for example limited to 45 degrees, which can be helpful in avoiding instability or lock-up conditions. Cables, pushrods or other actuators can be used to control the rotation of the nozzle relative to the base part. Elastomeric, springy, or compliant members can be connected to the nozzle, coupler and base part to create predictable, deterministic motion given simple push/pull inputs from cables or actuators. In some cases, additional linkages can be employed to further constrain motion, for example linkages or gears can be used to constrain the angular rotation about pairs of parallel axes to be equal or to be in some other deterministic ratio.
[0084] Referring now to FIGS. 17-24 , additional implementations of the interlocking feature, similar to those described above in FIG. 5 , are described. FIG. 17 a shows an isometric view of an element 16002 which can be made of a continuous material 16004 . Element 16002 can have an interlocking feature 16006 in one or more locations.
[0085] Interlocking features 16006 can have a neck 16008 and one or more locking areas 16010 . FIG. 17 b shows a top view of the element 16002 , and FIG. 17 c shows a front view of element 16002 . Interlocking features 16006 with neck 16008 and locking areas 16010 can be seen.
[0086] Element 16002 can be formed by deposition of material 16004 such that element 16002 is continuous—i.e. it does not have any breaks in it. Material 16004 can be or can contain continuous fibers. Interlocking features 16006 can be formed by forcing continuous material into a cavity in another part or in previously deposited material (for example see FIGS. 21 a and 21 b ). The exact structure of interlocking features 16006 can take a variety of forms and the exact packing or path of continuous material 16004 can vary considerably, but it can form neck 16008 and locking areas 16010 regardless of specific packing arrangement. This is similar to the way a length of rope pushed into a box will take the net shape of the box regardless of the specific coil or path of the rope. Material 16004 can be a thermoplastic, fibers, a thermoset, a metal, a composite, a medium with living cells, a biologic material, a mineral material or any combination thereof.
[0087] Referring to FIG. 18 , a layer 17002 made up of elements 16002 deposited next to one another is shown. Elements 16002 can be joined (all formed continuously) or they can be separate. Layer 17002 can be a planar array of elements 16002 or it can be non-planar or it can be curved or it can be irregular. Gaps 17004 and 17006 are left between elements 16002 in areas where elements 16002 don't touch. Gaps 17004 can be larger than gaps 17006 .
[0088] FIGS. 19 a - 19 c show isometric, top, and front views, respectively, of an element 18002 , which is generally similar to element 16002 of FIGS. 17 a - c , but can have a different shape or be formed in a different orientation. Element 18002 can have interlocking features 18006 similar to interlocking features 16006 . FIG. 20 shows a layer 19002 made up of elements 18002 deposited next to one another. Layer 19002 can be similar to layer 17002 but it can be formed in a different orientation and it can be formed on top of layer 17002 (see FIG. 21 a ).
[0089] FIGS. 21 a and 21 b show an incomplete part with two layers together. This represents layers in a partially built part. In detail, FIG. 21 a shows a front view of a part 20002 which includes layer 17002 and layer 19002 . Interlocking features 16006 and 18006 are visible as part of layers 17002 and 19002 respectively. Interlocking features 18006 can have their shape defined as they are formed by being pushed into spaces in the shape of layer 17002 , such as gaps 17004 and 17006 . FIG. 21 b shows an isometric view of part 20002 .
[0090] Referring now to FIGS. 22 a and 22 b , a part that is being built with three interlocking layers together is shown. In more detail, FIG. 22 a shows a front view of a part 21002 . Part 21002 includes layers 17002 , 19002 and a third layer 21004 . Layer 21004 can be the same as layer 17002 , but the pattern is shifted. Locking features (not visible) from layer 21004 pass though narrow gaps in layer 19002 and fill larger gaps in layer 17002 . The narrow gaps can be similar to gaps 17006 in FIG. 18 . However, such gaps are not visible in this figure. The larger gaps can be gaps 17004 . By taking the shape of the narrow gaps in layer 19002 and then filling the larger gap in layer 17002 , an interlocking feature of layer 21004 can create a physical interference or lock between the layers which can prevent separation of the layers. A physical interference can be stronger and be more effective at preventing delamination of layers than a chemical bond alone. Material including strong fibers can thus be oriented transverse to the layers in the interlocking features and the strength of part 21002 can be closer to isotropic than in a typical part without interlocking features or transverse fibers between layers.
[0091] FIG. 23 a shows a front view of a part 22002 made of four interlocking layers including layers 17002 , 19002 , 21004 and a fourth layer 22004 . Layer 22004 may be the same as layer 19002 but it can be shifted to fit properly and achieve the desired arrangement of gaps and locking features. A set of 4 layers such as part 22002 may form a repeating unit, that is no more unique layer shapes or states are needed to continue to build the part. A fifth layer added on top of layer 22004 can be identical in shape and lateral position (shift) to layer 17002 . Sets of these four layers can be repeated indefinitely to achieve a desired part thickness. FIG. 23 b shows an isometric view of part 22002 .
[0092] Referring now to FIGS. 24 a and 24 b , a part that is being built with twelve interlocking layers together is shown. FIG. 24 a shows a front view of a part 23002 made of three parts 22002 , which are each four interlocking layers, arranged so that part 23002 has a total of twelve interlocking layers. FIG. 24 b shows an isometric view of part 23002 .
[0093] In all implementations shown above, all layers can be made of a single continuous material or fiber or fiber bundle. In some cases, each layer or element can be made of separate materials or fibers or fiber bundles.
[0094] Implementations of the subject matter described in this specification can be implemented in combination with digital electronic circuitry, or computer software, firmware, or hardware. Implementations of the subject matter described in this specification can be implemented in an additive manufacturing system that uses one or more modules of computer program instructions encoded on a computer-readable medium for execution by, or to control the operation of, data processing apparatus. The computer-readable medium can be a manufactured product, such as hard drive in a computer system or an optical disc sold through retail channels, or an embedded system. The computer-readable medium can be acquired separately and later encoded with the one or more modules of computer program instructions, such as by delivery of the one or more modules of computer program instructions over a wired or wireless network. The computer-readable medium can be a machine-readable storage device, a machine-readable storage substrate, a memory device, or a combination of one or more of them.
[0095] The term “data processing apparatus” encompasses all apparatus, devices, and machines for processing data, including by way of example a programmable processor, a computer, or multiple processors or computers. The apparatus can include, in addition to hardware, code that creates an execution environment for the computer program in question, e.g., code that constitutes processor firmware, a protocol stack, a database management system, an operating system, a runtime environment, or a combination of one or more of them. In addition, the apparatus can employ various different computing model infrastructures, such as web services, distributed computing and grid computing infrastructures.
[0096] A computer program (also known as a program, software, software application, script, or code) can be written in any form of programming language, including compiled or interpreted languages, declarative or procedural languages, and it can be deployed in any form, including as a stand-alone program or as a module, component, subroutine, or other unit suitable for use in a computing environment. A computer program does not necessarily correspond to a file in a file system. A program can be stored in a portion of a file that holds other programs or data (e.g., one or more scripts stored in a markup language document), in a single file dedicated to the program in question, or in multiple coordinated files (e.g., files that store one or more modules, sub-programs, or portions of code). A computer program can be deployed to be executed on one computer or on multiple computers that are located at one site or distributed across multiple sites and interconnected by a communication network.
[0097] Processors suitable for the execution of a computer program include, by way of example, both general and special purpose microprocessors, and any one or more processors of any kind of digital computer. Generally, a processor will receive instructions and data from a read-only memory or a random access memory or both. The essential elements of a computer are a processor for performing instructions and one or more memory devices for storing instructions and data. Generally, a computer will also include, or be operatively coupled to receive data from or transfer data to, or both, one or more mass storage devices for storing data, e.g., magnetic, magneto-optical disks, or optical disks. However, a computer need not have such devices. Moreover, a computer can be embedded in another device, e.g., a mobile telephone, a personal digital assistant (PDA), a mobile audio or video player, a game console, a Global Positioning System (GPS) receiver, or a portable storage device (e.g., a universal serial bus (USB) flash drive), to name just a few. Devices suitable for storing computer program instructions and data include all forms of non-volatile memory, media and memory devices, including by way of example semiconductor memory devices, e.g., EPROM, EEPROM, and flash memory devices; magnetic disks, e.g., internal hard disks or removable disks; magneto-optical disks; and CD-ROM and DVD-ROM disks. The processor and the memory can be supplemented by, or incorporated in, special purpose logic circuitry.
[0098] To provide for interaction with a user, implementations of the subject matter described in this specification can be implemented using a computer having a display device, e.g., a CRT (cathode ray tube) or LCD (liquid crystal display) monitor, for displaying information to the user and a keyboard and a pointing device, e.g., a mouse or a trackball, by which the user can provide input to the computer. Other kinds of devices can be used to provide for interaction with a user as well; for example, feedback provided to the user can be any form of sensory feedback, e.g., visual feedback, auditory feedback, or tactile feedback; and input from the user can be received in any form, including acoustic, speech, or tactile input.
[0099] Implementations of the subject matter described in this specification can be implemented using a computing system that includes a back-end component, e.g., as a data server, or that includes a middleware component, e.g., an application server, or that includes a front-end component, e.g., a client computer having a graphical user interface or a Web browser through which a user can interact with an implementation of the subject matter described is this specification, or any combination of one or more such back-end, middleware, or front-end components. The components of the system can be interconnected by any form or medium of digital data communication, e.g., a communication network. Examples of communication networks include a local area network (“LAN”) and a wide area network (“WAN”), an inter-network (e.g., the Internet), and peer-to-peer networks (e.g., ad hoc peer-to-peer networks).
[0100] The computing system can include clients and servers. A client and server are generally remote from each other and typically interact through a communication network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other.
[0101] While this specification contains many implementation details, these should not be construed as limitations on the scope of the invention or of what may be claimed, but rather as descriptions of features specific to particular implementations of the invention. Certain features that are described in this specification in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.
[0102] Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described program components and systems can generally be integrated together in a single software product or packaged into multiple software products.
[0103] Thus, particular implementations of the invention have been described. Other implementations are within the scope of the following claims. | A system for fabricating an object includes an extruder for one or more deposition materials having at least one nozzle and a movable support for the nozzle. The nozzle has a nozzle axis and is rotatably attached to the movable support via a connector that is actuatable relative to the movable support to change an angular orientation of the nozzle axis, thus varying an angle between the nozzle axis and a deposition surface. The system also includes a controller that can apply a correction factor calculated for a path of the nozzle when an acute angle is formed between the nozzle axis and the deposition surface, the correction factor for moving toward the acute angle being different from that when moving away from it. The correction factor removes differences in thickness of the deposited material caused by variations in the angle formed between the nozzle axis and the deposition surface. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a continuation of International Application Serial No. PCT/DE2003/003118, with an international filing date of Sep. 19, 2003, and designating the United States, the entire contents of which is hereby incorporated by reference to the same extent as if fully rewritten.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention concerns a method and a system for reducing a jerk produced by the range shift of a CVT transmission with power division.
[0004] 2. Description of the Related Art
[0005] Transmissions with continuously adjustable transmission ratio, especially belt-driven conical pulley transmissions with two conical disk pairs spanned by an endless torque-transmitting means, are increasingly utilized in motor vehicles because of the comfort advantages and fuel economy savings that can be achieved thereby. Because of the limited transmission ratio adjustment, which is made possible by the two conical disk pairs of the transmission ratio adjustment unit, also designated as a variator (variable speed drive), through opposite adjustment of the spacing between the conical disks of the conical disk pairs, the further development of such transmissions is thus intensively investigated so that the adjustment range of the variator can be used twice, in that it is carried out once in the one direction and then in the other direction.
[0006] FIG. 1 shows an exemplary CVT transmission with power division:
[0007] An engine 2 of a motor vehicle is connected with the input shaft 4 of a variator VAR containing two conical disk pairs spanned by an endless torque-transmitting means. The variator is connected with the output shaft 6 of the transmission by a first planetary gear set P 1 . A power division path of the transmission leads from the input shaft 4 through a clutch K 2 and a second planetary gear set P 2 to the output shaft 6 .
[0008] More precisely, the input side of clutch K 2 is non-rotatably connected with the input shaft 4 and the output side with the planet carrier of planetary gear set P 1 and the ring gear of planetary gear set P 2 . The output shaft 6 is non-rotatably connected with the ring gear of the planetary gear set P 1 and the planet carrier of planetary gear set P 2 . The output shaft of the variator is connected with the sun gear of the planetary gear set P 1 . The sun gear of the planetary gear set P 2 is selectively fixed or freely rotatable through a shift clutch K 1 . To match a motor vehicle, the output shaft 6 is connected with the drive wheels 10 of the motor vehicle through a transmission ratio stage 8 , wherein 12 symbolizes the elastic elements contained in the power train of the motor vehicle, which make the power train susceptible to vibration.
[0009] The variator VAR, and the shift clutches K 1 and K 2 are controlled by a control unit 14 with a microprocessor 16 , a program memory 18 , and a data memory 20 . The control unit 14 has inputs 22 , which are connected with sensors of the power train, for example rotational speed sensors, load sensors, temperature sensors, an accelerator pedal position sensor, a transmission selector lever position sensor, etc. The control unit 14 generates output signals at its outputs 24 , in accordance with which the actuators of the variator VAR, and the shift clutches K 1 and K 2 are operated.
[0010] The construction and function of the described system are known and are therefore not described in detail.
[0011] FIG. 2 shows the overall transmission ratio i GES of the transmission as a function of the transmission ratio i VAR of the variator VAR, and the positions of the shift clutches K 1 and K 2 .
[0012] In the first range of the transmission, while driving at high transmission ratios or at low speed, the shift clutch K 2 is disengaged, and the shift clutch K 1 engaged, so that the sun gear of the planetary gear set P 2 is stationary, and the ring gear of the planetary gear set P 2 rotates together with the planet carrier of the planetary gear set P 1 . The transmission runs in the non-power-division range, while its transmission ratio changes corresponding to the transmission ratio of the variator i VAR . When the variator reaches its longest possible transmission ratio (i VAR approximately =0.5), a shift occurs in the overall transmission ratio U, in which the shift clutch K 1 is disengaged and the shift clutch K 2 is engaged, so that a power-division operation takes place, which is carried out at higher speeds, and which leads to the longest possible overall transmission ratio i GES of the transmission of approximately 0.8. As shown, in that way by a spread of about 4 for the variator, a spread of about 7 for the overall transmission ratio can be achieved.
[0013] A problem that is encountered during a range shift of the transmission consists in the fact that rotating masses within the transmission, especially when shifting during rotational speed gradients take place, for example kick-down downshifts, require high acceleration output. That acceleration output is lost in the traction force, and thereby causes a shift jerk, or a shift jerking, which is detectable in the motor vehicle, and is relatively uncomfortable.
[0014] The invention is based on the object to avoid such jerks in a range shift.
SUMMARY OF THE INVENTION
[0015] A first solution of the object of the invention is achieved with a method for the reduction of a jerk produced by the range shift of a CVT transmission with power division, in which the variator is acted upon in such a way by a short-term transmission ratio adjustment impulse that a cancellation jerk caused thereby weakens the jerk caused by the range shift.
[0016] Advantageously, the cancellation jerk is produced directly after a range shift. The controlled change of the clutch torque can then in substantial part be concluded.
[0017] Advantageously, the duration of the cancellation jerk corresponds to approximately a quarter of a jerking period.
[0018] In a preferred embodiment of the method, the magnitude of the cancellation jerk corresponds approximately with the magnitude of the jerk caused by the range shift.
[0019] A further solution of the object of the invention is achieved with a method for the reduction of a jerk produced by the range shift of a CVT transmission with power division, in which the actuation of the shift clutches that bring about the range shift which stimulates a jerk is modified corresponding with the rotary mass accelerations resulting from the range shift.
[0020] Preferably, the engaging shift clutch is engaged prematurely.
[0021] In a further advantageous embodiment the contact pressure of the engaged shift clutch is increased.
[0022] For the described method, in an advantageously employable method for controlling the operation of a shift clutch effected as brake in a CVT transmission with power division, the input and output rotational speed of the variator, as well as the rotational speed in the power-division transmission range are measured, from which the slippage rotational speed of the shift clutch is determined and supplied to a slip regulator.
[0023] A system for reducing a jerk caused by range shift of a CVT transmission with power division, for solving the object of the invention, contains a transmission with a variator, two planetary gear sets, and two shift clutches, by means of which the flow of torque of the transmission can be switched in different ways from an input shaft drivable by an engine to an output shaft driving a motor vehicle, actuators for operating the variator and the shift clutches, and a control unit for controlling the actuators as a function of the operating parameters of the motor vehicle and a driver's desire, whereby the control unit controls the actuators corresponding with a method in accordance with one or several of the above-stated method claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The invention will be explained below on the basis of exemplary schematic drawings and with further details in which drawings:
[0025] FIG. 1 shows a basic connection diagram of a known transmission with power division;
[0026] FIG. 2 shows the transmission ratio of the transmission in accordance with FIG. 1 , as a function of the transmission ratio of the variator;
[0027] FIG. 3 shows graphs for explaining a method in accordance with the invention;
[0028] FIGS. 4 and 5 show graphs to explain the effectiveness of the method in accordance with the invention; and
[0029] FIGS. 6 to 8 show graphs to explain a further method in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] As can be seen from FIG. 1 , in the first region ( FIG. 2 ), or the non-power-division region, the sun gear of the planetary gear set P 2 is stationary, because the clutch K 1 is engaged. In the power division operation, however, the ring gear of the planetary gear set P 2 , and the planet carrier of the planetary gear set P 1 rotate at the rotational speed of the input shaft 4 (clutch K 2 engaged), and the sun gear of the planetary gear set P 2 is freely rotatable, whereby its rotation is determined by the rotation of the output shaft 6 and the input shaft 4 or its planet carrier and the ring gear. When shifting, internal transmission rotary masses must then be accelerated and/or decelerated, which can lead to a jerk in the longitudinal direction of the motor vehicle.
[0031] Generally speaking, there exist in power-division transmissions internal transmission rotary masses whose rotational speed behavior is neither synchronous to the input rotational speed nor synchronous to the output rotational speed. The rotational acceleration of those rotary masses changes abruptly at a range change, so that the output power also undergoes a jump.
[0032] Known solutions for the reduction of jerks caused by such rotational speed jumps are based on the engagement of the engine or the smoothing of clutch actuations. Other solutions suggest special variator regulators, which recognize an existing jerk and which regulate the variator to modulate in a damping effective way.
[0033] In accordance with the invention it is proposed to cancel a jerk excitation by an opposite excitation. Necessary for that purpose is derivable knowledge of the magnitude and the instant of excitation of the particular transmission.
[0034] For employing the essential change of the variator VAR in a range shift concerns the variator torque, which changes the magnitude and the sign. As a consequence thereof, the contact pressure requirement and the support change, that is, the required contact pressure between the conical disk pairs, and the endless torque-transmitting means to maintain the transmission ratio change. The changes resulting from a range shift are basically known and can therefore be predicted by control technology, so that a range shift is not connected with a sudden drift of the transmission ratio.
[0035] In accordance with the invention, through the subsequent control or subsequent adjustment of the contact pressure required beyond the support function, a short-term adjustment of the variator to produce a cancellation jerk takes place.
[0036] One such cancellation jerk can, in theory, be produced before or after or also during the range shift. In both cases, the principle of cancellation is operative. Overall, many application cases have shown that it is preferable when the cancellation jerk is produced after the range shifts.
[0037] The cancellation jerk is produced in that an adjustment force impulse for adjusting the variator is produced, which has a defined magnitude and duration. The duration advantageously lies within the range of a quarter of a jerk period, especially within the range of 50 milliseconds to 200 milliseconds, as is often the case. The magnitude of the actively induced cancellation jerk is proportional to the strength of the excitation to be canceled. For the magnitude of the cancellation jerk, in numerous transmissions, especially transmissions with the structure in accordance with FIG. 1 , the driving rotational speed gradient serves as a useful measure. Other suitable signals are the transmission ratio gradient or the acceleration jump of the internal transmission rotary masses which is to be expected at a range change. Furthermore, suitable values for determining the magnitude of the cancellation jerk to be applied are the so-called target signals (for example, target transmission ratio, or target rotational speed gradient). Those target signals depend generally less sensitively on measured signals, and are therefore more feedback-free (feedback is potentially unstable). Typical values for the magnitude of a cancellation jerk are between 10 kN and 50 kN. The proportionality constant, which designates the relationship between the magnitude of the cancellation jerk and the strength of the excitation to be canceled can be determined, for example, experimentally.
[0038] FIG. 3 explains the method in accordance with the invention by way of two examples.
[0039] Both figures on the left show the existing motor vehicle acceleration a FZG in m/s 2 as a function of the time t in seconds, without use of the cancellation jerk in accordance with the invention. The middle graphs show the transmission ratio adjustment impulse for adjusting the overall transmission ratio i GES . That adjustment impulse leads to a cancellation jerk, which in both graphs on the right is shown crosshatched.
[0040] The three upper graphs (I) show the conditions for a motor vehicle that experiences a delayed jerk at a range shift (initiation of the excitation vibration is a reduction in the acceleration). That excitation jerking is superimposed with an adjustment impulse in accordance with the upper middle graph, in which the transmission ratio is changed in the direction of UD (underdrive) to OD (overdrive), whereby a cancellation jerk (upper right in FIG. 3 ) is produced, which is opposite to the excitation jerk, so that the excitation jerking and the cancellation jerking produced by the adjustment impulse cancel each other, whereby the range shift takes place largely jerk-free.
[0041] The three lower drawings (II) of FIG. 3 show the conditions for the case when the motor vehicle is first accelerated in a range shift without a specific adjusting impulse for the variator adjustment. Here, the adjusting impulse takes place in the direction of an adjustment of the transmission ratio from OD to UD.
[0042] Overall, in accordance with the invention, with a specific introduction of an adjusting impulse in the variator, the jerk in range shift can largely be avoided.
[0043] With the help of FIGS. 4 and 5 a special example for the effectiveness of the method in accordance with the invention is explained. In FIG. 4 time is shown in the abscissa in each case. The uppermost curve I shows the rotational speed of the output-side disk set of the variator, curve II shows the transmission ratio of the variator, whereby the range shift takes place at the minimum transmission ratio (see the arrow). Curve III shows the adjustment force of the variator, and curve IV shows the motor vehicle acceleration.
[0044] As can be seen (curve IV) the vehicle jerks severely at the range shift.
[0045] FIG. 5 shows the same conditions as FIG. 4 , with the difference, however, that the adjustment force is raised higher at, or immediately after the range shift. That leads to a slight S-shaped path as can be seen from curve II, which in turn excites a cancellation impulse, so that in accordance with FIG. 4 , the motor vehicle acceleration during the range shift takes place essentially jerk-free.
[0046] As explained, it is thereby possible to largely or completely suppress a shift jerk that occurs during the range shift by means of an adjustment impulse to the variator when shifting, which leads to a cancellation impulse opposite to the shift impulse. The direction and magnitude of an effective adjustment impulse on the variator transmission ratio the in direction of an adjustment, are a function of the transmission construction and the shift direction.
[0047] A further possibility to eliminate or to avoid the shift jerk, consists in a modification of the operation of the shift clutches K 1 and K 2 ( FIG. 1 ), which is explained on the basis of FIGS. 6 to 8 .
[0048] In the left part of FIG. 6 there is illustrated to what degree in which the shift clutch (abscissa) to be disengaged is disengaged, the takeover clutch to be engaged is being engaged (ordinate). In each case, the transmittable frictional torque of the shift clutches is shown in kNm. In accordance with the left part of FIG. 6 , an approximate straight line equation applies for both clutch torques.
[0049] In the right part of FIG. 6 , the abscissa represents in each case the time t corresponding with the shift of only one engaged shift clutch, to only the other engaged shift clutch. Curve A denotes the engine rotational speed, curve B denotes the transmittable torque of the disengaging shift clutch, curve C denotes the transmittable torque of the engaging clutch, curve D shows the variator transmission ratio (shift at the minimum), and curve E denotes the motor vehicle acceleration. As can be seen, in the illustrated case, the shift takes place without substantial change of the engine rotational speed with a slight motor vehicle jerking after the shift.
[0050] FIG. 7 corresponds with FIG. 6 ; the course of the clutch torques again approximates a straight line. In the case of FIG. 7 , the range shift of the transmission, however, takes place during a rotational speed gradient of the engine. In accordance with the rotational speed gradient, the range change is combined with a large excess acceleration, which leads to a strong jerk of the motor vehicle (arrow at the not completely shown curve E) with subsequent jerking.
[0051] FIG. 8 shows the conditions of FIG. 7 , however with a “detour-overlapping” in accordance with the invention. As can be seen from the left part of FIG. 8 and the curves B and C, the takeover clutch is already engaged in the shift in accordance with FIG. 8 , while the disengaging clutch still transmits high torques. That condition is associated with a tension, which reaches a predetermined quantity, and absorbs the excess acceleration. For the two clutch torques no straight line equation applies, but their course shows a distinct “detour.” That detour means the simultaneously engaged condition of both clutches. The resulting motor vehicle acceleration (curve E of FIG. 8 ) does not have a distinct overshoot anymore, as compared to curve E in FIG. 7 . As a result, in spite of the rotational speed gradients (curve A) the range change in comparison with FIG. 7 is distinctly more comfortable.
[0052] It is apparent that the methods in accordance with FIG. 3 , and FIG. 5 , as well as FIG. 8 , can be applied in power-division transmissions of the most varied structural types, whereby the adjustment pulse ( FIG. 3 ) and the detour ( FIG. 8 ) are each appropriately selected. Likewise, it can also be advantageous to form the detour still more curved. Thereby, in the middle of the range change, for example, a tension gap can be produced, which is advantageous for canceling opposite jerks.
[0053] A further problem that appears in the control of the range shift of a power-division CVT transmission is the following:
[0054] For controlling or regulating such a power-division transmission, in general only two rotational speed sensors are required for the rotational speed of both conical disk pairs. Insofar as the transmission condition is determined by shift clutches in each case (one clutch slip-free; shift clutches K 1 , and K 2 of FIG. 1 ), the required functions of the transmission ratio control or regulation of the variator can be produced from the rotational speeds of the disk sets, the operation of the shift clutches, also from the rotational speeds of the disk sets and the starting control from the rotational speed of the input-side disk sets, and the engine rotational speed.
[0055] For optimizing the costs and structural space it is advantageous from the start to eliminate a starting clutch, not shown in FIG. 1 , and to produce starting through the low-range clutch (clutch K 1 in FIG. 2 ). For further optimizing costs and structural space it is advantageous, instead of a complete two-mass-flywheel (then the mass of the input-side disk set operates as a secondary mass of the two-mass-flywheel), or the complete two-mass-flywheel, to save and to install a slip regulation for noise reduction. For a slip regulation, in each case a most exact possible slip signal of the controlled clutch is required.
[0056] In the transmission in accordance with FIG. 1 , the slip of shift clutch K 1 , which represents a brake for the sun gear, is identical with the rotational speed of the shaft of the sun gear braked by the clutch. When reducing the slip, or engaging the clutch, that rotational speed becomes very low, which makes its detection with a sensor more difficult. Common speed sensors are based on the evaluation of the impulse of a trigger-wheel. At a low rotational speed only a few impulses are produced in long intervals. That makes a regulation impossible when expensive trigger-wheels with a fine gradation are not installed.
[0057] In accordance with the invention, it is accordingly proposed to supplement the rotational speed of the input shaft 4 of VAR and the rotational speed of the output shaft of VAR, to also detect the rotational speed in the divided transmission branch (rotational speed of the output shaft of shift clutch K 2 ) or of the planet carrier of the planetary gear set P 1 , as well as the rotational speed of the ring gear of the planetary gear set P 2 with a sensor is suggested. That rotational speed continuously lies in a precisely measurable range between, for example, 1,000 and 6,000 RPM. From the three measured rotational speeds, the rotational speed of the braked shaft of the shift clutch K 1 or the slip rotational speed can be calculated exactly, on the basis of the existing transmission ratios, and supplied to a slip regulator contained in control unit 14 .
[0058] For the illustrated transmission configuration the following applies:
n S2 =n V *( i 1 +i 2 −1)/ i 1 −n SS2 *(1− i 2 )/ i 1
whereby n S2 is the rotational speed of the sun gear of planetary gear set P 2 ,
n v the rotational speed of the ring gear of planetary gear set P 2 , i 2 the transmission ratio of planetary gear set P 2 , and n SS2 the rotational speed of the output-side disk set of the variator VAR.
[0062] In the case of i 1 =−2.5 and i 2 =−1.5, it results in the simple formula:
n S2 =2 *n V −n SS2
[0063] As is apparent from the foregoing, the accuracy of the determined rotational speed of the sun gear of planetary gear set P 2 corresponds to the accuracy of the other rotational speeds.
[0064] A similar formula can be derived, in order to calculate the rotational speed n S2 from the output rotational speed of the transmission and the rotational speed of the output-side disk set of the variator.
[0065] The methods described above can be applied individually or together in any desired combination. | A method and a system for reducing a jerk produced by the range shift of a transmission with a power division arrangement. The transmission includes a variable speed drive in the form of a continuously variable transmission, and a pair of planetary gear sets and a pair of shift clutches to enable power to be divided between two branches within the transmission. During a range shift between two operating ranges the variable speed drive is acted upon by a short-term transmission ratio adjustment impulse in such a way that a cancellation jerk caused thereby the adjustment impulse weakens the jerk caused by the range shift. | 5 |
TECHNICAL FIELD
The present invention relates to a capacitive load cell for estimating occupant weight applied to a vehicle seat, and more particularly to a load cell apparatus that is shielded to prevent electromagnetic interference while being substantially insensitive to capacitive coupling between the load cell and other objects including the shield.
BACKGROUND OF THE INVENTION
Various sensing technologies have been utilized to classify the occupant of a vehicle seat for purposes of determining whether to enable or disable air bag deployment, and/or for purposes of determining how forcefully an air bag should be deployed. The present invention is directed to an approach in which at least one capacitive load cell is installed in a vehicle seat, and the capacitance of the load cell is measured to provide an indication of the weight applied to the seat and/or the distribution of the applied weight. In general, capacitive load cells are well known in the sensing art, such as in the U.S. Pat. No. 4,266,263 to Haberl et al., issued on May 5, 1981. Capacitive load cells have also been applied to vehicle seats for sensing occupant weight and distribution; see, for example, the U.S. Pat. Nos. 4,836,033 to Seitz; U.S. Pat. No. 5,878,620 to Gilbert et al.; U.S. Pat. No. 6,448,789 to Kraetzl; and U.S. Pat. No. 6,499,359 to Washeleski et al.
One of the problems encountered with using a capacitive load cell in a vehicle seat is that stray or parasitic capacitance between the load cell and other objects, including objects resting on or under the seat, tend to influence measurement of the load cell capacitance. Another problem is electromagnetic interference from various electrical devices both inside and outside the vehicle. And in applications that include more than one capacitive load cell or a multi-plate sensor such as disclosed in the aforementioned U.S. Pat. No. 4,836,033 to Seitz, conductive or wet objects placed on the seat can capacitively couple the cells.
The problems associated with electromagnetic coupling and interference can be addressed to some degree by shielding the load cell, as mentioned in the aforementioned U.S. Pat. No. 6,499,359 to Washeleski et al. An analogous approach is suggested in the U.S. Pat. No. 6,703,845 to Stanley et al. in regard to a sensor designed to capacitively interact with a seat occupant, where a driven shield is placed between the sensor and a seat heater element disposed beneath the sensor. However, introducing a shield significantly increases problems associated with stray or parasitic capacitance. Accordingly, what is needed is a capacitive load cell and sensing circuit that provides an accurate and reliable measure of load cell capacitance.
SUMMARY OF THE INVENTION
The present invention is directed to an improved sensor apparatus for measuring weight applied to a vehicle seat with a shielded capacitive load cell, where the load cell capacitance is determined so as to minimize the effect of stray or parasitic capacitance between the load cell and other objects including the shield. The capacitance is determined by coupling the load cell conductors across input and output terminals of an operational amplifier that is tied to a reference voltage, forcing a constant current through the load cell and measuring the resulting rate of change in voltage at the amplifier output. In a vehicle seat sensor application including an electromagnetic interference shield between the sensor and the seating surface, the amplifier output is coupled to the load cell electrode furthest from the shield, the amplifier maintains the other load cell electrode at a virtual reference voltage, and the shield is tied to the reference voltage.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded diagram of a vehicle seat and a sensing apparatus including a capacitive load cell and electronic controller according to the present invention;
FIG. 2 is a circuit diagram of the electronic controller of FIG. 1 , where the load cell of FIG. 1 is depicted as an equivalent capacitance; and
FIG. 3 graphically depicts various voltages typically present in the circuit of FIG. 2 as a function of time.
DESCRIPTION OF THE PREFERRED EMBODIMENT
While the shielded capacitive load cell apparatus of the present invention may be used in various applications, it is disclosed herein in the context of an apparatus for detecting the weight and/or distribution of weight applied to a vehicle seat. In general, a capacitive load cell comprises upper and lower conductor plates separated by a compressible non-conductive medium, such that mechanical loading of the cell reduces the separation distance of the conductor plates, increasing the electrical capacitance between the upper and lower plates. Preferably, the capacitive load cell is disposed between the frame and bottom cushion of the seat as depicted herein, but it will be understood that the load cell may be installed in a different location such as in the bottom cushion, in or behind a back cushion, and so on.
Referring to FIG. 1 , the reference numeral 10 generally designates a seat bottom and sensor apparatus according to this invention. The sensor apparatus includes a shielded capacitive load cell 12 and an electronic control unit (ECU) 14 . The load cell 12 is disposed between the seat frame 16 and a foam cushion 18 , and includes an upper substrate 20 , a fluid-filled elastomeric bladder 22 , and a lower substrate 24 . A reference plane conductor 28 is formed on lower substrate 24 adjacent bladder 22 , and a number of charge plate conductors 30 are formed on upper substrate 20 adjacent bladder 22 . A shield conductor 32 is formed on the opposing or outboard face of upper substrate 20 to shield the load cell from electromagnetic interference. The upper and lower substrates 20 , 24 are non-conductive, and may be formed of a material such as polyurethane with a thickness of about 0.5 mm. The conductors 28 , 30 , 32 may be metal foil pads laminated to the respective substrates 20 , 24 . The reference plane conductor 28 , the shield conductor 32 , and each of the charge plate conductors 30 are separately coupled to ECU 14 , which periodically measures capacitance values between the reference plane conductor 28 and each of the charge plate conductors 30 . The measured capacitances provide an indication of the weight applied to seat cushion 18 , as well as the distribution of the weight, for purposes of detecting the presence of an occupant and classifying the occupant as a child, an adult, a child seat, or some other classification.
The conventional method of measuring capacitance (as disclosed in the aforementioned U.S. Pat. No. 4,836,033 to Seitz, for example) involves coupling a charging circuit including a low distortion sinusoidal voltage source and a precision resistor in parallel with the load cell capacitor to form a voltage divider, and measuring the voltage at a node between the capacitor and the precision resistor. The measured voltage Vm is related to the RMS voltage Vs of the voltage source, the source frequency ω (in radians), the resistance R of the precision resistor and the load cell capacitance C according to:
| Vm|=|Vs |/(1 +ωCR 2 ) 1/2
While the conventional method of measuring capacitance seems relatively straight-forward, various practical considerations make it difficult to implement. First, parasitic or stray capacitance between the load cell conductors and other objects can make it difficult or impossible to accurately measure the load cell capacitance; this is particularly true when a metallic shield such as the conductor 32 is placed in close proximity to the load cell conductors to prevent electromagnetic interference. Second, it is difficult to inexpensively produce low distortion sinusoidal voltage sources and precision resistors. Third, the non-linear relationship between Vm and C makes it difficult to accurately measure capacitance over a wide range of values. Fourth, any leakage current at the measurement node will generate a non-linear error in the calculated capacitance value. And fifth, an analog-to-digital data converter is required to convert the measured voltage Vm to a digital value usable by ECU 14 .
The present invention addresses the above-described problems with a capacitance measuring circuit that is inexpensive to implement, linear and virtually immune to errors due to parasitic capacitance and leakage currents. A preferred embodiment of the capacitance measuring circuit is shown in FIG. 2 , where the reference plane conductor 28 and a selected charge plate conductor 30 are represented as an equivalent variable capacitor 40 . Parasitic capacitance between the reference plane conductor 28 and other objects is represented by the capacitor 42 , and parasitic capacitance between the charge plate conductor 30 and other objects including the shield conductor 32 is represented by the capacitor 44 . The heart of the capacitance measuring circuit is an operational amplifier 46 referenced to a DC supply voltage Vdd (5 VDC, for example) and the circuit ground Vss. The reference plane conductor 28 is coupled to the amplifier's output at circuit node A, while the charge plate conductor 30 is coupled to the amplifier's negative input at circuit node B. The positive input of amplifier 46 is connected to a reference voltage V REF (2.5 VDC, for example), as is the shield conductor 32 . A solid state switching device 48 (illustrated in FIG. 2 as a mechanical switch) controlled by a digital clock signal V CLK alternately couples circuit node B to current source 50 and current sink 52 (implemented with current mirrors, for example), which are configured to source and sink the identical current magnitude I CS .
The operational amplifier 46 characteristically attempts to maintain the voltage at its negative input equal to the reference voltage V REF by varying its output voltage V O at circuit node A. As a result, the amplifier's output voltage V O decreases in magnitude at a linear rate when circuit node A is coupled to current source 50 , and increases in magnitude at the same linear rate when circuit node A is coupled to current sink 52 . The linear rate of increase and decrease (i.e., ramp rate RR) is linearly proportional to both I CS and the load cell capacitance C according to:
RR=I CS /C
Any RF or other interference currents present at circuit node B can be dissipated by utilizing ferrite beads at the amplifier inputs to attenuate the interference frequencies. Additionally, the capacitor 54 provides AC coupling between the inputs; this causes the interference to be in common mode for improved rejection by amplifier 46 . The frequency of the clock signal V CLK can be relatively low (a few kilohertz or less) so that the capacitance measurement is substantially unaffected by the interference minimizing components.
The period of V CLK is such that the amplifier output voltage V O reaches the respective voltage limit Vdd or Vss before the switching device 48 changes state. The resulting operation of the circuit is graphically depicted in FIG. 3 , where V O increases from 0V to 5V in the time interval t 0 –t 3 (and t 8 –t 11 ) due to the operation of current sink 52 and decreases from 5V to 0V in the time interval t 4 –t 7 due to the operation of current source 50 . The circuit of FIG. 2 measures the ramp rate RR by measuring the time for V O to increase or decrease by a reference amount defined by upper and lower reference voltages V UP and V LW between 0V and 5V. In the illustrated embodiment, V UP has a value of 4.25V, and V LW has a value of 0.75V, as indicated in FIG. 3 . Referring to FIG. 2 , the comparators 56 and 58 respectively compare V O to reference voltages V UP and V LW , and provide outputs to NOR-gate 60 to produce a digital counter voltage V CT on line 62 . As shown in FIG. 3 , V CT assumes a logic-one level when V CT is between V UP and V LW , and otherwise assumes a logic-zero level. Of course, hysteresis may be added to comparators 56 and 58 to prevent additional state changes due to noise. Since the change in output voltage is the same regardless of whether V O is increasing or decreasing, the duration of the logic-one intervals of V CT (i.e., intervals t 1 –t 2 , t 5 –t 6 , t 9 –t 10 , etc.) can be used to accurately and directly represent the load cell capacitance C. That is, the measured interval ΔT is given by [C* (V UP −V LW )]/I CS , where V UP , V LW and I CS are all constants. In the diagram of FIG. 2 , the counter 64 measures the ΔT intervals and produces a Trise output on line 66 corresponding to the periods of increasing V O , and a Tfall output on line 68 corresponding to the periods of decreasing V O . Of course, the dead time between successive measurements of the ΔT interval could be nearly eliminated by coordinating the state changing of switching device 48 with the outputs of comparators 56 and 58 ; this would improve the sampling rate of the circuit, which may be important in applications where several load cell capacitances are successively measured.
It will thus be seen that the circuit of FIG. 2 overcomes the above-noted problems associated with the conventional capacitance measurement approach. The shield conductor 32 is tied to the fixed reference voltage V REF , operational amplifier 46 maintains the charge plates 30 at a virtual reference voltage V REF ′ substantially equal to V REF , and the reference plane conductor 28 is tied to circuit node A which linearly increases and decreases in voltage. Accordingly, parasitic capacitance between the charge plates 30 and the shield conductor 32 is minimized. Furthermore, the effect of parasitic capacitance 44 is attenuated by the gain G of operational amplifier 46 ; that is, the measured capacitance is given by the sum [C 40 +(C 44 /G)], where C 40 is the capacitance of load cell 12 , and C 44 is the capacitance of parasitic capacitor 44 . If the gain G is sufficient to maintain V REF ′ substantially equal to V REF , the parasitic capacitance 44 will not significantly influence the measurement accuracy. Moreover, the parasitic capacitance 42 will not significantly influence the measurement accuracy so long as operational amplifier 46 has sufficient drive capability to charge parasitic capacitance 42 at the ramp rate of output voltage V O . Also, the relationship between the measured time (Trise or Tfall) and the load cell capacitance is linear (instead of nonlinear) so that the load cell capacitance can be measured over a wide range of values, such as 1000-to-1. Finally, the circuit of FIG. 3 is easily and cost effectively implemented since the input and output signals are square-waves (i.e., low distortion sinusoidal sources and analog-to-digital signal conversion are not required), and the current sources 50 , 52 are implemented and calibrated more easily than precision resistors. In a discrete implementation, the current sources 50 and 52 and switching device 48 could be replaced by a single precision resistor of resistance R coupled to a digital input such as V CLK ; in this case I VS =V REF ′/R since operational amplifier 46 holds the circuit node B at virtual reference voltage V REF ′.
Any leakage current at the amplifier output (i.e., circuit node A) will not affect the capacitance measurement so long as operational amplifier 46 has sufficient drive strength to handle the additional load. Since leakage currents at the amplifier inputs can produce deviation between Trise and Tfall, the load cell capacitance can be represented by a normalized time Tnor according to the equation:
T nor=(2 *T rise* T fall)/( T rise+ T fall)
However, since input leakage currents greater than I CS can impair the circuit operation, the circuit of FIG. 3 may include additional elements for detecting and compensating for input leakage currents. Such additional elements include a logic circuit 70 for detecting input leakage currents by computing the difference between Trise and Tfall, and a digitally controlled source (voltage source 72 and resistor 74 ) for introducing a DC current into or out of circuit node B to force Trise=Tfall. Ordinarily, the voltage source 72 is set to V REF so that the compensation current is zero. If logic circuit 70 detects that Trise is greater than Tfall, the source voltage is incremented until Trise=Tfall. Similarly, if logic circuit 70 detects that Trise is less than Tfall, the source voltage is decremented until Trise=Tfall. Of course, the voltage source 72 and resistor 74 can be replaced by an adjustable current supply of some other design, if desired.
While the method of the present invention has been described with respect to the illustrated embodiment, it is recognized that numerous modifications and variations in addition to those mentioned herein will occur to those skilled in the art. For example, a compressible insulator other than the elastomeric bladder 22 may be used, a multiplexer may be used to selectively couple the capacitance measurement circuit to different charge plates 30 of the sensor assembly, the charge plates 30 and reference plane conductor 28 may be reversed, the ramp rate RR may be determined by measuring the voltage change over a fixed time interval, and so on. Furthermore, the shield conductor 32 may be maintained at a reference voltage (including ground potential) other than V REF if desired; although this would increase parasitic capacitance, the operational amplifier 46 minimizes the effects of parasitic capacitance as described above. Accordingly, it is intended that the invention not be limited to the disclosed embodiment, but that it have the full scope permitted by the language of the following claims. | The capacitance of a shielded capacitive load cell is determined so as to minimize the effect of stray or parasitic capacitance between the load cell and other objects including the shield. The load cell conductors are coupled across input and output terminals of an operational amplifier that is tied to a reference voltage. A constant current is applied to the load cell, and the resulting rate of change in voltage at the amplifier output is measured as a representation of the load cell capacitance. In a vehicle seat sensor application including an electromagnetic interference shield between the load cell and the seating surface, the amplifier output is coupled to the load cell electrode furthest from the shield, the amplifier maintains the other load cell electrode at a virtual reference voltage, and the shield is tied to the reference voltage. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to computer network applications, and more particularly to computer network applications which facilitate the design of integrated circuits.
2. Related Art
In today's technological climate, there is a continuing advancement in computing technology and processing power, as well as the increased availability of computing facilities and platforms. Despite such computing technology progress, however, the process of designing integrated circuits has remained stagnant. That is, today's engineers still undergo a mostly manual process when designing and testing integrated circuits (or “chips”) for use in electronic products.
In general, the chip design process can be viewed and explained as a series of six sequential phases: (1) system architecture exploration; (2) software development; (3) design; (4) verification; (5) synthesis, layout and static timing analysis (STA); and (6) auto test pattern generation (ATPG).
First, in the system architecture exploration phase, a chip designer explores different system architectures. Depending on the requirements of the system (i.e., the product) for which the chip is being designed, the chip designer may need to analyze any or all of the following factors: frequency/performance; bus bandwidth and latency; interrupt latency; memory latency and bandwidth; cache size; and software compatibility. Today, much of this is done manually, although using a cycle-accurate simulator sometimes helps. With the advent of multi-million gate SOC (“system on chip” or application specific integrated circuit (ASIC)) designs, the above analyses may be required for multiple cores on a chip.
Second, in the software development phase, the designer makes hardware/firmware/driver determinations for the system. Many different methodologies are now employed. Often, the chip design engineer needs actual hardware to do software development. If this is the case, they must decide whether to purchase standard boards or wait until their chip is actually manufactured before starting software design. In many cases, design engineers desire to start software development simultaneously with hardware development. Conventional tools exist that model hardware behavior in order to enable early software design. Many of these are part of an integrated software development environment (IDE) that offers project management, compilation control and debug functionality. These tools, however, are stand-alone and not integrated into the other five phases of chip design.
Third, in the design phase, the actual register transfer level (RTL) design is typically done as a manual process using pencil and paper, or some computer screen editor (e.g., Emacs). In some cases, a graphical interface may be used to design state machines using state transition diagrams. As will be appreciated by one skilled in the relevant art(s), a state transition diagram consist of circles to represent states and directed line segments to represent transitions between the states, wherein one or more actions (outputs) may be associated with each transition.
Fourth, in the verification phase, design engineers typically utilize simulators to “load” the developed software onto the designed hardware (i.e., the chip). The verification phase, in essence, involves the design engineer determining if the chip functions as called for in the design specification. Such functional verification is computer intensive. Generally speaking, the chip designer submits their design and then executes some type of electronic design automation (EDA) tool (e.g., simulators, formal verifiers or code linters). After the EDA tool is executed, the engineer analyzes the results. These results are in the form of text log files and result files. Then, graphical waveform viewing is also often done after simulations. One shortcoming of this process is that the design engineer must manually submit designs as well as manually verify the rest of the chip design, then manually build a simulation engine. More experienced engineers find this process relatively simple, yet error prone. More novice design engineers, however, find a need to keep careful notes given that the process is fairly detailed and manual.
Fifth, in the synthesis, layout and STA (collectively referred to as the “back-end”) phase, the following user inputs are required: the design database (i.e., the RTL module files); synthesis constraints and compile options; and a floor plan (typically the most important user input to layout and is generated using graphical EDA floor planners). The synthesis is the translation of the RTL to actual logic gate implementations. The layout refers to the actual physical placement of gates onto the silicon wafer. STA is the timing verification of the chip (i.e., “how fast does it run?”). For most projects, synthesis, layout and STA are computationally intensive tasks with little user interaction. Initially, default synthesis constraints can be used. After that, constraint optimization is mostly done manually, although it can be automated. Most typically, default compile options can be used, although the design engineer may sometimes make manual tweaks. Today, synthesis, layout and STA are typically done by scripts specifically created for each design project.
Sixth, in the ATPG phase, a test sequence is generated. This test sequence is designed in order to test the chip once it has been fabricated (e.g., testing for “stuck-at zero” or “stuck-at one” faults in a CMOS chip). The ATPG phase is another design step that is computationally intensive. As done today, it requires the final net list as input with some small user input file. After the test sequence is executed, an engineer analyzes the output log files to see if any improvements can be made in the design.
The final output of the design process is typically a magnetic tape (“tape-out”) in the GDSII binary format (developed by Cadence Design Systems, Inc. of San Jose, Calif.), which can then be sent by the design engineer to a foundry for actual fabrication of the chip.
The design flow for an integrated circuit is described in more detail in Michael J. S. Smith, “Application Specific Integrated Circuits,” Addison-Wesley, ISBN 0-201-50022-1 (USA 1997), which is incorporated herein by reference in its entirety.
In sum, the six-phase chip design process explained above is complex and time-consuming. While automated tools exist for certain stages of design (e.g., the Design Compiler™ tool, available from Synopsys, Inc. of Mountain View, Calif. for synthesis and the FastScan™ tool, available from Mentor Graphics Corp. of Wilsonville, Oreg. for ATPG), no single integrated tool is currently available to aide engineers at every stage of product design (i.e., from conception to tape-out).
Given the foregoing, what is needed is a system, method and computer program product for a total integrated circuit design tool.
SUMMARY OF THE INVENTION
The present invention, which meets the above-identified need, is a system, method and computer program product for total Web-based integrated circuit design. The present invention allows design engineers to utilize a well-understood graphical interface (i.e., a Web browser) to access a wealth of data and services. The present invention allows designers to evaluate and choose competing standard architectures, and to more efficiently design cores and systems-on-a-chip (SOCs). In essence, the present invention is a “virtual lab” which allows and aides design engineers at every stage of product design. This includes, without limitation, architecture choice, implementation options, software development, and hardware design.
The system of the present invention includes an application database that stores information about users of the system and reference designs for integrated circuits. The system also includes a plurality of servers, each connected to the application database, that possess the code logic necessary to provide the virtual lab functionality described herein while accessing the application database. A gateway (i.e., a Web server) is also included which services connections (e.g., Web connections) from a plurality of geographically remote user machines over at least a portion of the Internet. The system also includes means for allowing the plurality of user machines to perform all phases of integrated circuit design by communicating with one of the plurality of servers via the gateway and a graphical user interface.
The method and computer program product of the present invention involve receiving from the user a selection indicative of an application for which the user is designing an integrated circuit (IC). Next, the application database is accessed in order to retrieve reference designs for the selected application.
Then, the user selects, via the graphical user interface (which is provided to the user over at least a portion of the Internet), one of the reference designs for the application. Once a reference design is selected, the user is provided, via the graphical user interface, a system simulation tool, which allows the user to select, simulate and prototype the hardware, software and middleware of the IC being designed.
The method and computer program product also provide the user with a chip design flow tool. The tool allows the user to perform register transfer level design, verification, synthesis, layout and static timing analysis of the IC being designed. Next, the user is provided with one or more compiler and debugger tools in order to facilitate the software development of the IC being designed.
One advantage of the present invention is that a company of design engineers can avoid the purchase of expensive tools for each of the six phases of chip design, some of which are going to be used infrequently. Further, the use of the present invention allows smaller companies (e.g., “start-up” companies) to avoid the purchase of several tools and computing facilities, and having to establish design methodologies—all of which smaller, newer companies have difficulty doing due to limited capital and inexperience.
Another advantage of the present invention is that can be utilized for “platform-based” SOC design where a design engineer is presented with several reference design choices that may be, for example, further integrated or modified, as well as “block-based” SOC design where the design engineer is presented with a list of several design components that may be used to construct a system from scratch (rather than reference designs).
Another advantage of the present invention, as to the system architecture exploration phase, is that a designer can use the Web to “drag and drop” several cores into a design, upload software or a benchmark, and then simulate the system assuming some interconnection scheme. In essence, the present invention allows a chip designer to “try before they buy.”
Another advantage of the present invention, as to the software development phase, is that by making the functionality described herein available over the Web, design engineers save time and energy by not having to install and maintain the software or computer servers used for simulation. That is, an application service provider (ASP) offering the tool of the present invention can make a library of optimized functions available “on-line” thereby giving software developers a “jump start” in industry standard areas like Fast Fourier Transform (FFT), floating point emulation, etc.
Another advantage of the present invention, as to the verification phase, is that the Web can improve these tasks by acting as a “front-end” to a set of common scripts that better manage the entire verification phase process. This can significantly simplify the methods by which engineers design and verify RTL. This would also give novice design engineers a faster learning curve and provide expert design engineers with less opportunities for making oversights. The Web scripts can work closely with a database of circuit verification scripts (CVS) to enable: submission and check-in of designs, release of designs for internal use (i.e., “SILVER tagging”), graduation of designs after regressions (i.e., “GOLD tagging”), check-out of all current modules for simulation, building of custom simulation engines, access to pre-built simulation engines (SILVER and GOLD), submission of standard regressions to a compute farm, submission of single tests to compute farm or local machine, access to simulation/regression results, including waveforms, and submission of new functional tests to the database.
Another advantage of the present invention, as to the synthesis, layout and STA phase, is that the Web can improve the computationally-intensive tasks in the same way it can improve functional verification. That is, it can automate and standardize these steps and give access to shared computer resources. Because the flow is being automated and simplified, this also gives the ASP the opportunity to offer multiple EDA tool options for synthesis and layout. By offering different flows, design engineers can choose the one that best fits their design flow.
Yet another advantage of the present invention, as to the ATPG phase, is that the Web provides an advantage over conventional techniques by automating and standardizing the ATPG process and provides remote access to computer servers.
Further features and advantages of the invention as well as the structure and operation of various embodiments of the present invention are described in detail below with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
The features and advantages of the present invention will become more apparent from the detailed description set forth below when taken in conjunction with the drawings in which like reference numbers indicate identical or functionally similar elements.
FIG. 1 is a block diagram representing the system architecture of an embodiment of the present invention, showing connectivity among the parts;
FIG. 2 is a flowchart representing the overall operation according to one embodiment of the present invention;
FIGS. 3A-3D are exemplary window or screen shots that could be generated by the graphical user interface of the present invention during the overall operation shown in FIG. 2;
FIG. 4 is an exemplary window or screen shot that could be generated by the graphical user interface in a Web site navigation embodiment of the present invention; and
FIG. 5 is a block diagram of an exemplary computer system useful for implementing the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Table of Contents
I. Overview
II. Example System Architecture
III. Application Database
IV. Software Architecture
V. Example System Operation
VI. Environment
VII. Conclusion
I. Overview
The present invention is a system, method and computer program product for the Web-based integrated circuit design.
In an embodiment of the present invention, an application service provider provides and allows access, perhaps on a subscriber basis, to a total integrated circuit design tool (i.e., a “virtual lab”) via the global Internet. That is, the application service provider would provide the hardware (e.g., servers) and software (e.g., database) infrastructure, application software, customer support, and billing mechanism to allow its customers (e.g., chip design engineers and the like) to remotely perform all phases (and aspects) of integrated circuit design.
More specifically, the application service provider would provide a World Wide Web site where a design engineer, using any computing platform and Web browser software, to remotely perform all phases of integrated circuit design as described herein.
As suggested above, in an embodiment of the present invention, an ASP may provide users with access to the integrated circuit design tool of the present invention and charge on a subscriber or per-use basis.
In an alternate embodiment, users may access the integrated circuit design tool of the present invention via direct dial-up lines rather than through the global Internet.
In yet another embodiment of the present invention, the integrated circuit design tool of the present invention, instead of being accessed via the global Internet, would run locally on proprietary equipment and be networked among the local or wide area network (e.g., over an Ethernet, intranet, or extranet) of an entity allowing multiple users (e.g., employees of a single company that owns proprietary equipment) to access and use the integrated circuit design tool of the present invention.
The present invention is described herein in terms of the Web-based chip design example. This is for convenience only and is not intended to limit the application of the present invention. In fact, after reading the following description, it will be apparent to one skilled in the relevant art(s) how to implement the following invention in alternative embodiments (e.g., hardware design in general).
The terms “user,” “customer,” “design engineer,” “engineer,” “designer,” and the plural form of these terms are used interchangeably to refer to those who would access, use, and/or benefit from the present invention.
II. Example System Architecture
Referring to FIG. 1, a block diagram illustrating the physical architecture of a Web-based integrated circuit design (WBICD) system 100 , according to an embodiment of the present invention is shown. FIG. 1 also shows connectivity among the various components of WBICD system 100 . It should be understood that the particular WBICD system 100 in FIG. 1 (i.e., a integrated circuit design tool system) is shown for illustrative purposes only and does not limit the invention. Other implementations for performing the functions described herein will be apparent to persons skilled in the relevant art(s) based on the teachings contained herein, and the invention is directed to such other implementations.
As will be apparent to one skilled in the relevant art(s), all of the components “inside” WBICD system 100 are connected and communicate via a communication medium such as a local area network (LAN) or a wide area network (WAN) 101 running a secure communications protocol (e.g., 128-bit secure sockets layer (SSL)).
WBICD system 100 includes a plurality of application servers 102 (shown as application servers 102 a . . . n ) that serve as the processing system of the present invention. Servers 102 , as explained in detail below, include the software code logic that implements the integrated circuit design tool operation of WBICD system 100 . While a plurality of separate servers are shown in FIG. 1, it will be apparent to one skilled in the relevant art(s) that the WBICD system 100 may utilize one or more servers in a distributed fashion (or possibly mirrored for fault tolerance) connected via LAN 101 .
Also connected to LAN 101 is an application database 104 . This database, as explained in more detail below, stores information related to the users (e.g., design engineers) utilizing WBICD system 100 . Such information includes, as will be appreciated by one skilled in the relevant art(s), user registration, log-ins, passwords, company information, stored project files, account logs and the like.
WBICD system 100 also includes a plurality of administrative workstations 106 (shown as workstations 106 a . . . n ) that may be used by the WBICD organization (i.e., the ASP) to update, maintain, monitor, and log statistics related to servers 102 and WBICD system 100 in general. Also, administrative workstations 106 may be used “off-line” by ASP personnel in order to enter configuration data, as described below, in order to customize WBICD system 100 performance.
WBICD system 100 also includes a gateway 108 which acts as the interface between the servers 102 and the external (i.e., outside of the ASP's infrastructure) devices. Consequently, gateway 108 is connected to a firewall 110 . Generally speaking, a firewall, which is well-known in the relevant art(s), is a dedicated gateway machine with special security precaution software. It is typically used, for example, to service connections and protect a cluster of more loosely-administered machines hidden behind it from an external invasion. Thus, firewall 110 serves as the connection and separation between the LAN 101 , which includes the plurality of network elements (i.e., elements 102 - 108 ) “inside” of LAN 101 , and the global Internet 103 (or some other communications network) “outside” of LAN 101 .
Connected to the Internet, outside of the LAN 101 , includes a plurality of external computing devices 112 that allow users (i.e., design engineers) to remotely access and use WBICD system 100 . External computing devices 112 would include, for example, a desktop computer 112 a, a laptop 112 b, a personal digital assistant (PDA) 112 c.
In one embodiment of the present invention, gateway 108 is a Web server which sends out Web pages in response to Hypertext Transfer Protocol (HTTP) requests from remote browsers (i.e., external computing devices 112 ). The Web server would provide the “front end” to the users of the present invention. That is, the Web server would provide the graphical user interface (GUI) to users of WBICD system 100 in the form of Web pages. Such users may access the Web server at the WBICD ASP's site via the Internet (and thus, the World Wide Web) 103 . In such an embodiment, because SSL runs on the Internet as well, all points of communication between the users 112 and the ASP's servers 102 would be secure.
While only one gateway 108 is shown in FIG. 1, it will be apparent to one skilled in the relevant art(s) that WBICD system 100 may utilize one or more gateways in a distributed fashion (or possibly mirrored for fault tolerance) connected via LAN 101 . In such an embodiment, as will be apparent to one skilled in the relevant art(s) after reading the description herein, each gateway 108 could be dedicated to, and support connections from, a specific type of external client device 112 (and possibly using a different communications network than the global Internet 103 ).
Lastly, while one database 104 is shown in FIG. 1 for ease of explanation, it will be apparent to one skilled in the relevant art(s) that WBICD system 100 may utilize databases physically located on one or more computers which may or may not be the same as any of servers 102 .
More detailed descriptions of WBICD system 100 components, as well as their functionality, are provided below.
III. Application Database
Application database 104 stores the various types of information that WBICD system 100 would need to store in order to provide the integrated circuit design tool of the present invention. Such information, includes user registration information (name, address, billing information, etc.), log-ins, user and group passwords, company information, stored project files, account logs, optimized function libraries for software development, common CVS, reference designs and associated data sheets, etc., as will be apparent to one skilled in the relevant art(s) after reading the teachings herein.
In an embodiment of the present invention, application database 104 is implemented using a relational database product (e.g., Microsoft® Access, Microsoft® SQL Server, IBM® DB2®, ORACLE®, INGRES®, or the like). As is well known in the relevant art(s), relational databases allow the definition of data structures, storage and retrieval operations, and integrity constraints, where data and relations between them are organized in tables. Further, tables are a collection of records and each record in a table possesses the same fields.
In an alternate embodiment of the present invention, application database 104 is implemented using an object database product (e.g., Ode available from Bell Laboratories of Murray Hill, N.J., POET available from the POET Software Corporation of San Mateo, Calif., ObjectStore available from Object Design, Inc. of Burlington, Mass., and the like). As is well known in the relevant art(s), data in object databases are stored as objects and can be interpreted only using the methods specified by each data object's class.
As will be appreciated by one skilled in the relevant art(s), whether application database 104 is an object, relational, and/or even flat-files depends on the character of the data being stored by the ASP which, in turn, is driven by the specific interactive, multi-user applications being offered by the ASP. Server 102 contains specific code logic to assemble components from any combination of these database models and to build the required answer to a query. In any event, gateway 108 , computing devices 112 , and/or administration workstation 106 are unaware of how, where, or in what format such data is stored.
IV. Software Architecture
In an embodiment of the present invention, servers 102 can be implemented using a Microsoft® Windows NT™ server platform or a Sun Ultra server running the Solaris operating system. Servers 102 execute a (processing) software application implemented in a high level programming language such as, for example, Java or C++. In an embodiment of the present invention, the software application communicates with database 104 using, for example, a C++ object interface.
In an embodiment of the present invention where gateway 108 is a Web sever, a secure GUI “front-end” for WBICD system 100 is provided. In an embodiment of the present invention, the front-end is implemented using the Active Server Pages (ASP), Visual BASIC (VB) script, and JavaScript™ sever-side scripting environments that allow for the creation of dynamic Web pages.
V. Example System Operation
Referring to FIG. 2, a flowchart depicting an embodiment of the operation and control flow 200 of WBICD system 100 of the present invention is shown. More specifically, control flow 200 depicts, in flowchart form, an example of a design engineer utilizing (via Web navigation) the integrated circuit design tool of the present invention. The description of FIG. 2 is presented with particularized reference to individual WBICD system 100 components. Control flow 200 begins at step 202 , with control passing immediately to step 203 .
In step 203 , an authorized user, employing an external computing device 112 , connects to the ASP's gateway 108 and logs in to begin using the “virtual lab” tool of the present invention. Such a login process would include entering a valid user name and password which are then authenticated by the system 100 , as will be apparent to one skilled in the relevant art(s).
In step 204 , WBICD system 100 allows the user to perform application selection. That is, in step 204 , the user (e.g., a design engineer) chooses, via a GUI, the type of product for which they are designing a chip (i.e., start a new design “project”). Such application choices include, without limitation, a set-top box, a voice over Internet Protocol (VoIP) appliance, a Bluetooth appliance, a router, etc.
In step 206 , WBICD system 100 allows the user to view a number of reference designs for the particular application selected in step 204 . As will be appreciated by one skilled in the relevant art(s), a reference design is a means of recommending a design where one or more parties publish a schematic or other document with a recommendation/endorsement to use its semiconductor integrated circuit products with one or more vendor's semiconductor integrated circuits products or technology. Such reference designs would be made available to the user by the ASP and stored on application database 104 . In an embodiment, the ASP, other users, and/or IC manufacturers would make their reference designs available on WBICD system 100 .
Referring to FIG. 3A, an exemplary window or screen shot 310 that could be generated by the graphical user interface, in the Web site navigation embodiment of the present invention, is shown. The top-half of screen 310 illustrates the GUI presented to the user after selecting, for example, a Bluetooth appliance type application in step 204 and then selecting one of several available reference designs for such an application in step 206 . The bottom half of screen 310 displays a list the components (e.g., memory, processors, etc.) within the selected reference design for such an application. In an embodiment, steps 204 and 206 correspond to a portion of the first phase (i.e., system architecture exploration phase) of the chip design process described above.
Once the user decides on an application and chooses among several of the reference designs for that application, a button 302 can be clicked to begin the SOC design process. Control flow 300 then proceeds to step 208 .
Returning to control flow 200 (and FIG. 2 ), in step 208 , WBICD system 100 allows the user to access a system simulation tool. In an embodiment, step 208 corresponds to a portion of the first phase (i.e., system architecture exploration phase) and third phase (i.e., design phase) of the chip design process described above. In step 208 , WBICD system 100 allows the design engineer to select, simulate and prototype the hardware, software and middleware of the IC product being designed. This step gives the designer feedback about the reference design and the components chosen to implement the reference design, and allows for any desired or necessary re-configuration of the reference design.
Referring to FIG. 3B, an exemplary window or screen shot 320 that could be generated by the graphical user interface, in the Web site navigation embodiment of the present invention, is shown. Screen 320 illustrates the GUI presented to the user during step 208 . Should the user select any component (e.g., by a mouse double-click on the component), WBICD system 100 will display a GUI listing alternate choices for that component, along with a description, name of the supplier or vendor, characteristic information and link to the vendor's Web site. An exemplary GUI screen 400 is shown in FIG. 4 containing such information. Screen 400 , in one embodiment, may also include a column of select boxes which would allow a designer to view “side-by-side” comparisons of different components. Once a number of components are selected, a “compare” button on screen 400 (not shown) may be selected in order to view a screen containing more detailed information on the selected components. A return button may be included in each display or screen to return to the SOC design process.
Returning to control flow 200 (and FIG. 2 ), in step 210 , WBICD system 100 allows the user to proceed in the chip design flow process. In an embodiment, step 210 corresponds to portions of the third phase (i.e., design), and the fourth (verification), fifth (synthesis, layout and STA) and sixth (ATPG) phases of the chip design process described above. That is, the user is provided with tools and GUI screens to perform design flows from RTL to GDSII in order to obtain a final SOC, all while having access to emulation tools. An exemplary flow of screens 330 is shown in FIG. 3 C.
Returning to control flow 200 (and FIG. 2 ), in step 212 , WBICD system 100 allows the user to perform application development. Thus, in an embodiment, step 212 corresponds to the second phase (i.e., software development) of the chip design process described above. That is, WBICD system 100 allows the user access to a variety of compilers and debugger tools to accomplish the software development aspect of the chip design project. In an embodiment, WBICD system 100 allows access to a compilers and debugger tools available from a variety of vendors via a GUI screen. An exemplary screen 340 is shown in FIG. 3 D.
Returning to control flow 200 (and FIG. 2 ), after step 212 is completed, the design project is completed and the chip for the selected application is designed. Control flow 200 then ends as indicated by step 214 .
In an embodiment of the present invention, rather than going through the entire design process (i.e., flow 300 ), a user may decide during the system architecture exploration phase (i.e., during or after steps 204 - 206 ) to simply purchase their required chip from a vendor, rather than continuing flow 300 and manufacturing it themselves. In such an instance, WBICD system 100 facilitates such purchase. That is, in an embodiment, WBICD system 100 includes GUI screens that enable the user to “shop” and select an available vendor which can actually manufacture the chip they desire.
It should be understood that control flow 200 , which highlights the functionality and advantages of WBICD system 100 , is presented for example purposes only. The architecture of the present invention is sufficiently flexible and configurable such that users may utilize WBICD system 100 in ways other than that shown in FIG. 2 . Further, the present invention is sufficiently flexible and configurable such that the information contained in the GUI screens of FIGS. 3 and 4 can be presented to users in ways other than those shown in FIGS. 3 and 4.
VI. Environment
The present invention (i.e., WBICD system 100 , flow 200 or any of the parts thereof) may be implemented using hardware, software or a combination thereof and may be implemented in one or more computer systems or other processing systems. In fact, an example of a computer system 500 is shown in FIG. 5 . The computer system 500 represents any single or multi-processor computer. In conjunction, single-threaded and multi-threaded applications can be used. Unified or distributed memory systems can be used. Computer system 500 , or portions thereof, may be used to implement the present invention. For example, the System 100 of the present invention may comprise software running on a computer system such as computer system 500 .
In one example, the System 100 of the present invention is implemented in a multi-platform (platform independent) programming language such as JAVA™, programming language/structured query language (PL/SQL), hyper-text mark-up language (HTML), practical extraction report language (PERL), common gateway interface/structured query language (CGI/SQL) or the like. Java™-enabled and JavaScript™-enabled browsers are used, such as, Netscape™, HotJava™, and Microsof™ Explorer™ browsers. Active content Web pages can be used. Such active content Web pages can include Java™ applets or ActiveX™ controls, or any other active content technology developed now or in the future. The present invention, however, is not intended to be limited to Java™, JavaScrip™, or their enabled browsers, and can be implemented in any programming language and browser, developed now or in the future, as would be apparent to a person skilled in the relevant art(s) given this description.
In another example, the System 100 of the present invention, may be implemented using a high-level programming language (e.g., C++) and applications written for the Microsoft Windows™ NT or SUN™ OS environments. It will be apparent to persons skilled in the relevant art(s) how to implement the invention in alternative embodiments from the teachings herein.
Computer system 500 includes one or more processors, such as processor 544 . One or more processors 544 can execute software implementing the routines described above. Each processor 544 is connected to a communication infrastructure 542 (e.g., a communications bus, cross-bar, or network). Various software embodiments are described in terms of this exemplary computer system. After reading this description, it will become apparent to a person skilled in the relevant art how to implement the invention using other computer systems and/or computer architectures.
Computer system 500 can include a display interface 502 that forwards graphics, text, and other data from the communication infrastructure 542 (or from a frame buffer not shown) for display on the display unit 530 .
Computer system 500 also includes a main memory 546 , preferably random access memory (RAM), and can also include a secondary memory 548 . The secondary memory 548 can include, for example, a hard disk drive 550 and/or a removable storage drive 552 , representing a floppy disk drive, a magnetic tape drive, an optical disk drive, etc. The removable storage drive 552 reads from and/or writes to a removable storage unit 554 in a well known manner. Removable storage unit 554 represents a floppy disk, magnetic tape, optical disk, etc., which is read by and written to by removable storage drive 552 . As will be appreciated, the removable storage unit 554 includes a computer usable storage medium having stored therein computer software and/or data.
In alternative embodiments, secondary memory 548 may include other similar means for allowing computer programs or other instructions to be loaded into computer system 500 . Such means can include, for example, a removable storage unit 562 and an interface 560 . Examples can include a program cartridge and cartridge interface (such as that found in video game console devices), a removable memory chip (such as an EPROM, or PROM) and associated socket, and other removable storage units 562 and interfaces 560 which allow software and data to be transferred from the removable storage unit 562 to computer system 500 .
Computer system 500 can also include a communications interface 564 . Communications interface 564 allows software and data to be transferred between computer system 500 and external devices via communications path 566 . Examples of communications interface 564 can include a modem, a network interface (such as Ethernet card), a communications port, interfaces described above, etc. Software and data transferred via communications interface 564 are in the form of signals 568 which can be electronic, electromagnetic, optical or other signals capable of being received by communications interface 564 , via communications path 566 . Note that communications interface 564 provides a means by which computer system 500 can interface to a network such as the Internet.
The present invention can be implemented using software running (that is, executing) in an environment similar to that described above. In this document, the term “computer program product” is used to generally refer to removable storage unit 554 , a hard disk installed in hard disk drive 550 , or a carrier wave carrying software over a communication path 566 (wireless link or cable) to communication interface 564 . A computer useable medium can include magnetic media, optical media, or other recordable media, or media that transmits a carrier wave or other signal. These computer program products are means for providing software to computer system 500 .
Computer programs (also called computer control logic) are stored in main memory 546 and/or secondary memory 548 . Computer programs can also be received via communications interface 564 . Such computer programs, when executed, enable the computer system 500 to perform the features of the present invention as discussed herein. In particular, the computer programs, when executed, enable the processor 544 to perform features of the present invention. Accordingly, such computer programs represent controllers of the computer system 500 .
The present invention can be implemented as control logic in software, firmware, hardware or any combination thereof. In an embodiment where the invention is implemented using software, the software may be stored in a computer program product and loaded into computer system 500 using removable storage drive 552 , hard disk drive 550 , or interface 560 . Alternatively, the computer program product may be downloaded to computer system 500 over communications path 566 . The control logic (software), when executed by the one or more processors 544 , causes the processor(s) 544 to perform functions of the invention as described herein.
In another embodiment, the invention is implemented primarily in firmware and/or hardware using, for example, hardware components such as application specific integrated circuits (ASICs). Implementation of a hardware state machine so as to perform the functions described herein will be apparent to persons skilled in the relevant art(s) from the teachings herein.
VII. Conclusion
While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example, and not limitation. For example, the present invention is described above in platform-based SOC design terms, but those skilled in the relevant art(s) will recognize its applicability to block-based SOC design as well. It will also be apparent to persons skilled in the relevant art(s) that various other changes in form and detail may be made therein without departing from the spirit and scope of the invention. This is especially true in light of technology and terms within the relevant art(s) that may be later developed. Thus, the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. | A Web-based integrated circuit design system, method and computer program product tool allows design engineers to utilize a well-understood graphical interface (i.e., a Web browser) to access a wealth of data and services. The services and data include competing standard architectures and reference designs. The integrated circuit design tool allows users (e.g., design engineers) to efficiently design cores and systems-on-a-chip (SOCs). The integrated circuit design tool is a “virtual lab” which allows and aides design engineers at every stage of IC product design—architecture choice, implementation options, software development, and hardware design. | 6 |
This application is a continuation of application Ser. No. 08/557,053 filed Feb. 26, 1996, now abandoned, which is a 371 of PCT/EP94/01012 filed Mar. 31, 1994.
BACKGROUND OF THE INVENTION
Cryogenic cooling devices 1 ) are low-temperature cooling machines in which a thermodynamic cyclic process is running. A single-stage refrigerator comprises a working space in which a displacer reciprocates between two dead centres OT and UT. Related to the displacer is a regenerator through which a working gas also reciprocates corresponding to the motion of the displacer. During the reciprocating motion of the displacer, heat is continually withdrawn from the housing of the refrigerator in the area of one of the two dead centres. With a single-stage refrigerator of this kind it is possible to generate temperatures down to about 30 K. Often refrigerators are of a dual-stage design (refer to DE-A-38 36 884, for example). With dual-stage or three-stage refrigerators it is possible to generate temperatures down to below 10 K. In the refrigerator according to the mentioned document, a gas drive is employed to produce the reciprocating motion of the displacer. For this, a cylinder and piston arrangement is related to the warm side of the displacer whereby said arrangement must be supplied with a driving gas.
Refrigerators of the kind affected here must be equipped with additional control facilities, through which the supply of the working gas into the working cylinder and also the supply for the gas drive is controlled. It is common to employ helium both as the working gas and the driving gas. In designs of this kind, it is sufficient to equip the refrigerator with two connections, one of which is supplied with high pressure helium (20 bar, for example) and where the other is supplied with low pressure helium (5 bar, for example).
During the motion of the displacer, forces occur which are greatest at the dead centres. These forces are transferred to the housing of the refrigerator and thus also to any connected devices. Generally, such devices will be highly sensitive measuring instruments (nuclear magnetic resonance tomographs, electron beam microscopes, for example), the measurement results of which are adversely influenced by the occurring vibrations. In the past, several proposals have been made to dampen these interfering vibrations. From the European Patent 19 426 it is known to arrange a damping arrangement between a refrigerator and an electron beam microscope, but this arrangement is relatively involved. From European Patent Application 160 808 it is known to arrange a flat spring within the working space of a refrigerator. Said flat spring takes up a certain amount of space within the working space so that the efficiency of the refrigerating machine is reduced. In DE-A-38 36 884 it is proposed to separate, in time, the cooling process from the measurement process. This solution requires complex control arrangements and reduces the time available to the measurements.
SUMMARY OF THE INVENTION
It is the task of the present invention to operate a refrigerator with a gas drive in such a way that an effective reduction of the vibrations can be attained through relatively simple means.
According to the present invention, this task is solved by the measures of the patent claims. The present invention relies on the finding that the gas drive in known refrigerators is effective during the entire time of each of the motional phases of the displacer, meaning that the displacer is subjected to a considerable acceleration during the entire time of its motional phases. At the dead centres this leads to relatively strong impacts which are responsible for the vibrations. However, if the displacer is--in line with the present invention--only accelerated at times or only at the beginning of its motional phases, then the final velocities at the dead centres will be lower and the impacts at the housing less hard. By controlling the quantity of gas through which the gas drive is supplied for both motional directions it is possible to control the amount of drive energy and thus attain the desired goal. Through the measures according to the present invention it is possible to reduce the occurring vibrations by a factor of 4 or more, without significantly impairing the efficiency of the refrigerator.
DESCRIPTION OF THE INVENTION
Further advantages and details of the present invention shall be explained by referring to the design examples presented in drawing FIGS. 1 to 5.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-section schematic of a refrigerator of a type which the present invention is applicable;
FIG. 2 is a cross-section of an embodiment of a rotating disc of a disc valve in accordance with the invention;
FIG. 3 is a cross-section of an embodiment fixed disc of a disc valve in accordance with the invention;
FIG. 4 is a cross-section of another embodiment of a rotating disc of a disc valve in accordance with the invention;
FIG. 5 is a cross-section of another embodiment fixed disc of a disc valve in accordance with the invention;
FIG. 6 is a cross-section of another embodiment of a fixed disc of a disc valve in accordance with the invention;
FIG. 7 is a cross-section of another embodiment rotating disc of a disc valve in accordance with the invention;
FIG. 8 is a warm-to-cold side motion diagram illustration motional characteristics of an embodiment of the invention;
FIG. 9 is a cold-to-warm side motion diagram illustrating motional characteristics of an embodiment of the invention.
The dual-stage refrigerator 1 presented in the drawing figure has a housing which consists of the two parts 2 and 3. The cylindrical working spaces 4 and 5 for the two displacer stages 6 and 7 are housed in housing part 2.
The upper displacer stage 6 is equipped, on its warm side, with a drive piston 8, the corresponding cylinder 9 of which is located in a guide bush 10 which terminates the working space 4 against housing part 3. The guide bush 10 is equipped with bore holes 11, 12 and 13. Bore hole 11 opens into working space 4 and serves the purpose of supplying this space with the working gas. Bore hole 13 opens into a cross hole 14 which is connected by a circular groove 15 to the outside wall of guide bush 10. Bore hole 12 is indicated by a dash-dot line and serves the purpose of supplying the drive cylinder 9 with the driving gas. The various bore holes are located in different planes so that they do not cross each other, this being indicated by the dashed or dash-dot lines. They all open into the upper side of the guide bush 10 which in this area is designed as a fixed valve disc 16.
Housed in housing part 3 is a motor 17 which actuates a rotating valve disc 19 via the shaft 18. The fixed valve disc 16 and the rotating valve disc 19 which is under the influence of pressure spring 20, form a control valve which serves the purpose of supplying, in a basically known manner, the bore holes with high pressure and low pressure gas. In the design example presented, working gas and driving gas are identical. Preferably helium is employed.
The connections for the high pressure and the low pressure gas are marked 21 and 22 respectively. The separating plane 23 between the housing parts 2 and 3 is located at the level of the control valve 16, 19. It is selected in such a way that after removal of the upper housing part 3 with motor 17 and rotating valve disc 19, a flat pot-shaped space 24 is present above the fixed valve disc 16. At the level of this space 24, a bore hole 25 is provided which penetrates the wall of housing part 2 whereby said bore hole connects space 24 with the high pressure connection 21. The low pressure connection 22 is connected to the bore hole 26 in housing part 2 2 ) which opens at the level of the circular groove 15 of guide bush 10.
During operation of the presented refrigerator, the working gas which is at high pressure flows via connection 21 into chamber 24. From there the various bore holes are supplied with the aid of control valve 16, 19. After its expansion in refrigerator stages 4, 5 the working gas enters bore holes 13, 14 and flows out via circular groove 15 and the low pressure connection 22. The pressure of the working gas which is applied to the high pressure connection 21 is commonly about 20 to 22 bar, whereas the pressure of the working gas at the low pressure connection 22 amounts to about 5 to 7 bar.
The speed of the motor 17 and the design of the facing sides of fixed (16) and rotating (19) valve disc are decisive for the gas supply to working space 4 and drive cylinder 9. From DE-A-38 36 884 a design for the control valve is known, where a relatively wide outer recess in the rotating valve disc also supplies, at times, the openings of two bore holes which also have a relatively large diameter with high pressure gas. One of these two bore holes serves the drive cylinder. Due to the selected dimensions, the displacer is accelerated during its entire motional phase from the warm to the cold side of the working space. This equally applies to the motional phase of the displacer from the cold to the warm side of the working space, since the oblong recess which at times connects the openings of the two supply bore holes to the low pressure gas connection, has similarly large dimensions.
Drawing FIGS. 2 and 3 show designs for the valve disc 16 and 19, through which the gas can be controlled as desired in the sense of the present invention. The fixed valve disc 16, the top view of which is shown (drawing FIG. 3), permits a view of the openings 27, 28, 29 of the bore holes 11, 12 or 13. As in the case of a state of the art design, the bore hole 13 and its opening 29 are located in the centre whereas the radial distance of the openings 27, 28 of bore holes 11 or 12 is--opposed to the state of the art--no longer the same with respect to the rotational axis of valve disc 19 (circles 31, 32). Moreover, opening 28 of bore hole 12 has a significantly smaller diameter compared to the opening 27 of bore hole 11.
The rotating valve disc 19, the design of which is shown in drawing FIG. 2 in a ghosted view through valve disc 19, rotates corresponding to the direction of arrow 33 on the fixed valve disc 16. A bore hole 34 having a relatively wide cross section which connects to high pressure space 24 and which penetrates valve disc 19 is related to circle 31. The recess 35 related to circle 32 is designed as a relatively narrow slot. Moreover, valve disc 19 is equipped with a relatively large recess 36 which extends from the centre to circle 31. Slot-like recess 37 extends from this recess 36 to circle 32.
During the rotation of the valve disc 19, the control openings 34 to 37 of valve disc 19 and the control openings 27 to 29 of valve disc 16 pass over against each other. At first slot 35 on circle 32 reaches the opening 28 of bore hole 12. Because of this, the drive cylinder 9 is linked for a relatively short time to space 24 which is at high pressure and the displacer 6 is accelerated in the direction of the cold side of the working space. Thereafter, bore hole 34 on circle 31 of the rotating valve disc reaches the opening 27 of bore hole 11 in the fixed valve disc 16. For the--relatively long--period of time during which these openings 34 and 27 pass over against each other, the working space 4 3 ) is supplied with high pressure gas. Next, the slot 37 on circle 32 reaches the opening 28 of bore hole 12 so that the drive cylinder 9 is linked for a short period of time to the bore hole 13 which is at low pressure. The displacer 6 thus moves to its warm side. Finally, the recess 36 reaches the opening 27 of bore hole 11 on circle 31 so that the gas in the working space 4 4 ) is expanded to a low pressure. Thereafter the cycle repeats itself.
Drawing FIGS. 4 and 5 show a design example where in the valve discs 16, 19 two each bore holes 11, 11', 12, 12' and 34, 34' which are each offset by 180° and their corresponding openings, are provided. The oblong recess 36 extends on both sides of the centre up to circle 31. Two slots 37, 37' which extend up to circle 32 are present. In this design, the displacer 6 performs twice the number of strokes per turn of valve disc 19.
In the presented and described design example, the openings 27, 28 (27', 28') of bore holes 11 (11') 5 ) and 12 (12') in the fixed valve disc 16 6 ) are located on circles 31, 32 of different radii. Also the bore holes 34 (34') and recesses 35 (35'), 36 (36') 7 ), 37 (37') in the rotating valve disc 19 are located on circles of correspondingly different radii. Thus there exists the possibility of being able to set up large differences with respect to the pass over periods. The supply bore holes for the working space 4 8 ) which must be supplied with high pressure or low pressure for a relatively long periods of time open on circle 31 having the smaller diameter. The supply bore holes for the gas drive open on circle 32 with the larger diameter. Short pass over periods are not attained through smaller bore holes or recesses but instead through the higher circumferential velocity.
The pass over periods for the gas drive which depend on the speed of the rotating valve disc 19, the position and design of the openings 27 to 29, recesses 35 to 37 as well as bore hole 34, are preferably selected as follows: To effect the motion of displacer 6 towards its cold side, drive cylinder 9 is only linked to the high pressure connection 21 during the first fraction of the time of its entire motion. This fraction is selected--preferably empirically--so that the vibrations caused by the arrival of the displacer at the stops in the housing are considerably reduced and so that the efficiency of the refrigerator is not yet significantly impaired. The order of magnitude of this fraction amounts to about one third of the entire motional period. To effect the motion of displacer 6 in the reverse direction, the pass over time must be selected so short that the link between the drive cylinder 9 and the low pressure connection 22 has already been closed before the displacer attains its dead centre. Due to the further movement of the drive piston, the gas which is still present in the drive cylinder is compressed so that a damping effect (gas cushion) is attained. The pressure increase of the remaining gas is preferably selected in such a manner that a pressure is attained just before the dead centre is reached, which is somewhat higher than the high pressure level.
Drawing FIGS. 6 and 7 show design examples of the fixed and rotating valve discs through which an acceleration of displacer 6, 7 is effected several times and for short periods. For this, either the bore hole 28 of the fixed valve disc 16 is (for example) divided into three bore holes 41, 42, 43 or the recesses 35, 37 in the rotating valve disc 19 have been divided into (for example) three recesses 44 to 46 and 47 to 49, respectively.
Drawing FIGS. 8 and 9 show the effect of these measures. In each of the upper system of coordinates the path s of the displacer has been drawn vs. the time t. Each of the lower system of coordinates shows the points of time t 1 , t 2 and t 3 at which the high pressure (drawing FIG. 8) or the low pressure (drawing FIG. 9) is applied to the working cylinder 9.
Drawing FIG. 8 shows the motion of the displacer from the warm to the cold side. At points of time t 1 , t 2 and t 3 high pressure gas is applied to the drive cylinder for the time t in each case (5% of the time for the entire motion, for example). Thus the displacer is subjected to three brief thrusts which let it move to the cold side in such a manner that the accelerating and decelerating motions alternate (motion curve 51 9 )). The impact of the displacer 6, 7 at housing 2 (dashed line 52 10 )) which substantially causes the vibrations, is relatively small. The motion of the displacer 6, 7 from the cold to the warm side runs correspondingly (refer to motion curve 53 11 ) in drawing FIG. 9 with stop line 54 12 )). The periods of time t are selected in such a manner that in each case a damping gas cushion is generated.
The designs according to drawing FIGS. 6 to 9 permit the control of the motion sequence of displacer 6, 7 with the aid of short pressure bursts. In comparison to steadily accelerated displacers, the displacer 6, 7 which moves according to the present invention does reach its dead centre at a later point of time; any significant reduction in the efficiency of the refrigerator does, however, not result. | This invention concerns a method of operating a cryogenic cooling device (1) with a cylinder (4, 5) in which a piston (6, 7) reciprocates and with a gas drive (8, 9) which produces the motion of the piston. In order to reduce the vibrations which occur during operation, the invention proposes that the gas drive (8, 9) is controlled in such a way that the piston (6, 7) is only accelerated for part of the stroke. | 5 |
BACKGROUND OF THE INVENTION
This application is a continuation-in-part of U.S. Ser. No. 07/694,939 filed May 2, 1991 now U.S. Pat. No. 5,327,843.
FIELD OF THE INVENTION
This invention relates to helm, throttle and directional controls for small craft such as outboard, inboard, and inboard/outboard powered boats and similar water vehicles. More specifically, the present invention concerns a safety device which fits between an actuating member and an actuated member in helm, throttle and directional controls.
The actuating member may be a control drive shaft connected to the steering wheel of a boat, and the actuated member may be a driven shaft coupled to a control cable for the boat's steering device.
The actuating member may also be a control drive shaft connected to a throttle control lever and/or a reverse control lever for the boat's powerplant, and the actuated member may be a driven shaft coupled to a throttle control cable and/or a reverse gear control cable.
Description of Related Art
In connection with helm controls, it is a basic requirement that undesired and unintentional changes in the setting of the steering device should be prevented, especially for safety reasons. In fact, should the helmsman fall accidentally overboard, the water flow around the steering device is liable to act such that the steering device left to itself swings into an ever tighter turn, whereby the boat will circle around the man in the water on a closing spiral course and become a positive hazard.
Powerplant controls also require that no undesired change be applied fortuitously to any pre-selected settings.
A most widely employed method of preventing undesired and fortuitous changes to the setting of the actuated member has been that of braking the rotational movement of the actuating member such as by means of a slip clutch between the actuating and actuated members. However, this tends to make the actuating-member stiffer and tiring to operate, and in any event cannot provide failsafe unalterability of the setting where, for example, the forces acting on the actuated member are large ones.
SUMMARY OF THE INVENTION
Therefore, it is the object of this invention to provide a safety device for small craft helm, throttle and directional controls which can fulfill the above-specified demands.
This object is achieved by a safety device for small craft helm, throttle and directional controls, intended for operation between an actuating member and an actuated member of the helm, throttle and directional controls, characterized in that the actuating and actuated members are coupled rotatively together through a one-way mechanical coupling means wherein a resilient force holds the actuated member constantly in a locked position, and release is accomplished automatically by moving the actuating member against said resilient force to transfer motion to the actuated member from the actuating member.
BRIEF DESCRIPTION OF THE DRAWINGS
For a clearer understanding of the features and advantages of this invention, some embodiments thereof will be described hereinafter with reference to the accompanying drawings, wherein:
FIG. 1 is a perspective view of a steering wheel and associated helm box for the control cable in the steering system of a water vehicle;
FIG. 2A shows a first embodiment of the safety device according to the invention;
FIG. 2B shows a second embodiment of the safety device according to the invention;
FIG. 3A is a view of the safety device in FIG. 2A with parts shown in longitudinal section;
FIG. 3B is a view of the safety device in FIG. 2B with parts shown in longitudinal section;
FIG. 4A is a cross-sectional view taken along the line 4A--4A in FIG. 3A;
FIG. 4B is a cross-sectional view taken along the line 4B--4B in FIG. 3B;
FIG. 5A shows a third embodiment of the safety device according to the invention with parts shown in longitudinal section;
FIG. 5B shows a fourth embodiment of the safety device according to the invention with parts shown in longitudinal section;
FIG. 6A is a cross-sectional view taken along the line 6A--6A in FIG. 5A;
FIG. 6B is a cross-sectional view taken along the line 6B--6B in FIG. 5B;
FIG. 7 is a longitudinal section view of a fifth embodiment of the inventive safety device;
FIG. 8 is a cross-sectional view through the safety device shown in FIG. 7;
FIG. 9 is a perspective view of a dual-action, single lever control box providing control of the speed and reverse gear of a water vehicle powerplant and incorporating the safety device of this invention;
FIG. 10 is a cross-sectional view through the control box shown in FIG. 9, as equipped with the safety device of this invention; and
FIG. 11 depicts an applicative situation of the safety device according to the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The safety device of this invention will be first described as applied to a steering wheel type of helm for a water vehicle with reference to FIGS. 1 through 8 of the drawings.
With specific reference to FIG. 1, shown at 1 is the steering wheel of the helm of a water vehicle, e.g. a motor boat. The steering wheel drive shaft 2 penetrates a box 3 accommodating a unit whereby the helm control cable 4 can be operated. Of course, this cable control unit may be any suitable type to convert the rotary movement of the steering wheel 1 into a linear movement of the cable 4, and may either be of the rack-and-pinion, or chain-and-sprocket, or other comparable types. The safety device of this invention is interposed between the shaft 2 and the input end of the cable 4 of the control unit.
A first embodiment of the safety device according to the invention will be now described with reference to FIGS. 2A, 3A, and 4A.
Shown at 5 in these drawing figures is a stationary pin, which may be affixed to the bottom of the box 3, for example. Tightly wound around this pin 5 is a rectangular coil spring 6a having its ends 106a and 206a bent to project radially outwards, from diametrically opposite positions of the spring, as shown best in FIG. 4A. That end of the shaft 2 which extends into the box 3 is shaped as a half-cup 7a, so as to embrace the pin 5 and the spring 6a wound thereon with some radial and axial clearance, and extends circumferentially around the pin 5 through an angle of (for example) 180°-2alpha, as shown best in FIG. 4A. The radius for the half-cup shape 7a should be such that the latter engages, as the shaft 2 is rotated, with ends 106a and 206a, respectively, of the spring 6a, for purposes to be explained. Further, in all embodiments the value 180°-2alpha is determined according to size and positioning of at least one of several elements including elements 9a-7a and spring ends 106a and 206a. Thus 180°-2alpha is not limitative.
The half-cup 7a is also formed, at the base thereof where it does not interfere with said ends of the spring 6a, with two teeth or dogs 107, 207 which extend circumferentially and symmetrically from either side through angle alpha, whereby the half-cup shape will extend through 180° at the location of the teeth.
Reference numeral 8 is the driven shaft for operating the steering arrangement. In the embodiment shown, this driven shaft 8 is a tubular shaft mounted for free rotation on the shaft 2 concentrically therewith. The driven shaft 8 is terminated with a half-cup shape 9a having the same radius as the shape 7a and extending around the pin 5 through an angle of 180°-2alpha. Keyed on the other end of driven shaft 8 is a pinion gear 10 which may either mesh directly with the cable 4 in helical form as shown in FIG. 3A, or with a rack connected to the cable 4.
Shaft 2 forms the actuating member for the helm system shown and shaft 8 its actuated member.
The device just described operates as follows.
Making reference in particular to FIGS. 1, 2A, and 4A, it will be assumed that the steering wheel 1 is turned in the counterclockwise direction, for example, as indicated by an arrow F in FIG. 2A.
The half-cup shape 7a will be turned accordingly in that direction through the shaft 2 of the wheel 1. During a first fractional rotation, through the angle alpha in FIG. 4A, shape 7a will abut against a planar surface of the end 106a of the rectangular spring 6a and urge it in the opposite direction from the winding direction of the spring 6a around the pin 5. This results in the winding of spring 6a being expanded, with consequent attenuation or removal of the frictional engagement between the spring 6a and the pin 5, whereby the spring 6a can be entrained to rotate with the shaft 2 of the steering wheel 1.
Concurrently therewith, as shown in FIG. 2A the tooth 107 on the shape 7a will come to bear on the shape 9a unitary with shaft 8, so that shaft 8 is also entrained rotatively by the steering wheel shaft 2, to therefore rotate the pinion gear 10 operating the helm control cable 4.
It has been found that use of a rectangular spring of, for example, a square cross-section applies a uniformly even tension against a shape to which it is applied, particularly an opposing planar surface as presented by shape 9a. A similar phenomenon occurs at the other end 206a of the spring 6a as described further hereinbelow. In other words, although the prior device using a cylindrical coil spring as described in parent application Ser. No. 07/694,939 operates exceptionally well, over extended periods of time, the circular shape of the spring end may wear a groove in shape 7a or 9a resulting in "play" of the steering system. Because of the uniformity of mating surfaces when using a planar spring pushing surface, the formation of a groove in either of shapes 7a or 9a does not occur. It has been further discovered that use of such a spring results in less force required to operate the steering system due to the broad surface contact of the planar surfaces as opposed to a "point" type of contact which occurs with the end of a cylindrical coil spring heretofore used.
Testing of the instant device with the use of a rectangular coil spring at a load of 407 Kg in push and pull at about 20 cycles per minute resulted in up to 300,000 turning cycles of the steering mechanism without spring breakage.
It should be understood that although a rectangular coil spring is disclosed and shown, any coil spring having two opposing parallel planar surfaces would be acceptable for use as long as the planar surfaces are positioned to engage with shapes 7a or 9a as shown.
Because of the effectiveness of the rectangular shaped coil spring, it is also possible to eliminate use of dogs or teeth 107, 207, simply allowing opposing shape 7b or 9b to act in a reverse direction on an opposing planar surface of the spring 6b than that which is acted on initially as shown and described below in connection with FIGS. 2B, 3B and 4B. In other words, shapes 7b and 9b may function as bidirectional actuators against opposing surfaces of the ends 106b, 206b of the rectangular coil spring 6b.
Returning again to the discussion of the first embodiment, a similar effect would occur as the steering wheel 1 is turned clockwise in FIGS. 2A, 3A and 4A. Shape 7a engages here the opposite end 206a of the spring 6a, and the tooth 207 on shape 7a comes to bear on shape 9. Upon releasing the steering wheel, the spring 6a will resume its original condition of close adhesion to the pin 5. At this stage, a tensile force applied to the cable 4 from the steering device of the water vehicle will cause one edge of shape 9a to strike one end, 106a or 206a, of the spring 6a along the winding direction of the spring around the pin 5, whereby the spring 6 will be locked onto the pin 5 by the strong frictional resistance and stop the movement of shape 9a, so that the steering device cannot swing out of the setting imparted immediately prior to releasing the steering wheel. It should be emphasized that the action of shape 9a on the spring 6a tends to enhance the frictional engagement with the pin 5.
A second embodiment of the safety device according to the invention will be now described with reference to FIGS. 2B, 3B, and 4B.
As described briefly above and shown in FIG. 2B, an opposing side of the rectangular spring end 106b will urge directly against the shape 9 thereby eliminating use of the tooth 107a of FIG. 2A.
Shown at 5 in these drawing figures is a stationary pin, which may be affixed to the bottom of the box 3, for example. Tightly wound around this pin 5 is a rectangular coil spring 6b having its ends 106b and 206b bent to project radially outwards, from diametrically opposite positions of the spring, as shown best in FIG. 4B. That end of the shaft 2 which extends into the box 3 is shaped as a half-cup 7b, so as to embrace the pin 5 and the spring 6b wound thereon with some radial and axial clearance, and extends circumferentially around the pin 5 through an angle of (for example) 180°-2alpha, as shown best in FIG. 4B with alpha being measured from a contact surface of half-cup 7b to a center line of spring ends 106b, 206b. The radius for the half-cup shape 7b should be such that the latter engages, as the shaft 2 is rotated, with ends 106b and 206b, respectively, of the spring 6b, for purposes to be explained. Further, in these embodiments, the value 180°-2alpha is determined according to size and positioning of at least one of several elements including elements 9b-7b and spring ends 106b and 206b. Thus, 180°-2alpha is not limitative.
The half-cup 7b includes an uninterrupted surface 307 as best shown in FIG. 2B which engages in complete surface contact with corresponding planar surfaces of the ends 106b, 206b of the rectangular coil spring 6b.
Reference numeral 8 is again the driven shaft for operating the steering arrangement. In the embodiment shown, this driven shaft 8 is a tubular shaft mounted for free rotation on the shaft 2 concentrically therewith. The driven shaft 8 is terminated with a half-cup shape 9b having the same radius as the shape 7b and extending around the pin 5 through an angle of 180°-2alpha. Keyed on the other end of driven shaft 8 is a pinion gear 10 which may either mesh directly with the cable 4 in helical form as shown in FIG. 3B, or with a rack connected to the cable 4.
Shaft 2 forms the actuating member for the helm system shown and shaft 8 its actuated member.
The device just described operates as follows.
Making reference in particular to FIGS. 1, 2B, and 4B, it will be assumed that the steering wheel 1 is turned in the counterclockwise direction, for example, as indicated by an arrow F in FIG. 2B.
The half-cup shape 7b will be turned accordingly in that direction through the shaft 2 of the wheel 1. During a first fractional rotation, through the angle alpha in FIG. 4B, shape 7b will abut against a planar surface of the end 106b of the rectangular spring 6b and urge it in the opposite direction from the winding direction of the spring 6b around the pin 5. This results in the winding of spring 6b being expanded, with consequent attenuation or removal of the frictional engagement between the spring 6b and the pin 5, whereby the spring 6b can be entrained to rotate with the shaft 2 of the steering wheel 1.
Concurrently therewith, as shown in FIG. 2B an opposing planar surface of spring 106b will come to bear on the shape 9b unitary with shaft 8, so that shaft 8 is also entrained rotatively by the steering wheel shaft 2, to therefore rotate the pinion gear 10 operating the helm control cable 4.
Testing of the instant device with the use of a rectangular spring again resulted in up to 300,000 turning cycles of the steering mechanism without spring breakage.
It should be understood that although a rectangular coil spring is disclosed and shown, any coil spring having two opposing parallel planar surfaces would be acceptable for use as long as the opposing planar surfaces of spring 106b are positioned to engage in planar surface contact with shapes 7b or 9b.
Because of the effectiveness of the rectangular shaped coil spring, it is therefore possible to eliminate use of dogs or teeth 107, 207, simply allowing opposing shape 7b or 9b to act in a reverse direction on an opposing planar surface of the spring 6b than that which is acted on initially. In other words, shapes 7b and 9b may function as bidirectional actuators against opposing surfaces of the ends 106b, 206b of the rectangular coil spring 6b.
A similar effect would occur as the steering wheel 1 is turned clockwise in FIGS. 2B, 3B and 4B. Shape 7b engages here the opposite end 206b of the spring 6b, and the opposing surface of spring end 206b comes to bear on shape 9b. Upon releasing the steering wheel, the spring 6b will resume its original condition of close adhesion to the pin 5. At this stage, a tensile force applied to the cable 4 from the steering device of the water vehicle will cause one edge of shape 9b to strike one end, 106b or 206b, of the spring 6b along the winding direction of the spring around the pin 5, whereby the spring 6b will be locked onto the pin 5 by the strong frictional resistance and stop the movement of shape 9b, so that the steering device cannot swing out of the setting imparted immediately prior to releasing the steering wheel. It should be emphasized that the action of shape 9b on the spring 6b tends to enhance the frictional engagement with the pin 5.
FIGS. 5A and 6A show a device quite similar to that in FIGS. 2A, 3A, and 4A, and similar corresponding parts of this device will be referenced, therefore, as in the previously described embodiment.
With reference to the drawing figures, the spring 6a is disposed with radial clearance around the two half-cup shapes 7a and 9a, respectively unitary with the drive shaft 2 and the driven shaft 8, and is urged against the concentrical bush 5' affixed to the helm box 3 in any suitable manner.
The ends 106a, 206a of the spring 6a are bent radially inwards so as to intervene between the half-cup shapes 7a and 9a.
The operation of the safety device is here quite the equivalent for all the rest of that of the safety device embodied in FIGS. 2A, 3A, and 4A, it being understood that in this case the spring 6a will interact by frictional engagement with the bush 5'.
FIGS. 5B and 6B show a device quite similar to that in FIGS. 2B, 3B, and 4B, and similar corresponding parts of this device will be referenced, therefore, as in the previously described embodiment.
With reference to the drawing figures, the spring 6b is disposed with radial clearance around the two half-cup shapes 7b and 9b, respectively unitary with the drive shaft 2 and the driven shaft 8, and is urged against the concentrical bush 5' affixed to the helm box 3 in any suitable manner.
The ends 106b, 206b of the spring 6b are bent radially inwards so as to intervene between the half-cup shapes 7b and 9b.
The operation of the safety device is here quite the equivalent for all the rest of that of the safety device embodied in FIGS. 2B, 3B, and 4B, it being understood that in this case the spring 6b will interact by frictional engagement with the bush 5'.
FIGS. 7 and 8 show a further embodiment of the safety device according to the invention.
With reference to these drawings, indicated at 2 is the drive shaft. This shaft is terminated with two radial arms 11 and 12 projecting from radially opposite positions. Connected to those arms 11 and 12 are two cylinder segment elements 13 and 14 which extend over an arc of about 90° and are each provided with a tooth or dog 15 and 16, respectively, centrally thereon, the teeth or dogs extending radially toward the center. The two segments 13 and 14 are accommodated inside a cylindrical case 17 attached to the box 3 in a freely rotatable manner with a small radial clearance. Located within the case 17, between the segments 13 and 14, is an element 18 connected to the drive shaft 8.
This element 18 is formed, at diametrically opposite locations thereon, with two notches 118,118' engaging the teeth 15 and 16 with a backlash 2alpha. It also has, at diametrically opposite locations orthogonal to the notches 118, 118' two substantially straight surfaces 218, 218'. Two spaces 23 and 24, bound by the surfaces 218, 218', the inner wall of the cylindrical case 17, and the ends of the cylinder segments 13 and 14, accommodate two ball pairs 19, 19' and 20, 20' which are constantly biased in opposite directions towards the ends of the segments 13 and 14 by two springs 21 and 22. The diameters of the balls 19, 19' and 20, 20' are sized such that, in their rest position, the balls will wedge between the ends of the camming surfaces 218, 218' and the inner wall of the case 17.
The device just described operates as follows.
With the parts in the positions illustrated by FIG. 8, any attempt at rotating the driven shaft 8 in either direction would be defeated by the balls 19, 19' and 20, 20' wedging themselves between the surfaces 218, 218' and the inner wall of the case 17. A rotation of the drive shaft 2 will drive the elements 13 and 14 through a fraction of their stroke equivalent to the backlash angle alpha, whereby the ends of the elements are caused to act on two diametrically opposed balls, e.g. balls 19' and 20 when the shaft 2 is turned counterclockwise, and pry them out of the angle between the wall of the case 17 and the corresponding surface 218, 218' of element 18, thus enabling the shaft 2 to transfer rotary motion to the element 18 through the teeth 15 and 16, and thence to the driven shaft 8. On relieving the shaft 2 of the force applied, the device will be restored automatically to its locked condition by the action from the springs 21 and 22.
It is understood that the invention is not limited to the embodiments described and illustrated. As an example, the balls 19, 19' and 20, 20' could be replaced with some other rolling members, such as rollers.
With reference to FIGS. 9 and 10, the safety device of this invention will be discussed hereinbelow as applied to a throttle control and reverse gear control for a water vehicle.
Shown in FIG. 9 is a remote control box 25 of the single lever 26 type as commonly employed to control the speed and direction of boats powered with outboard motors, or inboard engines, or inboard/outboard units equipped with hydraulically operated reverse gears.
As best shown in FIG. 10, the control lever 26 is keyed to one end of the actuating shaft 2 relating to the safety device shown in FIGS. 2A, 3A, and 4A. The safety device could be obviously embodied alternatively as shown in FIGS. 2B, 3B and 4B and as shown in FIGS. 5 through 8.
The operation of the device shown is self-evident. By moving the lever 26 in the direction of the arrow F in FIG. 9, for example, shape 7a is rotated in a counterclockwise direction through the shaft 2. During a first fractional rotation corresponding to angle alpha in FIG. 4A, shape 7a is brought to bear onto the planar surface of end 106a of spring 6a, and repel this spring end in the opposite direction from the winding direction of the spring 6a around the pin 5. This results in the turns of the spring 6a being expanded and the frictional engagement of the spring 6a and the shaft 5 being consequently released, whereby the spring 6a is allowed to rotate together with the shaft 2 of the lever 26. Concurrently therewith, the tooth 107a on shape 7a comes to bear on the shape 9a unitary with shaft 8, whereby the shaft 8 will be also driven rotatively by the shaft 2 of the lever 26, resulting in rotation of the pinion gear 10 which operates the cable 4 wherethrough the engine throttle control can be adjusted.
A similar effect occurs when the lever 26 is moved in the opposite direction, in which case shape 7a will engage the other end 206a of the spring 6a and the tooth 207 on shape 7a will abut against shape 9a. On releasing the control lever 26, the spring 6a will return to its original condition of close adhesion to the pin 5, thus locking the control system securely on the selected setting therefor and preventing all possibilities of the control system from being operated unintentionally and accidentally.
Of course, with respect to operation of FIGS. 2B, 3B and 4B, opposing planar surfaces of the rectangular coil spring ends 106b, 206b will act on and be acted on by planar surfaces of the half-cups 7b and 9b as described above.
More generally, the actuating member and actuated member may be any elements in an upstream or downstream location, respectively, in the path of movement of a water vehicle helm and throttle/direction controls.
Depicted in FIG. 11 is a situation where a helmsman, shown at 30, has fallen overboard from a water vehicle, shown at 31, having its helm or steering system equipped with a safety device according to the invention. As shown in full lines, the water vehicle 31, presently with no one at the helm, will keep running in the same (straight, in the example) direction of its course before the helmsman fell overboard, since the steering device 32 of the water vehicle is locked by the inventive safety device in the same position as before the incident. Absent the safety device of this invention, the water flow around the steering device 32 would gradually bring the steering device to a position of tightest turn of the boat, whereby the boat would close in toward the man in the water along a spiral course and endanger his safety.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. | In a helm, throttle and directional control system for small craft, a safety device arranged to operate between an actuating member and an actuated member has such members coupled rotatively together by means of mechanical one-way coupling devices wherein a resilient force holds the actuated member constantly biassed to a locked position, and wherein the locking action is released by moving the actuating member against the resilient force, thereby motion can be transferred to the actuated member from the actuating member. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 10/091,838 filed by Dean C. Alberson, et al., on Mar. 6, 2002, which is hereby incorporated by reference.
[0002] This application is related to U.S. patent application Ser. No. 10/967,886 filed by Dean C. Alberson et al., Oct. 18, 2004, now U.S. Pat. No. 7,112,004.
TECHNICAL FIELD OF THE INVENTION
[0003] The present invention relates generally to crash cushions and terminals used in highway applications to mitigate and preclude injuries to occupants of errant vehicles.
BACKGROUND OF THE INVENTION
[0004] Roadway crash cushions are widely used to absorb impacts and decelerate impacting vehicles in a controlled manner. Typically, crash cushions are positioned to shield fixed objects located within the roadway environment. Crash cushions are often positioned in front of obstacles such as concrete columns and abutments. Also, crash cushions are often located at the end of a guardrail installation to prevent the upraised end of the guardrail from spearing an impacting vehicle.
[0005] There are numerous crash cushion designs known that rely upon frangible members, or members that are intended to shatter or be destroyed upon impact, to absorb the energy associated with a vehicular impact. Examples are found in U.S. Pat. No. 3,768,781 issued to Walker et al. and U.S. Pat. No. 3,982,734 issued to Walker (both employing energy cells having internal frangible members of e.g., vermiculite). One problem with the use of frangible members is the crash cushion must be completely replaced after each collision. Thus, time and expense is incurred in replacing the frangible members.
[0006] A number of previous crash cushion designs rely upon the permanent deformation of plastics or steels to absorb the kinetic energy of errant impacting vehicles. A design of that nature suffers from the same drawbacks as those designs incorporating frangible members. The cost and time associated with replacing or repairing the deformed portions of the cushion is significant.
[0007] There have been a few attempts to provide reusable or restorable crash cushions. However, for the most part, these attempts have proven impractical or unworkable in practice. U.S. Pat. No. 4,452,431 issued to Stephens et al, for instance, describes a crash cushion wherein fluid filled buffer elements are compressed during a collision. It is intended that energy be absorbed as the fluid is released from the buffer elements under pressure. In practice, it is difficult to maintain the fluid filled cylinders as they are prone to loss of fluid through evaporation, vandalism and the like. Also, after a severe impact, holes or punctures may occur in the buffer elements rendering them incapable of holding fluid.
[0008] U.S. Pat. No. 4,674,911 issued to Gertz describes a pneumatic crash cushion that is intended to be reusable. This crash cushion employs a plurality of air chambers and valve members to absorb and dissipate impact energy. This arrangement is relatively complex and prone to failure. In addition, the numerous specialized components used in its construction make it expensive.
[0009] The Reusable Energy Absorbing Crash Terminal (“REACT”) 350 is a crash cushion wherein a plurality of polyethylene cylinders are used to absorb impact energy. The cylinders are retained within a framework of side cables and supporting frames. This system is effective and reusable to a great degree due to the ability of the cylinders to restore themselves after impact. The cylinders typically return to 85%-90% of their original shape after impact. Unfortunately, the REACT system is also expensive to construct. The number of manufacturers producing large diameter polyethylene cylinders is limited and, as a consequence, prices for the cylinders are elevated.
[0010] An improvement that addresses the problems of the prior art would be desirable.
[0011] SUMMARY OF THE INVENTION
[0012] The present invention provides devices and methods relating to roadway crash cushions. An energy absorbing terminal is described that is made up of a plurality of cells partially defined by cambered panels made of thermoplastic. The panels are supported upon steel diaphragms. The cambered portion of the thermoplastic panels provides a predetermined point of flexure for each panel and, thus, allows for energy dissipation during a collision. The stiffness of the crash cushion is variable by altering material thicknesses and diaphragm spacing.
[0013] In operation, a vehicle colliding in an end-on manner with the upstream end of the energy absorbing terminal will cause the cambered panels to bend angularly at their points of flexure and, thus, cause the cells to collapse axially. The use of thermoplastic, such as polyethylene, results in a reversible, self-restoring collapse of the terminal, meaning the terminal is reusable after most collisions.
[0014] The invention provides a number of advantages over conventional crash cushions, including cost, ease of construction, and maintenance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a plan view of an example crash cushion arrangement constructed in accordance with the present invention prior to impact from an errant vehicle.
[0016] FIG. 2 is a side view of the arrangement depicted in FIG. 1 .
[0017] FIG. 3 is a plan view of the crash cushion depicted in FIGS. 1 and 2 after being struck by an impacting vehicle.
[0018] FIG. 4 is a front view of a diaphragm used within the crash cushion shown in FIGS. 1, 2 , and 3 .
[0019] FIG. 5 is a side view of the diaphragm shown in FIG. 4 .
[0020] FIG. 6 is a plan view of the diaphragm shown in FIGS. 4 and 5 .
[0021] FIG. 7 is a schematic depiction of an exemplary crash cushion shown prior to an end on impact by a vehicle.
[0022] FIG. 8 is a schematic depiction of the crash cushion shown in FIG. 7 , at approximately 0.18 seconds following an end-on impact.
[0023] FIG. 9 is a schematic depiction of the crash cushion shown in FIG. 7 , at approximately 0.27 seconds following an end-on impact.
[0024] FIG. 10 is a schematic depiction of the crash cushion shown in FIG. 7 , at approximately 0.345 seconds following an end-on impact.
DETAILED DESCRIPTION OF THE INVENTION
[0025] FIGS. 1-3 illustrate an example hybrid energy absorbing reusable terminal (“HEART”) crash cushion 10 that is constructed in accordance with the present invention. The crash cushion 10 is shown installed on a concrete pad 12 (visible in FIG. 2 ) that has been placed within a section of ground 14 . Although not shown, it should be understood that the crash cushion 10 is typically installed adjacent a rigid obstacle, such as a bridge abutment, concrete post or other barrier. In addition, the crash cushion 10 may be located at the upstream end of a guardrail installation.
[0026] The crash cushion 10 includes a nose portion 16 , central body portion 18 and downstream end portion 20 . An approaching vehicle 22 is shown adjacent the nose portion 16 of the cushion 10 in FIGS. 1 and 2 . The nose portion 16 consists of a sheet of plastic, or other suitable material, that is curved or bent into a “u” shape. The nose portion 16 may be painted with a bright color, such as yellow, or have reflective tape applied so that the cushion 10 may be easily recognized by drivers. The downstream end portion 20 includes a pair of upstanding rigid posts 24 , 26 that are typically formed of concrete or steel and are securely anchored, either to the ground 32 or to an adjacent abutment, post or other barrier (not shown).
[0027] The central body portion 18 also includes a steel basetrack formed from a pair of parallel rail members 28 , 30 that are attached to the ground 32 . Anchor members 19 , such as bolts, are typically used to secure the rail members 28 , 30 to a concrete slab 21 . The central body portion 18 features a plurality of openings 34 that are arranged linearly along the length of the cushion 10 . In the described embodiment, the openings 34 are shown to be hexagonally shaped. While the hexagonal shape is presently preferred, it should be understood that other suitable shapes may be used, including, for example, octagonal, rectangular and square. The central body portion 18 incorporates two substantially parallel rows 36 , 38 of cambered panels that are arrayed in an end-to end manner along their lengths. The panel rows 36 , 38 may comprise a single integrally formed sheet of plastic. Alternatively, they may be formed of a number of individual cambered panel members placed in an end-to-end, adjoining manner at each rectangular frame 40 . It is presently preferred that the rows of panel members 36 , 38 be formed of polyethylene. A suitable polyethylene material for use in this application is PPI recommended designation PE3408 high molecular weight, high density polyethylene. A currently preferred thickness for the panel members 36 , 38 is approximately 1¼″. It is noted that the panel members 36 , 38 are created so as to be substantially stiff and sturdy in practice and to possess substantial “shape memory” so that they tend to substantially return to their initial form and configuration following elastic deformation. Presently, panel members having a secured in place height of about 20 inches have provided suitable resistance to collapse and sufficiently return to original shape. It is noted that the thickness of a given panel member as well as its height may be adjusted as desired to increase or decrease resistance to expected end-on collision forces. For example, increasing the height of the panel members 36 , 38 will increase the amount of panel material that would be bent by a colliding vehicle and would, therefore, be stiffer than a cushion that incorporated panel members of lesser height.
[0028] The crushable cells include rectangular frames or diaphragms 40 that join the parallel panel rows 36 , 38 together. In the drawings, individual diaphragms are designated consecutively from the upstream end of the cushion 10 as diaphragms 40 a , 40 b , 40 c , etc. The diaphragms 40 are preferably formed of steel box beam members welded to one another. In a currently preferred construction, bolts or rivets 42 (visible in FIG. 2 ) are used to affix the panel rows 36 , 38 to the frames 40 . Referring now to FIGS. 4-6 , a single exemplary diaphragm, or frame, 40 is shown in greater detail. The diaphragm 40 includes a widened upper portion, generally shown at 50 , and a narrower lower portion 52 . The lower portion 52 includes a pair of generally vertically oriented support members 54 and a connecting cross-piece 56 . U-shaped engagement shoes 58 are secured to one side of each of the support members 54 and slidably engage the rail members 28 , 30 . The upper portion 50 includes a pair of vertically disposed side members 59 with upper and lower cross-members 60 , 62 that interconnect the side members 59 to form a rectangular frame. Additional vertical and horizontal cross-members 64 , 66 , respectively, are secured to one another within the rectangular frame for added support. Plate gussets 68 are welded into each comer of the rectangular upper portion 50 in order to help to maintain rigidity and stiffness for the diaphragm 40 .
[0029] Tension cables are used to provide the crash cushion additional strength and stability and, thereby, materially assist in the lateral redirection of side impacts into the cushion 10 . As shown in FIGS. 1 and 2 , a pair of forward, or upstream, tension cables 72 , 74 are disposed through a forward plate 76 , threaded through the upstream diaphragms 40 a , 40 b and are then secured to the third diaphragm 40 c . A currently preferred method of securing the tension cables to a diaphragm is to secure a threaded end cap (not shown) onto each end of each cable and then thread a nut onto the end cap after passing the end cap through an aperture in the diaphragm. In the exemplary construction shown, a pair of rearward tension cables 78 , 80 are secured to the third diaphragm 40 c and extend rearwardly through corresponding diaphragm apertures toward the downstream end of the central portion 18 .
[0030] Longitudinal tension in the cushion 10 is provided by the side panels 36 , 38 that tend to want to remain in a substantially flattened (unfolded) configuration due to shape memory. As noted, prebending of the panels is done to provide a point of planned bending for the panels 36 , 38 at the cambered portions 44 .
[0031] FIGS. 7-10 are schematic representations of a crash cushion constructed in accordance with the present invention and illustrate the mechanics of collapse over time. In FIG. 7 , the cushion 10 has not yet been collapsed by an end on impact. Thus, the cushion 10 is at rest, and in a fully extended position. In FIG. 8 , an end on collision has taken place. The cushion 10 has been impacted by a vehicle (small car), shown schematically as load 82 , traveling at approximately 62 mph. The cushion 10 is shown at approximately 1.8 seconds into the collision in FIG. 8 . As can be seen, the cushion 10 has begun to collapse at two primary locations along its length. One of the locations 84 is proximate the upstream end of the cushion 10 . The second location 86 is proximate the downstream end of the cushion 10 . In FIG. 9 , the cushion 10 is shown approximately 0.27 seconds after the impact. By this time, a third location 88 of axial collapse has begun to form. This third location 88 is proximate the central point along the length of the cushion 10 . In FIG. 10 , the cushion 10 is essentially completely crushed or collapsed.
[0032] There are significant advantages to a system that provides for separate collapsing portions spread out in terms of location upon the cushion as well as time. These advantages include efficient use of material and aid in self-restoring nature of cushion. A collapse concentrated in one point along the length could cause that portion of the cushion 10 to be inelastically damaged.
[0033] As noted, the cells 34 may be hexagonal, octagonal, rectangular or square in shape, being formed between two adjacent frames 40 and the two panel rows 36 , 38 . As shown in FIG. 1 , the cells 34 need not all be the same size. The different lengths of the cells provides for differing resistances to collapse. The frames 40 have rollers or shoes (not shown) that engage the rails 28 , 30 in a manner known in the art so that the frames 40 may move longitudinally along the rails 28 , 30 . During an end-on collision with the crash cushion 10 , there is a dynamic wave that propagates through the cushion 10 and may collapse sections other that the lead sections (defined between the upstream frame 40 a , 40 b , 40 c , and 40 d ). Additionally, some inertial properties can be used by collapsing the segments in varying order.
[0034] It is noted that each of the panel segments, such as segment 43 of each row 36 , 38 are cambered at a point 44 approximately midway between adjacent frames 40 . This cambered portion 44 forms a point of flexure and preplanned weakness for the panel segment 43 , thereby permitting the segment 43 to collapse upon the application of an end-on force. The bend also prevents large acceleration spikes from being needed for initial column buckling of the segments 43 . Currently, it is preferred that the amount of bend at the cambered point 44 be about 5-10 degrees, as this amount of bend has been found to provide enough eccentricity to assure proper buckling. The bend at the cambered point 44 may be formed by using a press device of a type known in the art.
[0035] In operation, the cells 34 are substantially, reversably compressed during an end-on impact by a vehicle 22 . The use of a resilient, thermoplastic material, such as polyethylene, ensures that the terminal 10 will be self-restoring after minor end-on impacts. The nose 16 may be crushed during the impact, but should be easily replaceable. The posts 24 , 26 serve as a reinforcement portion at the downstream end of the terminal 10 . The central portion 18 is compressed against the posts 24 , 26 .
[0036] The terminal 10 of the present invention provides a number of advantages over prior art terminals. The first is cost. As compared to systems that incorporate polyethylene cylinders, suitable sheets of polyethylene may be obtained readily and inexpensively from a number of suppliers. Secondly, if it becomes necessary to replace one or more of rows 36 or 38 , or individual panels 43 within those rows, this may be accomplished quickly and easily, requiring only removal and replacement of the fasteners 42 used to secure them to the frames 40 .
[0037] Those of skill in the art will recognize that many changes and modifications may be made to the devices and methods of the present invention without departing from the scope and spirit of the invention. Thus, the scope of the invention is limited only by the terms of the claims that follow and their equivalents. | An energy absorbing terminal is described that is made up of a plurality of cells partially defined by cambered panels made of thermoplastic or another suitable material. The panels are supported upon rectangular frames. The cambered portion of the panels provides a predetermined point of flexure for each panel and, thus, allows for energy dissipation during a collision. The stiffness of the crash cushion may be varied by altering material thicknesses and diaphragm spacing. In operation, a vehicle colliding in an end-on manner with the upstream end of the energy absorbing terminal will cause each of the cambered panels to bend angularly at its point of flexure and, thus, cause the cells to collapse axially. The use of thermoplastic, such as polyethylene results in a reversible, self-restoring collapse for the terminal, meaning that the terminal is reusable after most collisions. | 4 |
BRIEF SUMMARY OF THE INVENTION
This invention relates to improvements in blade gauges for facilitating adjustment of the extent to which the blade tip of an extensible-blade surgical knife projects beyond the end of a cutting depth limiting foot attached to the body of the knife. The invention has particular utility in the adjustment of knives used in ophthalmological procedures such as radial keratotomy.
A typical keratotomy knife comprises a knife body, generally in the form of an elongated cylinder, containing a stem which is axially movable. A diamond blade is fixed at the end of the stem. The blade is at least partly surrounded by a foot, which serves not only to protect the blade, but also to limit the cutting depth. The limit of cutting depth is the extent to which the blade projects beyond the end of the foot. Axial positioning of the stem, and thus the extent to which the blade projects beyond the foot, is controlled by a screw mechanism within the knife body. Ordinarily, the control on the knife body for adjusting the position of the internal stem includes markings for providing an indirect indication of the cutting depth.
In radial keratotomy particularly, cutting depth is critical. Blade replacement, and interchange of parts can introduce errors into the indirect cutting depth indications provided by the knife itself. Accordingly, surgeons are reluctant to rely upon the indicator on the knife alone. They prefer to use a separate gauge which directly measures the extent to which the blade projects beyond the foot. The separate gauge can be used as an adjunct to the indicator on the knife itself, to confirm the readings given by the knife-carried indicator. Alternatively, the gauge can be used by itself as a setting device. In the latter case, the gauge is preset to the desired reading, and, with the knife in proper relationship to the gauge, the blade projection adjuster is operated until the blade reaches the desired position.
An example of a blade gauge used in conjunction with keratotomy knives appears in Knepshield et al. U.S. Pat. No. 4,499,898, issued Feb. 19, 1985. The Knepshield gauge comprises a gauge stand with knife-positioning elements engageable with a knife body to ensure proper positioning of the knife body with respect to the stand. A rotatable disc indicator, having a cylindrical exterior surface, is supported in a mounting slot on the gauge stand so that its cylindrical surface can be brought into abutment with the tip of the foot of the knife. The disc indicator is then clamped in place on the gauge stand by the tightening of a screw, but still allowed to rotate. The blade of the knife, projects beyond the cylindrical edge of the disc, and overlies the face of the disc. The face of the disc has a circle formed on it which is eccentric with respect to the cylindrical edge of the disc. Thus, the area between the eccentric circle and the edge of the disc varies in width. The disc is rotated until the eccentric circle is directly underneath the end of the knife blade, and the extent to which the knife blade projects beyond the end of the foot is determined from markings on the face of the disc, which may be read against the blade itself.
The present invention is an improvement over the gauge described in the Knepshield et al. patent.
The principal features of the invention include: a knife-support cradle which slides relative to a base; a gauge element which is initially in abutment with the end of the cutting depth limiting foot of the knife, but which moves away from the foot; contrasting colors on opposite sides of the edge of a gauge element; and a unitary wire hold-down clip for the knife body.
A preferred gauge in accordance with the invention comprises a base having guide means, a cradle slidably supported on the base and guided by the guide means, means on the cradle for holding the body of an extensible-blade surgical knife so that the cutting edge of the blade lies in a plane parallel to the direction of extension and retraction of the blade and fixed with respect to the cradle, and gauge means on the base comprising a gauge element having an edge located closely adjacent to said plane and substantially parallel thereto, said edge extending transverse to the direction of extension and retraction of the blade. The gauge element is capable of movement relative to the base parallel to said plane, through a range of positions including a reference position fixed with respect to the base, so that a projection of said edge onto the blade in a direction perpendicular to said plane, is movable in the direction of extension and retraction of the blade as the gauge element moves. Indicator means provide a reading of the position of said gauge element relative to the reference position. Means are provided for adjusting the position of the cradle on the base, thereby adjusting the location of the cradle relative to the reference position of the gauge element. Releasable means are provided for fixing the cradle with respect to the base, thereby fixing said location, while allowing said movement of the gauge element relative to the base.
Preferably, the gauge element is slidably supported on the base, and the gauge means also comprises a block fixed to the base, and thread means for adjustably moving the gauge element relative to the block in the direction of projection and retraction of the blade. The gauge element has a face extending from its edge in a direction perpendicular to the aforementioned plane in which the blade's cutting edge lies. This face is positioned to be abutted by the end of the cutting depth limiting foot of a knife held on the cradle so that, with the indicator means showing the gauge element at the reference position, the end of the foot can be brought into abutment with said face by operation of said means for adjusting the position of the cradle on the base. Thereafter, the face of the gauge element can be moved away from the foot by operation of said thread means to determine the extent to which the tip of the blade extends beyond the end of the foot.
The gauge element preferably has a second face extending from its edge in parallel to the aforementioned plane in which the cutting edge of the blade lies. The gauge element is slidable on a surface of the base which is also parallel to said plane. This second face of the gauge element and the surface on which the gauge element slides are of contrasting colors, so that the relationship of the tip of the knife blade to the edge of the gauge element can readily be determined visually.
Preferably, the cradle has an upwardly extending post having a top face with an arcuate recess for receiving the body of the knife, and also having front and rear faces extending transverse to the direction of elongation of the knife. Each of these front and rear faces has a hole for receiving the end of a spring wire clamping means used to hold the body of the knife in the arcuate recess. The holes are aligned along a line parallel to the direction of elongation of the knife. The clamping means comprises a unitary length of spring wire having its ends respectively located in the holes in the front and rear faces of the post, whereby the clamping means can pivot about said line. The length of spring wire comprises a first inverted J-shaped section located substantially in a first plane on the rear side of the post and a second inverted J-shaped section located substantially in a second plane on the front side of the post. The first and second planes are parallel to each other and transverse to the direction of elongation of the knife. Each of the J-shaped sections comprises a leg and an arcuate section. Each leg connects one of the ends of the wire to one end of an arcuate section. The clamping means also comprises a connecting section extending substantially parallel to the direction of elongation of the knife and connecting together the ends of the two arcuate sections which are remote from the legs. The clamping means is shaped so that its spring characteristic holds its ends in the holes in the front and rear faces of the post, and so that the arcuate sections are capable of overlying a knife body located in the recess and holding the knife body in place in the recess. The J-shaped sections are shaped, and the holes are positioned, so that an imaginary line extending from end of each J-shaped section to the other end of the same section is located substantially below the center of the arc of the arcuate recess when the clamping means is holding the knife body in the recess.
The principal object of the present invention is to provide an improved blade gauge which is more accurate, more versatile, and easier to use than the gauge described in the Knepshield et al. patent. The manner in which this object is accomplished and various further objects and advantages of the invention will be apparent from the following detailed description when read in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a section taken on a vertical plane extending longitudinally through a gauge in accordance with the invention, with a keratotomy knife shown in broken lines;
FIG. 2 is a top plan view of the gauge, partially broken away to show the manner in which an adjusting stem is held by balls in a movable gauge element;
FIG. 3 is a vertical section taken on plane 3--3 in FIG. 1;
FIG. 4 is a perspective view of a typical keratotomy knife with which the gauge is used;
FIG. 5 is a fragmentary top plan view showing the gauge element at a reference position, with its face in contact with the foot of a keratotomy knife; and
FIG. 6 is a fragmentary top plan view showing the gauge element moved away from the foot of the keratotomy knife and positioned directly underneath the tip of the knife blade.
DETAILED DESCRIPTION
As shown in FIGS. 1 and 2, the gauge of the invention comprises a base 10, a knife-supporting cradle 12, and gauge means 14.
A channel 16, best shown in FIG. 2, extends lengthwise along the top of the base from one end to the other. Cradle 12 is supported by horizontal surfaces 18 and 20 within the channel, and is slidable thereon.
As shown in FIG. 3, base 10 has overhanging elements 22 and 24 which engage the sides of cradle 12, guiding it by constraining it against horizontal movement in directions other than along the length of the channel. Slots 26 and 28 are found respectively underneath overhanging parts 22 and 24. These slots are used to fix a part of gauge means 14 to the base, as will be described.
The floor of channel 16 is also provided with a recess 30 located between cradle support surfaces 18 and 20. Recess 30 facilitates tightening of the cradle against surfaces 18 and 20 by a clamp which comprises knurled wheel 32, and a threaded stem 34 which is threaded into hole 36 in the base, as shown in FIG. 1. Threaded stem 34 extends through a slot 38 in the cradle. When the clamp is tightened, the underside of wheel 32 bears against the upper surface of the cradle, fixing the cradle with respect to the base. When the clamp is loosened, slot 38 allows a limited longitudinal movement of the cradle in channel 16.
A knife 40 is held on the cradle by support pedestals 42, 44 and 46. The knife is held down by wire clamp 48 on pedestal 44.
The knife is positioned so that its blade 50, when extended, is located just above the level of the upper surface of a movable gauge element 52. The gauge element is slidable longitudinally on the base, and is guided in channel 16. Blade 50 can extend over gauge element 52 in close proximity to the top surface of the gauge element, as shown in FIG. 1. The gauge element is secured to an adjusting stem 54 by a ball bearing 50 and a set screw 58, as shown in FIG. 2. Set screw 58 holds ball 56 in groove 60 on stem 54. Another ball is similarly held in groove 60 on the opposite side of the stem. Threads 62 on stem 54 are engaged with internal threads in a barrel 64, which is fixed to, and extends outwardly from, block 66. Block 66 has feet (not shown) which fit into slots 26 and 28 (FIG. 3) underneath overhanging parts 22 and 24. The block is urged upwardly against overhanging parts 22 and 24 by set screw 68 (FIG. 1), and thereby held securely in a fixed position with respect to base 10. A knurled micrometer barrel 70 is secured to stem 54 by a set screw 72. The micrometer barrel 70 is hollow, and barrel 64 extends partway into the end of the barrel 70. A compression spring 73 bears against the end of barrel 64, and urges the micrometer barrel outwardly, thereby eliminating play between threads 62 and the mating threads on the interior surface of barrel 64.
As shown in FIG. 2, markings 74 on the micrometer barrel, when read in conjunction with markings 76 on the exterior of barrel 64, provide an indication of the position of gauge element 52 relative to block 66.
In FIGS. 1 and 2, gauge element 52 is shown positioned against a face of block 66. When the edge of barrel 72 is aligned with the zero marking on barrel 64, gauge element 52 will be separated from block 66. In operation, the gauge element is moved toward the block by counterclockwise rotation of micrometer barrel 72.
The keratotomy knife shown in FIG. 4 has a cutting depth limiting foot 78 surrounding the blade 50. The extent to which the blade projects beyond the end of foot 78 is adjustable by suitable adjusting means within the knife body.
A tapered section 80 extends from foot 78 toward a series of knurled sections 82, 84, 86 and 88. The knurled sections are separated by gaps 90, 92 and 94. Beyond knurled section 82, there is provided a reduced section 96 having flat faces, one of which is seen at 98. These flat faces are perpendicular to the plane in which the knife blade lies, and cooperate with vertical faces 100 and 102 (FIG. 2) of pedestal 44 to prevent rotation of the knife, and thereby hold the knife blade in parallel relation to the upper face of gauge element 52.
As shown in FIG. 1, pedestal 46 engages the end of the tapered section of the knife body, and is of a height such that it positions the knife blade in very close proximity to the upper face of gauge element 52 while preventing contact between the blade and the gauge element.
Referring now to FIGS. 1 and 3, wire clamp 48 on intermediate pedestal 44 comprises a first vertical section 104, an arcuate section 106, a horizontal connecting section 108 (FIG. 2), a second vertical section 110, and a second arcuate section 112. The connecting section 108 connects the ends of arcuate sections 106 and 112. Vertical sections 104 and 110 extend downwardly along the sides of pedestal 44, and terminate in horizontal sections 114 and 116 respectively, which extend into opposite ends of a through hole in the pedestal. The wire clamp is pivotable in the through hole.
When section 94 (FIG. 4) of the knife is positioned in semi-circular trough 118 of pedestal 48 (FIG. 3), the wire clamp is positioned over knurled parts 86 and 88 of the knife body. Because of its spring characteristic, the wire clamp holds the knife securely in place, thereby reducing the likelihood of accidental damage to the blade.
Referring to FIG. 3, the lower ends of the straight sections of the wire clamp 48 are positioned well below the trough 118 so that if an imaginary line were to be drawn from the end of arcuate section 106 remote from section 104 to end 114, there is a point on the imaginary line directly below, and a substantial distance below, the center of the arc of recess 118. This insures that the wire clamp will not accidentially swing out of its clamping position, but at the same time allows it to be manually engaged with, and disengaged from, the knife body by manipulation of connecting section 108 to deform the spring clamp slightly.
Referring to FIG. 5, which shows gauge element 52 separated from fixed gauge block 66, vertical face 124 of gauge element 52 is in contact with the end of cutting depth limiting foot 78. Knife blade 50 overlies planar top surface 120 of gauge element 52. This top surface and surface 122 of recess 30 in the face of the channel are of contrasting colors, providing a high degree of visibility for the knife blade. Preferably, the parts are made of aluminum. Gauge element 52 is anodized and dyed black. Surface 122 is also anodized, but preferably remains in the ordinary undyed aluminum color.
In FIG. 6, gauge element 52 is shown with its face 124 separated from the cutting depth limiting foot, and with the edge at which surface 120 meets face 124 directly underneath the tip of the knife blade. The contrasting colors of surfaces 120 and 122 allow the relationship between this edge and the tip of the knife blade to be determined accurately so that the extent to which the blade projects beyond the end of the foot can be read from the markings associated with adjusting micrometer barrel 70. Typically, the knife blade is viewed through a low-power magnifier. The knife blade is maintained very close to the plane of gauge element surface 120 to minimize the effect of parallax.
The gauge is normally used to aid the surgeon in setting a knife to a desired cutting depth. The procedure for setting the knife normally begins with the blade 50 fully retracted into foot 78. The cradle is first moved away from the gauge element, and the knife is placed on the cradle and secured by spring clamp 48. The gauge means is brought to the "zero" or reference position depicted in FIG. 5 by adjustment of micrometer barrel 70. The cradle is then moved along channel 16 until the end of the cutting depth limiting foot 78 engages face 124 of gauge element 52, as shown in FIG. 5. The blade, however, is not extended at this time. The cradle is locked into position relative to base 10 by means of clamp 32. The micrometer barrel 70 is rotated counterclockwise until its markings indicate the desired cutting depth. This rotation of the micrometer barrel causes the gauge element to back away from the foot by a distance equal to the desired cutting depth. The knife blade is then extended while the relationship between the tip of the blade and the gauge element is observed through a magnifier. When the tip of the blade reaches the edge of the gauge element, the knife is adjusted to the desired cutting depth.
While the gauge can be used, in the manner just described, to aid in adjusting the knife, it can also be used to measure the extent to which an already extended blade projects beyond the foot. To accomplish this, the gauge element is brought to the "zero" position, the knife is clamped in place on the cradle, and the cradle is moved toward the gauge element until the foot abuts gauge element face 124 as shown in FIG. 5. The knife blade overlies top surface 120 of the gauge element at this time. The cradle is then locked to the base, and the gauge element is backed away from the front until the edge of the gauge element is directly underneath the tip of the blade as shown in FIG. 6. The cutting depth can then be read directly from the markings on the micrometer barrel.
The knife itself will normally have its own markings, and the indications given by the markings on the knife will be confirmed by the indications provided by the gauge in either mode of operation. Confirmation is particularly important in radial keratotomy, because cutting depth is critical, and the indicator on the knife itself provides only an indirect indication of cutting depth, and may be in error due to wear, blade breakage, or improper blade installation.
The gauge has the particular advantage that it allows accurate measurement of the extent to which a knife blade projects beyond its foot throughout a range from zero cutting depth to well beyond the maximum usable cutting depth. Because this range extends all the way to zero cutting depth, a knife can be calibrated against the gauge throughout the entire range of cutting depths. The ability to calibrate an adjustable knife in this way greatly contributes to the surgeon's confidence in the indirect cutting depth indications given by the knife itself.
The gauge provides accurate and easily readable indications of cutting depth. It also has the advantage that its cradle can be easily replaced by removal of clamp 32 so that the same base and gauge means can be used with a variety of different cradles adapted for different styles of knives.
As mentioned previously, the invention also has the advantage that the wire clamp securely holds the knife in the cradle, thereby greatly reducing the likelihood of breakage of the knife blade by dropping the knife.
Finally, improved accuracy is achieved by the contrast between the gauge element and the surface adjacent to the gauge element.
Various modifications can be made to the invention described. For example, while the gauge element preferably moves parallel to the knife axis, this is not necessarily the case. Fine adjustment of the gauge element can be achieved without the micrometer assembly shown in the drawings, by adoption of a wedge-shaped gauge element movable along a surface which is oblique in plan view with respect to the knife axis. By using a wedge, a relatively large amount of movement of the gauge element in the oblique direction will result in a relatively small, but accurately determinable movement of the projection of the edge of the gauge element onto the knife blade. Consequently, accurate readings can be obtained. Many other modifications may, of course, be made to the invention herein described without departing from its scope as defined by the following claims. | A gauge for use in determining the extent to which the cutting blade of an extensible-blade keratotomy knife projects beyond the end of a cutting depth limiting foot, comprises a base, a knife-holding cradle slidable on the base, a clamping screw for clamping the cradle to the base in any selected position within a range, a block fixed to the base, and a gauge element slidable on the base and adjustably movable with respect to the block toward and away from the cradle. With a knife mounted on the cradle, and the gauge element at a predetermined reference position, the cradle is moved until the foot of the knife abuts one face of the gauge element. The gauge element is then moved away from the foot by an adjusting screw, until an edge of the gauge element underlies the tip of the knife blade. The top face of the gauge element and the base surface on which the gauge element slides are of contrasting colors. The cradle includes a post for supporting the knife body with a unitary spring wire hold-down clip pivoted on the post. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates to a method and apparatus for achieving even transverse distribution and propagation of a flowing medium.
BACKGROUND OF THE INVENTION
[0002] In the cellulose and paper industries, for example, it is necessary to be able to form webs of fiber suspensions in an even and wide distributed flow in the transverse and longitudinal directions on a base, such as a roll, drum or the like. An uneven formation may thus result in an impaired pulp quality, for example due to fiber damages at subsequent press nips in thicker formed sections, canalization of the washing liquid, and poor efficiency during displacement washing.
[0003] Distribution of the flow of the flowing medium is controlled substantially by frictional losses (i.e. pressure drop) when the medium flows through a distributor. In order to ensure an even distribution, propagation and discharge of the medium in the transverse direction along a long and narrow gap, e.g. in a rectangular shaped distribution section, which is often desired, any of the following two principles mentioned can be applied:
[0004] Design the distributor such that the pressure drop along each streamline, for an evenly distributed outlet flow, from the inlet to the outlet, become essentially the same.
[0005] Provide a large pressure drop at the outlet of the distributor such that the differences in friction losses along different streamlines become negligible compared to the outlet friction losses.
[0006] One problem in applying the first principle (1) above is that the variation in velocity along individual streamlines of the flowing medium is hard to predict. This fact in combination with limited knowledge about the boundary layer behavior of e.g. suspensions of wood fibers, makes it difficult to predict the pressure drop along the streamlines. One problem is clogging of the distributor when the fibers tend to slow down or adhere to the inner faces of the distributor which influences the runnability. Known distributors have also been shown to be sensitive to variations in the flow velocity.
[0007] One object of the present invention is to provide a method and an apparatus according to the first principle, where an improved propagation and distribution of a flowing medium is accomplished and where the above mentioned problems are minimized.
SUMMARY OF THE INVENTION
[0008] This and other objects of the present invention have now been realized by the discovery of a method for obtaining an even transverse distribution and propagation of a flowing medium supplied through a conduit, the method comprising deflecting the flowing medium during diverging propagation of the flowing medium along at least one distribution gap having a frictional surface and a first depth, and conveying the flowing medium from the at least one distribution gap to an outlet gap having a second depth, the second depth being greater than the first depth, through a passage having an edge extending substantially transverse to the direction of flow of the flowing medium, the edge being shaped such that the propagation of the flowing medium as it flows within the distribution gap provides a substantially even and parallel flow of the flowing medium along the outlet gap. In a preferred embodiment, the method includes deflecting the flowing medium by diverging propagation along a plurality of the distribution gaps, each of the plurality of distribution gaps having a different depth. Preferably, the plurality of distribution gaps has a depth in the range of 8 to 60 mm.
[0009] In accordance with one embodiment of the method of the present invention, the second depth is from 1 . 2 to 4 times the first depth.
[0010] In accordance with another embodiment of the method of the present invention, the at least one distribution gap includes at least two diverging frictional surfaces interconnected by an edge shaped in the form of a circular arc.
[0011] In accordance with another embodiment of the method of the present invention, the method includes conveying the flowing medium so as to propagate the flowing medium in a rectangular cross-sectional shape. In accordance with another embodiment of the method of the present invention, the method includes redirecting the conveying of the flowing medium in at least one curved section.
[0012] In accordance with the present invention, the above and other objects have also been realized by the discovery of a distributor for the even transverse distribution and propagation of a flowing medium comprising a distribution housing including a supply conduit for supply of the flowing medium and at least one distribution gap having a frictional surface and a first depth for deflecting the flowing medium during the propagation, the distribution gap having a diverging shape for propagation of the flowing medium, and an outlet gap having a second depth for passage of the flowing medium after passage through the distribution gap, the second depth being greater than the first depth, and the distribution housing further comprising a passage between the distribution gap and the outlet gap, the passage comprising an edge extending substantially transverse to the direction of flow of the flowing medium, the edge being shaped such that the propagation of the flowing medium as it flows within the distribution gap provides a substantially even and parallel flow of the flowing medium along the outlet gap. In a preferred embodiment, the distributor comprises a plurality of the distribution gaps, each of the plurality of distribution gaps having a different depth.
[0013] In accordance with one embodiment of the distributor of the present invention, the plurality of distribution gaps has a depth in the range of 8 to 60 mm.
[0014] In accordance with another embodiment of the distributor of the present invention, the second depth is from 1.2 to 4 times the first depth.
[0015] In accordance with another embodiment of the distributor of the present invention, the at least one distribution gap has a substantially rectangular cross-sectional shape.
[0016] In accordance with another embodiment of the distributor of the present invention, the at least one distribution gap comprises at least two diverging frictional surfaces interconnected by an edge in the shape of a circular arc.
[0017] In accordance with another embodiment of the distributor of the present invention, the distributor includes at least one curved section for redirecting the flow of the flowing medium from the supply conduit to the outlet gap.
[0018] The objects of the present invention are achieved by a method for obtaining even transverse distribution and propagation of a flowing medium where: the medium is supplied through a conduit and is deflected during propagation in at least one distribution gap defined by a frictional surface; the medium is deflected during diverging propagation along the distribution gap; the medium is conveyed from the distribution gap through a passage to an outlet gap having a larger column depth than the depth of the distribution gap; the medium is conveyed over an edge, that constitutes a passage to the outlet gap, extending substantially transverse to the direction of flow; and the edge is shaped such that the frictional surface obtains propagation along the flowing path of the diverging medium in the distribution gap that provides a substantially even and parallel flow of the flowing medium along the outlet gap.
[0019] In that respect, frictional losses, in accordance with the present invention, for an evenly distributed outlet flow, become essentially similar for all streamlines. The shape of the edge is intended to vary the quantity of frictional surface along different streamlines in the distribution gap, in order to therefore provide an evenly distributed flow out of the outlet gap. Owing to the increase of the cross-section of the outlet gap during passage of the edge that extends substantially in the transverse direction, the pressure drop per unit of length along a streamline decreases, which causes the shaping of the outlet gap to become of reduced significance, in relation to other parts of the apparatus.
[0020] By “medium” in this description is meant liquids, gases, foam, fiber suspensions or other mixture of substances.
[0021] After passage through the gaps, the flowing medium passes an outlet opening. Preferably, the outlet opening is preceded by several distribution gaps having different column depths for the purpose of controlling frictional losses in different parts of the machine.
[0022] An outlet gap may suitably have a column depth at the outlet opening that is in the size of 1.2 to 4 times the column depth of the preceding gap.
[0023] By “frictional surface” in this description is meant those surfaces with which the flowing medium is in contact. It is the quantity of frictional surface in the distribution gap, alternatively the distribution gaps, and not the outlet gap, that controls the profile of the flow. The shape of the edge may compensate for frictional losses in the outlet gap.
[0024] In accordance with the present invention, a distributor has been discovered for the even transverse distribution and propagation of a flowing medium. The distributor comprises a distribution housing with a conduit for supply of the medium and deflection during propagation in at least one distribution gap arranged in the distributor defined by a frictional surface. The distribution housing comprises an outlet opening through which the medium passes after its passage through the distributor. The distribution gap is shaped with a diverging propagation. The distribution housing comprises a passage between the distribution gap and an outlet gap which is arranged with a larger column depth than the depth of the distribution gap. The passage comprises an edge, extending substantially transverse to the direction of flow, and which constitutes a passage to the outlet gap. The edge is shaped such that the frictional surface obtains a propagation along the flowing path of the diverging medium in the distribution gap that provides a substantially even and parallel flow of the flowing medium along the outlet gap.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The present invention will now be described in more detail with reference to the following detailed description, which in turn refers to the accompanying drawings, without limiting the interpretation of the invention thereto, where
[0026] FIG. 1A is a perspective, schematic, top view of a distributor according to an embodiment of the present invention;
[0027] FIG. 1B is a side, elevational, cross-sectional view taken along section A-A of the distributor shown in FIG. 1A ;
[0028] FIG. 2A is a top, elevational, partially schematic view of an edge of the distributor according to the present invention, showing the effect on the flow distribution out of the distributor;
[0029] FIG. 2B is a top, elevational, partially schematic view of an edge of another distributor according to the present invention, showing the effect on the flow distribution out of the distributor;
[0030] FIG. 2C is a top, elevational, partially schematic view of an edge of another distributor according to the present invention, showing the effect of the flow distribution out of the distributor;
[0031] FIG. 2D is a top, elevational, partially schematic view of an edge of another distributor according to the present invention, showing the effect on the flow distribution out of the distributor;
[0032] FIG. 3 is a top, elevational, partially schematic view of another embodiment of a distributor according to the present invention;
[0033] FIG. 4A is a side, perspective view of yet another embodiment of a distributor according to the present invention;
[0034] FIG. 4B is a side, elevational, cross-sectional view taken along section A-A of the distributor shown in FIG. 4A ; and
[0035] FIG. 5 is a top, elevational, partially schematic view of yet another embodiment of a distributor according to the present invention.
DETAILED DESCRIPTION
[0036] Turning to the figures, FIGS. 1A and 1B show a distributor according to an embodiment of the present invention for even, transverse distribution and propagation of a flowing medium. The distributor comprises a distribution housing 2 with a conduit 4 for supply of the medium and a wide outlet opening 6 . The distribution housing is shaped with a distribution chamber 8 and an outlet chamber 10 , which chambers are formed by limiting surfaces 12 , whose inner faces are denoted as frictional surfaces. The supply conduit 4 in FIG. 1 is arranged at an angle to the distribution chamber 8 , but may also be arranged in parallel to the direction of the flow S. The distribution chamber 8 has a distribution gap 14 that extends from the connection of the conduit in a diverging, conical propagation to a passage 16 having an edge 18 , extending substantially transverse to the direction of the flow, with a radius of curvature R, which edge 18 e.g. has the shape of an arc, at which passage 16 the outlet chamber 10 is connected. The distribution gap 14 of the distribution chamber communicates through the passage 16 with an outlet gap 20 of the outlet chamber, which outlet chamber 20 is arranged with a larger column depth than the depth of the distribution gap 14 of the distribution housing 2 , which outlet gap 20 extends from the passage 16 to the rectangular outlet opening 6 . Both gaps, 14 and 20 , have a substantially rectangular cross-section. The pressure drop along each streamline, from the supply through the conduit 4 to a discharge of the output flow of the medium through the outlet opening 6 , for an evenly distributed outlet flow, is essentially the same, providing a substantially even and parallel outlet flow.
[0037] Since the distance along each streamline is not equal in the outlet chamber 10 , the pressure drop in this chamber shall be relatively small in comparison to the pressure drop in other parts of the apparatus.
[0038] The supply conduit 4 can be arranged in the vicinity of the intersecting line C for the diverging, limiting surfaces. Preferably, the distribution chamber 8 , from the inlet forward to the edge extending essentially in the transverse direction, is provided with two diverging limiting surfaces, which are preferably interconnected by an edge 18 shaped as a circular arc.
[0039] According to one embodiment of the present invention, the passage between the distribution channel 8 and the outlet chamber 10 can be provided with sections of a plurality of distribution gaps, having different column depths, which is described more closely below with reference to FIG. 5 . Thus; the number of gaps with different column depths can be more than two, suitably three or four, and the passage between two or a plurality of gaps may be provided by an edge shaped in a similar way as the edge 18 described herein. The distribution gaps may have increasing column depths along the direction of the flow. However, according to a preferred embodiment, the distributor according to the present invention comprises alternating increasing and decreasing column depths of the distribution gaps.
[0040] The purpose of arranging a plurality of gaps is to be able to control frictional losses in different parts of the machine. The gaps may have a column depth in the range of 8 to 60 mm.
[0041] An outlet gap at the outlet opening 6 can have a column depth (h 2 ) that is in the size of 1.2 to 4 times the column depth (h 1 ) of the preceding gap, and preferably 1.5 to 4 times the column depth (h 1 ) of the preceding gap.
[0042] The same reference numerals are used in the drawings to the extent that details in the different embodiments are in correspondence.
[0043] FIGS. 2 A-D show variations of the shape of the edge 18 and illustrate how the flow picture is altered when changing the curvature of an arc-formed edge.
[0044] According to one embodiment, the edge 18 may have a substantially circular arc-formed extension with a radius of curvature R, which radius may have a different curvature for different embodiments of distributors, such as for example is shown in FIGS. 2 A-C. The supply conduit 4 can be arranged in a center on a chord of the circular arc. Preferably, the distributor chamber 8 , from the inlet forward to the circular arc of the apparatus, is substantially cone-shaped. This section may form a sector of a circle. FIG. 2C shows an embodiment of the circular arc where all radii R of the sector of the circle converge in one central point C (see also FIG. 1A ). In this way it is also ensured that the path each streamline follows from the inlet forward to the circular arc is equally long. Then the supply conduit 4 is placed in the central point C. The radius of curvature R of the circular arc may be larger than what is shown in FIG. 2C , such as is evident from FIGS. 2A and 2B . A shape according to FIG. 2B is assumed to produce an evenly distributed flow V along the entire outlet opening 6 , there will be a change to a shallower circular arc, i.e. having a larger radius of curvature R 1 than the shape of the edge with the radius of curvature R 2 in FIG. 2B , resulting in a larger flow V 1 in the middle of the outlet opening and a smaller flow V 2 against the side edges 12 ′ of the outlet opening, in comparison to that of FIG. 2B . If, instead, in comparison with FIG. 2B , a deeper circular arc is provided, i.e. one having a smaller radius of curvature R than the shape of the edge having the radius of curvature R 2 in FIG. 2B , this results in a lower flow V 2 in the middle of the outlet opening and a larger flow V 1 at the side edges 12 ′ of the outlet opening in comparison to the shaping according to FIG. 2B .
[0045] In FIG. 2D is shown an embodiment of another shape of the edge 18 , in this case made of two essentially straight edge sections, 22 and 24 , that meet at a point near the middle of the outlet opening 6 . The edge sections, 22 and 24 , form an angle ax between them. The flow picture for the embodiment shown in FIG. 2D is similar to that of FIG. 2C , i.e. the flow V 1 is largest at the side edges 12 ′ of the outlet opening and lower V 2 in the middle of the outlet opening in comparison to the shaping according to FIG. 2B . The edge may also be provided with other angles between the straight sections of the edges, 22 and 24 , depending on which flow picture is desired along the outlet opening. The edge 18 may also be provided with more than two edge sections (not shown).
[0046] In FIG. 3 is shown another embodiment according to the present invention. By an essentially circular arc-formed edge 18 it is meant that sections of the edge 18 may have differing shapes, but that the passage between the distribution gap 14 and the outlet gap 20 mainly follows the shape of a circular arc. For instance, the circular arc may terminate against the respective side edges 12 ′ of the apparatus with straight sections 22 , which sections substantially extends parallel with the side edges 12 ′ of the outlet chamber. The circular arc may thus be shortened against the side edges 12 ′ in order to compensate for increasing frictional losses at the edges 12 ′.
[0047] According to the present invention, the flow moves through a channel extending substantially in a plane. For that reason, redirection of the flow is minimized, whereby problems with clogging can be minimized. According to yet one embodiment according to the present invention, as evident from FIGS. 4 A-B, the apparatus may nevertheless comprise at least one redirection 24 , such as a curved section or the like. The pressure drop in consequence of the redirection is negligible. This design can be preferred for technical assembly reasons.
[0048] FIG. 5 shows a preferred embodiment according to the present invention, where the distributor comprises a first distribution gap 14 ′, a second distribution gap 14 ″, a third distribution gap 14 ′″ and an outlet gap 20 . The first distribution gap 14 ′ is arranged from the inlet forward to a first circular arc-shaped edge 18 ′ that interconnects two diverging limiting surfaces that constitutes a first distribution chamber 8 ′. The second distribution gap 14 ″ is arranged from the first circular arc-shaped edge 18 ′ forward to a second circular arc-shaped edge 18 ″ that interconnects two diverging limiting surfaces that constitutes a second distribution chamber 8 ″. The third distribution gap 14 ′″ is arranged from the second circular arc-shaped edge 18 ″ forward to an edge 18 ′″ extending essentially linearly in the transverse direction, that interconnects two substantially diverging limiting surfaces that constitutes a third distribution chamber 8 ′″. The edge extending in the transverse direction constitutes the passage to the outlet gap 20 . Sections of the side edges 12 ″ of the gaps 14 ′, 14 ″, 14 ′″ and 20 are angled in the broken points P at the second distribution gap 14 ″ and at the third distribution gap 14 ′″. The second distribution gap 14 ″ preferably has a lower column depth than the first distribution gap 14 ′. The third distribution gap 14 ′″ preferably has an equal column depth as the first distribution gap 14 ′. The outlet gap 20 has preferably a larger column depth than the third distribution gap 14 ″.
[0049] With reference now to the FIGS. 1-5 , a fiber suspension having a concentration of e.g. up to 12% may thus be supplied to the distribution housing 2 through the supply conduit 4 . The fiber suspension that enters the distribution chamber, 8 , 8 ′, hits the inner limiting surfaces 12 of the housing and is thereby deflected. The suspension is spread from the inlet by decreasing speed outwardly in the distribution gap, 14 , 14 ′, in the diverging distribution chamber, 8 , 8 ′, to the passage 16 where it once more is deflected when it passes the edge, 18 , 18 ′, of a preferred circular arc-shape and passes into the outlet gap 20 having a larger column depth, alternatively passes into yet another distribution gap 14 ″ having a preferred lower column depth and thereafter a distribution gap having a higher column depth than the preceding gap before the outlet gap 20 as described with reference to FIG. 5 . After the suspension has been conveyed into the outlet chamber 10 , the suspension is forced against the outlet opening 6 to flow in an even substantial parallel flow with a constant velocity.
[0050] Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims. | Methods for achieving even transverse distribution and propagation of a flowing medium are disclosed in which the flowing medium is supplied through a conduit and is deflected during diverging propagation in at least one distribution gap The method includes deflecting the flowing medium during diverging propagation along the distribution gap in which the medium is conveyed through a passage to an outlet gap having a larger depth than the depth of the distribution gap. The medium is conveyed over an edge of the passage extending transverse to the direction of the flow, and the edge is designed to obtain a propagation along the flowing path of the diverging medium that provides a substantially even and parallel flow of the medium along the outlet gap. Apparatus for achieving this method is also disclosed. | 3 |
[0001] This is a continuation-in-part of application Ser. No. 09/274,609, filed Mar. 23, 1999; application Ser. No. 09/452,346, filed Dec. 1, 1999; and application Ser. No. 09/311,126, filed May 13, 1999, which is a continuation-in-part of application Ser. No. 09/153,144, filed Sep. 14, 1998, now U.S. Pat. No. 6,097,147.
FIELD OF INVENTION
[0002] The present invention is directed to organic light emitting devices (OLEDs) comprised of emissive layers that contain an organometallic phosphorescent compound.
BACKGROUND OF THE INVENTION
[0003] Organic light emitting devices (OLEDs) are comprised of several organic layers in which one of the layers is comprised of an organic material that can be made to electroluminesce by applying a voltage across the device, C. W. Tang et al., Appl. Phys. Lett. 1987, 51, 913. Certain OLEDs have been shown to have sufficient brightness, range of color and operating lifetimes for use as a practical alternative technology to LCD-based full color flat-panel displays (S. R. Forrest, P. E. Burrows and M. E. Thompson, Laser Focus World, February 1995). Since many of the thin organic films used in such devices are transparent in the visible spectral region, they allow for the realization of a completely new type of display pixel in which red (R), green (G), and blue (B) emitting OLEDs are placed in a vertically stacked geometry to provide a simple fabrication process, a small R-G-B pixel size, and a large fill factor, International Patent Application No. PCT/US95/15790.
[0004] A transparent OLED (TOLED), which represents a significant step toward realizing high resolution, independently addressable stacked R-G-B pixels, was reported in International Patent Application No. PCT/US97/02681 in which the TOLED had greater than 71% transparency when turned off and emitted light from both top and bottom device surfaces with high efficiency (approaching 1% quantum efficiency) when the device was turned on. The TOLED used transparent indium tin oxide (ITO) as the hole-injecting electrode and a Mg—Ag-ITO electrode layer for electron-injection. A device was disclosed in which the ITO side of the Mg—Ag-ITO electrode layer was used as a hole-injecting contact for a second, different color-emitting OLED stacked on top of the TOLED. Each layer in the stacked OLED (SOLED) was independently addressable and emitted its own characteristic color. This colored emission could be transmitted through the adjacently stacked, transparent, independently addressable, organic layer or layers, the transparent contacts and the glass substrate, thus allowing the device to emit any color that could be produced by varying the relative output of the red and blue color-emitting layers.
[0005] The PCT/US95/15790 application disclosed an integrated SOLED for which both intensity and color could be independently varied and controlled with external power supplies in a color tunable display device. The PCT/US95/15790 application, thus, illustrates a principle for achieving integrated, full color pixels that provide high image resolution, which is made possible by the compact pixel size. Furthermore, relatively low cost fabrication techniques, as compared with prior art methods, may be utilized for making such devices.
[0006] Because light is generated in organic materials from the decay of molecular excited states or excitons, understanding their properties and interactions is crucial to the design of efficient light emitting devices currently of significant interest due to their potential uses in displays, lasers, and other illumination applications. For example, if the symmetry of an exciton is different from that of the ground state, then the radiative relaxation of the exciton is disallowed and luminescence will be slow and inefficient. Because the ground state is usually anti-symmetric under exchange of spins of electrons comprising the exciton, the decay of a symmetric exciton breaks symmetry. Such excitons are known as triplets, the term reflecting the degeneracy of the state. For every three triplet excitons that are formed by electrical excitation in an OLED, only one symmetric state (or singlet) exciton is created. (M. A. Baldo, D. F. O'Brien, M. E. Thompson and S. R. Forrest, Very high-efficiency green organic light-emitting devices based on electrophosphorescence, Applied Physics Letters, 1999, 75, 4-6.) Luminescence from a symmetry-disallowed process is known as phosphorescence. Characteristically, phosphorescence may persist for up to several seconds after excitation due to the low probability of the transition. In contrast, fluorescence originates in the rapid decay of a singlet exciton. Since this process occurs between states of like symmetry, it may be very efficient.
[0007] Many organic materials exhibit fluorescence from singlet excitons. However, only a very few have been identified which are also capable of efficient room temperature phosphorescence from triplets. Thus, in most fluorescent dyes, the energy contained in the triplet states is wasted. However, if the triplet excited state is perturbed, for example, through spin-orbit coupling (typically introduced by the presence of a heavy metal atom), then efficient phosphoresence is more likely. In this case, the triplet exciton assumes some singlet character and it has a higher probability of radiative decay to the ground state. Indeed, phosphorescent dyes with these properties have demonstrated high efficiency electroluminescence.
[0008] Only a few organic materials have been identified which show efficient room temperature phosphorescence from triplets. In contrast, many fluorescent dyes are known (C. H. Chen, J. Shi, and C. W. Tang, “Recent developments in molecular organic electroluminescent materials,” Macromolecular Symposia, 1997, 125, 1-48; U. Brackmann, Lambdachrome Laser Dyes (Lambda Physik, Gottingen, 1997)) and fluorescent efficiencies in solution approaching 100% are not uncommon. (C. H. Chen, 1997, op. cit.) Fluorescence is also not affected by triplet-triplet annihilation, which degrades phosphorescent emission at high excitation densities. (M. A. Baldo, et al., “High efficiency phosphorescent emission from organic electroluminescent devices,” Nature, 1998, 395, 151-154; M. A. Baldo, M. E. Thompson, and S. R. Forrest, “An analytic model of triplet-triplet annihilation in electrophosphorescent devices,” 1999). Consequently, fluorescent materials are suited to many electroluminescent applications, particularly passive matrix displays.
[0009] To understand the different embodiments of this invention, it is useful to discuss the underlying mechanistic theory of energy transfer. There are two mechanisms commonly discussed for the transfer of energy to an acceptor molecule. In the first mechanism of Dexter transport (D. L. Dexter, “A theory of sensitized luminescence in solids,” J. Chem. Phys., 1953, 21, 836-850), the exciton may hop directly from one molecule to the next. This is a short-range process dependent on the overlap of molecular orbitals of neighboring molecules. It also preserves the symmetry of the donor and acceptor pair (E. Wigner and E. W. Wittmer, Uber die Struktur der zweiatomigen Molekelspektren nach der Quantenmechanik, Zeitschrift fur Physik, 1928, 51, 859-886; M. Klessinger and J. Michl, Excited states and photochemistry of organic molecules (VCH Publishers, New York, 1995)). Thus, the energy transfer of Eq. (1) is not possible via Dexter mechanism. In the second mechanism of Förster transfer (T. Förster, Zwischenmolekulare Energiewanderung and Fluoreszenz, Annalen der Physik, 1948, 2, 55-75; T. Forster, Fluoreszenz organisciler Verbindugen (Vandenhoek and Ruprecht, Gottinghen, 1951), the energy transfer of Eq. (1) is possible. In Forster transfer, similar to a transmitter and an antenna, dipoles on the donor and acceptor molecules couple and energy may be transferred. Dipoles are generated from allowed transitions in both donor and acceptor molecules. This typically restricts the Forster mechanism to transfers between singlet states.
[0010] Nevertheless, as long as the phosphor can emit light due to some perturbation of the state such as due to spin-orbit coupling introduced by a heavy metal atom, it may participate as the donor in Forster transfer. The efficiency of the process is determined by the luminescent efficiency of the phosphor (F Wilkinson, in Advances in Photochemistry (eds. W. A. Noyes, G. Hammond, and J. N. Pitts), pp. 241-268, John Wiley & Sons, New York, 1964), i.e., if a radiative transition is more probable than a non-radiative decay, then energy transfer will be efficient. Such triplet-singlet transfers were predicted by Forster (T. Forster, “Transfer mechanisms of electronic excitation,” Discussions of the Faraday Society, 1959, 27, 7-17) and confirmed by Ermolaev and Sveshnikova (V. L. Ermolaev and E. B. Sveshnikova, “Inductive-resonance transfer of energy from aromatic molecules in the triplet state,” Doklady Akademii Nauk SSSR, 1963, 149, 1295-1298), who detected the energy transfer using a range of phosphorescent donors and fluorescent acceptors in rigid media at 77K or 90K. Large transfer distances are observed; for example, with triphenylamine as the donor and chrysoidine as the acceptor, the interaction range is 52 Å.
[0011] The remaining condition for Forster transfer is that the absorption spectrum should overlap the emission spectrum of the donor assuming the energy levels between the excited and ground state molecular pair are in resonance. In one example of this application, we use the green phosphor fac tris(2-phenylpyridine)iridium (Ir(Ppy) 3 ; M. A. Baldo, et al., Appl. Phys. Lett., 1999, 75, 4-6) and the red fluorescent dye [2-methyl-6-[2-(2,3,6,7-tetrahydro-1H,5H-benzo[ij]quinolizin-9-yl) ethenyl]-4H-pyran-ylidene]propane-dinitrile] (DCM2“; C. W. Tang, S. A. VanSlyke, and C. H. Chen, “Electroluminescence of doped organic films,” J. Appl. Phys., 1989, 65, 3610-3616). DCM2 absorbs in the green, and, depending on the local polarization field (V. Bulovic, et al., “Bright, saturated, red-to-yellow organic light-emitting devices based on polarization-induced spectral shifts,” Chem. Phys. Lett., 1998, 287, 455-460), it emits at wavelengths between λ=570 nm and λ=650 nm.
[0012] It is possible to implement Forster energy transfer from a triplet state by doping a fluorescent guest into a phosphorescent host material. Unfortunately, such systems are affected by competitive energy transfer mechanisms that degrade the overall efficiency. In particular, the close proximity of the host and guest increase the likelihood of Dexter transfer between the host to the guest triplets. Once excitons reach the guest triplet state, they are effectively lost since these fluorescent dyes typically exhibit extremely inefficient phosphorescence.
[0013] To maximize the transfer of host triplets to fluorescent dye singlets, it is desirable to maximize Dexter transfer into the triplet state of the phosphor while also minimizing transfer into the triplet state of the fluorescent dye. Since the Dexter mechanism transfers energy between neighboring molecules, reducing the concentration of the fluorescent dye decreases the probability of triplet-triplet transfer to the dye. On the other hand, long range Forster transfer to the singlet state is unaffected. In contrast, transfer into the triplet state of the phosphor is necessary to harness host triplets, and may be improved by increasing the concentration of the phosphor.
[0014] Devices whose structure is based upon the use of layers of organic optoelectronic materials generally rely on a common mechanism leading to optical emission. Typically, this mechanism is based upon the radiative recombination of a trapped charge. Specifically, OLEDs are comprised of at least two thin organic layers separating the anode and cathode of the device. The material of one of these layers is specifically chosen based on the material's ability to transport holes, a “hole transporting layer” (HTL), and the material of the other layer is specifically selected according to its ability to transport electrons, an “electron transporting layer” (ETL). With such a construction, the device can be viewed as a diode with a forward bias when the potential applied to the anode is higher than the potential applied to the cathode. Under these bias conditions, the anode injects holes (positive charge carriers) into the hole transporting layer, while the cathode injects electrons into the electron transporting layer. The portion of the luminescent medium adjacent to the anode thus forms a hole injecting and transporting zone while the portion of the luminescent medium adjacent to the cathode forms an electron injecting and transporting zone. The injected holes and electrons each migrate toward the oppositely charged electrode. When an electron and hole localize on the same molecule, a Frenkel exciton is formed. Recombination of this short-lived state may be visualized as an electron dropping from its conduction potential to a valence band, with relaxation occurring, under certain conditions, preferentially via a photoemissive mechanism. Under this view of the mechanism of operation of typical thin-layer organic devices, the electroluminescent layer comprises a luminescence zone receiving mobile charge carriers (electrons and holes) from each electrode.
[0015] As noted above, light emission from OLEDs is typically via fluorescence or phosphorescence. There are issues with the use of phosphorescence. It has been noted that phosphorescent efficiency decreases rapidly at high current densities. It may be that long phosphorescent lifetimes cause saturation of emissive sites, and triplet-triplet annihilation may produce efficiency losses. Another difference between fluorescence and phosphorescence is that energy transfer of triplets from a conductive host to a luminescent guest molecule is typically slower than that of singlets; the long range dipole-dipole coupling (Förster transfer) which dominates energy transfer of singlets is (theoretically) forbidden for triplets by the principle of spin symmetry conservation. Thus, for triplets, energy transfer typically occurs by diffusion of excitons to neighboring molecules (Dexter transfer); significant overlap of donor and acceptor excitonic wavefunctions is critical to energy transfer. Another issue is that triplet diffusion lengths are typically long (e.g., >1400 Å) compared with typical singlet diffusion lengths of about 200 Å. Thus, if phosphorescent devices are to achieve their potential, device structures need to be optimized for triplet properties. In this invention, we exploit the property of long triplet diffusion lengths to improve external quantum efficiency.
[0016] Successful utilization of phosphorescence holds enormous promise for organic electroluminescent devices. For example, an advantage of phosphorescence is that all excitons (formed by the recombination of holes and electrons in an EL), which are (in part) triplet-based in phosphorescent devices, may participate in energy transfer and luminescence in certain electroluminescent materials. In contrast, only a small percentage of excitons in fluorescent devices, which are singlet-based, result in fluorescent luminescence.
[0017] An alternative is to use phosphorescence processes to improve the efficiency of fluorescence processes. Fluorescence is in principle 75% less efficient due to the three times higher number of symmetric excited states.
[0018] Because one typically has at least one electron transporting layer and at least one hole transporting layer, one has layers of different materials, forming a heterostructure. The materials that produce the electroluminescent emission are frequently the same materials that function either as the electron transporting layer or as the hole transporting layer. Such devices in which the electron transporting layer or the hole transporting layer also functions as the emissive layer are referred to as having a single heterostructure. Alternatively, the electroluminescent material may be present in a separate emissive layer between the hole transporting layer and the electron transporting layer in what is referred to as a double heterostructure. The separate emissive layer may contain the emissive molecule doped into a host or the emissive layer may consist essentially of the emissive molecule.
[0019] That is, in addition to emissive materials that are present as the predominant component in the charge carrier layer, that is, either in the hole transporting layer or in the electron transporting layer, and that function both as the charge carrier material as well as the emissive material, the emissive material may be present in relatively low concentrations as a dopant in the charge carrier layer. Whenever a dopant is present, the predominant material in the charge carrier layer may be referred to as a host compound or as a receiving compound. Materials that are present as host and dopant are selected so as to have a high level of energy transfer from the host to the dopant material. In addition, these materials need to be capable of producing acceptable electrical properties for the OLED. Furthermore, such host and dopant materials are preferably capable of being incorporated into the OLED using starting materials that can be readily incorporated into the OLED by using convenient fabrication techniques, in particular, by using vacuum-deposition techniques.
[0020] The exciton blocking layer used in the devices of the present invention (and previously disclosed in U.S. application Ser. No. 09/154,044) substantially blocks the diffusion of excitons, thus substantially keeping the excitons within the emission layer to enhance device efficiency. The material of blocking layer of the present invention is characterized by an energy difference (“band gap”) between its lowest unoccupied molecular orbital (LUMO) and its highest occupied molecular orbital (HOMO). in accordance with the present invention, this band gap substantially prevents the diffusion of excitons through the blocking layer, yet has only a minimal effect on the turn-on voltage of a completed electroluminescent device. The band gap is thus preferably greater than the energy level of excitons produced in an emission layer, such that such excitons are not able to exist in the blocking layer. Specifically, the band gap of the blocking layer is at least as great as the difference in energy between the triplet state and the ground state of the host.
[0021] It is desirable for OLEDs to be fabricated using materials that provide electroluminescent emission in a relatively narrow band centered near selected spectral regions, which correspond to one of the three primary colors, red, green and blue so that they may be used as a colored layer in an OLED or SOLED. It is also desirable that such compounds be capable of being readily deposited as a thin layer using vacuum deposition techniques so that they may be readily incorporated into an OLED that is prepared entirely from vacuum-deposited organic materials.
[0022] Co-pending application U.S. Ser. No. 08/774,087, filed Dec. 23, 1996, now U.S. Pat. No. 6,048,630, is directed to OLEDs containing emitting compounds that produce a saturated red emission.
SUMMARY OF THE INVENTION
[0023] The present invention is directed to organic light emitting devices wherein the emissive layer comprises an emissive molecule, optionally with a host material (wherein the emissive molecule is present as a dopant in said host material), which molecule is adapted to luminesce when a voltage is applied across the heterostructure, wherein the emissive molecule is selected from the group of phosphorescent organometallic complexes. The emissive molecule may be further selected from the group of phosphorescent organometallic platinum, iridium or osmium complexes and may be still further selected from the group of phosphorescent cyclometallated platinum, iridium or osmium complexes. A specific example of the emissive molecule is fac tris(2-phenylpyridine)iridium, denoted (Ir(ppy) 3 ) of formula
[0024] [In this, and later figures herein, we depict the dative bond from nitrogen to metal (here, Ir) as a straight line.]
[0025] The general arrangement of the layers is hole transporting layer, emissive layer, and electron transporting layer. For a hole conducting emissive layer, one may have an exciton blocking layer between the emissive layer and the electron transporting layer. For an electron conducting emissive layer, one may have an exciton blocking layer between the emissive layer and the hole transporting layer. The emissive layer may be equal to-the-hole transporting layer (in which case the exciton blocking layer is near or at the anode) or to the electron transporting layer (in which case the exciton blocking layer is near or at the cathode).
[0026] The emissive layer may be formed with a host material in which the emissive molecule resides as a guest or the emissive layer may be formed of the emissive molecule itself. In the former case, the host material may be a hole-transporting material selected from the group of substituted tri-aryl amines. The host material may be an electron-transporting material selected from the group of metal quinoxolates, oxadiazoles and triazoles. An example of a host material is 4,4′-N,N′-dicarbazole-biphenyl (CBP), which has the formula:
[0027] The emissive layer may also contain a polarization molecule, present as a dopant in said host material and having a dipole moment, that affects the wavelength of light emitted when said emissive dopant molecule luminesces.
[0028] A layer formed of an electron transporting material is used to transport electrons into the emissive layer comprising the emissive molecule and the (optional) host material. The electron transporting material may be an electron-transporting matrix selected from the group of metal quinoxolates, oxadiazoles and triazoles. An example of an electron transporting material is tris-(8-hydroxyquinoline)aluminum (Alq 3 ).
[0029] A layer formed of a hole transporting material is used to transport holes into the emissive layer comprising the emissive molecule and the (optional) host material. An example of a hole transporting material is 4,4′-bis[N-(1-naphthyl)-N-phenyl-amino]biphenyl [“c-NPD”].
[0030] The use of an exciton blocking layer (“barrier layer”) to confine excitons within the luminescent layer (“luminescent zone”) is greatly preferred. For a hole-transporting host, the blocking layer may be placed between the luminescent layer and the electron transport layer. An example of a material for such a barrier layer is 2,9-dimethyl-4,7-diphenyl-1,10-phenanthroline (also called bathocuproine or BCP), which has the formula:
[0031] For a situation with a blocking layer between a hole-conducting host and the electron transporting layer (as is the case in Example 2 below), one seeks the following characteristics, which are listed in order of relative importance.
[0032] 1. The difference in energy between the LUMO and HOMO of the blocking layer is greater than the difference in energy between the triplet and ground state singlet of the host material.
[0033] 2. Triplets in the host material are not quenched by the blocking layer.
[0034] 3. The ionization potential (IP) of the blocking layer is greater than the ionization potential of the host. (Meaning that holes are held in the host.)
[0035] 4. The energy level of the LUMO of the blocking layer and the energy level of the LUMO of the host are sufficiently close in energy such that there is less than 50% change in the overall conductivity of the device.
[0036] 5. The blocking layer is as thin as possible subject to having a thickness of the layer that is sufficient to effectively block the transport of excitons from the emissive layer into the adjacent layer.
[0037] That is, to block excitons and holes, the ionization potential of the blocking layer should be greater than that of the HTL, while the electron affinity of the blocking layer should be approximately equal to that of the ETL to allow for facile transport of electrons.
[0038] [For a situation in which the emissive (“emitting”) molecule is used without a hole transporting host, the above rules for selection of the blocking layer are modified by replacement of the word “host” by “emitting molecule.”]
[0039] For the complementary situation with a blocking layer between a electron-conducting host and the hole-transporting layer one seeks characteristics (listed in order of importance):
[0040] 1. The difference in energy between the LUMO and HOMO of the blocking layer is greater than the difference in energy between the triplet and ground state singlet of the host material.
[0041] 2. Triplets in the host material are not quenched by the blocking layer.
[0042] 3. The energy of the LUMO of the blocking layer is greater than the energy of the LUMO of the (electron-transporting) host. (Meaning that electrons are held in the host.)
[0043] 4. The ionization potential of the blocking layer and the ionization potential of the host are such that holes are readily injected from the blocker into the host and there is less than a 50% change in the overall conductivity of the device.
[0044] 5. The blocking layer is as thin as possible subject to having a thickness of the layer that is sufficient to effectively block the transport of excitons from the emissive layer into the adjacent layer.
[0045] [For a situation in which the emissive (“emitting”) molecule is used without an electron transporting host, the above rules for selection of the blocking layer are modified by replacement of the word “host” by “emitting molecule.”]
[0046] The present invention covers articles of manufacture comprising OLEDs comprising a new family of phosphorescent materials, which can be used as dopants in OLEDs, and methods of manufacturing the articles. These phosphorescent materials are cyclometallated platinum, iridium or osmium complexes, which provide electroluminiscent emission at a wavelength between 400 nm and 700 nm. The present invention is further directed to OLEDs that are capable of producing an emission that will appear blue, that will appear green, and that will appear red.
[0047] More specifically, OLEDs of the present invention comprise, for example, an emissive layer comprised of platinum (II) complexed with Bis[2-(2-phenyl)pyridinato-N,C2], Bis[2-(2′-thienyl)pyridinato-N,C3], and Bis[benzo(h)quinolinato-N,C]. The compound cis-Bis[2-(2′-thienyl)pyridinato-N,C3] Pt(II) gives a strong orange to yellow emission.
[0048] The invention is further directed to emissive layers wherein the emissive molecule is selected from the group of phosphorescent organometallic complexes, wherein the emissive molecule contains substituents selected from the class of electron donors and electron acceptors. The emissive molecule may be further selected from the group of phosphorescent organometallic platinum, iridium or osmium complexes and may be still further selected from the group of phosphorescent cyclometallated platinum, iridium or osmium complexes, wherein the organic molecule contains substituents selected from the class of electron donors and electron acceptors.
[0049] The invention is further directed to an organic light emitting device comprising a heterostructure for producing luminescence, wherein the emissive layer comprises a host material, an emissive molecule, present as a dopant in said host material, adapted to luminesce when a voltage is applied across the heterostructure, wherein the emissive molecule is selected from the group consisting of cyclometallated platinum, iridium or osmium complexes and wherein there is a polarization molecule, present as a dopant in the host material, which polarization molecule has a dipole moment and which polarization molecule alters the wavelength of the luminescent light emitted by the emissive dopant molecule. The polarization molecule may be an aromatic molecule substituted by electron donors and electron acceptors.
[0050] The present invention is directed to OLEDs, and a method of fabricating OLEDs, in which emission from the device is obtained via a phosphorescent decay process wherein the phosphorescent decay rate is rapid enough to meet the requirements of a display device. More specifically, the present invention is directed to OLEDs comprised of a material that is capable of receiving the energy from an exciton singlet or triplet state and emitting that energy as phosphorescent radiation.
[0051] The OLEDs of the present invention may be used in substantially any type of device which is comprised of an OLED, for example, in OLEDs that are incorporated into a larger display, a vehicle, a computer, a television, a printer, a large area wall, theater or stadium screen, a billboard or a sign.
[0052] The present invention is also directed to complexes of formula L L′ L″ M, wherein L, L′, and L″ are distinct bidentate ligands and M is a metal of atomic number greater than 40 which forms an octahedral complex with the three bidentate ligands and is preferably a member of the third row (of the transition series of the periodic table) transition metals, most preferably Ir and Pt. Alternatively, M can be a member of the second row transition metals, or of the main group metals, such as Zr and Sb. Some of such organometallic complexes electroluminesce, with emission coming from the lowest energy ligand or MLCT state. Such electroluminescent compounds can be used in the emitter layer of organic light emitting diodes, for example, as dopants in a host layer of an emitter layer in organic light emitting diodes. This invention is further directed to organometallic complexes of formula L L′ L″ M, wherein L, L′, and L″ are the same (represented by L 3 M) or different (represented by L L′ L″ M), wherein L, L′, and L″ are bidentate, monoanionic ligands, wherein M is a metal which forms octahedral complexes, is preferably a member of the third row of transition metals, more preferably Ir or Pt, and wherein the coordinating atoms of the ligands comprise sp 2 hybridized carbon and a heteroatom. The invention is further directed to compounds of formula L 2 MX, wherein L and X are distinct bidentate ligands, wherein X is a monoanionic bidentate ligand, wherein L coordinates to M via atoms of L comprising sp 2 hybridized carbon and heteroatoms, and wherein M is a metal forming an octahedral complex, preferably iridium or platinum. It is generally expected that the ligand L participates more in the emission process than does X. The invention is directed to meridianal isomers of L 3 M wherein the heteroatoms (such as nitrogen) of two ligands L are in a trans configuration. In the embodiment in which M is coordinated with an sp 2 hybridized carbon and a heteroatom of the ligand, it is preferred that the ring comprising the metal M, the sp 2 hybridized carbon and the heteroatom contains 5 or 6 atoms. These compounds can serve as dopants in a host layer which functions as a emitter layer in organic light emitting diodes.
[0053] Furthermore, the present invention is directed to the use of complexes of transition metal species M with bidentate ligands L and X in compounds of formula L 2 MX in the emitter layer of organic light emitting diodes. A preferred embodiment is compounds of formula L 2 IrX, wherein L and X are distinct bidentate ligands, as dopants in a host layer functioning as an emitter layer in organic light emitting diodes.
[0054] The present invention is also directed to an improved synthesis of organometallic molecules which function as emitters in light emitting devices. These compounds of this invention can be made according to the reaction:
L 2 M(∥-Cl) 2 ML 2 +XH→L 2 MX+HCl
[0055] wherein L 2 M(μ-Cl) 2 ML 2 is a chloride bridged dimer with L a bidentate ligand, and M a metal such as Ir; XH is a Bronsted acid which reacts with bridging chloride and serves to introduce a bidentate ligand X, where XH can be, for example, acetylacetone, 2-picolinic acid, or N-methylsalicyclanilide, and H represents hydrogen. The method involves combining the L 2 M(μ-Cl) 2 ML 2 chloride bridged dimer with the XH entity. The resultant product of the form L 2 MX has approximate octahedral disposition of the bidentate ligands L, L, and X about M.
[0056] The resultant compounds of formula L 2 MX can be used as phosphorescent emitters in organic light emitting devices. For example, the compound wherein L=(2-phenylbenzothiazole), X=acetylacetonate, and M=Ir (the compound abbreviated as BTIr) when used as a dopant in 4,4′-N,N′-dicarbazole-biphenyl (CBP) (at a level 12% by mass) to form an emitter layer in an OLED shows a quantum efficiency of 12%. For reference, the formula for CBP is:
[0057] The synthetic process to make L 2 MX compounds of the present invention may be used advantageously in a situation in which L, by itself, is fluorescent but the resultant L 2 MX is phosphorescent. One specific example of this is where L=coumarin-6.
[0058] The synthetic process of the present invention facilitates the combination of L and X pairs of certain desirable characteristics. For example, the present invention is further directed to the appropriate selection of L and X to allow color tuning of the complex L 2 MX relative to L 3 M. For example, Ir(ppy) 3 and (ppy) 2 Ir(acac) both give strong green emission with a λ max of 510 nm (ppy denotes phenyl pyridine). However, if the X ligand is formed from picolinic acid instead of from acetylacetone, there is a small blue shift of about 15 nm.
[0059] Furthermore, the present invention is also directed to a selection of X such that it has a certain HOMO level relative to the L 3 M complex so that carriers (holes or electrons) might be trapped on X (or on L) without a deterioration of emission quality. In this way, carriers (holes or electrons) which might otherwise contribute to deleterious oxidation or reduction of the phosphor would be impeded. The carrier that is remotely trapped could readily recombine with the opposite carrier either intramolecularly or with the carrier from an adjacent molecule.
[0060] The present invention, and its various embodiments, are discussed in more detail in the examples below. However, the embodiments may operate by different mechanisms. Without limitation and without limiting the scope of the invention, we discuss the different mechanisms by which various embodiments of the invention may operate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0061] [0061]FIG. 1. Electronic absorbance spectra of Pt(thpy) 2 , Pt(thq) 2 , and Pt(bph)(bpy).
[0062] [0062]FIG. 2. Emission spectra of Pt(thpy) 2 , Pt(thq) 2 , and Pt(bph)(bpy).
[0063] [0063]FIG. 3. Energy transfer from polyvinylcarbazole (PVK) to Pt(thpy) 2 in the solid film.
[0064] [0064]FIG. 4. Characteristics of OLED with Pt(thpy) 2 dopant: (a) I-V characteristic; (b) Light output curve.
[0065] [0065]FIG. 5. Quantum efficiency dependence on applied voltage for OLED with Pt(thpy) 2 dopant.
[0066] [0066]FIG. 6. Characteristics of the OLED device with Pt(thpy) 2 dopant: (a) normalized electroluminescence (EL) spectrum of the device at 22 V (b) CIE diagram based on normalized EL spectrum.
[0067] [0067]FIG. 7. Proposed energy level structure of the electrophosphorescent device of Example 2. The highest occupied molecular orbital (HOMO) energy and the lowest unoccupied molecular orbital (LUMO) energy are shown (see I. G. Hill and A. Kahn, J. Appl. Physics (1999)). Note that the HOMO and LUMO levels for Ir(ppy) 3 are not known. The inset shows structural chemical formulae for: (a) Ir(ppy) 3 ; (b) CBP; and (c) BCP.
[0068] [0068]FIG. 8. The external quantum efficiency of OLEDs using Ir(ppy) 3 : CBP luminescent layers. Peak efficiencies are observed for a mass ratio of 6% Ir(ppy) 3 to CBP. The 100% lr(ppy) 3 device has a slightly different structure than shown in FIG. 7. In it, the Ir(ppy) 3 layer is 300 A thick and there is no BCP blocking layer. The efficiency of a 6% Ir(ppy) 3 : CBP device grown without a BCP layer is also shown.
[0069] [0069]FIG. 9. The power efficiency and luminance of the 6% Ir(ppy) 3 : CBP device. At 100 cd/m 2 , the device requires 4.3 V and its power efficiency is 19 Im/W.
[0070] [0070]FIG. 10. The electroluminescent spectrum of 6% Ir(ppy) 3 : CBP. Inset: The Commission Internationale de L'Eclairage (CIE) chromaticity coordinates of Ir(ppy) 3 in CBP are shown relative to fluorescent green emitters Alq 3 and poly(p-phenylenevinylene) (PPV).
[0071] [0071]FIG. 11. Expected structure of L 2 IrX complexes along with the structure expected for PPIr. Four examples of X ligands used for these complexes are also shown. The structure shown is for an acac derivative. For the other X type ligands, the O—O ligand would be replaced with an N—O ligand.
[0072] [0072]FIG. 12. Comparison of facial and meridianal isomers of L 3 M.
[0073] [0073]FIG. 13. Molecular formulae of mer-isomers disclosed herewith: mer-Ir(ppy) 3 and mer-Ir(bq) 3 . PPY (or ppy) denotes phenyl pyridyl and BQ (or bq) denotes 7,8-benzoquinoline.
[0074] [0074]FIG. 14. Models of mer-Ir(ppy) 3 (left) and (ppy) 2 Ir(acac) (right).
[0075] [0075]FIG. 15. (a) Electroluminescent device data (quantum efficiency vs. current density) for 12% by mass “BTIr” in CBP. BTIr stands for bis (2-phenylbenzothiazole)iridium acetylacetonate; (b) Emission spectrum from same device
[0076] [0076]FIG. 16. Representative molecule to trap holes (L 2 IrX complex).
[0077] [0077]FIG. 17. Emission spectrum of Ir(3-MeOppy) 3 .
[0078] [0078]FIG. 18. Emission spectrum of tpyIrsd.
[0079] [0079]FIG. 19. Proton NMR spectrum of tpyIrsd (=typIrsd).
[0080] [0080]FIG. 20. Emission spectrum of thpyIrsd.
[0081] [0081]FIG. 21. Proton NMR spectrum of thpyIrsd.
[0082] [0082]FIG. 22. Emission spectrum of btIrsd.
[0083] [0083]FIG. 23. Proton NMR spectrum of btIrsd.
[0084] [0084]FIG. 24. Emission spectrum of BQIr.
[0085] [0085]FIG. 25. Proton NMR spectrum of BQIr.
[0086] [0086]FIG. 26. Emission spectrum of BQIrFA.
[0087] [0087]FIG. 27. Emission spectrum of THIr (=thpy; THPIr).
[0088] [0088]FIG. 28. Proton NMR spectrum of THPIr.
[0089] [0089]FIG. 29. Emission spectra of PPIr.
[0090] [0090]FIG. 30. Proton NMR spectrum of PPIr.
[0091] [0091]FIG. 31. Emission spectrum of BTHPIr (=BTPIr).
[0092] [0092]FIG. 32. Emission spectrum of tpyIr.
[0093] [0093]FIG. 33. Crystal structure of tpyIr showing trans arrangement of nitrogen.
[0094] [0094]FIG. 34. Emission spectrum of C6.
[0095] [0095]FIG. 35. Emission spectrum of C6Ir.
[0096] [0096]FIG. 36. Emission spectrum of PZIrP.
[0097] [0097]FIG. 37. Emission spectrum of BONIr.
[0098] [0098]FIG. 38. Proton NMR spectrum of BONIr.
[0099] [0099]FIG. 39. Emission spectrum of BTIr.
[0100] [0100]FIG. 40. Proton NMR spectrum of BTIr.
[0101] [0101]FIG. 41. Emission spectrum of BOIr.
[0102] [0102]FIG. 42. Proton NMR spectrum of BOIr.
[0103] [0103]FIG. 43. Emission spectrum of BTIrQ.
[0104] [0104]FIG. 44. Proton NMR spectrum of BTIrQ.
[0105] [0105]FIG. 45. Emission spectrum of BTIrP.
[0106] [0106]FIG. 46. Emission spectrum of BOIrP.
[0107] [0107]FIG. 47. Emission spectrum of btIr-type complexes with different ligands.
[0108] [0108]FIG. 48. Proton NMR spectrum of mer-Irbq.
[0109] [0109]FIG. 49. Other suitable L and X ligands for L 2 MX compounds. In all of these ligands listed, one can easily substitute S for O and still have a good ligand.
[0110] [0110]FIG. 50. Examples of L L′ L″ M compounds. In the listed examples of L L′ L″ M and L L′ M X compounds, the compounds would be expected to emit from the lowest energy ligand or the MLCT state, involving the bq or thpy ligands. In the listed example of an L M X X′ compound, emission therefrom is expected from the ppy ligand. The X and X′ ligands will modify the physical properties (for example, a hole trapping group could be added to either ligand).
DETAILED DESCRIPTION OF THE INVENTION
[0111] The present invention is generally directed to emissive molecules, which luminesce when a voltage is applied across a heterostructure of an organic light-emitting device and which molecules are selected from the group of phosphorescent organometallic complexes, and to structures, and correlative molecules of the structures, that optimize the emission of the light-emitting device. The term “organometallic” is as generally understood by one of ordinary skill, as given, for example, in “Inorganic Chemistry” (2nd edition) by Gary L. Miessler and Donald A. Tarr, Prentice-Hall (1998). The invention is further directed to emissive molecules within the emissive layer of an organic light-emitting device which molecules are comprised of phosphorescent cyclometallated platinum, iridium or osmium complexes. On electroluminescence, molecules in this class may produce emission which appears red, blue, or green. Discussions of the appearance of color, including descriptions of CIE charts, may be found in H. Zollinger, Color Chemistry, VCH Publishers, 1991 and H. J. A. Dartnall, J. K. Bowmaker, and J. D. Mollon, Proc. Roy. Soc. B (London), 1983, 220, 115-130.
[0112] The present invention will now be described in detail for specific preferred embodiments of the invention, it being understood that these embodiments are intended only as illustrative examples and the invention is not to be limited thereto.
[0113] Synthesis of the Cyclometallated Platinum Complexes
[0114] We have synthesized a number of different Pt cyclometallated complexes.
[0115] Numerous publications, reviews and books are dedicated to the chemistry of cyclometallated compounds, which also are called intramolecular-coordination compounds. (I. Omae, Organometallic Intramolecular-coordination compounds. N.Y. 1986. G. R. Newkome, W. E. Puckett, V. K. Gupta, G. E. Kiefer, Chem.Rev. 1986,86,451. A. D. Ryabov, Chem.Rev. 1990, 90, 403). Most of the publications depict mechanistical aspects of the subject and primarily on the cyclometallated compounds with one bi- or tri-dentate ligand bonded to metal by C-M single bond and having cycle closed with one or two other X-M bonds where X may be N, S, P, As, O. Not so much literature was devoted to bis- or tris-cyclometallated complexes, which do not possess any other ligands but C,N type bi-dentate ones. Some of the subject of this invention is in these compounds because they are not only expected to have interesting photochemical properties as most cyclometallated complexes do, but also should exhibit increased stability in comparison with their monocyclometallated analogues. Most of the work on bis-cyclopaladated and bis-cycloplatinated compounds was performed by von Zelewsky et al. (For a review see: M. Maestri, V. Balzani, Ch.Deuschel-Cornioley, A. von Zelewsky, Adv.Photochem. 1992 17, 1. L. Chassot, A. Von Zelewsky, Helv. Chim.Acta 1983, 66, 243. L. Chassot, E. Muler, A. von Zelewsky, Inorg. Chem. 1984, 23, 4249. S Bonafede, M. Ciano, F. Boletta, V. Balzani, L. Chassot, A. von Zelewsky, J Phys.Chem. 1986, 90, 3836. L. Chassot, A. von Zelewsky, D. Sandrini, M. Maestri, V. Balzani, J.Am.Chem.Soc. 1986, 108, 6084. Ch.Cornioley-Deuschel, A. von Zelewsky, Inorg.Chem. 1987, 26, 3354. L. Chassot, A. von Zelewsky, Inorg.Chem. 1987, 26, 2814. A. von Zelewsky, A. P. Suckling, H. Stoeckii-Evans, Inorg.Chem. 1993, 32, 4585. A. von Zelewsky, P. Belser, P. Hayoz, R. Dux, X. Hua, A. Suckling, H. Stoeckii-Evans, Coord.Chem.Rev. 1994, 132, 75. P. Jolliet, M. Gianini, A. von Zelewsky, G. Bernardinelli, H. Stoeckii-Evans, Inorg.Chem. 1996, 35, 4883. H. Wiedenhofer, S. Schutzenmeier, A. von Zelewsky, H. Yersin, J.Phys. Chem. 1995, 99, 13385. M. Gianini, A. von Zelewsky, H. Stoeckii-Evans, Inorg. Chem. 1997, 36, 6094.) In one of their early works, (M. Maestri, D. Sandrini, V. Balzani, L. Chassot, P. Jolliet A. von Zelewsky, Chem.Phys.Lett. 1985,122,375) luminescent properties of three bis-cycloplatinated complexes were investigated in detail. The summary of the previously reported results on Pt bis-cyclometallated complexes important for our current research is as follows:
[0116] i. in general, cyclometallated complexes having a 5-membered ring formed between the metal atom and C,X ligand are more stable.
[0117] ii. from the point of view of stability of resulting compounds, complexes not containing anionic ligands are preferred; thus, bis-cyclometallated complexes are preferred to mono-cyclometallated ones.
[0118] iii. a variety of Pt(Pd) cyclometallated complexes were synthesized, homoleptic (containing similar C,X ligands), heteroleptic (containing two different cyclometallating C,X ligands) and complexes with one C,C cyclometallating ligand and one N,N coordinating ligand.
[0119] iv. most bis-cyclometallated complexes show M + ions upon electron impact ionization in their mass spectra; this can be a base for our assumption on their stability upon vacuum deposition.
[0120] v. on the other hand, some of the complexes are found not to be stable in certain solvents; they undergo oxidative addition reactions leading to Pt(IV) or Pd(IV) octahedral complexes.
[0121] vi. optical properties are reported only for some of the complexes; mostly absorption data is presented. Low-energy electron transitions observed in both their absorption and emission spectra are assigned to MLCT transitions.
[0122] vii. reported luminescent properties are summarized in Table 1. Used abbreviations are explained in Scheme 1. Upon transition from bis-cyclometalated complexes with two C,N ligands to the complexes with one C,C and one N,N ligand batochromic shift in emission was observed. (M. Maestri, D. Sandrini, V. Balzani, A. von Zelewsky, C. Deuschel-Cornioley, P. Jolliet, Helv. Chim.Acia 1988, 71, 1053.
TABLE 1 Absorption and emission properties of several cycloplatinated complexes. Reproduced from A.von Zelewsky et. al (Chem. Phys. Lett., 1985, 122, 375 and Helv. Chim. Acta 1988, 17, 1053). Abbreviation explanations are given in Scheme 1. emission spectra absorption 77 K 293 K solvent λmax(ε) λmax(τ) λmax(τ) Pt(Phpy) 2 (1) CH 3 CN 402(12800) 491(4.0) — 291(27700) Pt(Thpy) 2 (2) CH 3 CN 418(10500) 570(12.0) 578(2.2) 303(26100) Pt(Bhq) 2 (3) CH 3 CN 421(9200) 492(6.5) — 367(12500) 307(15000) Pt(bph)(bpy)(4)
[0123] [0123]
[0124] We synthesized different bis-cycloplatinated complexes in order to investigate their optical properties in different hosts, both polymeric and molecular, and utilize them as dopants in corresponding hosts for organic light-emitting diodes (OLEDs). Usage of the complexes in molecular hosts in OLEDs prepared in the vacuum deposition process requires several conditions to be satisfied. The complexes should be sublimable and stable at the standard deposition conditions (vacuum ˜10 −6 torr). They should show emission properties interesting for OLED applications and be able to accept energy from host materials used, such as Alq 3 or NPD. On the other hand, in order to be useful in OLEDs prepared by wet techniques, the complexes should form true solutions in conventional solvents (e.g., CHCl 3 ) with a wide range of concentrations and exhibit both emission and efficient energy transfer from polymeric hosts (e.g., PVK). All these properties of cycloplatinated complexes were tested. In polymeric hosts we observe efficient luminescence from some of the materials.
[0125] Syntheses Proceeded as Follows:
[0126] 2-(2-thienyl)pyridine. Synthesis is shown in Scheme 2, and was performed according to procedure close to the published one (T. Kauffmann, A. Mitschker, A. Woltermann, Chem.Ber. 1983, 116, 992). For purification of the product, instead of recommended distillation, zonal sublimation was used (145-145-125° C., 2-3 hours). Light brownish white solid (yield 69%). Mass-spec: m/z: 237(18%), 161 (100%, M + ), 91 (71%). 1 H NMR (250 MHZ, DMSO-d 6 ) δ,ppm: 6.22-6.28 (d. of d., 1H), 6.70-6.80 (d. of d., 1H), 6.86-7.03 (m,3H), 7.60-7.65 (m,1H). 13 C NMR (250 MHZ, DMSO-d 6 ): 118.6, 122.3, 125.2, 128.3, 128.4, 137.1, 144.6, 149.4, 151.9.
[0127] 2-(2-thienyl)quinoline. Synthesis is displayed in Scheme 3, and was made according to published procedure (K. E. Chippendale, B. Iddon, H. Suschitzky, J.Chem.Soc. 1949, 90, 1871). Purification was made exactly following the literature as neither sublimation nor column chromatography did not give as good results as recrystallizations from (a) petroleum ether, and (b) EtOH-H 2 O (1:1) mixture. Pale yellow solid, gets more yellow with time (yield 84%). Mass-spec: m/z: 217 (32%), 216 (77%), 215 (83%), 214 (78%), 213 (77%), 212 (79%), 211(100%, M + ), 210 (93%), 209 (46%). 1 H NMR (250 MHZ, DMSO-d 6 ) δ,ppm: 7.18-7.24 (d. of d.,1H), 7.48-7.58 (d. of d. of d.,1H), 7.67-7.78 (m,2H), 7.91-7.97 (m,3H), 8.08-8.11 (d,1H),
[0128] 2-(2′bromophenyl)pyridine. Synthesis was performed according to literature (D. H. Hey, C. J. M. Stirling, G. H. Williams, J.Chem. Soc. 1955, 3963; R. A. Abramovich, J. G. Saha, J.Chem.Soc. 1964, 2175). It is outlined in Scheme 4. Literature on the subject was dedicated to the study of aromatic substitution in different systems, including pyridine, and study of isomeric ratios in the requiting product. Thus in order to resolve isomer mixtures of different substituted phenylpyridines, not 2-(2′-bromophenyl)pyridine, the authors utilized 8 ft.×{fraction ( 1 / 4 )} in. column packed with ethylene glycol succinate (10%) on Chromosorb W at 155° C. and some certain helium inlet pressure. For resolving the reaction mixture we obtained, we used column chromatography with hexanes:THF (1:1) and haxanes:THF:PrOH-1 (4:4:1) mixtures as eluents on silica gel because this solvent mixture gave best results in TLC (three well resolved spots). Only the first spot in the column gave mass spec major peak corresponding to n-(2′-bromophenyl)pyridines (m/z: 233, 235), in the remaining spots this peak was minor. Mass spec of the first fraction: m/z: 235 (97%), 233 (100%, M + ), 154 (86%), 127 (74%). 1 H NMR of the first fraction (250 MHZ, DMSO-d6) δ, ppm: 7.27-7.51 (m,4H), 7.59-7.96 (m,2H), 8.57-8.78 (m,2H).
[0129] Sublimation of the 1 st fraction product after column did not lead to disappearance of the peaks of contaminants in 1 H NMR spectrum, and we do not expect the sublimation to lead to resolving the isomers if present.
[0130] 2-phenylpyridine. Was synthesized by literature procedure (J. C. W. Evans, C. F. H. Allen, Org. Synth. Cell. 1943, 2, 517) and is displayed in Scheme 5. Pale yellow oil darkening in the air (yield 48%). 1 H NMR (250 MHZ, DMSO-d 6 ) of the product after vacuum distillation: δ,ppm: 6.70-6.76 (m,1H), 6.92-7.10 (m,3H), 7.27-7.30 (m,1H), 7.36-7.39 (q,1H), 7.60-7.68 (m,2H), 8.16-8.23 (m,1H)).
[0131] 2,2′-diaminobiphenyl. Was prepared by literature method (R. E. Moore, A. Furst, J.Org. Chem. 1958, 23, 1504) (Scheme 6). Pale pink solid (yield 69%). 1 H NMR (250 MHZ, DMSO-d 6 ) δ,ppm: 5.72-5.80 (t. of d.,2H), 5.87-5.93 (d. of d., 2H), 6.03-6.09 (d. of d.,2H), 6.13-6.23 (t. of d.,2H). Mass spec: m/z: 185 (40%), 184 (100%, M + ), 183 (73%), 168 (69%), 167 (87%), 166(62%), 139 (27%).
Scheme 6: Synthesis of 2,2′-dibromobiphenyl from 2,2′-dinitrobiphenyl
[0132] [0132]
[0133] 2,2′-dibromobiphenyl. (Scheme 6) (A. Uehara, J. C. Bailar, Jr., J.Organomet. Chem. 1982, 239,1).
[0134] 2,2′-dibromo-1,1′-binaphthyl. Was synthesized according to literature (H. Takaya, S. Akutagawa, R. Noyori, Org.Synth. 1989, 67,20) (Scheme 7).
[0135] trans-Dichloro-bis-(diethyl sulfide) platinum (II). Prepared by a published procedure (G. B. Kauffman, D. O. Cowan, Inorg. Synth. 1953, 6, 211) (Scheme 8). Bright yellow solid (yield 78%).
[0136] cis-Dichloro-bis-(diethyl sulfide)platinum (II). Prepared by a published procedure (G. B. Kauffman, D. O. Cowan, Inorg. Synth. 1953, 6, 211). (Scheme 8). Yellow solid (63%).
[0137] cis-Bis[2-(2-thienyl)pyridinato-N,C 5′ platinum (II). Was synthesized according to literature methods (L. Chassot, A. von Zelewsky, Inorg.Chem. 1993, 32, 4585). (Scheme 9). Bright red crystals (yield 39%). Mass spec: m/z: 518 (25%), 517 (20%), 516 (81%), 513 (100%,M + ), 514 (87%), 481 (15%), 354 (23%).
[0138] cis-Bis[2-(2′-thienyl)quinolinato-N,C 3 ) platinum (II). Was prepared following published procedures (P. Jolliet, M. Gianini, A. von Zelewsky, G. Bernardinelli, H. Stoeckii-Evans, Inorg.Chem. 1996, 35, 4883). (Scheme 10). Dark red solid (yield 21%).
[0139] Absorption spectra were recorded on AVIV Model 14DS-UV-Vis-IR spectrophotometer and corrected for background due to solvent absorption. Emission spectra were recorded on PTI QuantaMaster Model C-60SE spectrometer with 1527 PMT detector and corrected for detector sensitivity inhomogeneity.
[0140] Vacuum deposition experiments were performed using standard high vacuum system (Kurt J. Lesker vacuum chamber) with vacuum ˜10 −6 torr. Quartz plates (ChemGlass Inc.) or borosilicate glass-IndiumTin Oxide plates (ITO, Delta Technologies,Lmtd.), if used as substrates for deposition, were pre-cleaned according to the published procedure for the later (A. Shoustikov, Y. You, P. E. Burrows, M. E. Thomspon, S. R. Forrest, Synth.Met. 1997, 91, 217).
[0141] Thin film spin coating experiments were done with standard spin coater (Specialty Coating Systems, Inc.) with regulatable speed, acceleration speed, and deceleration speed. Most films were spun coat with 4000 RPM speed and maximum acceleration and deceleration for 40 seconds.
[0142] Optical Properties of the Pt Cyclometalated Complexes:
TABLE 1 Absorption and emission properties of several cycloplatinated complexes. Reproduced from A. von Zelewsky et. al (Chem. Phys. Lett., 1985, 122, 375 and Helv. Chim. Acta 1988, 71, 1053). Abbreviation explanations are given in Scheme 1. emission spectra absorption 77 K 293 K solvent λmax(ε) λmax(τ) λmax(τ) Pt(Phpy) 2 CH 3 CN 402(12800) 491(4.0) — 291(27700) Pt(Thpy) 2 CH 3 CN 418(10500) 570(12.0) 578(2.2) 303(26100) Pt(Bhq) 2 CH 3 CN 421(9200) 492(6.5) — 367(12500) 307(15000) Pt(bph)(bpy)
[0143] [0143]
[0144] Optical Properties in Solution:
[0145] Absorbance spectra of the complexes Pt(thpy) 2 , Pt(thq) 2 and Pt(bph)(bpy) in solution (CHCl 3 or CH 2 Cl 2 ) were normalized and are presented in FIG. 1. Absorption maximum for Pt(phpy) 2 showed a maximum at ca. 400 nm, but because the complex apparently requires further purification, the spectrum is not presented.
[0146] Normalized emission spectra are shown in FIG. 2. Excitation wavelengths for Pt(thpy) 2 , Pt(thq) 2 and Pt(bph)(bpy) are correspondingly 430 nm, 450 nm, and 449 nm (determined by maximum values in their excitation spectra). Pt(thpy) 2 gives strong orange to yellow emission, while Pt(thq) 2 gives two lines at 500 and 620 nm. The emission form these materials is due to efficient phosphorescence. Pt(bph)(bpy) gives blue emission, centered at 470 nm. The emission observed for Pt(bph)(bpy) is most likely due to fluorescence and not phosphorescence.
[0147] Emission lifetimes and quantum yields in solution:
Pt(thPy) 2 : 3.7 μs (CHCl 3 , deoxygenated for 10 min) 0.27 Pt(thq) 2 : 2.6 μs (CHCl 3 , deoxygenated for 10 min) not measured Pt(bph)(bpy): not in μs region (CH 2 O 2 , deoxygenated not measured for 10 min)
[0148] Optical properties in PS solid matrix:
[0149] Pt(thpy) 2 : Emission maximum is at 580 nm (lifetime 6.5 μs) upon excitation at 400 nm. Based on the increased lifetime for the sample in polystyrene we estimate a quantum efficiency in polystyrene for Pt(thpy) 2 of 0.47.
[0150] Pt(thq) 2 : Emission maximum at 608 nm (lifetime 7.44 μs) upon excitation at 450 nm.
[0151] Optical Properties of the complexes in PVK Film:
[0152] These measurements were made for Pt(thpy) 2 only. Polyvinylcarbazole (PVK) was excited at 250 nm and energy transfer from PVK to Pt(thpy) 2 was observed (FIG. 3). The best weight PVK:Pt(thpy) 2 ratio for the energy transfer was found to be ca. 100:6.3.
EXAMPLES OF LIGHT EMITTING DIODES
EXAMPLE 1
ITO/PVK:PBD.Pt(thpy) 2 (100:40:2)/Ag:Mg/Ag
[0153] Pt(thpy) 2 does not appear to be stable toward sublimation. In order to test it in an OLED we have fabricated a polymer blended OLED with Pt(thpy) 2 dopant. The optimal doping level was determined by the photoluminescence study described above. The emission from this device comes exclusively from the Pt(thpy) 2 dopant. Typical current-voltage characteristic and light output curve of the device are shown in FIG. 4. Quantum efficiency dependence on applied voltage is demonstrated in FIG. 5. Thus, at 22 V quantum efficiency is ca. 0.11%. The high voltage required to drive this device is a result of the polymer blend OLED structure and not the dopant. Similar device properties were observed for a polymer blend device made with a coumarin dopant in place of Pt(thpy) 2 . In addition, electroluminescence spectrum and CIE diagram are shown in FIG. 6.
EXAMPLE 2
[0154] In this example, we describe OLEDs employing the green, electrophosphorescent material fac tris(2-phenylpyridine)iridium (Ir(ppy) 3 ). This compound has the following formulaic representation:
[0155] The coincidence of a short triplet lifetime and reasonable photoluminescent efficiency allows Ir(ppy) 3 -based OLEDs to achieve peak quantum and power efficiencies of 8.0% (28 cd/A) and ˜30 Im/W respectively. At an applied bias of 4.3V, the luminance reaches 100 cd/m 2 and the quantum and power efficiencies are 7.5% (26 cd/A) and 19 Im/W, respectively.
[0156] Organic layers were deposited by high vacuum (10 −6 Torr) thermal evaporation onto a cleaned glass substrate precoated with transparent, conductive indium tin oxide. A 400 A thick layer of 4,4′-bis(N-(1-naphthyl)-N-phenyl-amino)biphenyl (α-NPD) is used to transport holes to the luminescent layer consisting of Ir(ppy) 3 in CBP. A 200 A thick layer of the electron transport material tris-(8-hydroxyquinoline)aluminum (Alq 3 ) is used to transport electrons into the Ir(ppy) 3 :CBP layer, and to reduce Ir(ppy) 3 luminescence absorption at the cathode. A shadow mask with 1 mm diameter openings was used to define the cathode consisting of a 1000 A thick layer of 25:1 Mg:Ag, with a 500 A thick Ag cap. As previously (O'Brien, et al., App. Phys. Lett. 1999, 74,.442-444), we found that a thin (60 A) barrier layer of 2,9-dimethyl-4,7-diphenyl-1,10-phenanthroline (bathocuproine, or BCP) inserted between the CBP and the Alq 3 was necessary to confine excitons within the luminescent zone and hence maintain high efficiencies. In O'Brien et al., Appl. Phys. Lett. 1999, 74, 442-444, it was argued that this layer prevents triplets from diffusing outside of the doped region. It was also suggested that CBP may readily transport holes and that BCP may be required to force exciton formation within the luminescent layer. In either case, the use of BCP clearly serves to trap excitons within the luminescent region. The molecular structural formulae of some of the materials used in the OLEDs, along with a proposed energy level diagram, is shown in FIG. 7.
[0157] [0157]FIG. 8 shows the external quantum efficiencies of several Ir(ppy) 3 -based OLEDs. The doped structures exhibit a slow decrease in quantum efficiency with increasing current. Similar to the results for the Alq 3 :PtOEP system the doped devices achieve a maximum efficiency (˜8%) for mass ratios of Ir(ppy) 3 :CBP of approximately 6-8%. Thus, the energy transfer pathway in Ir(ppy) 3 :CBP is likely to be similar to that in PtOEP:Alq 3 (Baldo, et al., Nature, 1998, 395, 151; O'Brien, 1999, op. cit.) i.e. via short range Dexter transfer of triplets from the host. At low Ir(ppy) 3 concentrations, the lumophores often lie beyond the Dexter transfer radius of an excited Alq 3 molecule, while at high concentrations, aggregate quenching is increased. Note that dipole-dipole (Forster) transfer is forbidden for triplet transfer, and in the PtOEP:Alq 3 system direct charge trapping was not found to be significant.
EXAMPLE 3
[0158] In addition to the doped device, we fabricated a heterostructure where the luminescent region was a homogeneous film of Ir(ppy) 3 . The reduction in efficiency (to ˜0.8% ) of neat Ir(ppy) 3 is reflected in the transient decay, which has a lifetime of only ˜100 ns, and deviates significantly from mono-exponential behavior. A 6% Ir(ppy) 3 :CBP device without a BCP barrier layer is also shown together with a 6% Ir(ppy) 3 :Alq 3 device with a BCP barrier layer. Here, very low quantum efficiencies are observed to increase with current. This behavior suggests a saturation of nonradiative sites as excitons migrate into the Alq 3 , either in the luminescent region or adjacent to the cathode.
EXAMPLE 4
[0159] In FIG. 9 we plot luminance and power efficiency as a function of voltage for the device of Example 2. The peak power efficiency is ˜30 lm/W with a quantum efficiency of 8%, (28 cd/A). At 100cd/m 2 , a power efficiency of 19 lm/W with a quantum efficiency of 7.5% (26 cd/A) is obtained at a voltage of 4.3V. The transient response of Ir(ppy) 3 in CBP is a mono-exponential phosphorescent decay of ˜500 ns, compared with a measured lifetime (e.g., King, et al., J. Am. Chem. Soc., 1985, 107, 1431-1432) of 2 μs in degassed toluene at room temperature. These lifetimes are short and indicative of strong spin-orbit coupling, and together with the absence of Ir(ppy) 3 fluorescence in the transient response, we expect that Ir(ppy) 3 possesses strong intersystem crossing from the singlet to the triplet state. Thus all emission originates from the long lived triplet state. Unfortunately, slow triplet relaxation can form a bottleneck in electrophosphorescence and one principal advantage of Ir(ppy) 3 is that it possesses a short triplet lifetime. The phosphorescent bottleneck is thereby substantially loosened. This results in only a gradual decrease in efficiency with increasing current, leading to a maximum luminance of ˜100,000 cd/m 2 .
EXAMPLE 5
[0160] In FIG. 10, the emission spectrum and Commission Internationale de L'Eclairage (CIE) coordinates of Ir(ppy) 3 are shown for the highest efficiency device. The peak wavelength is λ=510 nm and the full width at half maximum is 70 nm. The spectrum and CIE coordinates (x=0.27,y-0.63) are independent of current. Even at very high current densities (˜100 mA/cm 2 ) blue emission from CBP is negligible—an indication of complete energy transfer.
[0161] Other techniques known to one-of ordinary skill may be used in conjunction with the present invention. For example, the use of LiF cathodes (Hung, et al., Appl. Phys. Lett., 1997, 70, 152-154), shaped substrates (G. Gu, et al., Optics Letters, 1997, 22, 396-398), and novel hole transport materials that result in a reduction in operating voltage or increased quantum efficiency (B. Kippelen, et al., MRS (San Francisco, Spring, 1999) are also applicable to this work. These methods have yielded power efficiencies of ˜20 lm/W in fluorescent small molecule devices (Kippelen, Id.). The quantum efficiency in these devices (Kido and Iizumi, App. Phys. Lett., 1998, 73, 2721) at 100 cd/m 2 is typically ≦4.6% (lower than that of the present invention), and hence green-emitting electrophosphorescent devices with power efficiencies of >40 lm/W can be expected. Purely organic materials (Hoshino and Suzuki, Appl. Phys. Lett., 1996, 69, 224-226) may sometimes possess insufficient spin orbit coupling to show strong phosphorescence at room temperature. While one should not rule out the potential of purely organic phosphors, the preferred compounds may be transition metal complexes with aromatic ligands. The transition metal mixes singlet and triplet states, thereby enhancing intersystem crossing and reducing the lifetime of the triplet excited state.
[0162] The present invention is not limited to the emissive molecule of the examples. One of ordinary skill may modify the organic component of the Ir(ppy) 3 (directly below) to obtain desirable properties.
[0163] One may have alkyl substituents or alteration of the atoms of the aromatic structure.
[0164] These molecules, related to Ir(ppy) 3 , can be formed from commercially available ligands. The R groups can be alkyl or aryl and are preferably in the 3, 4, 7 and/or 8 positions on the ligand (for steric reasons). The compounds should give different color emission and may have different carrier transport rates. Thus, the modifications to the basic Ir(ppy) 3 structure in the three molecules can alter emissive properties in desirable ways.
[0165] Other possible emitters are illustrated below, by way of example.
[0166] This molecule is expected to have a blue-shifted emission compared to Ir(ppy) 3 . R and R′ can independently be alkyl or aryl.
[0167] Organometallic compounds of osmium may also be used in this invention. Examples include the following.
[0168] These osmium complexes will be octahedral with 6 d electrons (isoelectronic with the Ir analogs) and may have good intersystem crossing efficiency. R and R′ are independently selected from the group consisting of alkyl and aryl. They are believed to be unreported in the literature.
[0169] Herein, X can be selected from the group consisting of N or P. R and R′ are independently selected from the group alkyl and aryl.
[0170] The molecule of the hole-transporting layer of Example 2 is depicted below.
[0171] The present invention will work with other hole-transporting molecules known by one of ordinary skill to work in hole transporting layers of OLEDs.
[0172] The molecule used as the host in the emissive layer of Example 2 is depicted below.
[0173] The present invention will work with other molecules known by one of ordinary skill to work as hosts of emissive layers of OLEDs. For example, the host material could be a hole-transporting matrix and could be selected from the group consisting of substituted tri-aryl amines and polyvinylcarbazoles.
[0174] The molecule used as the exciton blocking layer of Example 2 is depicted below. The invention will work with other molecules used for the exciton blocking layer, provided they meet the requirements listed in the summary of the invention.
[0175] Molecules which are suitable as components for an exciton blocking layer are not necessarily the same as molecules which are suitable for a hole blocking layer. For example, the ability of a molecule to function as a hole blocker depends on the applied voltage, the higher the applied voltage, the less the hole blocking ability. The ability to block excitons is roughly independent of the applied voltage.
[0176] This invention is further directed to the synthesis and use of certain organometallic molecules of formula L 2 MX which may be doped into a host phase in an emitter layer of an organic light emitting diode. Optionally, the molecules of formula L 2 MX may be used at elevated concentrations or neat in the emitter layer. This invention is further directed to an organic light emitting device comprising an emitter layer comprising a molecule of the formula L 2 MX wherein L and X are inequivalent, bidentate ligands and M is a metal, preferably selected from the third row of the transition elements of the periodic table, and most preferably Ir or Pt, which forms octahedral complexes, and wherein the emitter layer produces an emission which has a maximum at a certain wavelength λ max . The general chemical formula for these molecules which are doped into the host phase is L 2 MX, wherein M is a transition metal ion which forms octahedral complexes, L is a bidentate ligand, and X is a distinct bidentate ligand. Examples of L are 2-(1-naphthyl)benzoxazole)), (2-phenylbenzoxazole), (2-phenylbenzothiazole), (2-phenylbenzothiazole), (7,8-benzoquinoline), coumarin, (thienylpyridine), phenylpyridine, benzothienylpyridine, 3-methoxy-2-phenylpyridine, thienylpyridine, and tolylpyridine. Examples of X are acetylacetonate (“acac”), hexafluoroacetylacetonate, salicylidene, picolinate, and 8-hydroxyquinolinate. Further examples of L and X are given in FIG. 49 and still further examples of L and X may be found in Comprehensive Coordination Chemistry, Volume 2, G. Wilkinson (editor-in-chief), Pergamon Press, especially in chapter 20.1 (beginning at page 715) by M. Calligaris and L. Randaccio and in chapter 20.4 (beginning at page 793) by R. S. Vagg.
[0177] Synthesis of Molecules of Formula L 2 MX
[0178] The compounds of formula L 2 MX can be made according to the reaction:
L 2 M(μ-Cl) 2 ML 2 +XH→L 2 MX+HCl
[0179] wherein L 2 M(μ-Cl) 2 ML 2 is a chloride bridged dimer with L a bidentate ligand, and M a metal such as Ir; XH is a Bronsted acid which reacts with bridging chloride and serves to introduce a bidentate ligand X, wherein XH can be, for example, acetylacetone, hexafluoroacetylacetone, 2-picolinic acid, or N-methylsalicyclanilide; and L 2 MX has approximate octahedral disposition of the bidentate ligands L, L, and X about M.
[0180] L 2 Ir(μ-Cl) 2 IrL 2 complexes were prepared from IrCl 3 .nH 2 O and the appropriate ligand by literature procedures (S. Sprouse, K. A. King, P. J. Spellane, R. J. Watts, J. Am. Chem. Soc., 1984, 106, 6647-6653; for general reference: G. A. Carlson, et al., Inorg. Chem., 1993, 32, 4483; B. Schmid, et al., Inorg. Chem., 1993, 33, 9; F. Garces, et al.; Inorg. Chem., 1988, 27, 3464; M. G. Colombo, et al., Inorg. Chem., 1993, 32, 3088; A. Mamo, et al., Inorg. Chem., 1997, 36, 5947; S. Serroni, et al.; J. Am. Chem. Soc., 1994, 116, 9086; A. P. Wilde, et al., J. Phys. Chem., 1991, 95, 629; J. H. van Diemen, et al., Inorg. Chem., 1992, 31, 3518; M. G. Colombo, et al., Inorg. Chem., 1994, 33, 545), as described below.
[0181] Ir(3-MeOppy) 3 . Ir(acac) 3 (0.57 g, 1.17 mmol) and 3-methoxy-2-phenylpyridine (1.3 g, 7.02 mmol) were mixed in 30 ml of glycerol and heated to 200° C. for 24 hrs under N 2 . The resulting mixture was added to 100 ml of 1 M HCl. The precipitate was collected by filtration and purified by column chromatography using CH 2 Cl 2 as the eluent to yield the product as bright yellow solids (0.35 g, 40%). MS (EI): m/z (relative intensity) 745 (M + , 100), 561 (30), 372 (35). Emission spectrum in FIG. 17.
[0182] tpyIrsd. The chloride bridge dimer (tpyIrCl) 2 (0.07 g, 0.06 mmol), salicylidene (0.022 g, 0.16 mmol) and Na 2 CO 3 (0.02 g, 0.09 mmol) were mixed in 10 ml of 1,2-dichloroethane and 2 ml of ethanol. The mixture was refluxed under N 2 for 6 hrs or until no dimer was revealed by TLC. The reaction was then cooled and the solvent evaporated. The excess salicylidene was removed by gentle heating under vacuum. The residual solid was redissolved in CH 2 Cl 2 and the insoluble inorganic materials were removed by filtration. The filtrate was concentrated and column chromatographed using CH 2 Cl 2 as the eluent to yield the product as bright yellow solids (0.07 g, 85%). MS (EI): m/z (relative intensity) 663 (M + , 75), 529 (100), 332 (35). The emission spectrum is in FIG. 18 and the proton NMR spectrum is in FIG. 19.
[0183] thpyIrsd. The chloride bridge dimer (thpyIrCl) 2 (0.21 g, 0.19 mmol) was treated the same way as (tpyIrCl) 2 . Yield: 0.21 g, 84%. MS (EI): m/z (relative intensity) 647 (M + , 100), 513 (30), 486 (15), 434 (20), 324 (25). The emission spectrum is in FIG. 20 and the proton NMR spectrum is in FIG. 21.
[0184] btIrsd. The chloride bridge dimer (btIrCl) 2 (0.05 g, 0.039 mmol) was treated the same way as (tpyIrCl) 2 . Yield: 0.05 g, 86%. MS (EI): m/z (relative intensity) 747 (M + , 100), 613 (100), 476 (30), 374 (25), 286 (32). The emission spectrum is in FIG. 22 and the proton NMR spectrum is in FIG. 23.
[0185] Ir(bq) 2 (acac), BQIr. The chloride bridged dimer (Ir(bq) 2 Cl) 2 (0.091 g, 0.078 mmol), acetylacetone (0.021 g) and sodium carbonate (0.083 g) were mixed in 10 ml of 2-ethoxyethanol. The mixture was refluxed under N 2 for 10 hrs or until no dimer was revealed by TLC. The reaction was then cooled and the yellow precipitate filtered. The product was purified by flash chromatography using dichloromethane. Product: bright yellow solids (yield 91%). 1 H NMR (360 MHz, acetone-d 6 ), ppm: 8.93 (d,2H), 8.47 (d,2H), 7.78 (m,4H), 7.25 (d,2H), 7.15 (d,2H), 6.87 (d,2H), 6.21 (d,2H), 5.70 (s,1H), 1.63 (s,6H). MS, e/z: 648 (M+,80%), 549 (100%). The emission spectrum is in FIG. 24 and the proton NMR spectrum is in FIG. 25.
[0186] Ir(bq) 2 (Facac), BQIrFA. The chloride bridged dimer (Ir(bq) 2 Cl) 2 (0.091 g, 0.078 mmol), hexafluoroacetylacetone (0.025 g) and sodium carbonate (0.083 g) were mixed in 10 ml of 2-ethoxyethanol. The mixture was refluxed under N 2 for 10 hrs or until no dimer was revealed by TLC. The reaction was then cooled and the yellow precipitate filtered. The product was purified by flash chromatography using dichloromethane. Product: yellow solids (yield 69%). 1 H NMR (360 MHz, acetone-d 6 ), ppm: 8.99 (d,2H), 8.55 (d,2H), 7.86 (m,4H), 7.30 (d,2H), 7.14 (d,2H), 6.97 (d,2H), 6.13 (d,2H), 5.75 (s,1H). MS, e/z: 684 (M+,59%), 549 (100%). Emission spectrum in FIG. 26.
[0187] Ir(thpy) 2 (acac), THPIr. The chloride bridged dimer (Ir(thpy) 2 Cl) 2 (0.082 g, 0.078 mmol), acetylacetone (0.025 g) and sodium carbonate (0.083 g) were mixed in 10 ml of 2-ethoxyethanol. The mixture was refluxed under N 2 for 10 hrs or until no dimer was revealed by TLC. The reaction was then cooled and the yellow precipitate filtered. The product was purified by flash chromatography using dichloromethane. Product: yellow-orange solid (yield 80%). 1 H NMR (360 MHz, acetone-d 6 ), ppm: 8.34 (d,2H), 7.79 (m,2H), 7.58 (d,2H), 7.21 (d,2H), 7.15 (d,2H), 6.07 (d,2H), 5.28 (s,1H), 1.70 (s,6H). MS, e/z: 612 (M+,89%), 513 (100%). The emission spectrum is in FIG. 27 (noted “THIr”) and the proton NMR spectrum is in FIG. 28.
[0188] Ir(ppy) 2 (acac), PPIr. The chloride bridged dimer (Ir(ppy) 2 Cl) 2 (0.080 g, 0.078 mmol), acetylacetone (0.025 g) and sodium carbonate (0.083 g) were mixed in 10 ml of 2-ethoxyethanol. The mixture was refluxed under N 2 for 10 hrs or until no dimer was revealed by TLC. The reaction was then cooled and the yellow precipitate filtered. The product was purified by flash chromatography using dichloromethane. Product: yellow solid (yield 87%). 1 H NMR (360 MHz, acetone-d 6 ), ppm: 8.54 (d,2H), 8.06 (d,2H), 7.92 (m,2H), 7.81 (d,2H), 7.35 (d,2H), 6.78 (m,2H), 6.69 (m,2H), 6.20 (d,2H), 5.12 (s,1H), 1.62 (s,6H). MS, e/z: 600 (M+,75%), 501 (100%). The emission spectrum is in FIG. 29 and the proton NMR spectrum is in FIG. 30.
[0189] Ir(bthpy) 2 (acac), BTPIr. The chloride bridged dimer (Ir(bthpy) 2 Cl) 2 (0.103 g, 0.078 mmol), acetylacetone (0.025 g) and sodium carbonate (0.083 g) were mixed in 10 ml of 2-ethoxyethanol. The mixture was refluxed under N 2 for 10 hrs or until no dimer was revealed by TLC. The reaction was then cooled and the yellow precipitate filtered. The product was purified by flash chromatography using dichloromethane. Product: yellow solid (yield 49%). MS, e/z: 712 (M+,66%), 613 (100%). Emission spectrum is in FIG. 31.
[0190] [Ir(ptpy) 2 Cl] 2 . A solution of IrCl 3 .xH 2 O (1.506 g, 5.030 mmol) and 2-(p-tolyl)pyridine (3.509 g, 20.74 mmol) in 2-ethoxyethanol (30 mL) was refluxed for 25 hours. The yellow-green mixture was cooled to room temperature and 20 mL of 1.0 M HCl was added to precipitate the product. The mixture was filtered and washed with 100 mL of 1.0 M HCl followed by 50 mL of methanol then dried. The product was obtained as a yellow powder (1.850 g, 65%).
[0191] [Ir(ppz) 2 Cl] 2 . A solution of IrCl 3 .xH2O (0.904 g, 3.027 mmol) and 1-phenylpyrazole (1.725 g, 11.96 mmol) in 2-ethoxyethanol (30 mL) was refluxed for 21 hours. The gray-green mixture was cooled to room temperature and 20 mL of 1.0 M HCl was added to precipitate the product. The mixture was filtered and washed with 100 mL of 1.0 M HCl followed by 50 mL of methanol then dried. The product was obtained as a light gray powder (1.133 g, 73%).
[0192] [Ir(C6) 2 Cl] 2 . A solution of IrCl 3 .xH 2 O (0.075 g, 0.251 mmol) and coumarin C6 [3-(2-benzothiazolyl)-7-(diethyl)coumarin] (Aldrich) (0.350 g, 1.00 mmol) in 2-ethoxyethanol (15 mL) was refluxed for 22 hours. The dark red mixture was cooled to room temperature and 20 mL of 1.0 M HCl was added to precipitate the product. The mixture was filtered and washed with 100 mL of 1.0 M HCl followed by 50 mL of methanol. The product was dissolved in and precipitated with methanol. The solid was filtered and washed with methanol until no green emission was observed in the filtrate. The product was obtained as an orange powder (0.0657 g, 28%).
[0193] Ir(ptpy) 2 (acac) (tpyIr). A solution of [Ir(ptpy) 2 Cl] 2 (1.705 g, 1.511 mmol), 2,4-pentanedione (3.013 g, 30.08 mmol) and (1.802 g, 17.04 mmol) in 1,2-dichloroethane (60 mL) was refluxed for 40 hours. The yellow-green mixture was cooled to room temperature and the solvent was removed under reduced pressure. The product was taken up in 50 mL of CH 2 Cl 2 and filtered through Celite. The solvent was removed under reduced pressure to yield orange crystals of the product (1.696 g, 89%). The emission spectrum is given in FIG. 32. The results of an x-ray diffraction study of the structure are given in FIG. 33. One sees that the nitrogen atoms of the tpy (“tolyl pyridyl”) groups are in a trans configuration. For the x-ray study, the number of reflections was 4663 and the R factor was 5.4%.
[0194] Ir(C6) 2 (acac) (C6Ir). Two drops of 2,4-pentanedione and an excess of Na 2 CO 3 was added to solution of [Ir(C6) 2 Cl] 2 in CDCl 3 . The tube was heated for 48 hours at 50° C. and then filtered through a short plug of Celite in a Pasteur pipet. The solvent and excess 2,4-pentanedione were removed under reduced pressure to yield the product as an orange solid. Emission of C6 in FIG. 34 and of C6Ir in FIG. 35.
[0195] Ir(ppz) 2 picolinate (PZIrp). A solution of [Ir(Ppz) 2 Cl] 2 (0.0545 g, 0.0530 mmol) and picolinic acid (0.0525 g, 0.426 mmol) in CH 2 Cl 2 (15 mL) was refluxed for 16 hours. The light green mixture was cooled to room temperature and the solvent was removed under reduced pressure. The resultant solid was taken up in 10 mL of methanol and a light green solid precipitated from the solution. The supernatant liquid was decanted off and the solid was dissolved in CH 2 Cl 2 and filtered through a short plug of silica. The solvent was removed under reduced pressure to yield light green crystals of the product (0.0075 g, 12%). Emission in FIG. 36.
[0196] 2-(1-naphthyl)benzoxazole, (BZO-Naph). (11.06 g, 101 mmol) of 2-aminophenol was mixed with (15.867 g, 92.2 mmol) of 1-naphthoic acid in the presence of polyphosphoric acid. The mixture was heated and stirred at 240° C. under N 2 for 8 hrs. The mixture was allowed to cool to 100° C., this was followed by addition of water. The insoluble residue was collected by filtration, washed with water then reslurried in an excess of 10% Na 2 CO 3 . The alkaline slurry was filtered and the product washed thoroughly with water and dried under vacuum. The product was purified by vacuum distillation. BP 140° C./0.3 mmHg. Yield 4.8 g (21%).
[0197] Tetrakis(2-(1-naphthyl)benzoxazoleC 2 ,N′)(μ-dichloro)diiridium. ((Ir 2 (BZO-Naph) 4 Cl) 2 ). Iridium trichloride hydrate (0.388 g) was combined with 2-(1-naphthyl)benzoxazole (1.2 g, 4.88 mmol). The mixture was dissolved in 2-ethoxyethanol (30 mL) then refluxed for 24 hrs. The solution was cooled to room temperature, the resulting orange solid product was collected in a centrifuge tube. The dimer was washed with methanol followed by chloroform through four cycles of centrifuge/redispersion cycles. Yield 0.66 g.
[0198] Bis(2-(1-naphthyl)benzoxazole)acetylacetonate, Ir(BZO-Naph) 2 (acac), (BONIr). The chloride bridged dimer (Ir 2 (BZO-Naph) 4 Cl) 2 (0.66 g, 0.46 mmol), acetylacetone (0.185 g) and sodium carbonate (0.2 g) were mixed in 20 ml of dichloroethane. The mixture was refluxed under N 2 for 60 hrs. The reaction was then cooled and the orange/red precipitate was collected in centrifuge tube. The product was washed with water/methanol (1:1) mixture followed by methanol wash through four cycles of centrifuge/redispersion cycles. The orange/red solid product was purified by sublimation. SP 250° C./2×10 −5 torr, yield 0.57 g (80%). The emission spectrum is in FIG. 37 and the proton NMR spectrum is in FIG. 38.
[0199] Bis(2-phenylbenzothiazole)Iridium acetylacetonate (BTIr). 9.8 mmol (0.98 g, 1.0 mL) of 2,4-pentanedione was added to a room-temperature solution of 2.1 mmol 2-phenylbenzothiazole Iridium chloride dimer (2.7 g) in 120 mL of 2-ethoxyethanol. Approximately 1 g of sodium carbonate was added, and the mixture was heated to reflux under nitrogen in an oil bath for several hours. Reaction mixture was cooled to room temperature, and the orange precipitate was filtered off via vacuum. The filtrate was concentrated and methanol was added to precipitate more product. Successive filtrations and precipitations afforded a 75% yield. The emission spectrum is in FIG. 39 and the proton NMR spectrum is in FIG. 40.
[0200] Bis(2-phenylbenzooxazole)Iridium acac (BOIr). 9.8 mmol (0.98 g, 1.0 mL) of 2,4-pentanedione was added to a room-temperature solution of 2.4 mmol 2-phenylbenzoxazole Iridium chloride dimer (3.0 g) in 120 mL of 2-ethoxyethanol. Approximately 1 g of sodium carbonate was added, and the mixture was heated to reflux under nitrogen in an oil bath overnight (˜16 hrs.). Reaction mixture was cooled to room temperature, and the yellow precipitate was filtered off via vacuum. The filtrate was concentrated and methanol was added to precipitate more product. Successive filtrations and precipitations afforded a 60% yield. The emission spectrum is in FIG. 41 and the proton NMR spectrum is in FIG. 42.
[0201] Bis(2-phenylbenzothiazole)Iridium (8-hydroxyquinolate) (BTIrQ). 4.7 mmol (0.68 g) of 8-hydroxyquinoline was added to a room-temperature solution of 0.14 mmol 2-phenylbenzothiazole Iridium chloride dimer (0.19 g) in 20 mL of 2-ethoxyethanol. Approximately 700 mg of sodium carbonate was added, and the mixture was heated to reflux under nitrogen in an oil bath overnight (23 hrs.). Reaction mixture was cooled to room temperature, and the red precipitate was filtered off via vacuum. The filtrate was concentrated and methanol was added to precipitate more product. Successive filtrations and precipitations afforded a 57% yield. The emission spectrum is in FIG. 43 and the proton NMR spectrum is in FIG. 44.
[0202] Bis(2-phenylbenzothiazole)Iridium picolinate (BTIrP). 2.14 mmol (0.26 g) of picolinic acid was added to a room-temperature solution of 0.80 mmol 2-phenylbenzothiazole Iridium chloride dimer (1.0 g) in 60 mL of dichloromethane. The mixture was heated to reflux under nitrogen in an oil bath for 8.5 hours. The reaction mixture was cooled to room temperature, and the yellow precipitate was filtered off via vacuum. The filtrate was concentrated and methanol was added to precipitate more product. Successive filtrations and precipitations yielded about 900 mg of impure product. Emission spectrum is in FIG. 45.
[0203] Bis(2-phenylbenzooxazole)Iridium picolinate (BOIrP). 0.52 mmol (0.064 g) of picolinic acid was added to a room-temperature solution of 0.14 mmol 2-phenylbenzoxazole Iridium chloride dimer (0.18 g) in 20 mL of dichloromethane. The mixture was heated to reflux under nitrogen in an oil bath overnight (17.5 hrs.). Reaction mixture was cooled to room temperature, and the yellow precipitate was filtered off via vacuum. The precipitate was dissolved in dichloromethane and transferred to a vial, and the solvent was removed. Emission spectrum is in FIG. 46.
[0204] Comparative emission spectra for different L′ in btIr complexes are shown in FIG. 47.
[0205] These syntheses just discussed have certain advantages over the prior art. Compounds of formula PtL 3 cannot be sublimed without decomposition. Obtaining compounds of formula IrL 3 can be problematic. Some ligands react cleanly with Ir(acac) 3 to give the tris complex, but more than half of the ligands we have studied do not react cleanly in the reaction:
3 L+Ir(acac) 3 →L 3 Ir+(acac)H;
[0206] typically 30% yield, L=2-phenytpyridine, benzoquinoline, 2-thienylpyridine. A preferred route to Ir complexes can be through the chloride-bridged dimer L 2 M(μ-Cl) 2 ML 2 via the reaction:
4 L+IrCl 3 .nH 2 O→L 2 M(μ-Cl) 2 ML 2 +4 HCl
[0207] Although fewer than 10% of the ligands we have studied failed to give the Ir dimer cleanly and in high yield, the conversion of the dimer into the tris complex IrL 3 is problematic working for only a few ligands. L 2 M(μ-Cl) 2 ML 2 +2Ag′+2L→L 3 Ir+2AgCl.
[0208] We have discovered that a far more fruitful approach to preparing phosphorescent complexes is to use chloride bridged dimers to create emitters. The dimer itself does not emit strongly, presumably because of strong self quenching by the adjacent metal (e.g., iridium) atoms. We have found that the chloride ligands can be replaced by a chelating ligand to give a stable, octahedral metal complex through the chemistry:
L 2 M(μ-Cl) 2 ML 2 +XH→L 2 MX+HCl
[0209] We have extensively studied the system wherein M=iridium. The resultant iridium complexes emit strongly, in most cases with lifetimes of 1-3 microseconds (“μsec”). Such a lifetime is indicative of phosphorescence (see Charles Kittel, Introduction to Solid State Physics). The transition in these materials is a metal ligand charge transfer (“MLCT”).
[0210] In the discussion that follows below, we analyze data of emission spectra and lifetimes of a number of different complexes, all of which can be characterized as L 2 MX (M=Ir), where L is a cyclometallated (bidentate) ligand and X is a bidentate ligand. In nearly every case, the emission in these complexes is based on an MLCT transition between Ir and the L ligand or a mixture of that transition and an intraligand transition. Specific examples are described below. Based on theoretical and spectroscopic studies, the complexes have an octahedral coordination about the metal (for example, for the nitrogen heterocycles of the L ligand, there is a trans disposition in the Ir octahedron). Specifically, in FIG. 11, we give the structure for L 2 IrX, wherein L=2-phenyl pyridine and X=acac, picolinate (from picolinic acid), salicylanilide, or 8-hydroxyquinolinate.
[0211] A slight variation of the synthetic route to make L 2 IrX allows formation of meridianal isomers of formula L 3 Ir. The L 3 Ir complexes that have been disclosed previously all have a facial disposition of the chelating ligands. Herewith, we disclose the formation and use of meridianal L 3 Ir complexes as phosphors in OLEDs. The two structures are shown in FIG. 12.
[0212] The facial L 3 Ir isomers have been prepared by the reaction of L with Ir(acac) 3 in refluxing glycerol as described in equation 2 (below). A preferred route into L 3 Ir complexes is through the chloride bridged dimer (L 2 Ir(μ-Cl) 2 IrL 2 ), equation 3+4 (below). The product of equation 4 is a facial isomer, identical to the one formed from Ir(acac) 3 . The benefit of the latter prep is a better yield of facial-L 3 Ir. If the third ligand is added to the dimer in the presence of base and acetylacetone (no Ag + ), a good yield of the meridianal isomer is obtained. The meridianal isomer does not convert to the facial one on recrystallization, refluxing in coordinating solvents or on sublimation. Two examples of these meridianal complexes have been formed, mer-Irppy and mer-Irbq (FIG. 13); however, we believe that any ligand that gives a stable facial-L 3 Ir can be made into a meridianal form as well.
3 L+Ir(acac) 3 →facial-L 3 Ir+acacH (1)
[0213] typically 30% yield, L=2-phenylpyridine, bezoquinoline, 2-thienylpyridine
4 L+IrCl 3 .nH 2 O→L 2 Ir(μ-Cl) 2 IrL 2 +4 HCl
[0214] typically >90% yield, see attached spectra for examples of L, also works well for all ligands that work in equation (2)
L 2 Ir(μ-Cl) 2 IrL 2 +2 Ag + +2 L→2 facial-L 3 Ir+2 AgCl
[0215] typically 30% yield, only works well for the same ligands that work well for equation (2)
L 2 Ir(μ-Cl) 2 IrL 2 +XH+Na 2 CO 3 +L→merdianal-L 3 Ir
[0216] typically >80% yield, XH=acetylacetone
[0217] Surprisingly, the photophysics of the meridianal isomers is different from that of the facial forms. This can be seen in the details of the spectra discussed below, which show a marked red shift and broadening in the meridianal isomer relative to its facial counterpart. The emission lines appear as if a red band has been added to the band characteristic of the facial-L 3 Ir. The structure of the meridianal isomer is similar to those of L 2 IrX complexes, with respect, for example, to the arrangement of the N atoms of the ligands about Ir. Specifically, for L=ppy ligands, the nitrogen of the L ligand is trans in both mer-Ir(ppy) 3 and in (ppy) 2 Ir(acac) further, one of the L ligands for the mer-L 3 Ir complexes has the same coordination as the X ligand of L 2 IrX complexes. In order to illustrate this point a model of mer-Ir(ppy) 3 is shown next to (Ppy) 2 Ir(acac) in FIG. 14. One of the ppy ligands of mer-Ir(ppy) 3 is coordinated to the Ir center in the same geometry as the acac ligand of (ppy) 2 Ir(acac).
[0218] The HOMO and LUMO energies of these L 3 Ir molecules are clearly affected by the choice of isomer. These energies are very important is controlling the current-voltage characteristics and lifetimes of OLEDs prepared with these phosphors. The syntheses for the two isomers depicted in FIG. 13 are as follows.
[0219] Syntheses of Meridianal Isomers
[0220] mer-Irbq: 91 mg (0.078 mmol) of [Ir(bq) 2 Cl] 2 dimer, 35.8 mg (0.2 mmol) of 7,8-benzoquinoline, 0.02 ml of acetylacetone (ca. 0.2 mmol) and 83 mg (0.78 mmol) of sodium carbonate were boiled in 12 ml of 2-ethoxyethanol (used as received) for 14 hours in inert atmosphere. Upon cooling yellow-orange precipitate forms and is isolated by filtration and flash chromatography (silica gel, CH 2 Cl 2 ) (yield 72%). 1H NMR (360 MHz, dichloromethane-d2), ppm: 8.31 (q,1H), 8.18 (q,1H), 8.12 (q,1H), 8.03(m,2H), 7.82 (m, 3H), 7.59 (m,2H), 7.47 (m,2H), 7.40 (d,1H), 7.17 (m,9), 6.81 (d,1H), 6.57 (d,1H). MS, e/z: 727 (100%, M+). NMR spectrum in FIG. 48.
[0221] mer-Ir(tpy) 3 : A solution of IrCl 3 .xH 2 O (0.301 g, 1.01 mmol), 2-(p-tolyl)pyridine (1.027 g, 6.069 mmol), 2,4-pentanedione (0.208 g, 2.08 mmol) and Na 2 CO 3 (0.350 g, 3.30 mmol) in 2-ethoxyethanol (30 mL) was refluxed for 65 hours. The yellow-green mixture was cooled to room temperature and 20 mL of 1.0 M HCl was added to precipitate the product. The mixture was filtered and washed with 100 mL of 1.0 M HCl followed by 50 mL of methanol then dried and the solid was dissolved in CH 2 Cl 2 and filtered through a short plug of silica. The solvent was removed under reduced pressure to yield the product as a yellow-orange powder (0.265 g, 38%).
[0222] This invention is further directed toward the use of the above-noted dopants in a host phase. This host phase may be comprised of molecules comprising a carbazole moiety. Molecules which fall within the scope of the invention are included in the following.
[0223] [A line segment denotes possible substitution at any available carbon atom or atoms of the indicated ring by alkyl or aryl groups.]
[0224] An additional preferred molecule with a carbazole functionality is 4,4′-N,N′-dicarbazole-biphenyl (CBP), which has the formula:
[0225] The light emitting device structure that we chose to use is very similar to the standard vacuum deposited one. As an overview, a hole transporting layer (“HTL”) is first deposited onto the ITO (indium tin oxide) coated glass substrate. For the device yielding 12% quantum efficiency, the HTL consisted of 30 nm (300 Å) of NPD. Onto the NPD a thin film of the organometallic compound doped into a host matrix is deposited to form an emitter layer. In the example, the emitter layer was CBP with 12% by weight bis(2-phenylbenzothiazole)iridium acetylacetonate (termed “BTIr”), and the layer thickness was 30 nm (300 Å). A blocking layer is deposited onto the emitter layer. The blocking layer consisted of bathcuproine (“BCP”), and the thickness was 20 nm (200 Å). An electron transport layer is deposited onto the blocking layer. The electron transport layer consisted of Alq 3 of thickness 20 nm. The device is finished by depositing a Mg—Ag electrode onto the electron transporting layer. This was of thickness 100 nm. All of the depositions were carried out at a vacuum less than 5×10 −5 Torr. The devices were tested in air, without packaging.
[0226] When we apply a voltage between the cathode and the anode, holes are injected from ITO to NPD and transported by the NPD layer, while electrons are injected from MgAg to Alq and transported through Alq and BCP. Then holes and electrons are injected into EML and carrier recombination occurs in CBP, the excited states were formed, energy transfer to BTIr occurs, and finally BTIr molecules are excited and decay radiatively.
[0227] As illustrated in FIG. 15, the quantum efficiency of this device is 12% at a current density of about 0.01 mA/cm 2 . Pertinent terms are as follows: ITO is a transparent conducting phase of indium tin oxide which functions as an anode; ITO is a degenerate semiconductor formed by doping a wide band semiconductor; the carrier concentration of the ITO is in excess of 10 19 /cm 3 ; BCP is an exciton blocking and electron transport layer; Alq 3 is an electron injection layer; other hole transport layer materials could be used, for example, TPD, a hole transport layer, can be used.
[0228] BCP functions as an electron transport layer and as an exciton blocking layer, which layer has a thickness of about 10 nm (100 Å). BCP is 2,9-dimethyl-4,7-diphenyl-1,10-phenanthroline (also called bathocuproine) which has the formula:
[0229] The Alq 3 , which functions as an electron injection/electron transport layer has the following formula:
[0230] In general, the doping level is varied to establish the optimum doping level.
[0231] As noted above, fluorescent materials have certain advantages as emitters in devices. If the L ligand that is used in making the L 2 MX (for example, M=Ir) complex has a high fluorescent quantum efficiency, it is possible to use the strong spin orbit coupling of the Ir metal to efficiently intersystem cross in and out of the triplet states of the ligands. The concept is that the Ir makes the L ligand an efficient phosphorescent center. Using this approach, it is possible to take any fluorescent dye and make an efficient phosphorescent molecule from it (that is, L fluorescent but L 2 MX (M=Ir) phosphorescent).
[0232] As an example, we prepared a L 2 IrX wherein L=coumarin and X=acac. We refer to this as coumarin-6 [“C6Ir”]. The complex gives intense orange emission, whereas coumarin by itself emits green. Both coumarin and C6Ir spectra are given in the Figures.
[0233] Other fluorescent dyes would be expected to show similar spectral shifts. Since the number of fluorescent dyes that have been developed for dye lasers and other applications is quite large, we expect that this approach would lead to a wide range of phosphorescent materials.
[0234] One needs a fluorescent dye with suitable functionality such that it can be metallated by the metal (for example, iridium) to make a 5- or 6-membered metallocycle. All of the L ligands we have studied to date have sp 2 hybridized carbons and heterocyclic N atoms in the ligands, such that one can form a five membered ring on reacting with Ir.
[0235] Potential degradation reactions, involving holes or electrons, can occur in the emitter layer. The resultant oxidation or reduction can alter the emitter, and degrade performance. In order to get the maximum efficiency for phosphor doped OLEDs, it is important to control the holes or electrons which lead to undesirable oxidation or reduction reactions. One way to do this is to trap carriers (holes or electrons) at the phosphorescent dopant. It may be beneficial to trap the carrier at a position remote from the atoms or ligands responsible for the phosphorescence. The carrier that is thus remotely trapped could readily recombine with the opposite carrier either intramolecularly or with the carrier from an adjacent molecule.
[0236] An example of a phosphor designed to trap holes is shown in FIG. 16. The diarylamine group on the salicylanlide group is expected to have a HOMO level 200-300 mV above that of the Ir complex (based on electrochemical measurements), leading to the holes being trapped exclusively at the amine groups. Holes will be readily trapped at the amine, but the emission from this molecule will come from MLCT and intraligand transitions from the Ir(phenylpyridine) system. An electron trapped on this molecule will most likely be in one of the pyridyl ligands. Intramolecular recombination will lead to the formation of an exciton, largely in the Ir(phenylpyridine) system. Since the trapping site is on the X ligand, which is typically not involved extensively in the luminescent process, the presence of the trapping site will not greatly affect the emission energy for the complex. Related molecules can be designed in which electron carriers are trapped remoted to the L 2 Ir system.
[0237] As found in the IrL 3 system, the emission color is strongly affected by the L ligand. This is consistent with the emission involving either MLCT or intraligand transitions. In all of the cases that we have been able to make both the tris complex (i.e., IrL 3 ) and the L 2 IrX complex, the emission spectra are very similar. For example Ir(ppy) 3 and (ppy) 2 Ir(acac) (acronym=PPIr) give strong green emission with a λ max of 510 nm. A similar trend is seen in comparing Ir(BQ) 3 and Ir(thpy) 3 to their L 2 Ir(acac) derivatives, i.e., in some cases, no significant shift in emission between the two complexes.
[0238] However, in other cases, the choice of X ligand affects both the energy of emission and efficiency. Acac and salicylanilide L 2 IrX complexes give very similar spectra. The picolinic acid derivatives that we have prepared thus far show a small blue shift (15 nm) in their emission spectra relative to the acac and salicylanilide complexes of the same ligands. This can be seen in the spectra for BTIr, BTIrsd and BTIrpic. In all three of these complexes we expect that the emission becomes principally form MLCT and Intra-L transitions and the picolinic acid ligands are changing the energies of the metal orbitals and thus affecting the MLCT bands.
[0239] If an X ligand is used whose triplet levels fall lower in energy than the “L 2 Ir” framework, emission from the X ligand can be observed. This is the case for the BTIRQ complex. In this complex the emission intensity is very weak and centered at 650 nm. This was surprising since the emission for the BT ligand based systems are all near 550 nm. The emission in this case is almost completely from Q based transitions. The phosphorescence spectra for heavy metal quinolates (e.g., IrQ 3 or PtQ 2 ) are centered at 650 nm. The complexes themselves emit with very low efficiency, <0.01. Both the energy and efficiency of the L 2 IrQ material is consistent “X” based emission. If the emission from the X ligand or the “IrX” system were efficient this could have been a good red emitter. It is important to note that while all of the examples listed here are strong “L” emitters, this does not preclude a good phosphor from being formed from “X” based emission.
[0240] The wrong choice of X ligand can also severally quench the emission from L 2 IrX complexes. Both hexafluoro-acac and diphenyl-acac complexes give either very weak emission of no emission at all when used as the X ligand in L 2 IrX complexes. The reasons why these ligands quench emission so strong are not at all clear, one of these ligands is more electron withdrawing than acac and the other more electron donating. We give the spectrum for BQIrFA in the Figures. The emission spectrum for this complex is slightly shifted from BQIr, as expected for the much stronger electron withdrawing nature of the hexafluoroacac ligand. The emission intensity from BQIrFA is at least 2 orders of magnitude weaker than BQIr. We have not explored the complexes of these ligands due to this severe quenching problem.
[0241] CBP was used in the device described herein. The invention will work with other hole-transporting molecules known by one of ordinary skill to work in hole transporting layers of OLEDs. Specifically, the invention will work with other molecules comprising a carbazole functionality, or an analogous aryl amine functionality.
[0242] The OLED of the present invention may be used in-substantially any type of device which is comprised of an OLED, for example, in OLEDs that are incorporated into a larger display, a vehicle, a computer, a television, a printer, a large area wall, theater or stadium screen, a billboard or a sign. | Organic light emitting devices are described wherein the emissive layer comprises a host material containing an emissive molecule, which molecule is adapted to luminesce when a voltage is applied across the heterostructure, and the emissive molecule is selected from the group of phosphorescent organometallic complexes, including cyclometallated platinum, iridium and osmium complexes. The organic light emitting devices optionally contain an exciton blocking layer. Furthermore, improved electroluminescent efficiency in organic light emitting devices is obtained with an emitter layer comprising organometallic complexes of transition metals of formula L 2 MX, wherein L and X are distinct bidentate ligands. Compounds of this formula can be synthesized more facilely than in previous approaches and synthetic options allow insertion of fluorescent molecules into a phosphorescent complex, ligands to fine tune the color of emission, and ligands to trap carriers. | 8 |
PRIORITY INFORMATION
This application is a continuation application claiming priority from U.S. patent application Ser. No. 10/443,489, filed on May 22, 2003, which claims the benefit of U.S. Provisional Application No. 60/384,601, filed on May 30, 2002.
FIELD OF THE INVENTION
The field of this invention is a seal for use in temperatures of over 300 degrees Fahrenheit and over 10,000 pounds per square inch (PSI) and more particularly a seal adapted for wireline use where insertion forces are limited.
BACKGROUND OF THE INVENTION
Currently, in downhole applications, there are different types of seals to handle high temperature and pressure applications. The present limits of service of these designs are roughly about 350 degrees Fahrenheit and about 13,500 PSI. Under more severe temperature or/and pressure conditions, the presently known designs have been tested and have failed to perform reliably.
Depending on the application, there are different types of seals for high temperatures or/and pressures. In the case of packers set in high temperature applications, U.S. Pat. No. 4,441,721 asbestos fibers impregnated with Inconel wire are used in conjunction with a stack of Belleville washers to hold the set under temperature extremes. Apart from packers or bridge plugs which require seal activation after placement in the proper position, there are other applications involving seals on tools that have to engage a seal bore receptacle downhole and still need to withstand these extremes of temperature and pressure. In many cases, the tool with the seal to land in a seal bore is delivered on wireline. This means that insertion forces are limited because minimal force can be transmitted from the surface through wireline. In these applications, the limited insertion force is a design parameter that has to be counterbalanced with the frictional resistance to insertion created by the interference of the seal in the seal bore. This interference is built into the design of the seal to allow sufficient contact with the seal bore after insertion for proper seal operation. Clearly if the interference is too great the insertion, particularly with a wireline, will become problematic. On the other hand, reducing the interference can result in seal failure under the proposed extreme conditions of pressure and temperature.
There are other design considerations for seals that engage a seal bore downhole. Clearly, on the trip downhole, the seal is exposed to mechanical contact with well tubulars or other equipment. The materials for the seal must be rugged enough to withstand such mechanical impacts as well as to withstand the temperatures and pressures anticipated in the downhole location.
These seals also need to control extreme pressure differentials in an uphole and a downhole direction. Such seals may be inserted and removed from several seal bores during their service life. The design has to be flexible enough to allow long service periods under such extreme conditions as well as the resiliency to allow removal and reinsertion without damage to the seal or the surrounding seal bore.
FIG. 1 illustrates the current commercially available seal that is promoted for severe duty applications. It illustrates a mirror image arrangement around a central adapter 16 . A pair of chevron packing rings 14 are disposed about the adapter 16 and outside of the rings 14 is a back-up v-ring 12 and outside of v-ring 12 is an end ring 10 to complete one half of the mirror image arrangement shown in FIG. 1 . The open portions of the v-shaped rings open toward the central adapter in an effort to position the rings to withstand pressure differentials from opposite directions. The rings are made of materials suitable for the anticipated temperatures. Tests at pressure extremes of over 13,500 PSI and temperatures above 350 degrees Fahrenheit revealed that this design was unsuitable for reliable service.
In an effort to improve on the performance of the seal shown in FIG. 1 , the design of FIG. 2 was tried. It featured a central o-ring 18 surrounded by a pair of center adapters 20 . On either side of the center adapters 20 the arrangement was similar to FIG. 1 except that the orientation of the v-shaped opening were now all away from the central o-ring 18 rather than towards each other as had been the case in the design of FIG. 1 . Additionally, there was an alternating pattern of material in the rings 22 and 24 of FIG. 2 as compared to the stacking of rings 14 of a like material as shown in FIG. 1 . This design of FIG. 2 showed improved performance in high temperature and pressure conditions but was not to be the final solution. The present invention, an illustrative example of which is discussed in the preferred embodiment below, addresses the temperature and pressure extremes while allowing for insertion using a wireline. It features an internal spring mechanism and a feature that prevents collapse of the spring and the sealing elements under extreme conditions. The opposing members in the assembly are also prevented from engaging each other under extreme conditions. The collapse-preventing feature also has a beneficial aspect of seal centralization as the seal is inserted into the seal bore. Those skilled in the art from a review of the description of the preferred embodiment below and the claims that appear thereafter will readily understand these and other beneficial features of the present invention.
SUMMARY OF THE INVENTION
A seal for use in temperature and pressure extremes is disclosed. It features springs internal to the sealing members and the ability to seal against pressure differentials from opposed directions. A spacer ring prevents contact from oppositely oriented seal components and at the same time prevents spring and seal collapse under extreme loading conditions. The seal assembly is self-centering in a downhole seal bore and can be used on tools delivered on wireline, where the insertion forces available are at a minimum. The seal can withstand pressure differentials in excess of 13,500 PSI and temperatures above 350 degrees Fahrenheit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a section view of a prior art seal for extreme temperature and pressure conditions;
FIG. 2 is an early version of the present invention developed by the inventors;
FIG. 3 is a section view of the seal of the present invention in a position before extreme temperature and pressure conditions are applied;
FIG. 4 is the view of FIG. 3 shown under fully loaded conditions; and
FIG. 5 is a view showing how the seal of the present invention would collapse if the central ring were to be omitted.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 3 , the seal S of the present invention is shown without the tool that it would be secured to. The seal bore into which the seal S is to be inserted is also omitted on the basis that those skilled in the art are readily familiar with downhole tools and seal bores into which seals such as seal S are inserted. For similar reasons, the surface wireline equipment and the wireline are omitted due to their familiarity to the person skilled in this art. It should be noted that seal S can be used on a subsurface safety valve that can be delivered on wireline. This is only the preferred use and those skilled in the art will recognize that the seal S can be used with a broad variety of tools and delivered downhole in a variety of ways other than a wireline. Seal S is preferably used in applications of sealing in a seal bore downhole under conditions of high pressure and temperature differentials. Seal S can withstand differentials in pressure in either direction in excess of 13,500 PSI and temperatures well in excess of 350 degrees Fahrenheit.
The components will be described from the downhole end 26 to the uphole end 28 . A female adapter 30 has an uphole oriented notch 32 , which is preferably v-shaped. Located in notch 32 is a chevron shaped ring 34 with a notch 36 oriented in an uphole direction. Mounted in notch 36 is chevron shaped ring 38 with a notch 40 oriented in an uphole direction. Lower seal 42 sits in notch 40 and has an uphole oriented opening 44 in which is disposed one or more generally u-shaped spring rings such as 46 and 48 that are shown stacked on each other with their respective openings oriented uphole. Spring rings 46 and 48 are preferably mounted within opening 44 and in an abutting relation. Inserted into opening 44 and opening 52 of upper seal 54 is ring 50 . Ring 50 has a radial component 56 extending toward the downhole tool (not shown). Located preferably within opening 52 are stacked and abutting spring rings 58 and 60 , which are preferably identical to spring rings 46 and 48 except that they are disposed in a mirror image relation to them. In fact, the upper portion of the seal S above the ring 50 is the mirror image of the previously described components that are located below ring 50 . In the preferred embodiment going uphole or downhole from ring 50 the hardness of the rings going from seal 42 to ring 38 to ring 34 is progressively harder. The same goes for their mirror image counterparts, seal 54 , ring 62 , ring 64 , and female adapter 66 . The preferred material for the female adapters 30 and 66 is Inconel 718 . For ring 64 and its counterpart ring 34 the preferred material is virgin polyetheretherketone. For ring 62 and its counterpart ring 38 the preferred material is a PTFE (Teflon) with 20% polyphenylenesulfide and some carbon. The preferred material for the seals 42 and 54 is a PTFE (Teflon) flourocarbon base with 15% graphite.
Seals 42 and 54 could have one ore more interior 68 or exterior 70 notches to promote sealing contact with the tool (not shown) and the seal bore (not shown) respectively. These notches promote some flexibility in response to pressure or thermal loads.
The operation of the seal S under a pressure differential from uphole is illustrated in FIG. 4 . Arrow 72 represents such pressure from uphole going around seal 54 because its opening 52 is oriented downhole. The wings 74 and 76 flex toward each other responsive to the pressure differential. The seal 54 is moved with respect to ring 50 . This movement allows the spring rings 58 and 60 to become more nested and to apply a greater spread force against wings 74 and 76 . However, ring 50 also prevents collapse of spring rings 58 and 60 because the described movement has resulted in positioning ring 50 in the openings defines by generally u-shaped spring rings 58 and 60 . For that same reason, wings 74 and 76 are prevented from collapse toward each other. Meanwhile, the pressure represented by arrow 72 enters opening 44 with the result that ring 50 is pushed into spring rings 46 and 48 to not only splay apart the wings 78 and 80 but also to keep such wings from collapsing and permanently deforming due to movement of ring 50 into the openings defined by nested spring rings 46 and 48 . Ring 50 pushes the spring rings 46 and 48 into a more nested relation but at the same time, its presence in their openings prevents collapse of not only spring rings 46 and 48 but also of wings 78 and 80 to their immediate exterior. Another benefit of ring 50 is that it is of the appropriate length to prevent wings 74 and 76 from contacting wings 78 and 80 under maximum loading conditions. Contact at such high temperatures and pressures could fuse the wings together with a seal failure being a possibility. This is illustrated in FIG. 5 where the ring 50 has been eliminated and wings 74 and 76 have contacted wings 78 and 80 . The spring rings in FIG. 5 have all buckled and are permanently deformed. This seal is likely to be in failure mode.
Another advantage of having the ring 50 is that upon insertion of the downhole end of seal S into a seal bore, ring 50 adds some rigidity to that portion of seal S already inserted into the seal bore to act as a centralizer for the remaining portions of seal S to facilitate its insertion without damage. Radial component 56 also helps in the centralizing function for insertion of seal S into a seal bore (not shown).
Those skilled in the art will appreciate that while FIG. 4 illustrates a pressure differential from uphole that the response of seal S to a differential pressure from downhole is essentially the mirror image of what was described as the situation in FIG. 4 . The design of seal S is unique in high temperature and pressure service and one such feature is the internal spring component. While spring rings having a generally u-shaped cross-section have been illustrated other cross-sectional shapes for the spring rings are contemplated as long as the response is to splay out the wings while exhibiting resiliency to return to a neutral position when the extreme pressure or temperature conditions are removed. The use of a separation ring to keep the wings apart and to prevent their collapse and the collapse of the spring rings inside them allows the seal S to withstand cycles of temperature and pressure extremes and continue to be serviceable. The placement of the components in a nesting relation in conjunction with ring 50 and radial component 56 helps to centralize seal S with respect to the downhole tool to which it is mounted as well as to facilitate its insertion into a seal bore. This is because the downhole end 26 , upon entering the seal bore centralizes the seal S so that the rest of it is simply advanced into the seal bore without damage.
While the seal S is ideal for high pressure and temperature applications, it can also be serviceable in less severe environments and can be delivered into a seal bore by a variety of conveyances such as coiled tubing, rigid pipe as well as wireline, among others. Its construction makes it easily insertable in a wireline application, when minimal force is available get the seal S into the seal bore.
The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape and materials, as well as in the details of the illustrated construction, may be made without departing from the spirit of the invention. | A seal for use in temperature and pressure extremes is disclosed. It features springs internal to the sealing members and the ability to seal against pressure differentials from opposed directions. A spacer ring prevents contact from oppositely oriented seal components and at the same time prevents spring and seal collapse under extreme loading conditions. The seal assembly is self-centering in a downhole seal bore and can be used on tools delivered on wireline, where the insertion forces available are at a minimum. The seal can withstand pressure differentials in excess of 13,500 PSI and temperatures above 350 degrees Fahrenheit. | 4 |
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to a method of making seals including a sealing lip of low friction material which is adapted to engage a relatively moveable part. More specifically, the invention relates to a method of molding an oil seal wherein a wafer of low friction material and a seal case are clamped against a portion of a mold by rings of elastomeric material while the elastomeric material is molded to form the body of the oil, or shaft, seal.
2. Prior Art
Oil seals are used in many different types of machinery to seal lubricated areas of relatively moveable parts. A high quality oil seal should exert a minimum of friction between moveable parts and must be capable of forming a tight seal even after extended periods of use. Polytetrafluoroethylene (PFTE) or other low friction material is sometimes used at the sealing lip of a seal for long wear and its low friction characteristics. However, since PTFE is a stiff material it is often desireable to use it in combination with an elastomeric backing material which is flexible enough to compensate for some misalignment of the seal or shaft runout.
A shaft seal is a frequently used type of oil seal which is installed in a bore to seal against a rotating shaft. Shaft seals having a sealing lip of low friction material secured to a rigid case by means of an elastomeric material are precision parts manufactured to close tolerances. The sealing lip and rigid case must be accurately located to assure satisfactory seal performance.
Holding a wafer of low friction material in a mold as it is formed during the molding operation has always been a problem in the manufacture of such a seal. Similarly, establishing the location of the rigid case within the mold can be difficult when the outer diameter of the case is to be covered with elastomeric material during the same molding process.
Various methods of molding shaft seals having a lip made of low friction material are known in the prior art. However, prior art methods frequently fail to locate the wafer of low friction material precisely relative to the case, especially when the seal case includes an elastomeric outer diameter.
One such prior art method is disclosed in U.S. Pat. No. 4,171,561 to Bainard wherein a wafer of low friction material is secured to a rigid metal case by a molded elastomeric material. In the Bainard seal, the metal case is not positively located during the molding operation. Consequently, the metal case may be lifted by the elastomeric material during the molding operation thereby preventing the metal case from being precisely located relative to the sealing lip in the finished product.
Another prior art method of molding a shaft seal having a low friction lip is disclosed in U.S. Pat. No. 4,159,298 to Bainard in which a transfer mold is used to make a seal having an annular metal case and a polytetrafluoroethylene (PTFE) sealing element bonded together with elastomeric material. The metal case is held in place during the molding operation by a plurality of support pins that may become worn or distorted in time, resulting in the expense of frequent inspection and replacement. The pins also create bare spots on the metal case which may be objectionable under certain circumstances. In addition, the annular PTFE wafer is not held in place during the molding operation, making it subject to migration during molding.
A prior art method of molding a seal having an elastomer coating on the outer diameter is disclosed in U.S. Pat. No. 4,006,210 to Denton. However, the Denton molding apparatus and process yields a seal in which the location of the seal lip and case are subject to substantial variation in location relative to one another. In the Denton seal design the PTFE wafer is held directly against the metal case without intermediate elastomer for providing adequate flexibility to compensate for shaft run out or variation in the location of the seal lip relative to the metal case.
In summary, none of the methods shown in the above patents positively preclude migration or mislocation of the metal case or PTFE wafer. It is to this end that the present invention is directed.
SUMMARY OF THE INVENTION
The present invention relates to a method of molding a seal in which two separate elastomeric prep rings are used to form the body of the seal interconnecting the seal case with the wafer of low friction material. During the molding operation, one prep ring of elastomeric material flows across one side of the wafer as the other prep ring flows across one side of the case to encase it in elastomeric material. The prep rings flow together in the flex section of the seal to form a unitary elastomeric body for the seal.
During the molding operation, the first prep ring is held against the metal case between the upper and lower portions of the mold. Similarly, the second prep ring and wafer of low friction material are held together by the upper and lower portions of the mold during the molding operation. The portion of the mold engaging the wafer of low friction material preferably has concentric ridges or other gripping means for holding the wafer in place during the molding operation.
The wafer and elastomeric material are trimmed subsequent to the molding operation to create a precisely located and well defined seal lip. The seal lip is cut by rotating the seal on a spindle and cutting the low friction material and elastomeric material from the wafer side with a knife to form a clean edge on the seal.
It is therefore an object of the present invention to provide a method of molding an oil seal having a wafer of low friction material and a rigid case which are held against part of the mold by first and second rings of elastomeric material throughout the molding operation. The method of the present invention consistently produces a seal of high quality with the wafer of low friction material and rigid case being precisely located relative to one another throughout the molding operation and in the final oil seal. The seal may also be provided with a molded elastomeric outer diameter without any loss in accuracy.
Another object of the present invention is to eliminate the need for support pins in the mold to hold the rigid case and the wafer of low friction material during the molding operation. This feature reduces the cost of the mold and also reduces the complexity of the mold.
These and other advantages will be better understood after studying the following detailed description and claims in view of the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial cross-sectional view through a mold used in manufacturing a shaft seal showing the location of the component parts of the seal prior to molding in accordance with the invention.
FIG. 2 is a partial cross-sectional view of a mold during the molding operation showing the flow of the elastomeric material.
FIG. 3 is a partial cross-sectional view of a molded seal prior to the final trimming operation.
FIG. 4 is a partial cross-sectional view of one type of seal made in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, one form of the seal 10 is shown in FIG. 4. The seal 10 includes a case 12 which is a cup shaped annular member preferably press formed from steel. The seal 10 has a lip portion 13 of low friction material having a sealing lip 14 which is adapted to engage a shaft. Hydrodynamic pumping elements 15 may be provided on the lip portion 13 to improve the seal performance. The low friction material is preferably a wafer of sintered polytetrafluoroethylene (PTFE). The seal 10 includes an elastomeric body 16 which is molded to and interconnects the case 12 and lip portion 13. An annular coil spring 17 is shown in the disclosed embodiment disposed within an annular molded groove 50 within the elastomeric body 16 for holding the lip 14 in engagement with the shaft. The portion of the elastomeric body interconnecting the case 12 and lip portion 13 is commonly referred to as a flex section 18.
In the disclosed embodiment the seal 10 is a shaft seal having an internal sealing lip 14 adapted to engage a shaft. However, it should be realized that the method may be applied to other types of seals, such as bore seals having an external sealing lip adapted to contact the internal diameter of a bore.
The apparatus used in practicing the present invention, as shown in FIGS. 1 and 2, comprises a mold cavity, generally indicated by the reference numeral 19, formed in a mold, generally indicated by the reference numeral 20. The mold 20 comprises a lower die 21 defining the lower surface of the mold cavity 19, an insert 22 defining the outer perimeter of the mold cavity 19, and an upper die 23 defining the upper portion of the mold cavity 19. The upper die 23 in the disclosed embodiment is moveable relative to the lower die 21 and insert 22 to permit the mold 20 to be opened and closed. If a hydrodynamic pumping element 15 is called for on a seal, the lower most frustoconical portion 24 of the upper die 23 which forms the lip portion 13 during molding may include one or more molding elements 25 for forming the hydrodynamic pumping element 15.
In the embodiment shown in the drawings the hydrodynamic pumping element 15 is a helical groove or ridge. As a shaft rotates relative to the seal 10, any oil located between the shaft and the seal would be moved away from the sealing lip 14 by the hydrodynamic pumping element 15. As an alternative, a plurality of flutes or vanes may be formed near the lip 14 to accomplish the same function as is well known in the art.
Referring now to FIG. 1, loading the seal components into the mold 20 will be explained in detail. The following steps may be performed in any one of several sequences or may be performed simultaneously, depending on the skill or preference of the mold machine operator. The case 12 is loaded into an upper portion 31 of the mold cavity 19 so that the radial flange 26 rests upon the top surface 27 of the lower die 21. The cylindrical flange 28 of the case 12 is sized such that flange 28 closely abuts the surface 29 of the lower die 21 about its circumference.
The first prep ring 32 is then laid upon the upper side of the radial flange 26 in the upper portion 31 of the mold cavity 19. The first prep ring 32 is preferably an annular member formed of uncured elastomeric material.
The second prep ring 35 which is an annular ring of uncured elastomeric material of the same or compatible material as that of the first prep ring is placed in the lower portion 36 of the mold cavity 19.
A ring shaped wafer 38 of PTFE is then placed on top of the second prep ring so that its lower side 39 contacts the second prep ring 35.
It should be understood when studying the drawings that the elements of the seal 10 and mold 20 are annular members which are shown in partial cross-section. The cylindrical flange 28 of the case 12 is therefore initially located on the cylindrical surface 29 of the lower die 21. The wafer 38 is located in the lower portion of the cavity 19 and is centered on the frustoconical surface 40 of the lower die 21 at a height determined by the thickness of the second prep ring 35. The case 12 and wafer 38 are thereby precisely located by the die 20 prior to the molding operation.
Referring to FIG. 2, the molding step of the present invention will be described. After the case 12, wafer 38, and first and second prep rings 32, 35 have been loaded into the mold cavity 19, the mold 20 is ready for the molding step. The rubber molding die 20 is preferably preheated to a temperature sufficient to melt and cure the elastomeric material of the first and second prep rings 32 and 35. Initially, the upper die 23 is caused to move toward the lower die 21 and insert 22 to force the first prep ring 32 against the upper side 33 of the radial flange 26. Simultaneously, the upper die 23 is caused to press the wafer 38 against the second prep ring 35. As the upper die 23 continues its movement the first and second prep rings 32 and 35 are caused to flow and fill the remaining open portion of the cavity 19. The first prep ring 32 flows along the cylindrical flange 28 to form the outer diameter 41 of the finished seal 10 and along the upper side 33 of the radial flange 26 toward the second prep ring 35 and wafer 38. Simultaneously, the second prep ring 35 flows across the lower side 39 of the wafer 38 filling the lower portion 36 of the mold cavity 19 including a portion located between the case 12 and lip portion 13. In some dies excess elastomeric material may overflow to form a thin flash portion 42 between the upper die 23 and lower die 21 or insert 22 in the space identified by the numeral 44 which is subsequently trimmed off.
During the molding operation the wafer 38 is held by a plurality of concentric ridges 43 formed in the upper die 23. The concentric ridges 43 in the disclosed embodiment have a saw tooth configuration which partially deforms and securely grips the wafer 38. The wafer 38 is deformed by reason of the heat and pressure of the upper die 23 acting thereon.
It will be noted that during the molding operation the first prep ring 32 holds the case 12 firmly against top surface 27 of the lower die 21 to prevent elastomeric material from being forced between the case 12 and lower die 21. This prevents the elastomeric material from lifting the case 12 off of the top surface 27 by hydraulic pressure acting on the lower surface of the flange 26. In this regard, it is important that the portion of flange 26 supported by the top surface 27 is substantial and preferably greater than the unsupported portion of flange 26. This assures accurate location of the metal case 12 in the finished seal 10.
The second prep ring 35 holds the wafer 38 firmly against the upper die to prevent elastomeric material from flowing between the upper die 23 and the wafer 38 during the molding operation. As a result, the upper side of the wafer 38 remains free of elastomeric material. This is a desirable object of the present invention since elastomeric material on the lip 14 of the finished seal could reduce the efficiency of the seal by creating additional friction between the seal lip 14 and the shaft, and also by interfering with the sealing function of the lip 14.
As the second prep ring 35 flows against the wafer 38, the wafer 38 is forced into engagement with the frustoconical portion 24 of upper die 23. The frustoconical portion 24 may include one or more mold elements 25 comprising protrusions or cavities for forming one spiral groove or a plurality of flutes which act as hydrodynamic elements 15 on the finished lip portion 13 to improve the sealing capability of the seal 10.
The upper die 23 continues moving downwardly until the mold cavity 19 defines the desired shape of the finished seal 10. Upon upper die 23 reaching this final position, the mold cavity 19 remains closed until the seal is fully cured, following which the upper die 23 is opened and the seal may be removed from the die 20.
The seal is then placed on a rotatable spindle (not shown) and rotated as a knife 48, as shown in FIG. 3, cuts the wafer 38 and elastomeric body 16 at the lip portion 13 to form the lip 14. The lip 14 thus formed is smooth and substantially free of any irregularity. Since the knife enters from the wafer side of the seal 10 any ragged edges caused by entry of the knife 48 into the seal form on the elastomeric side of the seal 10.
An important feature of the present invention is the sizing of the first and second preps so that they flow together and merge in a non-critical area such as the flex section 18 as described. For example, if the first and second prep rings 32 and 35 were to flow together at the lip portion 13, part of the first prep ring 32 could possibly flow between the wafer 38 and the upper die 23. Likewise, if the second prep ring 35 was sized to merge with the first prep ring 32 adjacent the case 12, the second prep ring 35 could flow between the case 12 and the top surface 27 of the lower die 21.
The foregoing is a description of one embodiment of the present invention and should be read as being exemplary and is not to be construed in a limiting sense. | A method of making a seal of the type which includes a rigid case, a first seal portion of an elastomeric material and a second seal portion of a low friction material. The method includes placing the rigid case, a wafer of low friction material and two elastomeric blanks into a mold, closing the mold to maintain the aforementioned case, blanks and wafer in position and thereafter further closing the mold to form the seal. | 8 |
CROSS REFERENCE
This application claims the benefit of European patent application No. EP 11305185.8, filed Feb. 22, 2011 and the benefit of PCT patent application No. PCT/EP2012/052668, filed Feb. 16, 2012, the respective contents of which are hereby incorporated by reference in their entirety.
FIELD OF THE INVENTION
The invention relates to the technical field of optical communication systems using polarization division multiplexing, and in particular to the transmission of optical packets or bursts.
BACKGROUND
The association of optical packet transmission with polarization division multiplexing (PDM) is receiving attention for the development of high data-rate, highly flexible communication systems. Coherent receivers have been originally designed for optical circuit connections. The convergence time of a conventional polarization demultiplexing algorithm takes typically a few thousand symbols. In packet transmission, every packet has its own state of polarization (SOP). Repeating the conventional convergence process for each and every packet would consume a large amount of the bandwidth.
EP-A-2273700 teaches methods for speeding up convergence of a polarization demultiplexing filter in a coherent receiver adapted to optical packet reception. These methods involve the generation of optical packets comprising a header section including a single-polarization optical signal and a payload section including a polarization division multiplexed optical signal. To generate such an optical packet, EP-A-2273700 teaches methods that require turning on and off the drivers of MZ modulators and changing the bias of Mach-Zehnder (MZ) modulators at a very high speed between the header section and payload section.
SUMMARY
In an embodiment, the invention provides a method for transmitting digital data on an optical channel, comprising:
generating first and second baseband digital signals, modulating a first polarized optical carrier wave component in accordance with the first baseband digital signal, modulating a second polarized optical carrier wave component in accordance with the second baseband digital signal, wherein the second polarized optical carrier wave component has an orthogonal state of polarization to the first polarized optical carrier wave component and combining the first and second modulated optical carrier wave components into a propagation medium, wherein the first and second baseband digital signals are generated in a correlated manner, so that the modulated optical carrier wave components are combined as a modulated single-polarization optical carrier wave.
According to embodiments, such a method may comprise one or more of the features below:
the first and second baseband digital signals are equal or opposite. the first polarized optical carrier wave component and the second polarized optical carrier wave component have a linear polarization state and the resulting single-polarization optical carrier wave also has a linear polarization state. Alternatively, the polarized optical carrier wave components may have other states of polarization, e.g. circular. the polarized optical carrier wave components are phase-modulated. the phase modulation is a QPSK modulation. the modulating is performed with Mach-Zehnder modulators.
In an embodiment, the invention also provides a method for generating an optical packet on an optical channel, the optical packet comprising a header section including a single-polarization optical signal and a payload section including a polarization division multiplexed optical signal, the method comprising:
generating the single-polarization optical signal of the header section with the above method, wherein first portions of the first and second baseband digital signals are generated in a correlated manner to obtain the single-polarization optical signal of the header section, and generating second portions of the first and second baseband digital signals in an essentially uncorrelated manner to obtain the polarization division multiplexed optical signal of the payload section.
In an embodiment, the method further comprises changing an operating mode of a baseband signal generation module between the generating of the header section and the generating of the payload section.
In an embodiment, the method further comprises generating a second single-polarization optical signal of the header section with a similar method, wherein third portions of the first and second baseband digital signals are generated in a correlated manner with a different correlation from the first portions of the baseband digital signals, so as to obtain the second single-polarization optical signal of the header section in a polarization state orthogonal to the polarization state of the first single-polarization optical signal of the header section.
In an embodiment, the invention also provides a optical transmitter for generating polarization division multiplexed optical signals, comprising:
a baseband signal generation module for generating first and second baseband digital signals, a first modulator for modulating a first polarized optical carrier wave component in accordance with the first baseband digital signal a second modulator for modulating a second polarized optical carrier wave component in accordance with the second baseband digital signal, wherein the second polarized optical carrier wave component has an orthogonal polarization to the first polarized optical carrier wave component, and an optical combiner for combining the first and second modulated optical carrier wave components into a propagation medium, wherein the baseband signal generation module is adapted to operate in first and second operating modes, wherein the baseband signal generation module in the first operating mode generates the first and second baseband digital signals in a correlated manner so that the modulated optical carrier wave components are combined as a modulated single-polarization optical carrier wave in the propagation medium and, wherein the baseband signal generation module in the second operating mode generates the first and second baseband digital signals in an essentially uncorrelated manner so that the modulated optical carrier wave components are combined as a polarization division multiplexed optical signal.
In an embodiment, the optical transmitter further comprises a packet forming module for forming the first and second polarized optical carrier wave components as an optical packet.
In an embodiment, the invention also provides a optical transmitter for generating polarization division multiplexed optical signals, comprising:
a baseband signal generation module for generating first and second baseband digital signals, a first modulator for modulating a first polarized optical carrier wave component in accordance with the first baseband digital signal a second modulator for modulating a second polarized optical carrier wave component in accordance with the second baseband digital signal, wherein the second polarized optical carrier wave component has an orthogonal polarization to the first polarized optical carrier wave component, and an optical combiner for combining the first and second modulated optical carrier wave components into a propagation medium, a first optical gate selectively operable in a passing state for passing the first polarized optical carrier wave component to the optical combiner or in a blocking state for blocking the first polarized optical carrier wave component, and a gating controller adapted to switch the first optical gate between the blocking state and the passing state to obtain a transmitted optical signal in the propagation medium selected in the group consisting of the second polarized optical carrier wave component alone and the combination of the first and second polarized optical carrier wave components.
According to embodiments, such an optical transmitter can comprise one or more of the features below:
a second optical gate selectively operable in a passing state for passing the second polarized optical carrier wave component to the optical combiner or in a blocking state for blocking the second polarized optical carrier wave component, wherein the gating controller is adapted to also switch the second optical gate between the blocking state and the passing state to obtain a transmitted optical signal in the propagation medium selected in the group consisting of the first polarized optical carrier wave component alone, the second polarized optical carrier wave component alone and the combination of the first and second polarized optical carrier wave components.
the gating controller is adapted to switch the optical gates so as to form an optical packet comprising a header section including a single-polarization optical signal and a payload section including a polarization division multiplexed optical signal. the or each optical gate comprises a semiconductor optical amplifier.
Aspects of the invention stem for the observation that changing the bias of MZ modulators at a high-speed may generate undesirable transients likely to impose severe limitations on the quality of the modulated optical signals.
Aspects of the invention are based on the idea of operating PDM optical transmitters to selectively generate single-polarization or dual-polarization optical signals without changing the bias of MZ modulators.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments described hereinafter, by way of example, with reference to the drawings.
FIG. 1 is a functional representation of PDM optical transmitter in accordance with a first embodiment.
FIG. 2 is a schematic representation of an optical packet that can be obtained with the transmitter of FIG. 1 .
FIG. 3 is a functional representation of PDM optical transmitter in accordance with a second embodiment.
DETAILED DESCRIPTION OF THE EMBODIMENTS
With reference to FIG. 1 , an optical transmitter 1 adapted to generate a PDM optical signal is schematically shown. Transmitter 1 comprises a laser source 2 to generate an optical carrier wave at a selected wavelength suitable for WDM transmissions. A beam splitter 3 splits the optical carrier wave into two carrier wave components propagating in respective waveguides 4 and 5 . A respective optical modulator 6 and 7 is arranged on each of the waveguides 4 and 5 to impart a modulation on the corresponding carrier wave component as a function of respective baseband signals 11 and 12 , which are generated by a baseband signal generator 10 at the same data-rate. Optical modulators 6 and 7 may be any type of modulators. In a preferred embodiment, optical modulators 6 and 7 are MZ modulator arrangements adapted to generate PSK modulations, e.g. Binary Phase-Shift Keying or Quaternary Phase Shift Keying. Such arrangements are known in the art. In particular, the baseband signals 11 and 12 may comprise NRZ-coded signals driving MZ modulators so that each signal transition causes a 90° or 180° phase-shift in a corresponding carrier wave component.
At the output of waveguides 4 and 5 , a polarization beam combiner 8 selects an x-polarized component of the modulated carrier wave component coming from waveguide 4 and a y-polarized component of the modulated carrier wave component coming from waveguide 5 and superposes both polarized components into an output waveguide 9 , e.g. an optical fiber connected to a communications network. As used herein, x and y refer to two orthogonal states of polarization defined by the physical structure of the polarization beam combiner 8 , as known in the art.
In FIG. 1 , the modulated carrier wave component coming from waveguide 4 is denoted by E in,x and the corresponding baseband signal 11 is denoted by x-data. In FIG. 1 , the modulated carrier wave component coming from waveguide 5 is denoted by E in,y and the corresponding baseband signal 12 is denoted by y-data.
As a result, the optical signal Ê transmitted in the output waveguide 9 can be expressed as:
Ê=Ê in,x {circumflex over (x)}+E in,y ŷ, (1)
where ^ denote a vector.
In ordinary PDM transmissions, this principle is used to transfer essentially independent streams of data on the respective field components E in,x and E in,y so as to substantially double the data-rate compared to a single-polarization transmission at the same baseband rate. As a result, the SOP of the output optical signal Ê keeps changing and the instantaneous SOP depends on the data-streams x-data and y-data at any given instant.
However, it is observed that when the data-streams are equal, Eq. (1) can be rewritten:
Ê=E in,x ( {circumflex over (x)}|ŷ ), (2)
i.e. the SOP of the output signal Ê is constant and the output signal Ê is a linearly polarized field along direction {circumflex over (x)}+ŷ.
In the same manner, it is observed that when the data-streams are mutually opposite, Eq. (1) can be rewritten:
Ê=E in,x ( {circumflex over (x)}−ŷ ), (3)
i.e. the SOP of the output signal Ê is constant and the output signal Ê is a linearly polarized field along direction {circumflex over (x)}−ŷ.
Therefore, it is observed that optical transmitter 10 can be operated to generate a single polarization signal along direction {circumflex over (x)}+ŷ or a single polarization signal along direction {circumflex over (x)}−ŷ or a dual-polarization optical signal just by changing the binary content of the baseband signals 11 and 12 without modifying the operating point of the modulators 6 and 7 .
The above principle can be exploited to generate optical packets having a PDM payload preceded by a single-polarization header intended to speed-up convergence of a polarization demultiplexing filter in a coherent receiver, as known in the art. The packet header may include one single-polarization section or two different single-polarization sections having orthogonal SOPs. In addition, a PDM header section can be added to refine filter convergence at the receiver before the payload is received. An embodiment of such a packet header 20 with three sections is schematically shown on FIG. 2 as a function of time.
In FIG. 2 , header section 21 comprises a linearly polarized field along direction {circumflex over (x)}+ŷ, header section 22 comprises a linearly polarized field along direction {circumflex over (x)}−ŷ, whereas 23 denotes a PDM header section. Alternatively, PDM section 23 can be a packet payload. It will be appreciated that the only operation required in the transmitter 10 between each subsequent header section or between the packet header and packet payload amounts to changing the binary content of baseband signals 11 and 12 . Such change is made in the electrical domain and can be performed at a very high speed without creating impairments in the optical signal. In addition, by superimposing both correlated field components, it will be appreciated that a resulting output power and OSNR are improved compared to a single field component.
To generate the optical signal Ê in the form of optical packets, optical transmitter 10 may comprise a packet shaper (not shown) in the form of a semiconductor optical amplifier (SOA) or other optical gate arranged within laser source 2 , between laser source 2 and beam splitter 3 or at any other suitable location.
Turning now to FIG. 3 , there is shown another embodiment of an optical transmitter 101 adapted to selectively generate single-polarization and dual-polarization signals, in particular in the form of optical packets. Elements which are similar or identical to the embodiment of FIG. 1 are designated by the same numeral increased by 100.
In the transmitter 101 , SOAs 30 and 40 are mounted on the waveguides 104 and 105 respectively. Each SOA 30 and 40 is operated as an optical gate under the control of a gating controller 50 to selectively extinguish the corresponding carrier wave component or pass it to the polarization beam combiner 108 .
To generate an optical packet having a similar structure to that of FIG. 2 , the gating controller 50 controls the switching state of the SOAs as follows:
For the first header section 21 , SOA 40 is in the blocking state and SOA 30 is in the passing state. The resulting first header section 21 is now polarized along direction {circumflex over (x)} instead of {circumflex over (x)}+ŷ. In this header section, it is only necessary to generate baseband signal 111 , whereas baseband signal 112 is obviously unnecessary and ineffective. For the second header section 22 , SOA 30 is in the blocking state and SOA 40 is in the passing state. The resulting second header section 22 is now polarized along direction ŷ instead of {circumflex over (x)}−ŷ. In this header section, it is only necessary to generate baseband signal 112 , whereas baseband signal 111 is obviously unnecessary and ineffective. For the third header section 23 and/or payload, SOAs 30 and 40 are both in the passing state. To terminate the current optical packet and create a guard band before a subsequent optical packet, SOAs 30 and 40 are both switched in the blocking state.
Alternatively, optical gates other than SOAs can be arranged and controlled in the same manner as SOAs 30 and 40 , such as silicon photonics optical gates.
In the example shown, the modulators 106 and 107 are QPSK modulators comprising two arms, an MZ modulator in each arm and a 90°-phase shift in the lower arm. Other types of modulators can be used in the same manner.
In PDM transmissions, x-data and y-data are generated as independent data streams that do not have a long-lasting correlation. However, coding techniques and protocol functions can create temporary correlations between signals, i.e. as a result of redundancy coding, frame retransmissions, etc.
Elements such as the control units and signal generation modules could be e.g. hardware means like e.g. an ASIC, or a combination of hardware and software means, e.g. an ASIC and an FPGA, or at least one microprocessor and at least one memory with software modules located therein.
The invention is not limited to the described embodiments. The appended claims are to be construed as embodying all modification and alternative constructions that may be occurred to one skilled in the art, which fairly fall within the basic teaching here, set forth.
The use of the verb “to comprise” or “to include” and its conjugations does not exclude the presence of elements or steps other than those stated in a claim. Furthermore, the use of the article “a” or “an” preceding an element or step does not exclude the presence of a plurality of such elements or steps.
In the claims, any reference signs placed between parentheses shall not be construed as limiting the scope of the claims. | A optical transmitter and method for transmitting digital data on an optical channel, performing the steps of generating first and second baseband digital signals, modulating a first polarized optical carrier wave component in accordance with the first baseband digital signal, modulating a second polarized optical carrier wave component in accordance with the second baseband digital signal, wherein the second polarized optical carrier wave component has an orthogonal polarization to the first polarized optical carrier wave component and combining the first and second modulated optical carrier wave components into a propagation medium. The first and second baseband digital signals are generated in a correlated manner so that the modulated optical carrier wave components are combined as a modulated single-polarization optical carrier wave. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/368,866, filed Jul. 29, 2010, which application is hereby incorporated herein by reference, in its entirety.
TECHNICAL FIELD
[0002] The invention relates generally to the air quality of an enclosed space and, more particularly, to a system for introducing fresh air into an enclosed space, particularly a building or home.
BACKGROUND
[0003] Over the past forty years, the construction industry in the United States focused its efforts on improving occupant comfort in a finished building. A key way to increase occupant comfort involved the introduction of heating, ventilating, and air-conditioning (hereinafter “HVAC”) equipment on a large scale. This equipment allowed occupants to control the interior environment of the building so that the occupant could keep the interior building temperature in a range the occupant considered comfortable.
[0004] Unfortunately, this HVAC equipment increased energy consumption, which in turn increased the cost to own and operate the building. As a result, the construction industry and the HVAC industry began to research the causes behind the large energy consumption of HVAC equipment. The industries discovered that construction standards at the time allowed for air outside the building to seep into the building and conditioned air inside the building to seep out of the building. This seepage, or air exchange, necessitated that the HVAC equipment operate more frequently to keep the interior building temperature in the desired range. Increased operation meant increased energy consumption and increased costs to the building owner/occupant. To combat this, the construction industry has developed methods and practices during the last forty years to decrease the amount of air exchange, in effect the construction industry has developed methods to better seal buildings and decrease the amount of outside air seeping into the interior space.
[0005] A second cause for increased energy consumption related to the HVAC equipment itself. When first introduced, HVAC equipment drew air exclusively from the area outside of the building. The HVAC equipment would then cool or heat the air prior to exhausting the treated air into the interior building environment. The HVAC industry discovered that if the HVAC equipment instead drew air from the interior space, it required less energy to heat or cool the air to the desired temperature, thus reducing costs to building owner/occupant. Presently, HVAC equipment draws air almost exclusively from the interior building space, virtually eliminating the amount of non-recycled air introduced into the building's interior.
[0006] During the time period that buildings became better sealed and HVAC equipment more efficient, the United States has seen a significant increase in the incidence of obesity, diabetes, Alzheimer's, asthma, and birth defects, such as autism, as well as lower energy levels among the populace. This can be traced at least in part to exposure to decreased oxygen levels. In a sealed environment, occupants within the space are breathing air that has already been processed through the occupant's body. Thus, with each breath, the occupant in a sealed environment is reducing the amount of available oxygen. A reduction in available oxygen can lead to a decrease in body functions, causing the body to burn fewer calories and store more fat. Similarly, the reduction in the amount of available oxygen is known to exacerbate the symptoms of those suffering from mental illness and increase the instances of asthma. In addition, a reduction in available oxygen can cause mutations in a child's in utero development leading to conditions like autism.
[0007] Therefore, it would be desirable for a system to increase the amount of available oxygen in a building environment, thus helping to reduce obesity, diabetes, Alzheimer's, asthma and the risk of potential birth defects, alleviate the symptoms of mental illness, and increase energy levels of occupants of buildings, without reducing the efficiency of an HVAC system.
SUMMARY
[0008] The present invention, accordingly, provides a Fresh Air Recovery System comprising an intake opening in a first wall defining a portion of an enclosed space allowing air on an exterior side of the first wall to pass through the first wall into the enclosed space; and an exhaust opening in a second wall defining a portion of the enclosed space allowing air on an interior side of the second wall to pass through the second wall into an ambient environment.
[0009] 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
[0010] 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:
[0011] FIG. 1 exemplifies a perspective view of a building embodying features of the fresh air recovery system of the present invention;
[0012] FIG. 2 illustrates a plan view of the building of FIG. 1 ;
[0013] FIG. 3 illustrates an elevation view of the building of FIG. 1 ; and
[0014] FIG. 4 exemplifies a perspective view of an alternative building embodying features of the fresh air recovery system of the present invention.
DETAILED DESCRIPTION
[0015] In the following discussion, numerous specific details are set forth to provide a thorough understanding of the present invention. However, it will be obvious to those skilled in the art that the present invention may be practiced without such specific details. Additionally, for the most part, details concerning basic building construction and materials and the like have been omitted inasmuch as such details are not considered necessary to obtain a complete understanding of the present invention, and are considered to be within the skills of persons of ordinary skill in the relevant art.
[0016] Referring to FIG. 1 , there is shown a fresh air recovery system 10 having an exemplified by a building 100 defining an enclosed space 200 . The building 100 comprises at least a first wall 101 , a second wall 102 , a third wall 103 , a fourth wall 104 , a floor 105 , and a ceiling 106 , each defining a portion of the outer boundaries of the building 100 . The enclosed space 200 comprises a volume of air that is sealed from a volume of air existing outside of the enclosed space 200 . In the embodiment exemplified, air cannot pass between the enclosed space 200 and a space outside of the building 100 . As used herein, the term “sealed” implies a negligible (possibly zero) rate of air transfer across the outer boundaries of the building 100 such that an entity placed within the enclosed space 200 that relies upon oxygen respiration to survive will deplete the available amount of oxygen in the air contained within the volume of the enclosed space over time.
[0017] In accordance with principles of the present invention, the building 100 preferably includes a first opening 301 and a second opening 302 strategically positioned to facilitate maximum air flow through the entire space 200 . By way of example, and as exemplified in FIG. 1 , the first wall 101 further defines a first opening 301 preferably located proximate to the ceiling 106 and the third wall 103 . The second wall 102 further defines a second opening 302 preferably located proximate to the floor 105 and the fourth wall 104 . An electronically controlled vent 311 , preferably having varying states of being open between completely open and completely closed, fits within the first wall opening 301 such that movement of the vanes of the vent 311 may alternatively allow more or less air to pass through the first wall opening 301 between the area outside the building 100 and the enclosed space 200 . Similarly, an exhaust fan 312 fits within the second wall opening 302 such that operation of the exhaust fan 312 alternatively increases and decreases the volume of air passing from the enclosed space 200 to the area outside of the building 100 . The fan 312 is preferably configured to be operable at a variable speed. A person of ordinary skill in the art will understand that the locations of the first wall opening 301 and the second wall opening 302 may vary in order to maximize the air flow rate between the enclosed space 200 and the area outside the building 100 .
[0018] In a preferred embodiment, an electronic controller 300 is coupled to the vent 311 via electrical wires 304 and to the exhaust fan 312 via electrical wires 304 for controlling operation of each. The controller 300 is preferably configured for manual operation and/or automated operation utilizing a timer (preferably integrated into the controller), an oxygen sensor, a carbon dioxide sensor, humidity sensor, and/or an air pressure sensor. The oxygen sensor, carbon dioxide sensor, humidity sensor, and/or air pressure sensor are preferably positioned both the interior and exterior of the building 100 , preferably proximate to the vent 311 and/or wherever people generally reside or sleep, and are coupled to the controller 300 via wires 308 . The sensors positioned on the interior of the building 100 are designated collectively by the reference numeral 320 , and the sensors positioned on the exterior of the building 100 are designated collectively by the reference numeral 322 . While it is preferred that both interior and exterior sensors be used, the system is operable with only interior sensors, or even no sensors, and as discussed below, is operable manually.
[0019] In a first preferred embodiment, the exhaust fan 312 and the vent 311 are manually controlled via the controller 300 , necessitating that the operation of each device occur at the initiation of manual action. In a second preferred embodiment, the exhaust fan 312 and the vent 311 are electronically controlled by the timer coupled to the controller 300 that initiates the operation of the exhaust fan 312 and the vent 311 at timed intervals throughout a 24-hour period.
[0020] In a third preferred embodiment, the exhaust fan 312 and the vent 311 are electronically controlled by the oxygen sensors 320 and 322 coupled to the controller 300 that initiates operation, to the degree necessary, of the exhaust fan 312 and the vent 311 when the interior oxygen sensor 320 reads less than a preset level of oxygen within the volume of space where the oxygen sensor 320 is placed, and the exterior oxygen sensor 322 , if there is one, reads a higher level of oxygen.
[0021] In a fourth preferred embodiment, the exhaust fan 312 and the vent 311 are electronically controlled by the carbon dioxide sensors 320 and 322 coupled to the controller 300 that initiates operation, to the degree necessary, of the exhaust fan 312 and the vent 311 when the interior carbon dioxide sensor 320 reads more than a preset level of carbon dioxide within the volume of space where the carbon dioxide sensor is placed, and the exterior carbon dioxide sensor 322 , if there is one, reads a lower level of carbon dioxide.
[0022] In a fifth preferred embodiment, the exhaust fan 312 and the vent 311 are electronically controlled by the humidity sensors 320 and 322 coupled to the controller 300 that initiates operation, to the degree necessary, of the exhaust fan 312 and of the vent 311 when the interior humidity sensors sensor 320 reads more than a preset level of humidity within the volume of space where the carbon dioxide sensor is placed, and the exterior humidity sensor 322 , if there is one, reads a lower level of humidity.
[0023] In a sixth preferred embodiment, the exhaust fan 312 and the vent 311 are electronically controlled by the air pressure sensors 320 and 322 coupled to the controller 300 that initiates opening to the degree necessary of the vent 311 ( 1 ) to decrease air pressure when the interior air pressure is high and exterior air pressure is low, or (2) to increase air pressure if interior air pressure is low and exterior air pressure is high. Alternatively, if both interior and exterior air pressure are high, then the exhaust fan 312 may be activated to pass air from the interior to the exterior. If both interior and exterior air pressure are low, then the exhaust fan 312 may be activated in reverse to pass air from the exterior to the interior. The air pressure sensors 320 and 322 may be used in conjunction with other methods described herein to, for example, close a vent 311 before or after powering off a fan 312 as needed to maintain air pressure. A person of ordinary skill in the art will understand that the means for controlling the exhaust fan 312 and the vent 311 may alternatively use any of the above means in combination with one another such that the overall system operates as described below.
[0024] When operation is desired, e.g., a manual determination to operate the fresh air recovery system 10 is reached, a preset oxygen level is reached, a preset carbon dioxide level is reached, a preset time occurs, and/or a preset air pressure is reached, as discussed above, the vent 311 is activated so that outside air (i.e., air outside the building 100 ) may freely flow into the enclosed space 200 . In addition, the exhaust fan 312 is operated, preferably synchronously with the vent 311 , to draw air within the enclosed space 200 into the area exterior to the building 100 . Alternatively, operation of the exhaust fan 312 and the vent 311 may reverse the air flow, drawing outside air into the enclosed space 200 through the exhaust fan 312 and exhausting air through the vent 311 . Operation of the exhaust fan 312 and the vent 311 continues until the air within the enclosed space 200 is sufficiently exchanged with air outside the enclosed space 200 , e.g., a manual determination is made to cease operation, a preset oxygen level is reached, a preset carbon dioxide level is reached, and/or a preset time occurs. If the building 100 is equipped with HVAC, then the HVAC is preferably powered off while the vent 311 and fan 312 are operating.
[0025] FIG. 4 exemplifies an alternative embodiment of the invention in which building 400 comprises multiple rooms, exemplified as two rooms 410 and 412 . As shown, the building 400 is preferably provided with one fan 312 , but each room 410 and 412 is preferably provided with a respective vent 311 and 411 . The vent 311 is preferably provided with an oxygen sensor, a carbon dioxide sensor, humidity sensor, and/or an air pressure sensor, collectively designated with the reference numeral 320 for interior (of room 410 ) sensors, and collectively designated with the reference numeral 322 for exterior (of room 410 ) sensors, as described above. Similarly, the vent 411 is preferably provided with an oxygen sensor, a carbon dioxide sensor, humidity sensor, and/or an air pressure sensor, collectively designated with the reference numeral 420 for interior (of room 410 ) sensors, and collectively designated with the reference numeral 422 for exterior (of room 410 ) sensors, as described above. The fan 312 and vents 311 and 411 are controlled by the controller 300 manually or automatically from the respective sensors 320 , 322 for vent 311 , and sensors 420 and 422 for vent 411 . Similarly as described above with respect to FIG. 1 . A door 414 between the rooms allows for air to flow between the rooms. The door 414 may optionally have a raised lower edge to allow air flow even when the door is closed. In operation, the controller 300 runs the fan 312 while each vent 311 and 411 is sequentially opened and then closed, so that only one vent 311 or 411 is open at a time. In larger buildings, multiple fans 312 may be employed.
[0026] In further alternative embodiments, additional walls may exist within the enclosed space 200 defined by the outer boundaries of the building 100 . In these instances, additional openings may be placed within the interior walls to allow for free passage of air throughout the enclosed space 200 . A person of ordinary skill in the art will also understand that the first wall opening 301 and the second wall opening 302 may include filters and other media to inhibit the movement of undesired objects and allergens from passing into the enclosed space 200 . In addition, other embodiments may include multiple exhaust fans 312 and/or multiple vents 311 as needed to efficiently exchange air within the enclosed space for air outside the enclosed space. Still further, the fresh air recovery system of the present invention may be integrated into an otherwise conventional system that has ventilation already installed within the building 100 . Still further, the one or multiple exhaust fans 312 and one or multiple vents 311 may be electronically coupled via the wires 304 and 306 , or other means, such as a wireless connection, low voltage connection, or the like, so that, should other controls fail, operation of the one or multiple exhaust fans 312 is always synchronized with operation of the one or multiple exhaust fans 312 , so that relatively constant air pressure within the space 200 is maintained, the air pressure preferably being sensed by an air pressure sensor coupled with the controller 300 .
[0027] It may be appreciated that by implementing the present invention, many advantages over the conventional art is obtained. For example, the amount of available oxygen in a building environment is increased, thus helping to reduce obesity, diabetes, asthma, the risk of potential birth defects, and Alzheimer's, increase occupant energy levels, and alleviate the symptoms of mental illness. Moving a relatively large quantity of air through a building relatively quickly over a short period of time is much more efficient than having air slowly leaking in continuously through, e.g., cracks in window seals.
[0028] 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. Many such variations and modifications may be considered obvious and desirable by those skilled in the art based upon a review of the foregoing description of preferred embodiments. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention. | The present invention, accordingly, provides a fresh air recovery system preferably including at least one intake opening in a first wall defining a portion of an enclosed space allowing air on an exterior side of the first wall to pass through the first wall into the enclosed space; and at least one exhaust opening in a second wall defining a portion of the enclosed space allowing air on an interior side of the second wall to pass through the second wall into an ambient environment external to the enclosed space. | 5 |
This application claims priority to U.S. provisional application Ser. No. 60/002,866 filed Aug. 28, 1995.
______________________________________U.S. PATENTS______________________________________3,886,554 5/1975 Braun et al.4,054,881 10/1977 Raab4,298,874 11/1981 Kuipers4,314,251 2/1982 Raab4,346,384 8/1982 Raab4,328,548 5/1982 Crow et al.4,560,930 12/1985 Kouno4,622,644 10/1986 Hansen4,710,708 12/1987 Roden et al.4,7,28,959 3/1988 Maloney et al.4,742,356 5/1988 Kuipers4,737,794 4/1988 Jones4,777,329 10/1988 Mallicoat4,812,812 3/1989 Flowerdew et al.4,829,250 5/1989 Rotier4,951,263 8/1990 Shope4,922,925 5/1990 Crandall et al.5,109,194 4/1992 Cantaloube5,168,222 12/1992 Volsin5,315,308 5/1994 Nehorai et al.______________________________________
OTHER PUBLICATIONS
Articles:
Bryson, S. Measurement and Calibration of Static Distortion of Position Data from 3D trackers. 1992, pp.244-255 of SPIE Vol. 1669 Stereoscopic Displays and Application III.
Foxin, E. and Durlach, N., An Interial Head-Orientation Tracker with Automatic Drift Compensation for Use eith HMD'S. Proceedings of VRST-94 (Virtual Reality Siftwere Techology) World Scientific Publishing Co., River Ridge, 1994.
Raab, F. H., et al., Magnetic Position and Orientation Tracking System, IEEE Transactions on Aerospace and Electronic Systems. September 1979; pp. 709-717 of vol. AES-15, NO.5
SUMMARY
The field of position trackers is well established and growing, recent development of virtual reality equipment put an emphasis on a short range tracking sensors for helmet mounted display (HMD).
In addition these sensors have applications: in automobile crash testing where geometrical data has to be logged directly during the test and in the medical field of rehabilitation and injury claims where this device can track movement of the human body. The total list of possible uses of multi-dimensional tracking sensor is very diverse; animation, teleoperation, and training simulation are representatives of current uses. As the enabling technology becomes refined, applications will multiply.
The recent increases in performance and cost effectiveness of digital signal processing and data converter products have driven the feasibility of EM correlation techniques in the field of position tracking. The disclosed technique does not suffer from the obvious tradeoffs and built in limitations of other approaches. The range is limited only by the power of the transmitter and exceeds the requirements for current applications by several orders of magnitude. Also this method is not a subject to line-of-site restrictions, nor is the tracked unit restricted to certain (generally upright) orientations. A further advantage is a low latency due to the short time of flight for the signal. Metallic, ferrometallic, or CRT devices may be present near the tracked unit without causing significant interference. This robust technique can be employed in a wide variety of computer applications where known methods have limited uses.
BACKGROUND
The problem of creating at least three degree-of-freedom (3D) tracking devices is a long-standing one and publications have existed in this field for many years. There are a variety of original attempts to determine the position and movement of a target. The recent example is a global positioning system (GPS) where the signal received from at least four satellites can give the position of the receiver. Loran C operates on a similar principle that is based on ground deployed radio beacons. Over the course of time many tracking systems were developed to track moving vehicles. Most of them employ either directional antennas or they compare the phase of the arriving signal to the different parts of the multi-section antennas. While these systems perform well in their applications, either speed, accuracy or cost prohibits their employment in real time computer applications.
A large number of electromagnetic (EM) trackers are available for computer applications. Most of them are based on near field EM propagation. Polhemus Incorporated pioneered the field of AC magnetic trackers and holds many of patents since 1977. The Ascension Corporation has developed a novel design, a DC magnetic tracker that is less prone to interference from metal. A variety of ultrasonic trackers are also known. In the field of optical tracking the pioneering work done at the University of North Carolina has shown the efficacy of this method. Since that time mechanical devices and a combination of inertial-global positioning systems (MIT publication), have been developed to determine the position and orientation of the objects.
While research is still being conducted in all of these fields, these technologies are relatively mature. However all of these techniques, while highly evolved, are subject to limitations that are inherent to each method. No single current technology is able to meet the requirements for range, accuracy, cordlessness, freedom from interference, and freedom of movement that demanding computer applications require.
DESCRIPTION OF THE DRAWINGS
FIG. 1--Basic configuration of the system.
FIG. 2--Example of the transmitter circuit.
FIG. 3--Example of the receiver circuit.
FIG. 4--Example of the matched filter block diagram.
FIG. 5--Example of the none-coherent detector block diagram.
FIG. 6--Estimation of expected value and confidence interval of vector r x from a simultaneous measurements.
DETAILED DESCRIPTION
The following disclosure describes: a device to measure the position vector of the tracked unit, the reconstruction procedure for the device and the calibration method for the described system
DEVICE
To determine the position of the transmitter moving in the cube, it is sufficient to measure the differences between a propagation time of the carrier from transmitter to each stationary antenna element of the array receiver. If the number of antenna elements is larger then the number of dimensions by at least one, that is, four for 3D measurement, then the differences in propagation time at each antenna element determine two concurrent position points of which only one is correct. Further raising the number of antenna elements by at least one, that is 5 for 3D tracking, it is possible to uniquely determine a position of the target. Both configurations can find applications, however, the system with more antenna elements has the additional advantages of an over-determined system and much faster reconstruction algorithm.
The proposed position measurement equipment consists of a minimum five units for 3D measurements (FIG. 1). Four units are stationary units S n formed by the antenna elements of the array receiver, where r n are the position vectors of these units determined by the calibration. The one movable unit M is the transmitter antenna at which position vector r x is to be measured. In addition the tracking device consists of data acquisition and control system (CS). The CS is a digital signal processor based station capable of rapid data collection. The system CS performs not only all the signal processing functions but also the reconstruction algorithm of the position vector r x . The S n units are spread over the area of interest forming the best possible triangulation pattern for the measurements. This triangulation area can be very small or very large, ranging from meters to many kilometers. The S n unit dispersal pattern is non-restrictive; therefore any convenient location is satisfactory. As the M unit is moved to the various points of interest, the CS unit is dynamically calculating the absolute position of r x .
The M, S n system forms a conventional telemetric channel. The transmitter (FIG. 2) consists of system clock (CL) and a field programmable gate array chip that performs a state machine (SM) type function. If the system is required to operate at a frequency higher than the maximum clocking speed of the chip, than the output signal can be mixed with a high frequency carrier or preferably multiplied (MU) by an amplifier operating deeply in C class. The signal from MU is sent to the power amplifier (PA) followed by the omnidirectional antenna (ANT). In many applications of short distance tracking blocks MU and PA can be omitted.
A transmitted signal can employ any time domain function S T (t) that sufficiently satisfies a principle: ##EQU1## for any τ≢nT and τεℑ
where:
n--integer
T--period of S T (t)
ℑ--is the area of possible signal delays
The S T (t) is generally known and dependent on limited set of unknown parameters (usually frequency and phase ω,φ). As an example S T (t,ω,φ) can be represented by sinusoidal carrier modulated by Gold's sequence using Biphase-Shift Keying modulation (direct Sequence Spread Spectrum communication). For some applications the receiver can have lock-in capabilities allowing small changes of τ. In these cases ℑ could be relatively small and the signal S T (t,ω,φ) can be represented even by the continuous wave (CW) employing a narrow bandwidth communication. However narrow bandwidth communication is applicable in certain situations, but this type of communication is not suitable in a multi-path propagation environment. If the multi-path propagation has significant influence or if applications require a rapid position measurement of several transmitters then the lock-in capabilities are not available and ℑ has to cover all measured space. In those cases the condition (1) should be valid for all values of potential propagation's delays.
The time-of-flight of the transmitted signal is proportional to the length of the propagation path (distance), which is ultimately a function of speed of the light. The receiver system is comprised of several antenna elements and has the capability of simultaneous or coherent reception of the transmitted signal from all its elements (array receiver). The signal received by the n-th element of the receiver array can be described as: ##EQU2##
where:
I l ,n --unknown propagation coefficient of l-th propagation path to n-th antenna
τ n --generally unknown but constant inherent receiver's delay of the n-th element
d l ,n --unknown distance of the l-th propagation path from the transmitter antenna to n-th element of the receiver antenna
FIG. 3 shows an example of the receiver circuit. The received signal S n (t,ω,φ) is amplified in a low noise amplifier (LNA) and mixed with the signals S LI (t,ω,φ) and S LQ (t, ω,φ) from a local code generator (LG). LG has similar structure to the transmitter with the additional ability to adjust parameters ω,φ of the signals S LI (t,ω,φ) and S LQ (t,ω,φ). Similarly like S T (t,ω, φ), S LI (t,ω,φ) and S LQ (t,ω,φ) has to fulfill following principles: ##EQU3## for any τ 0 =nT+d 0 and τ 1 ≢τ 0 and τεℑ
where:
d 0 --unknown coefficient to be determined which is a measure of the propagation time
Following the mixer the signal passes through the analog band pass filter (BPF) combined with a ΔΣ type of analog to a digital (AID) converter. The mixer, LG and BPF form a first stage of Wiener filter where the square root of uncorrelated signal is minimized by the adjustment of the ω 0 ,φ 0 parameters. Further operations are performed exclusively by a digital signal processor (DSP).
The signal xI n and xQ n from each A/D converter is passed to a linear match filter (MF) which block diagram is shown on FIG. 4. Impulse responses of the filter hmfI(t) and hmfQ(t) are described as: ##EQU4##
where:
x--convolution operator
α--known time scale factor
ω 0 ,φ 0 --estimated values for ω,φ
Functions y m (t) and y n (t) from each MF are cross correlated by CR. The maximum of cross correlation function R mn (τ) of y m (t) and y n (t) corresponds to the difference between the propagation time τ m ,n of the received signals S m (t,ω,φ) and S n (t,ω,φ).
In a multi-path propagation case the cross correlation function R mn (τ) will have several local maxims. Many researchers published data indicating that, if line-of-sight exists, the direct propagation will exceed the reflection/refraction propagation by approximately 20 dB (indoor environment). In this case the system should search for global maximum of R mn (τ) to calculate τ m ,n. Similarly even if line-of-sight does not exists, but scattering of the transmitted signal is symmetrically distributed along the transmitter receiver axis (random medium), then the global maximum of R mn (τ) will approximate to τ m ,n of a direct propagation path.
The time differences τ m ,n are re-scaled by the speed of light c to obtain the measurements in the spatial domain d m ,n =τ m ,n *c, that is, the differences between the lengths of the transmitted signal propagation paths. Values of d m ,n from each channel are treated as an output signal from the array receiver and they form matrix D a base input to the reconstruction procedure (RP).
To estimate the value of propagation independent parameter (or parameters) of S T (t,ω,φ) (usually frequency ω) described receiver uses non coherent detector (NCD) which example is shown on FIG. 5. Based on information from NCD local generator regulator (LGR) adjusts LG for optimum shape of S LI (t,ω,φ) and S LQ (t,ω,φ).
RECONSTRUCTION PROCEDURE
The reconstruction procedure takes the output of the receiver D= d m ,n !, which is the measured differences in length between propagation paths from each neighboring channel and calculates the position vector of the tracked unit r x . Described reconstruction procedure employs system of linear equations to resolve r x base on data D= d m ,n !. The following equation can be used to reconstruct the position vector r x : ##EQU5##
where:
--vector scalar product
v--unknown arbitrary scalar variable
r n --position vector of n-th antenna component
d mn --signal from receiver
Equation (5) can be rewritten in its matrix form: ##EQU6##
where:
x.sub.ξ --ξ-th coordinate of vector r x
a n ξ --ξ-th coordinate of vector 2(r 5 -r n )
b n =|r 5 | 2 -|r n | 2
Using proposed procedure in 3D, a minimum five channel array receiver is required. Many direct numerical methods are known to solve the equation (6). The system (6) is over-determined so there are five combinations of this form. Further improvements can be achieved by adding more antenna elements. In a fully deterministic case all solutions should have exactly the same value. However in non deterministic conditions (noisy environment, multi-path propagation, jamming) the over-determined measurement gives an additional ability to calculate the weighted center--expected value of the vector r x and the confidence interval--error of the measurement (FIG. 6).
CALIBRATION PROCEDURE
The calibration procedure allows to completely determine the structure of the reconstruction equation.
To apply the reconstruction procedure outlined by equation (6) the elements a n ξ and b n of the matrixes have to be known. One method is to measure the coordinates of each S n unit and apply the findings to calculate the matrix elements. This direct method requires not only the employment of the independent positioning system but also all measurement errors will create additional inaccuracy in the tracking device.
A more efficient method is to measure the elements of matrixes directly using a calibration procedure. This procedure is based on several measurements of the values of d mn for different and known positions of the unit M. The unknown vector r x in equation (6) will be substituted by several known vectors r xi . At least (ξ+1) 2 /ξ measurements are required to determine fully the equation (6), where ξ is dimension. All measurements have to be sufficiently spread and linearly independent, that is no three positions can be on a straight line. The calibration process can employ a still fixture and the transmitter can be placed at each of its corners. The measurements will be taken separately at each position of the transmitter.
The linear equation (6) can be rewritten in the form: ##EQU7##
For tracking in 3D at least six measurements has to be taken deriving the following system of equations: ##EQU8##
where:
X k --coordinates of M unit at k-th measurement
D k --value of D at k-th measurement
D k 2 --value of D 2 at k-th measurement
R!-6x1--matrix of unknown variables
The relation (8) is a 24 by 22 linear equation and it can be solved using one of many known linear algebra methods. The elements a n ξ and b n of matrixes A and B from equation (8) found during calibration can be applied directly to the reconstruction relation (6). | The multi-dimensional tracking sensor especially for virtual reality and other real time computer applications. The disclosure describes an electro-magnetic (EM) tracking sensor that consists of a small lightweight transmitter with a transmitting antenna located on the target to be tracked and an array receiver with several local stationary antenna elements (FIG. 1). Multiple antenna elements of the array receiver lie on the perimeter of the measured space in positions determined by a self-calibration procedure. The proposed device calculates a cross correlation function between two signals at each receiving unit to determine a spatial position of the tracked element. | 6 |
BACKGROUND OF THE INVENTION
The invention fits within the Technology field, comprised of devices and/or systems used to dewater boreholes drilled for bench-blasting in quarries and mines.
Water, coming from rain and ground filtration, accumulates very frequently inside boreholes. The presence of water inside a borehole is a serious problem that causes difficulty in loading explosives, reduces their performance and substantially increases the cost of blasting, since the use of more expensive water-resistant explosives is needed.
This invention intends to provide the user of explosives for bench-blasting (in quarries, mines, public works, etc.) with a useful and easy-to-use technical solution that also reduces the possibility of the water extraction system getting stuck, or lost inside the borehole.
All the inventions included in this field of technology can be classified into two main groups:
1. Continuous Systems, such as submersible pumps, and those systems making use of the Venturi Effect. 2. Discontinuous Systems, by which borehole water extraction is carried out in several repetitive cycles.
As a result of the Report of the State of the Art and Previous Examination elaborated by the OEPM, Inventions U.S. Pat. No. 3,647,319 (in forward D1) and U.S. Pat. No. 3,971,437 (in forward D2) are mentioned as the two closest ones to the Invention proposed in this document. Other inventions mentioned by the OEPM were DE 4005574 A1 and U.S. Pat. No. 6,672,392B2.
Pursuant to the previous classification, D2 would be a Continuous System.
Inventions Ref: 397942, D1, ES 2253970, and the present invention P200600704, would be classified as Discontinuous Systems. Within this group, there is a special mention for the sub-group made up of those systems using the physical principle of Pneumatic Displacement as the means to displace water from the borehole. Inventions Ref. 397942, D1, and P200600704 are included in this sub-group. Attention is also drawn to the existence of another sub-division within this Group, made up of those inventions using a vacuum circuit alternately with a compressed-air circuit. This specific design incorporates important operative improvements, despite the resultant major complication in the final design of the invention. Another differentiating feature is that only the Invention P200600704 described in this document can be included in this sub-division. Inventions DE 4005574A1 and U.S. Pat. No. 6,672,392B2 are not related to this specific Technology field (boreholes dewatering) and, therefore, cannot be included in the classification above.
Differences Between P200600704 and D1.
According to what is stated in the original description document of D1, there are substantial differences between the above-mentioned invention (D1) and P200600704, that give this invention substantial operative advantages:
1. A constant clearance is left between the dewatering system and the borehole along its whole length, reducing the risk of the extraction system becoming stuck or lost inside the borehole.
In P200600704, the body of the pump consists of a double hose (1)+(15) with a constant external section. This double hose is inserted into the borehole from a hose reel placed in proximity to the borehole, and it covers its entire length. Thus, a sufficient clearance is left between the internal walls of the borehole and the external face of the hose.
This clearance is kept constant, without any bulges, throughout the length of the borehole.
In contrast, D1 is described as a tubular body (tube) closed at its top end, and inserted into the borehole. It remains connected to the outside by means of two pneumatic hoses with a smaller diameter than that of the tubular body. Therefore, this design, does not maintain a constant clearance between the dewatering system and the borehole along its full length, having a critical point located in the aperture created by the intersection between the tubular body and the two hoses that hold it from the outside. Experience and practice show that those systems that cannot leave a constant clearance between the device and the inner walls of the borehole are very prone to becoming stuck in its interior, resulting in the loss of the device as it cannot then be retrieved.
2. Invention P200600704 uses a flexible hose to confine the volume to be pressurized through the use of a hermetically sealed cap that is placed on the outside of the borehole and any vertical protrusion from the borehole. There is a clear benefit in using a flexible hose because it is easier to extract the hose despite encounters with any obstacles on its way to the surface.
By contrast, D1 uses a rigid tube that, due to the normal conditions of drilling, can never have a length exceeding two or two and a half meters. Since a borehole is never completely straight, it is very difficult to repeat the action of insertion and extraction of the tube. This forces Invention D1, to keep its closing cap located inside the borehole.
3. Vacuum Phase in Invention P200600704: Substantial Improvement in the Performance of Water Extraction Cycles.
The introduction of a Vacuum phase as a part of the dewatering cycles is a fundamental innovation that has not been considered in any previous invention in this field of Technology. This Vacuum phase brings a substantial improvement in the performance of dewatering cycles. This improvement becomes significant in the final cycles, when a smaller volume of water remains in the interior of the borehole, and would normally be very difficult to extract.
Differences Between P200600704 and Other Inventions Mentioned by the OEPM
Invention D2, mentioned in the Report of the Preliminary Study (OEPM), patent (U.S. Pat. No. 3,971,437) in 1976, describes a system similar to the Invention Ref 397942, as it also produces an effect of hermetic sealing against the walls of the borehole. This is done by means of a bladder that is filled with compressed air. Therefore, this cannot be considered to represent any system equivalent to P200600704 (thus excluding its inventive applicability).
In summary, Inventions DE 4005574 A1 and U.S. Pat. No. 6,672,392 B2 cannot be included within this Technology field as they can never be used to dewater boreholes for bench-blasting:
Both inventions are permanently fixed to the ground by means of a casing (DE 4005574 A1) or by means of a set of metallic pipes (U.S. Pat. No. 6,672,392 B2). By contrast, P200600704 is never fixed to the ground, keeping a clearance between the hose and the inner walls of the borehole along its whole length.
Both inventions make use of rigid tubes to extract water. By contrast, P200600704 uses a flexible hose to dewater the boreholes.
The objects of these inventions are not related at all to borehole dewatering for bench-blasting:
Extracting water from a large diameter well-hole, in the case of invention DE 4005574 A1 Extracting water and gas from a large diameter well-hole in a gas field, in the case of invention U.S. Pat. No. 6,672,392 B2.
DETAILED DESCRIPTION OF THE INVENTION
Description of the Parts that Constitute the Invention.
The constituent parts of the invention are detailed below in order to facilitate the understanding of the invention, its working principle and its possible use by an expert in the field.
The constituent parts of the invention are:
1. A Main Hose ( 1 ) characterized by:
Having a constant external diameter (and without projections) of such a manner that a sufficient and constant clearance is left between the walls of the borehole and the external section of the hose throughout its depth, and at all times during the different cycles of dewatering. Having a construction strong enough to resist the varying pressure during the essential phases of Vacuum (for example, reaching up to 0.4 atmospheres), and Exhaust (5 atmospheres, for example), thus achieving the optimum operation of the invention. This strength also enables the execution of the Exhaust phase while the main hose remains partially coiled in the reel. This is a significant operational advantage. This situation could arise when dewatering boreholes of different depths (very common, for example, in ramp-blasting, trench-blasting, etc.). Now, it would be possible to extract water from drilled holes of any depth, without needing to change any hose connection. Being flexible along its length, it can also be coiled into a reel, so it can adapt itself to potential deviations that are inherent to drilled boreholes, having a length sufficient to reach the bottom of a borehole of any current depth, while keeping the hose always connected to the reel.
2. A Sealing Cap ( 2 ) that is permanently placed at the exterior of the borehole; mounted on the Hose Reel ( 9 ) and connected ( 11 ) to one of the ends of the Main Hose ( 1 ); the top end always remains on the surface; with two air intakes, one of them fitted with an external connection ( 4 ) for air circulation (outlet or inlet) through the tube ( 34 ), depending on the phase of the cycle: exhaust/vacuum, and another intake with an interior connection ( 12 ) to connect the Interior Hose ( 15 ); this sealing cap is fitted with an external connection ( 5 ) to guide the water towards the Master Control ( 8 ) through the pipe ( 33 ), and from there to the external point of discharge during the extract phase (Position II, FIG. 7 ) or to guide the air towards the Master Control ( 8 ) and from there to the Vacuum Pump ( 18 ) during the Vacuum phase (Position I, FIG. 7 ). In the Vacuum phase the air is extracted from the interior of both hoses ( 1 )+( 15 ).
3. A Closing Element ( 30 ) that mates to the Main Hose ( 1 ) at the end that goes down to the bottom of the drilled hole, comprises of a Foot Valve ( 3 ), a Filter ( 13 ), and a Protective Element ( 14 ).
4. An Interior Hose ( 15 ). This Interior Hose ( 15 ) has a flexible length to enable it to be coiled in the reel. It is permanently connected to the interior connection ( 12 ) of the Closing Element ( 2 ). Therefore, this Interior Hose ( 15 ) remains inside the Main Hose ( 1 ) throughout its length during the whole dewatering process.
5. A Master Control ( 8 ) that is described later in its simpler variant to facilitate the understanding as to how the invention functions, and its use by an expert in the field. This constitutes the real “heart” of this system of water extraction, alternating the phases of Vacuum and Exhaust.
6. A Small Vacuum System (for example a Vacuum Pump) ( 18 ) and a small Compressor ( 17 ). They provide sufficient airflow and air pressure for operating the system in both phases (Vacuum: 200 l/s. and 0.2-0.4 bars. Exhaust: 300 l/s and 4-6 bars).
7. A Hose Reel ( 9 ) for Coiling the Main Hose ( 1 ) (and, consequently, the Interior Hose ( 15 )). It is recommended that the Hose Reel ( 9 ) is driven mechanically (for example, by means of an electric motor) ensuring correct ergonomics that would facilitate work conditions for operators. In order to allow the hoses to be coiled without being damaged by torsion, the Hose Reel ( 9 ) incorporates one of the following options:
Two swivels ( 6 ) and ( 7 ) fitted in each of the ends of the axle of the hose reel ( 9 ). Shown in FIG. 3 (option 1 ). Two concentric swivels, or as shown in FIG. 3 (option 2 ).
Description of the Functioning of the Invention.
An example is explained below in order to ensure an optimal understanding of the functioning of Invention P200600704. Please note, in order to facilitate the explanation below, the term HOSE will include the components: Main Hose ( 1 ), Interior Hose ( 15 ), Closing Element ( 30 ), Foot Valve ( 3 ), Filter ( 13 ) and Protective Element ( 14 ) as together they constitute a flexible tubular body that is introduced into the borehole.
EXAMPLE
Consider a borehole drilled at a diameter of 127 mm. The water level inside the drilled hole is 10 meters (this is equivalent to approx. 127 liters (12.7 l/m)). The Main Hose ( 1 ) is 30 m in length, its outside diameter is 70 mm, its inside diameter is 60 mm, having a thickness of 5 mm. The Interior Hose ( 15 ) is also 30 m in length, its outside diameter is 32 mm and its inside diameter is 24 mm. The linear volume of the interior of the HOSE is 2.5 l/m. The invention P200600704 incorporates a Compressor ( 17 ) (400 l/min and pressure limited to 6 bar) and a Vacuum Pump ( 18 ) of 400 l/min of suction up to a maximum extraction of 0.4 bars (Approx. 6 m of water depth).
Once the vehicle carrying the system P200600704 is positioned in the proximity of the borehole, the process starts by introducing the HOSE partially into the collar of the borehole. Then, by operating the hose reel, the HOSE will go down into the borehole so that, within approximately 15-20 seconds, its end will reach the bottom of the borehole, going through the water level.
The first cycle begins while the HOSE is going into the borehole. The position of the Master Control ( 8 ) should be either “0 (Off)” or “I (Suction)” (Position “I” is recommended in order to reduce the overall time of operation by overlapping the introduction of the HOSE and the suction of water by vacuum). In Position “I” valve keys ( 26 ) and ( 28 ) remain open so that water being sucked up is able to get into both the Main Hose ( 1 ) and the Interior Hose ( 15 ). Within a few seconds after starting the suction, the interior of the HOSE will be at a pressure of 0.4 bars. (Pressure Gauge ( 29 ) will show this value). This is equivalent to 6 additional meters of water inside the HOSE, and the water will reach a total depth of 16 m (10 m (hydrostatic)+6 m (vacuum). Therefore, the volume ready to be extracted in the first phase of Extract will be 40 liters of water (V=16 m×2.5 l/m). Setting the Master Control ( 8 ) into Position “II (Extract)” (valve keys ( 26 ), ( 27 ), ( 28 ) closed; valve key ( 25 ) opened), the air coming from the compressor ( 18 ) enters the Principal Hose ( 1 ) across the connection ( 4 ) placed in the Closing Element ( 2 ). In its journey the air has followed the route: ( 23 )+( 20 )+( 36 )+( 7 )+( 35 )+( 4 )+( 2 )+( 1 ). In this position (Position II) the compressed air penetrates the cavity between the interior hose ( 15 ) and the main hose ( 1 ), closing the Foot Valve ( 3 ) and displacing the water up the interior hose ( 15 ) towards the surface along its route: ( 15 )+( 12 )+( 5 )+( 33 )+( 6 )+( 34 )+( 19 )+( 24 )+( 38 ). After approximately 40-50 seconds with the Master Control ( 8 ) set in Position II (see FIG. 7 ), 40 liters of water will have been extracted in the first cycle and, after this time, only compressed air will be expelled across the Anti-return Valve ( 24 ) and the Discharge Hose ( 38 ). After the first cycle, approx. 87 liters of water, equivalent to approx. 7 meters of water depth in the drilled hole will remain.
The second cycle begins by setting the Master Control ( 8 ) to Position “I (Vacuum)” (closing the key valve ( 25 ), and opening the key valves ( 26 ) and ( 28 )). Within a few seconds of suction, the Pressure Gauge ( 29 ) will indicate approx. 0.4 bars, which means that there will be approximately 32 liters of water in the interior of the HOSE, occupying 13 meters. 7 meters (hydrostatic)+6 meters (vacuum). Moving from Position “I (Vacuum)” to Position “II (Extract)”, the above-mentioned volume of water (32 liters) will be extracted toward the point of discharge.
Alternating the phases of Vacuum and Extract through several cycles will achieve a complete dewatering of the borehole. In the worked example, the borehole will be absolutely dry after five cycles (See the attached picture summarizing the example).
HOLE DIAMETER
127.0
HOLE DEPTH (m)
20.0
WATER LEVEL IN THE BOREHOLE (m)
10.0
12.7 l/m
DIMENSIONS OF MAIN COMPONENTS
MAIN HOSE
Long
30 M
DIAMETER ext
70 mm
DIAMETER int
60 mm
INTERIOR HOSE
Long
30 M
DIAMETER ext
32 mm
DIAMETER int
24 mm
VACUUM
0.4 atm
6 m
LINEAR VOLUME (l/m)
2.5
Water
Water
Extracted
Remaining
Remaining
Hght
Vol.
Vol.
Vol.
Hght.
Dewatered
Cycle
(m)
(l)
(l)
(l)
(m)
(l)
1
10.0
127
40
87
6.9
40
2
6.9
87
32
55
4.4
71
3
4.4
55
26
30
2.3
97
4
2.3
30
21
9
0.7
118
5
0.7
9
9
0
0.0
127
Once the borehole has been dewatered, the HOSE is coiled back into the Hose Reel ( 9 ). Overlapping the introduction of the HOSE with the first phase of Vacuum, and the withdrawal of the HOSE with the last phase of Extract can save at least 15% of the total time of the process.
It has to be mentioned that, in this Invention, the process can be “reversible” by connecting ( 33 ) to ( 36 ) and ( 35 ) to ( 34 ), (i.e. interchanging connections ( 4 ) and ( 5 )) in such manner that the same dewatering effect will be achieved but, in this case, the compressed air will be driven through the Interior Hose ( 15 ) while the water will be displaced up across the annular gap between the Main Hose ( 1 ) and the Interior Hose ( 15 ).
BRIEF DESCRIPTION OF THE DRAWINGS
A set of drawings is attached, with the sole purpose of facilitating comprehension of the descriptions of the Invention and its operation.
FIG. 1 represents a side and a front view of Invention P200600704. The components shown in the picture are:
Main Hose ( 1 ) Interior Hose ( 15 ) Interior Swivel ( 30 ) Foot valve ( 3 ) Filter ( 13 ) Protective Element ( 14 ) Sealing Cap ( 2 ) Outlet Pipes ( 33 ) ( 34 ) Swivel ( 6 ) Master Control ( 8 ) Hose Reel ( 9 ) Compressor ( 17 ) Vacuum Pump ( 18 ) Air Pipes ( 35 ) ( 36 ) Swivel ( 7 ) Discharge Hose ( 38 ) Discharged Air+water ( 39 ) Anti-return Valve ( 24 )
FIG. 2 represents a detail view of:
Main Hose ( 1 ) Foot valve ( 3 ) Filter ( 13 ) Protective Element ( 14 ) Interior Hose ( 15 ) Interior Swivel ( 30 )
FIG. 3 a (option 1 ) and FIG. 3 b (option 2 ) represent two existing options for the closing cap being mounted in the axle.
Components shown on the picture are:
Sealing Cap ( 2 ) Swivel ( 7 ) [Option 2 ] Air Pipes ( 35 ) ( 36 ) Connection for Air Inlet/Outlet ( 4 ) Hose Reel ( 9 ) Connection ( 11 ) [Main Hose—Closing Cap] Connection ( 12 ) [Interior Hose—Closing Cap] Main Hose ( 1 ) Interior Hose ( 15 ) Outlet Pipes ( 33 ) ( 34 ) Swivel ( 6 ) [Option 1 ] Connection for Air/Water Outlet ( 5 ) Concentric Double Swivel ( 37 ) [Option 2 ]
FIG. 4 represents a schematic view of the Invention proceeding to borehole dewatering: Invention P200600704 is mounted on a “Pick Up” type vehicle ( 31 ) on top of a quarry face ( 40 ). The HOSE ( 1 ) is introduced into one of the wet boreholes ( 32 )
FIG. 5 represents a longitudinal view of any part of the HOSE inside a borehole. Components represented are:
Borehole ( 32 ) Main Hose ( 1 ) Interior Hose ( 15 ) Clearance [HOSE—Borehole] ( 16 ) Foot valve ( 3 ) Filter ( 13 ) Master Control ( 8 ) Hose Reel ( 9 ) Compressor ( 17 ) Vacuum Pump ( 18 )
FIG. 6 represents a transverse view [A-B Section] details: Components represented are:
Borehole ( 32 ) Main Hose ( 1 ) Interior Hose ( 15 ) Clearance [HOSE—Borehole] ( 16 )
FIGS. 7 a - 7 c represent the three different positions of the Master Control: FIG. 7 a corresponding to Position “0 (Off)”; FIG. 7 b corresponding to Position “I: (Vacuum)”; and FIG. 7 c corresponding to Position “II: (Extract)”. It also indicates the Pressure Gauge and the depth of the water inside the borehole, depending on the position of the Master Control. The elements shown are:
Master Control ( 8 ) Anti-return Valve ( 24 ) Pressure Gauge ( 29 ) Connection to the Pressure Gauge ( 41 ) Compressed Air Flow (orange arrow) Air Vacuum Flow (yellow arrow) Water Flow (blue arrow) Air Flow [at atmospheric conditions] (green arrow) Key valves controlling the flow of:
[Compressed air from Compressor to Master Control] ( 25 ) [Air from Vacuum pump to Master Control] ( 26 ) [Air from HOSE to the outside] ( 27 ) [Air between Main Hose and Interior Hose] ( 28 )
Connections, connecting:
[Compressor to Master Control] ( 23 ) [Vacuum to Master Control] ( 22 ) [Master Control to Main Hose] ( 20 ) [Master Control to Interior Hose] ( 19 ) [Master Control to the outside] ( 21 )
Description of the Different Positions:
Position “0” (Off): Key valves ( 25 ), ( 26 ) and ( 28 ) remain closed. Key valve ( 27 ) remains open. This allows the HOSE to be submerged into the water. Position “I” (Vacuum): Key valves ( 28 ) and ( 26 ) remain open. Key valves ( 25 ) and ( 27 ) remain closed. This connects the Vacuum Pump to the HOSE. Position “II” (Extract): Key Valves ( 26 ) ( 27 ) and ( 28 ) remain closed. Key valve ( 25 ) remains open. This allows the compressed air to enter the Main Hose, displacing the water up through the Interior Hose.
FIGS. 8 a - 8 g represent a process of borehole dewatering taking place in three cycles of vacuum and extract. | A system of de-watering boreholes by alternating cycles of aspiration and expulsion based on pneumatic displacement, includes a double hose to be introduced into a borehole. The double hose includes a flexible outer hose and a flexible inner hose separated by an annular space therebetween, the double hose adapted to reach a full depth of the borehole. The outer hose has an outer diameter less than a diameter of the borehole to provide an annular clearance between the borehole and the outer hose. An upper closing element is connected to an upper end of the double hose outside of the borehole, and has two outlets which permit entry and exit of air and water. A lower closing element is attached to the double hose at a lower end thereof, and includes a foot valve, a filter, and a protective element to serve as a battering ram. | 5 |
BACKGROUND OF THE INVENTION
[0001] Hemophilia A is an inherited disorder of blood coagulation characterized by a permanent tendency to hemorrhage due to a defect in the blood coagulation mechanism. Hemophilia A is caused by a deficiency in factor VIII. Factor VIII coagulant protein is a single-chain protein that regulates the activation of factor X by proteases in the intrinsic coagulation pathway. It is synthesized in liver parenchymal cells and circulates complexed to the von Willebrand protein. One in 10,000 males is born with deficiency or dysfunction of the factor VIII molecule. The resulting disorder, hemophilia A is characterized by bleeding into soft tissues, muscles, and weight-bearing joints. Although normal hemostasis requires 25 percent factor VIII activity, symptomatic patients usually have factor VIII levels below 5 percent.
[0002] Hemophilic bleeding occurs hours or days after injury, can involve any organ and, if untreated, may continue for days or weeks. This can result in large collections of partially clotted blood putting pressure on adjacent normal tissues and can cause necrosis of muscle, venous congestion, or ischemic damage to nerves. Hemophilia A is generally treated by administering to the patient either recombinant or plasmaderived factor Vm, or mild cases can be treated with desmopressin. However, there are times when treating such patients with factor Vm or desmopressin produces less than satisfactory results, and hemorrhaging continues.
[0003] Thus, there is a need to develop additional therapies for treating hemophilia A.
DESCRIPTION OF THE INVENTION
[0004] The present invention fills this need by administering factor XIII to patients with hemophilia A, preferably in conjunction with either factor VIII or desmopressin acetate or both factor VIII and desmopressin.
[0005] Diagnosis of Hemophilia A
[0006] Once a bleeding disorder has been determined to be present, the physician must determine what is the cause of the disorder. For diagnostic purposes, the hemostatic system is divided into two parts: the plasma coagulation factors, and platelets. With the exception of factor XIII deficiency, each of the known defects in coagulation proteins prolongs either the prothrombin time (PT), partial thromboplastin time (PTT), or both of these laboratory screening assays. A PT is performed by addition of a crude preparation of tissue factor (commonly an extract of brain) to citrate-anticoagulated plasma, recalcification of the plasma, and measurement of the clotting time. A PTT assay is performed by the addition of a surface activating agent, such as kaolin, silica, or ellagic acid, and phospholipid to citrate-anticoagulated plama. After incubation for a period sufficient to provide for the optimal activation of the contact factors, the plasma is recalcified and the clotting time measured. The name of the PTT assay emanates from the phospholipid reagents being originally derived from a lipid-enriched extract of complete thromboplastin, hence the term partial thromboplastin. The PTT assay is dependent on factors of both the intrinsic and common pathways. The PTT may be prolonged due to a deficiency of one or more of these factors or to the presence of inhibitors that affect their function. Although its commonly stated that decreases in factor levels to approximately 30% of normal are required to prolong the PTT, in practice the variability is considerable in sensitivity of different commercially available PTT reagents to the various factors. In fact, the levels may vary from 25% to 40%. See, Miale JB: Laboratory Medicine-Hematology. 6 th Ed., (CV Mosby, St. Louis, Mo., 1982).
[0007] If the PT and PTT are abnormal, quantitative assays of specific coagulation proteins are then carried out using the PT or PTT tests and plasma from congenitally deficient individuals as substrate. The corrective effect of varying concentration of patient plasma is measured and expressed as a percentage of normal pooled plasma standard. The interval range for most coagulation factors is from 50 to 150 percent of this average value, and the minimal level of most individual factors needed for adequate hemostasis is 25 percent.
[0008] Factor VIII
[0009] The specific activity of pure factor VIII ranges from 2,300 U/mg to 8,000 U/mg. For standardization, 1 U of factor VIII is defined as that amount of activity in 1 ml of normal pooled human plasma measured in a factor VIII assay by using factor VIII-deficient plasma. The frequency and severity of bleeding in hemophilia A may be predicted from the factor Vm procoagulant level assayed in comparison to a reference standard that is assumed to have factor VIII levels of 100%, corresponding to a factor VM activity of 1.0 U/ml of plasma. The factor VIII level in normal persons ranges from 0.50-2.0 U/ml. Those with factor VIII levels <1% of normal (<0.1 U/ml) have hemorrhages requiring therapy two to four times a month on average. Such patients are classified as severe hemophiliacs. Those with factor VIII levels >5% of normal (>0.05 U/ml) are considered mild hemophiliacs and usually hemorrhage only due to trauma or surgery.
[0010] Treatment of Hemophilia A
[0011] The hemostatically effective plasma level for each coagulation factor is different and depends in part on the nature, extent, and duration of the bleeding lesion.
[0012] The dose of replacement factor is calculated in units: 1 U is the activity of a given coagulation factor found in 1 ml of pooled, citrated fresh frozen human plasma. The factor must be given in sufficient quantity to allow for its clearance, metabolic half-life, and volume of distribution within the body.
[0013] The half-life of factor VIII in plasma is between 8 and 12 hours, which includes an initial rapid decline in level owing to diffusion into extravascular pools. The minimum hemostatic level of factor VIII for relatively mild hemorrhages is 30% (0.3 U/ml of plasma), while that for advanced joint or muscle bleeding or for other major hemorrhagic lesions is 50% (0.50 U/ml of plasma). One to several days of maintenance therapy is needed for such advanced lesions to heal. Resolution is generally achieved by repeating the infusion at 24-hour intervals at approximately 75% of the original dose. For life-threatening lesions or surgery, levels of 80%-100% (0.8-1.00 U/ml of plasma) should be achieved and the factor VIII level should be kept above the 30%-50% range by means of appropriate doses of factor VIII infused at intervals of 8-12 hours. This more frequent infusion regimen decreases the incidence of excessively low levels of factor VIII just prior to an infusion and also decreases the total amount of factor needed to maintain given in vivo minimum plasma levels. Constant infusion regimens are another option when levels need to be maintained above a set minimum.
[0014] Doses can be calculated by multiplying the recipient plasma volume in milliliters by the desired increment of factor VIII in units per milliliter. A simpler and reproducible dose calculation is that each unit of factor VIII infused per kilogram of body weight yields a 2% rise in plasma factor VIII level (i.e., 0.02 U/ml of plasma). An example of therapy for a 50-kg patient with an extensive laceration would include maintenance of a 30% factor VIII level in vivo until healing is complete. This can be accomplished by an initial infusion to the 60% level with 1500 U (30×50 kg) of factor VIII, followed by 750 U every 12 hours thereafter for 7-10 days, with dose adjustments being made every few days as indicated by factor VIII assays.
[0015] Treatment of Hemophilia A with Factor VIII and Factor XIII
[0016] The method of the present invention improves upon the above-described treatment of hemophilia A by administering factor XIII in conjunction with factor VIII. The factor XIII can be administered at any time alone or at the same time as factor VIII either to stop a hemorrhage or for prophylaxis.
[0017] Factor XIII, also known as fibrin-stabilizing factor, circulates in the plasma at a concentration of 20 μg/ml. The protein exists in plasma as a tetramer comprised of two A subunits and two B subunits. Each subunit has a molecular weight of 83,000 Da, and the complete protein has a molecular weight of approximately 330,000 Da. Factor XIII catalyzes the cross-linkage between the γ-glutamyl and ε-lysyl groups of different fibrin strands. The catalytic activity of factor XIII resides in the A subunits. The B subunits act as carriers for the A subunits in plasma factor XIII. The level of factor XIII in the plasma can be increased by administering a factor XIII concentrate derived from human placenta called FIBROGAMMIN® (Aventis Corp.) or by administration of recombinant factor XIII. . Recombinant factor XIII can be produced according to the process described in European Patent No. 0 268 772 B1.
[0018] A pharmaceutical composition comprising factor XIII can be formulated according to known methods to prepare pharmaceutically useful compositions, whereby the therapeutic proteins are combined in a mixture with a pharmaceutically acceptable carrier. A composition is said to be a “pharmaceutically acceptable carrier” if its administration can be tolerated by a recipient patient. A suitable pharmaceutical composition of factor XIII will contain 1 mM EDTA, 10 mM Glycine, 2% sucrose in water. An alternative formulation will be a factor XIII composition containing 20 mM histidine, 3% wt/volume sucrose, 2 mM glycine and 0.01% wt/vol. polysorbate, pH 8 . The concentration of factor XIII should preferably be 1-10 mg/mL, more preferably about 5 mg/mL.
[0019] Other suitable carriers are well known to those in the art. See, for example, Gennaro (ed.), Remington's Phannaceutical Sciences , 19 th Edition (Mack Publishing Company 1995).
[0020] Administration of Factor XIII
[0021] Factor XIII can be administered intravenously, intramuscularly or subcutaneously to treat hemophilia A. When administering therapeutic proteins by injection, the administration may be by continuous infusion or by single or multiple boluses. The levels of factor XIII in an individual can be determined by assays well known in the art such as the BERICHROM® F XIII assay (Dade Behring Marburgh GmbH, Marburg, Germany). The normal adult has an average of about 45 ml of plasma per kg of body weight. Each liter of blood has 1000 units (U) of factor XIII. The amount of factor XIII administered should be enough to bring an individual's level of factor XIII in the plasma to 100% of normal plasma or slightly above to 1-5% above normal. A dose of 0.45 U/kg would raise the level of factor XIII by about 1% compared to normal. One unit of factor XIII is about 10 μg of recombinant factor XIII, which contains only the dimerized A subunit. Thus, to raise the level of factor XIII by 1%, one would administer about 4.5 μg of the A 2 subunit per kilogram weight of the individual. So to raise the level 30% of normal, one would administer 13.5 U/kg. For a 75 kg individual this would be about 1,012.5 U. Some patients may have consumptive coagulopathies that involve factor XIII losses. In such cases, a higher dosing (e.g., 1-2U/kg-%) or multiple dosing of factor XIII (e.g., 1-2U/kg-%-day) may be required.
[0022] Treatment of Mild hemophilia A with Desmopressin
[0023] Patients with mild hemophilia A (factor VIII levels >5% of normal) do not bleed spontaneously, but usually only after trauma or surgical procedures. The current treatment of choice for patients with factor VM levels >10% is desmopressin.
[0024] Desmopressin is a synthetic analogue of the natural pituitary hormone 8 -arginine vasopressin. Although its exact mechanism is not known, it is thought to stimulate release of factor VIII from storage sites. The routine dosage is a 0.3 ?g/kg in 50 ml of normal saline given intravenously over a period of 30-40 minutes. To assess how an individual patient will respond to desmopressin, a staging test should be done. When the patient is not bleeding, a baseline factor VIII level is obtained and then the dose of desmopressin is administered. Thirty to 45 minutes after the infusion stops, a second factor VIII level is checked. The factor VIII level should rise at least threefold. If the levels rise to >80% of normal, the response is adequate for major surgery. In some patients the response desmopressin can only be used for minor hemorrhages since the factor VIII levels do not rise sufficiently. Desmopressin can also be administered with factor VIII if needed. When desmopressin is used for major surgery, it should be given 1 hour before surgery and then every 12 hours. Tachyphylaxis may occur after repeated doses of desmopressin secondary to depletion of factor VIII from storage sites. Thus factor VM levels frequently after the first two days of administration of desmopressin. If tachyphylaxis does occur, factor VIII should be administered.
[0025] Treatment of Mild Hemophilia with Desmopressin and Factor XIII
[0026] The present invention also encompasses administering factor XIII in conjunction with desmopressin to treat hemophilia A. The administration of factor XIII with desmopressin may even prevent the tachyphylaxis described above.
[0027] Factor VIII is produced by a number of companies in both a recombinant and plasma-derived formulations. Among these are the following: KOGENATE® (a recombinant factor VI) produced by Bayer Corp. West Haven, Conn.; RECOMBINATE® (a recombinant factor VIII) produced by Baxter Healthcare Corp., Glendale, Calif. HELIXATE® (a recombinant factor VIII) produced by Centeon L.L.C., King of Prussia, PA; HEMAFIL M (human, plasma-derived) produced by Baxter Healthcare Corp.; HUMATE-P CONCENTRATE® (human, plasma-derived) produced by Centeon L.L.C.; KOATE-DVI® (human, plasma-derived) produced by Bayer Biological; KOATE HP (human, plasma-derived) produced by Bayer Biological; MONOCLATE-P® (human, plasma-derived) produced by Centeon L.L.C.
[0028] Desmopressin acetate is produced by Rhône-Poulenc Rorer, Collegeville, Pa, by Ferring Pharmaceutical, Tarrytown, N.Y., and by Centeon, King of Prussia Pa. | Use of factor XIII for treating hemophilia A. A patient having hemophilia A is treated by administering factor XIII generally in conjunction with factor VIII or desmopressin. | 0 |
PRIORITY INFORMATION
This application claims the benefit of U.S. Provisional Application No. 60/366,115 on Mar. 20, 2002.
FIELD OF THE INVENTION
The field of this invention relates to a method of anchoring, sealing and circulating between a casing string and inner string therein.
BACKGROUND OF THE INVENTION
With the use of casing strings in wells, having small clearances between each string, it has become more common to run the casing string open ended to allow the fluid below the casing to escape through the inside of the casing to prevent an increase in pressure in the well that could break down the formation and cause a well control problem.
In order to run a casing string of this type into a sub sea well head it is necessary to run the casing inside the riser then attach a casing hanger and running tool to the casing and run the assembly in the well to the sub, sea tree using drill pipe. Normally the casing can then be cemented in place using conventional cementing plugs located at the hanger running tool and launched by dropping a ball or other device from the rig floor. In some instances it is desirable to run pipe below the hanger running tool to or near the bottom of the casing being run. This will eliminate the need for cementing plugs since there is no need to wipe the casing with cementing wiper plugs.
Should the well begin to flow the blow out preventer can be closed on the casing string isolating the annulus between the casing string being run and the well bore. The drill pipe being run inside the casing can also be isolated by connecting it to a top drive or by attaching a safety valve to the upper most joint of drill pipe. However this leaves the casing drill pipe (inner string) annulus open thereby exposing the well to extreme danger.
It is therefore clear there is a need for a device to isolate the annulus between the inner string and the casing string during the process of running the inner string inside the casing string.
Not only is it desirable to isolate this annulus space by placing a seal between the two members, it is also necessary to anchor the inner string to the casing string to prevent internal pressure in the casing string from pushing the inner string out of the well.
It is therefore clear there is a need for a device to anchor the inner string to the casing to prevent it from dropping into the well or being blown out of the well.
Should a gas bubble exist it must be circulated out of the well to place the well back under control. In order to circulate the well it is common practice to pump mud into the most inner string, in this case the drill pipe or inner string and out the annulus around the drill pipe.
It is therefore clear there is a need for a device to provide a means of circulating fluid through the well.
A device is disclosed that can be attached to the upper end of the casing string or casing hanger that will anchor the inner string to the casing to prevent it from moving. A seal is also disclosed that will seal the annulus between the inner string and casing at the surface, the device also provides for circulating fluid through the annulus space between the casing string and inner string.
Accordingly, it is an object of the present invention to provide a apparatus useful for anchoring, sealing and providing a circulation path in a casing string having an inner string. Accordingly, an apparatus is disclosed that provides for attaching and sealing to the upper end of the casing string or hanger and provides for the inner string to be run through the apparatus. A means of anchoring the inner string to the apparatus is also provided. Accordingly, an apparatus that provides a flow path for circulating fluid is disclosed. These and other objectives accomplished by the apparatus will become more apparent from a review of the detailed description below.
SUMMARY OF THE INVENTION
A apparatus is disclosed for attaching and sealing to the upper end of the casing allowing the inner string to be run through the apparatus. The apparatus provides a latch for anchoring the inner string and a seal for sealing on the inner string. Also disclosed is a flow path for providing for circulation of fluid between the inner string and casing annulus. Also disclosed is an inner string sub that provides a profile anchoring and sealing the inner string by the apparatus.
For running the inner string the apparatus provides an opening that does not restrict the passage of the tool joints of the inner string. Once it is decided to anchor or seal on the inner string the inner string sub is attached to the upper most joint of the inner string. This inner string sub is then lowered into the apparatus until the latching profile and seal area of the inner string sub is adjacent the latch and seal in the apparatus. The latch is then set by hydraulic pressure. The latch is tested by pulling or pushing (raising or lowering) the inner string. The seal can then be set by hydraulic pressure. Circulating fluid either into the casing inner string annulus or the inner string can test the seal.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of the apparatus.
FIG. 2 is a sectional elevational view of the apparatus attached to the upper end of the casing string.
FIG. 3 is the view of FIG. 2, except that the inner string is being run through the apparatus.
FIG. 4 is a sectional elevational view of the apparatus in FIG. 2, except that the inner string sub has been attached to the inner string and positioned in the apparatus with the latching device and seal activated to anchor and seal the inner string with the apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, an outer view of apparatus A is shown to illustrate the general location of components. Illustrated is a thread or latch 1 to engage the threads of the upper casing joint or profile of a hanger not shown in this illustration. The location of a seal 2 for sealing with the casing is illustrated. Also shown is the circulation port 3 whose purpose will be described later. Hydraulic ports 4 , 5 , 6 and 7 are illustrated. These ports are connected through hydraulic lines 4 ′, 5 ′, 6 ′ and 7 ′ to the latch and seal not shown in this illustration. Referring to FIG. 2, the apparatus A is shown connected to the upper end of the casing B by threads or latch 1 and sealed with the casing with seal 2 . The casing B is supported at the rig floor with slips or spider not shown. The circulating port 3 is connected to the inside of the casing B through passage 8 and annular area 9 between the casing B and apparatus A. For simplicity only hydraulic port 4 and hydraulic line 4 ′ are shown. Hydraulic port 4 is connected to the lower end of the seal setting piston 10 through port 11 . Ports 5 , 6 and 7 of FIG. 1 are connected through their respective passages to ports 12 , 13 and 14 . Ports 12 , 13 and 14 are shown out of position to simplify the illustration. Each port will be rotationally displaced as are passages 5 , 6 and 7 of FIG. 1 . So, hydraulic passage 5 of FIG. 1 is connected to the upper end of the seal setting piston 10 through port 12 , hydraulic passage 6 of FIG. 1 is connected to the lower end of the latch piston 15 through port 13 , and hydraulic passage 7 of FIG. 1 is connected to the upper end of the latch piston 15 through port 14 .
Seals 21 , 22 , and 23 isolate ports 11 , 12 , 13 and 14 from each other inside of lower housing 16 .
Upper housing 16 of the apparatus is connected to lower housing 17 with threads 18 . Latch Housing 19 is attached to upper housing 16 with threads 20 .
Seal 24 is shown in its normally released position. It is clear that the seal 24 can be set by pressuring through hydraulic port 4 of FIG. 1 to the lower end of the seal setting sleeve 10 . Seal 24 is maintained in the released position by application of hydraulic pressure being applied through port 6 then passing through internal passageways to port 12 located at the upper end of seal setting piston 10 and acting on the annular area between seals 31 and 32 .
The latch 25 is shown in its normal released position with the inner profile of the latch piston 15 in the mating contact with the outer profile of the latch 25 so that the latch 25 is in its expanded (normally relaxed) position. Latch 25 is preferably a single piece design providing for expansion and contraction and formed from a tubular having slots 26 and 27 alternately formed from opposite ends and terminating prior to exiting the part. Latch piston 15 is held in the latch 25 release position with hydraulic pressure applied in the area between seal 28 and 29 through ports 7 and 14 . As pressure is applied to port 7 it advances through the internal paths to port 14 thereby forcing latch piston 15 downward into contact with latch 25 at shoulder 30 . Latch 25 in turn is forced into contact with latch housing 19 at shoulder 33 .
Referring to FIG. 3 . The apparatus A is shown connected to the casing B with the inner string C being run through the apparatus. In this view inner string C consists of adjacent joints of pipe 34 and 35 . Shown in the view are the spaces 36 and 37 created when the seal 24 and latch 25 are in the released position. In this position adjacent joints of pipe may be continuously added or removed from the inner string C without damage to the seal 24 or latch 25 . To prevent the upset 38 of the inner string C from damaging the latch 25 or seal 24 the inner diameter 40 of the lower housing 17 and the inner diameter 39 of the upper housing 16 are both smaller than the inner diameters of the latch 25 and seal 24 when in the released or retracted positions.
Referring to FIG. 4 . The apparatus is shown with the inner string sub 42 attached to the uppermost joint of pipe 41 in the inner string C. Another joint of pipe 43 is connected to the upper end of the inner string sub 42 . The upper joint of pipe 43 can be connected to the rig hoisting system so as to manipulate the inner string by raising or lowering it.
The inner string sub 42 has formed on its outside surface a set of profiles 48 , 49 and 50 for engagement with mating profiles 51 , 52 and 53 respectfully. Profile 51 of the latch 25 is preferably longer than any of the profiles on the inner string sub 42 other than the lowermost profile 48 . These longer profiles 48 and 51 prevent the latch 25 from contracting until all profiles are located to their respective mates. For this reason, once the inner string sub 42 is inserted into the apparatus such that the seal diameter 46 is through the latch 25 , hydraulic pressure can then be applied through port 7 of the apparatus through the inner passages and to port 13 , seals 29 and 54 . Pressure applied to this area will force latch piston 15 upward. This upward force on latch piston 15 will cause surface 55 of the latch piston to ride up surface 56 of the latch 36 forcing latch 36 inward into contact with the outer surface of seal area 46 on the inner string sub 42 . As the inner string C is then lowered the profiles on the inner string sub 42 will be placed adjacent to the profiles of the latch 25 . With pressure being applied to the area on the latch piston 15 the latch 26 will be forced into mating contact with the profiles of the inner string sub 42 . This will lock the inner string C in place so that it can not move upward or downward thereby assuring the seal surface 46 is always adjacent to the seal 42 .
Should pressure not be applied to the Latch piston 15 to position the profiles adjacent to each other, lowering the inner string C will eventually cause shoulder 44 on the inner string sub 42 to come into contact with the upper surface 45 of the upper housing 16 causing the inner string C to stop in a position that the profiles on the inner string sub 42 will be placed adjacent to the profile in the latch 36 . This will also place the seal surface of the inner string sub 42 adjacent the seal 24 .
Once in this position the latch 36 and seal 24 can be placed in locking and sealing contact with the inner string mandrel 42 by applying pressure to their respective ports.
Although a seal 24 is shown which takes an axial force to actuate other types of seals can be used such as those that have a chevron shape that will seal without actuation. Although a hydraulic means is described to actuate the latch 36 other types of actuation such as mechanically moving the latch piston 1 are envisioned.
Once the inner string sub 42 is secured by the latch 36 , pressure in the annular area between the casing B and inner string C can be controlled. Circulation into or out of this annulus is possible through port 3 as described earlier.
The system is released by bleeding the pressure from the latch and seal ports causing them to retract away from the inner string sub 42 . | A apparatus is disclosed for attaching and sealing to the upper end of the casing allowing the inner string to be run through the apparatus. The apparatus provides a latch for anchoring the inner string and a seal for sealing on the inner string. Also disclosed is a flow path for providing for circulation of fluid between the inner string and casing annulus. Also disclosed is an inner string sub that provides a profile anchoring and sealing the inner string by the apparatus. | 4 |
[0001] This application claims the benefit under 35 U.S.C. 119 of the filing date of Provisional Application Ser. No. 60/817,690 filed Jul. 3, 2006.
[0002] This invention relates to a method of forming precast RC trusses and light-weight variable section beams, precast and cast-in-place variable section RC columns and walls, and other cast concrete components for structural, architectural, and/or industrial applications.
BACKGROUND OF THE INVENTION
[0003] Flexible formworks have been used commercially for on-grade and underwater applications for over thirty years. Commercial development of above- ground applications is more recent: Currently, one company (Fab-Form Industries, Surrey BC) manufactures and markets fabric formwork to the construction industry (foundation footing and column forms). Japanese architect Kenzo Unno has developed a fabric formwork system for cast-in-place RC walls. Academic research by Mark West has developed fabric formwork methods for manufacturing cast-in-place and precast RC columns, beams, and panels, including methods for producing high efficiency variable-section structures that significantly reduce material, dead weight and embodied energy.
SUMMARY OF THE INVENTION
[0004] It is one object of the invention to provide a novel method of forming a concrete truss of the above type.
[0005] According to one aspect of the invention there is provided a method of manufacturing concrete trusses comprising:
[0006] providing a plurality of mold members which connect together to define a cavity arranged to shape poured concrete into a truss of a required shape;
[0007] the cavity being shaped to define for the truss a top flange cavity to form from the poured concrete a top flange extending between two ends of the truss;
[0008] the cavity being shaped to define for the truss a bottom flange cavity to form from the poured concrete a bottom flange extending generally longitudinally;
[0009] the cavity being shaped to define for the truss a plurality of upstanding strut cavities to form from the poured concrete a plurality of struts extending between the top and bottom flange cavities;
[0010] at least one of the mold members defining a bottom surface for the bottom flange cavity of the truss;
[0011] the mold members being shaped to define closed areas which are located between the strut cavities, above the bottom flange cavity and below the top flange cavity which prevent the entry of concrete to form in the truss openings between the posts;
[0012] and forming the cavities of the mold members from rigid members and from fabric where the surfaces for the cavities are partly defined by the rigid members and partly by the fabric;
[0013] the fabric being stretched over the rigid members such that the fabric contacts the rigid members at contact parts thereof and the fabric is spaced from the rigid members at other parts thereof so as to form curved sections in the fabric as the fabric bridges over the other parts to the contact parts;
[0014] and forming curved sections in the truss at least on sides of the struts of the truss by shaping the poured concrete in the curved sections in the fabric.
[0015] Preferably the bottom flange cavity of the truss is shaped to define a bending moment curve for the truss.
[0016] Preferably the mold members include two side members which are pressed together on each side of the truss to be formed to form at least part of the cavities therebetween and wherein each of the side members is formed by rigid parts and fabric covering or between the rigid parts.
[0017] Preferably each of the side members has an inner cavity forming surface defined by rigid portions which locate the mold surfaces in directions longitudinal to the truss and vertically of the truss to define x and y plane and wherein between the rigid portions the surface is defined by the fabric which is smoothly curved between the rigid portions.
[0018] Preferably the side members have protruding portions such that the protruding portions of one side member project toward the raised portions of the other side member so as together to cooperate to define the closed areas with side edges of the raised portions defining the side edges of the truss openings and wherein the fabric is located on at least some of side edges of the raised portions so as to smoothly curve the truss away from the side edge.
[0019] Preferably each side member is covered by a single sheet of fabric. However individual pieces of fabric can be located in the areas between the rigid mold parts. The pieces of fabric may be connected using tailoring techniques well known to provide a required shaping. A The single piece allows easier fastening around the back of the mold part but the individual pieces, or the tailored and connected pieces of fabric can also be fastened to the back of the mold part using staples or other simple fastening elements. The molds can be made with a single flat sheet of fabric, either coated or uncoated. Three-dimensional tailoring, i.e. a membrane composed of differently shaped parts connected together, is also an option, though obviously more complex and involved.
[0020] Preferably the fabric is pulled around the back of the rigid mold members and fastened to a face of the rigid mold member facing away from the cavity.
[0021] Preferably the method includes shaping the fabric using tension to pull the fabric to a required location and fastening the fabric to the mold member.
[0022] Preferably the method includes shaping the fabric using a gauge to measure a required location of the fabric relative to rigid portions of the mold members.
[0023] Preferably the method includes shaping coated fabrics using heat to aid stretching.
[0024] Preferably the method includes providing reinforcing tension members in the tension zone areas of the beam, which may not be in the bottom depending on the truss design.
[0025] Preferably the mold members include a base member having an upper surface defining a bottom surface of the bottom flange and two side members which are arranged each on a respective side of the cavity.
[0026] Preferably the method includes providing reinforcing tension members along the tension zone areas of the beam wherein the reinforcing tension members are inserted within the space defined by the base member with one of the side members in place to define a receptacle for the tension members.
[0027] Conventional flexible formworks can only cast members with pure tension curves in all three dimensions. This method allows far greater geometric control of fabric-cast concrete members using an easily constructed formwork rig. Rigid clamps are used, that is any rigid formwork member that holds, or pinches, the fabric, holding the two membrane layers, to precisely control the X and Y dimensions of the cast to any desired geometry. The membrane is free to deflect only in the Z direction, allowing the formation of complex double curvature shapes. Casts with complex void shapes can also be easily formed. Traditional rigid formwork constructions can be used to support clamping elements. No special tools or scaffolding is required. Formwork constructions can be folded and transported. Sewing, heat sealing, or other tailoring is generally not required. Tailored sheets may be used, though are not preferred for simplicity of construction.
[0028] Thus the parts of the mold are:
[0029] A center piece shaped so that its top edge follows the longitudinal shape of the truss's bottom flange or profile, bearing in mind that the bottom edge of some truss shapes may not be a ‘flange’ proper.
[0030] Two rigid side pieces with the above protruding portions attached which are shaped to act as “Block-Out Clamps”.
[0031] Two flat, or possibly tailored sheets of fabric, or other flexible membrane material, to cover the two side pieces and Block-Out Clamps.
[0032] The method is as follows:
[0033] The two flat sheets of fabric are stretched over the Block-Out Clamps and rigid side pieces to form a continuous surface over each side piece assembly. The side pieces thus covered are placed on either side of the central piece.
[0034] The covered side pieces are pushed against either side of the center piece. This causes the top edge of the center piece to push (deflect) the stretched fabric sheets back against the rigid side-pieces, thus forming a gasketed seal along the top edges of the center piece, that is, along the entire length of the bottom of the mold. This forced deflection of the flexible membrane coverings also serves to further pre-tension the membrane coverings.
[0035] With one of the side pieces removed, tension reinforcing can be easily placed in the tension flange portion of the mold, or in other portions of the truss mold as required.
[0036] When the fabric-covered side pieces are in place, the Block-Out Clamps on either side touch each other thus clamping the two fabric sheets together (left and right) and forming the block-out pattern (i.e. the void shapes) in the cast truss. The joint formed between the pairs of pressed Block-Out Clamps can be sealed, if required/desired with a gasket material such as soft rubber.
[0037] The completed truss mold is filled with concrete. After the concrete has achieved its strength, the two side pieces are removed. The side pieces retain their stretched fabric coverings and are immediately ready for further casts after cleaning.
[0038] Tension reinforcing in rectangular trusses can be pre-stressed by pulling the reinforcing strands horizontally using hydraulic jacks or other mechanical means.
[0039] Tension reinforcing strands in curved, variable section trusses can be pre-stressed by pushing a fixed-length strand vertically downwards.
[0040] A variable section truss mold can also be used to form precast arches or arched trusses, that is, trusses curved along the top, by inverting a suitably reinforced variable section cast truss, that is, turning a cast truss “upside-down” with its reinforcing placed to suit the inversion of the structure.
[0041] A multitude of other truss designs can also be made using this method. For example: trusses for continuous trusses spanning over more than two supports, lenticular trusses, that is trusses with curved top and bottom flanges, etc.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] One embodiment of the invention will now be described in conjunction with the accompanying drawings in which:
[0043] FIG. 1 is a side elevational view of the mold structure with one side mold member removed to show the interior cavity shape.
[0044] FIG. 2 is a cross sectional view of the mold structure along the lines 2 - 2 with the mold complete.
[0045] FIG. 3 is a cross sectional view of the mold structure along the lines 3 - 3 with the mold complete.
[0046] FIG. 3A is a cross sectional view of the mold structure along the lines 3 - 3 with one of the two side mold members removed.
[0047] FIG. 4 is a cross sectional view of the mold structure along the lines 4 - 4 with the mold complete.
[0048] FIG. 4A is a cross sectional view of the mold structure along the lines 4 - 4 showing a modified arrangement of the mold .
[0049] In the drawings like characters of reference indicate corresponding parts in the different figures.
DETAILED DESCRIPTION
[0050] In the figures is shown a mold generally indicated at 10 which is formed from three mold parts best shown in FIG. 2 including a first side mold part 11 , a second side mold part 12 and a base mold part 13 . As shown in FIG. 1 the base mold part 13 provides an upper surface 14 which forms the bottom surface of the cavity generally indicated at 15 . The cavity 15 ( FIG. 1 ) is shaped to form the truss with which the present invention is concerned. The truss is of the type including a top flange, a bottom flange and a plurality of interconnecting struts where between each post and the next, the material is omitted to provide an opening. Thus the cavity includes an upper cavity portion 16 ( FIG. 1 ) for the top flange, a bottom cavity portion 17 ( FIG. 1 ) for the bottom flange and a plurality of cavity portions 18 ( FIG. 1 ) each defining a respective one of the plurality of struts. Between each strut and the next, the mold members close off the cavity in the area indicated at 19 ( FIG. 1 ) so that no material is formed in this area when the concrete is poured into the cavity of the mold.
[0051] In the example shown, the mold parts are formed from wooden panels fastened together so that the rigid center piece part 13 defines the structure and the inner surface 14 . Other techniques can of course be used for forming molds. However one advantage of the present invention is that the mold can be readily constructed from the panels and the fabric so that mold cost is kept very low allowing custom manufacture and design of particular trusses for particular end uses strictly in accordance with engineering requirements without the necessity for compromise of the shape of the truss due to manufacturing requirements.
[0052] For a bi-axially symmetrical cast, each of the side mold parts 11 and 12 is substantially identical and arranges a mirror image so that the side mold parts can be clamped together on each side of the base mold part to form and enclose the cavity. Asymmetrical molds can also be easily made, though the utility of such molds may perhaps be questionable. The side mold part 11 is thus formed from a side plate 20 together with protruding portions 22 which define the opening 19 . The protruding portions are again formed from panels of wood which are fastened to the inside surface of the outer plate 20 . Thus as shown in FIG. 2 the raised portions 21 have an inside surface 22 with the inside surfaces butting at the longitudinal center plane of the mold. This acts to form an area 23 between the mold parts which exclude the poured material to form the openings 19 .
[0053] Each of the side mold parts is covered by a layer of fabric 25 . The fabric is attached by fasteners 26 to the back surface 27 of the mold part and the fabric extends over the front surface of the mold covering the inside surface 28 of the side plate 20 and covering the surfaces 22 of the protruding portions 21 which act as a stand-off structure supporting pinch-plate 22 .
[0054] As shown in FIG. 3A , the mold is first partly assembled by attaching the side part 11 to the base part 13 by a clamping system schematically indicated at 28 . This forms one half of the cavity with the second side 12 removed leaving one side of the cavity open.
[0055] As shown in FIGS. 3A and 4 , between the projecting portions 21 , the fabric 25 is draped into a curved portion 30 between the edges 31 and 32 of adjacent ones of the raised portions 21 . The fabric extends in this draped section to a position close to the surface 28 of the outer plate 20 . The fabric is preferably spaced away from the surface 28 but may bottom out against the inside surface 28 of the outer plate 20 . Thus the fabric forms the smooth curve between the edges 31 and 32 in both the horizontal plane as shown in FIG. 4 and also in the vertical plane as shown in FIG. 3A . The fabric is pulled into place by tensioning and also by the use of depth gauges which determine or measure the depth of the curved section 30 between the edges 31 and 32 . The gauge sets the length of fabric fed into the space 30 . This is done prior to tensioning. Setting the fabric length with a gauge sets the final deflection geometry that will be formed after tensioning this section of the fabric. The fabric is pulled in the unsupported areas between pinch-plates 22 , that is in the areas of the struts.
[0056] The fabric is fastened to the outer surface of the side mold part and may be fastened by fasteners 26 A to the outer surface 22 of the raised portion 21 near the edges of the space 304 Thus the fabric is held in place and located by the raised portions but between the raised portions the fabric is free to curve under tension to the required position. The fabric is pulled by the mold maker to the required curvatures and is held in place by the tension of the fabric which is applied by the positioning of the fasteners 26 and 26 A.
[0057] The curvature of the fabric forms smooth curves on the outside surface of the concrete when poured to avoid sharp edges and sharp lines which can concentrate stresses and form cracks. The positioning of the fabric reduces the amount of concrete between the raised portions so that the proper curvature of the surfaces can be provided to transfer the loads effectively through the concrete structure. As is previously known, the most efficient longitudinal shape for a beam is that in which the beam's depth varies in proportion to its applied bending moment across its span. For a uniformly distributed load, this shape will be a parabolic curve. However other shapes can be provided which are either smoothly curved or have straight sections between the struts or load points. It will be appreciated that a truss of this type is in compression throughout its structure except at the bottom surface of the bottom beam in its tension zone areas. However, differently loaded and designed trusses may have tension in other parts of the beam—for example: a cantilever beam has tension along the top of the beam. At the tension location is provided tension members indicated at 35 and 36 . These tension members can be formed of any suitable material such as steel. As shown in FIG. 3A , the tension members can be simply located in place using standard reinforcing bar supports or chairs placed across the surface 14 . The chairs are used to locate the reinforcing some distance inside the outer surface of the cast so that the reinforcing material is protected from heat during fire. The dimension of this fire cover is set by building codes.
[0058] Alternatively the tension members can be pre-tensioned pre-attaching a fixed length of tension reinforcing material to either end of the mold and formed into the curvature required by locating members pressing down on the tensioning cables through the area within which the struts 18 are to be formed. Thus at each post a pressure member (not shown) is applied which presses down on the reinforcing rods or cables to pre-tension them and hold them in place above the surface 14 during the pour.
[0059] With the cables in place as shown in FIG. 3A the second side of the mold is added as shown in FIG. 3 so as to press the surfaces 22 together at the area 23 where the concrete is to be excluded. Turning now to FIG. 4A , an alternative arrangement for the exclusion zone indicated at 23 A is provided in which there is provided a bead or gasket 23 B located at the edge 31 of the raised portion 21 on top of the fabric. The bead thus pinches the fabric 25 at the edge 31 and more effectively prevents the penetration of the concrete into the area 23 A. The use of the bead 238 is advantageous in avoiding the formation of a knife edge in the cast concrete where the fabric sections meet at the edge 31 . Thus in FIG. 4 , it will be noted that a sharpened edge of the concrete can be formed in the area where the fabric enters the area between the two raised portions 21 . In the arrangement of FIG. 4A , the presence of the bead holds the fabric as a continuous smooth curve around the edge of the concrete post as it is formed at the junction between the two raised portions 21 . At the top of FIG. 4A is shown one example where the gasket is attached to one surface of the fabric at the raised portions 21 and in the bottom is shown an alternative arrangement in which there are two beads 23 C and 23 D each attached to the fabric at a respective one of the raised portions 21 . This bead or gasket material serves two functions: 1: it seals the joint between the raised portions, and 2: it shapes the mold cavity so that the concrete does not form a knife edge at the void openings of the truss. Concrete knife edge shapes chip easily. Standard construction and design practice will provide a certain thickness for any concrete edge to avoid easy chipping or fracture.
[0060] The objective of the arrangements described above is to create a beam that is structurally expressive of the bending moment for a specified loading condition, using a minimum amount of material while also minimizing the complexity of formation. A beam whose structural depth varies in proportion to its applied bending moment circumvents internal shear stresses. A beam of this type is essentially a light-weight open-web composite truss with a concrete compression flange and fire-proofed tension flange, formed to an efficient structural geometry. Other, more complex, beam types can be formed as well.
[0061] The formwork and techniques described below comprise a basic method which can be applied to the production of beams with various patterns of voids and struts, depending on the design load. Images included are taken from several generations of form.
[0062] The formwork in these examples is comprised of three main components; a catenary-shaped base, symmetrical fabric-covered web-forming sides, and if required pre-stressing devices for steel cable reinforcement. When assembled, the fabric-covered sides form a gasket seal with the base, and meet to create the open-web voids. The pre-stressing devices, if used, mount to the sides of the apparatus and allow the vertical adjustment of steel rod (or tubes) to create tension in the cable, the cable being held at either end of the beam.
[0063] The mold is formed using the following fabrication, assembly & techniques. The plywood base is cut to a bending moment curve of predetermined length and depth. This curve is scribed onto the two rectangular plywood sides as a reference for the creation of the void blocks, taking into account the thickness of the top and bottom flanges, vertical strut thickness, and corner radii to prevent stressed fabric tearing and to give integrity to the intersections. The void block-out assemblies are manufactured in pairs, each assembly with a depth being half the width of the base. The blocks are then fixed to the sides, ensuring alignment by sandwiching the sides and block together while fastening. The spaces between the blocks will form the vertical struts of the truss.
[0064] The two sides are now ready to be covered with fabric. As one example, a coated polyolefin woven fabric can be used; the coated side was used as the casting surface. The technique of affixing the fabric is key in achieving uniform thicknesses of the vertical struts. The fabric is stretched around the back of the form, beginning with the strut regions. A gauge can be used to measure a consistent depth, attaching the fabric on either side of the gap. Staples, screws or other fasteners are used to fix the fabric permanently. As one example, an uncoated woven polypropylene or polyethylene geotextile fabric can be used. As an alternate example, a coated woven polypropylene or polyethylene or glass fiber fabric can be used. Other fabrics can be used as well, of course. The fabric is stretched around the back of the form, beginning with the strut regions at the center of the span, and working outwards towards the support regions of the span. A depth gauge can be used to measure a consistent depth, stapling, or otherwise attaching the fabric on either side of the gap. Attention to the symmetry of the curvature created is important. Repeating this process on the other strut regions, working from the center outward to ensure symmetry, creates the strut forms. The remaining loose fabric is then stretched and attached by stables or other means in the same fashion eliminating wrinkles by varying the angle of pull. When using a coated polyolefin fabric, or other plastic membrane, heat can be applied selectively to wrinkled areas to allow stretching to produce smooth tension curves across the mold wall surface. When applying the fabric to the opposite side, comparisons should be made regularly to verify symmetry.
[0065] Formwork or edging for the top flange can now be attached to the sides. The term clamping is used here as a generic term for attachment of the side. Clamping the open side to the base or center piece creates half of the hollow cavity of the mold, and provides a space for the installation of the reinforcing steel and tensioning mechanisms.
[0066] The beam is reinforced by tension reinforcing placed in the tension flange. This reinforcing may be pre-tensioned by vertical posts located at the loading points of the truss design, that is at the struts.
[0067] Attachment of the cable at each end is achieved by clamping either end of the cable to the ends of the rigid mold structure. The clamps are fixed to the base, braced by the compression block side forms. The length of the tension cable is determined so that when the cable is depressing downwards at the truss load points, the cable will be stretched into position in the tension flange of the truss, thus pre-stressing the cable within the mold. The ends need to be clamped ensuring even tension between the individual strands of the cable, and overall symmetry.
[0068] The pre-tensioning devices may be located over the designed loading points of the beam (vertical struts) and may be attach to the rigid mold components or to any other resistant attachment for example a floor. Threaded or hydraulically controlled rods press down on the reinforcing steel thus tensioning the cable. Once the rods are at the proper depth, the remaining side can be clamped onto the assembly. Alignment of the two sides should be checked. The vertical steel should be plumb and well aligned as this will ensure that the cable follows a straight path from end to end.
[0069] During pouring, the form should be leveled and secure. Pouring should begin at or near the center, moving outwards until the voids are full but not the compression block. The technique for removing air bubbles is most successful by continuously vibrating the apparatus while pouring. Continuing to vibrate while the compression block is poured ensures that any trapped air will escape. Alternatively self compacting concrete can be used.
[0070] Another example is the “fish” truss which is a hybrid of a tension-cable structure and an arch.
[0071] The techniques and formwork are similar to those of the above described truss, with identical reinforcement and pouring technique.
[0072] The plywood base is scribed with a catenary curve just as the previous beam. The curve is inverted and overlaid to create the pattern for the arch element. There is a slight difference in the blocking pattern to account for the integrated arch, but otherwise the formwork is created in the same manner.
[0073] To form the “fish tail” sections of the beam, void blocks are placed at each end, held in place by fastening through the form side. These blocks are easily removed after the bean has been lifted from the form.
[0074] Several methods of mold construction are possible. While the side pieces of the scaled models and full-scale prototype shown are made of plywood, these side pieces could be constructed using other materials or constructed as solid panels or as open frames. The Block-Out Clamp shapes may be constructed as panels held off the surface of the side piece frame, or alternately, just the perimeter of the Block-Out Clamp shapes may be constructed. Clamping pressure to hold the two side pieces of the mold together could be gained by a variety of mechanical means including treaded rods, bolts, or wedges, or in larger constructions, hydraulic pistons.
[0075] A variety of coated and uncoated structural fabrics could be used. Options include woven polyethylene or polypropylene textiles, or woven glass fibre textiles with an impervious and robust coating (ex. Teflon, PVC).
[0076] Many different truss designs can be constructed by this method by altering the shape of the center piece and the shapes and patterns of the Block-Out Clamps.
[0077] Since various modifications can be made in my invention as herein above described, and many apparently widely different embodiments of same made within the spirit and scope of the claims without department from such spirit and scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense. | Complex, three-dimensional, variable section casts with a high level of dimensional control can be made from molds consisting of two flat or tailored sheets of flexible material (such as fabric) held between rigid clamps. The clamping materials control the shape and dimension of the mold in the X and Y directions while the flexible sheets are allowed to deflect in the Z direction. Void shapes in the truss can be obtained when the clamping material presses the two sheets together. | 4 |
This application is a continuation of U.S. patent application Ser. No. 09/334,492, filed Jun. 16, 1999 which is now abandoned.
The present invention relates to alkaline storage batteries such as nickel-hydrogen storage batteries, nickel-cadmium storage batteries, and nickel-zinc storage batteries.
FIELD OF THE INVENTION
BACKGROUND OF THE INVENTION
In recent years, alkaline storage batteries are in wide use ranging over power sources of various portable equipment to large size batteries for electric vehicles. In these alkaline batteries, nickel hydroxide electrode is generally employed as the positive electrode.
The methods of manufacturing nickel hydroxide electrodes can be broadly divided into two types, namely, sintered type and paste type. Sintered electrodes are made by immersing in an alkaline solution after immersing in a nickel nitrate solution or nickel sulfate solution and suffer the problem of complication of the manufacturing process and a low capacity density. On the other hand, paste type nickel electrodes are made by filling an active material primarily composed of nickel hydroxide onto a high-porosity foamed or fibrous substrate; their manufacturing process is simple and it is possible to achieve a high capacity.
As the nickel hydroxide itself has a low electric conductivity, rate of utilization of the positive active material tends to be low when filling it alone on the substrate because transfer of electrons cannot be smoothly performed. In order to solve this problem, a method is widely employed in which a cobalt compound is added to the positive active material paste. This is based on the understanding that the cobalt compound is easily oxidized during the initial charge to become high electric-conductivity cobalt oxyhydroxide thus functioning as electrically conducting networks among nickel hydroxide particles and between the current collector and nickel hydroxide particles. However, as cobalt is rare, it is necessary to form enough electrically conducting networks by addition of a smaller quantity of cobalt compound in order to provide a lower-cost battery as well as to achieve a further higher capacity.
In order to solve these problems, many proposals have been made as to the quantity and conditions of adding cobalt compounds such as metallic cobalt, cobalt oxide, cobalt hydroxide, etc. More recently, proposals have been made to cover the surface of nickel hydroxide particles with cobalt hydroxide to obtain an enhanced effect of addition of cobalt hydroxide of a smaller quantity.
For example, Japanese Laid-Open Patent Application No. Hei 9-45323 proposes a process of obtaining an active material for alkaline storage batteries by adding nickel hydroxide powder into an aqueous solution of cobalt compound followed by neutralizing in an aqueous solution adjusted to pH 10-12, then suspending in an alkaline aqueous solution and electrochemically oxidizing it. However, the cobalt oxyhydroxide obtained by electrochemical oxidation of β-type cobalt hydroxide has a specific electric conductivity on the order of 10 −5 S/cm, which is not very high. This process also suffers the problem of including a step of electrochemical oxidation of powders which tends to be complicated.
Also, in Japanese Laid-Open Patent Application No. Hei 8-148146, for example, it is proposed to improve the rate of utilization of the positive active material by producing higher-order cobalt oxides having a high electric conductivity on the surface of nickel hydroxide by heat treatment of nickel hydroxide of which the surface has been covered with cobalt hydroxide in an environment of coexisting oxygen and alkali metal hydroxides. However, in this method, tricobalt tetraoxide tends to be produced as a by-product while cobalt hydroxide is being oxidized, suggesting that not all the cobalt compound is effectively functioning thus not exhibiting full effect.
Also, as the reaction is one which takes place at the interface among vapor phase, solid phase, and liquid phase, the method has a drawback of suffering considerably high non-uniformity of reaction and of complication of the process of producing a high electric-conductivity cobalt compound on the surface of nickel hydroxide powder.
Further, though Japanese Laid-Open Patent Application No. Hei 10-125315 discloses an active material primarily composed of nickel hydroxide the surface of which is covered with a cobalt compound, it has been difficult to uniformly and stably produce cobalt oxyhydroxide having an especially high electric conductivity on nickel hydroxide.
The present invention addresses the previously existing problems as described above. It is an object of the invention to eliminate the problems encountered in oxidizing cobalt hydroxide and to produce cobalt oxyhydroxide with a high electric conductivity on the surface of nickel hydroxide with uniformity and stability while simplifying the process, thus improving the rate of utilization of the positive active material and discharge characteristic of alkaline storage batteries.
SUMMARY OF THE INVENTION
In accomplishing the above object, the present invention first produces α-type cobalt hydroxide on the surface of nickel hydroxide of the positive active material of an alkaline storage battery, followed by oxidizing treatment of it with an oxidizing agent such as sodium hypochlorite or potassium permanganate thereby producing cobalt oxyhydroxide with a high electric conductivity on the surface of nickel hydroxide with simplicity, uniformity and stability.
The positive active material for alkaline storage batteries as obtained above is subsqeuntly filled onto foamed metal and the like to obtain an electrode for alkaline storage batteries. The present invention also intends to improve the rate of utilization of the positive active material and discharge characteristic by making its specific electric conductivity to within the range 1 to 10 −4 S/cm.
The present invention utilizes a positive active material obtained by dispersing nickel hydroxide in an aqueous solution of cobalt (II) such as cobalt nitrate or cobalt sulfate, neutralizing it with a hydroxide of an alkali metal to render α-type cobalt hydroxide adhere on the surface of nickel hydroxide, followed by treating with an oxidizing agent to produce cobalt oxyhydroxide with a high electric conductivity on the surface of the active material. By forming a high electric conductivity cobalt oxyhydroxide on the surface of the active material, the low rate of utilization of the positive active material attributable to the property of a low electric-conductivity of nickel hydroxide can be significantly improved.
Here, it is conceivable that the higher the electronic conductivity of the cobalt hydroxide on the surface is, the more improved are the rate of utilization of the positive active material and discharge characteristic. According to the present invention, the specific electric conductivity can be made to such a high value as 1 to 10 −4 S/cm.
Also, as the present invention uses α-type cobalt hydroxide as the starting material, oxidizing treatment is simple, namely, α-type cobalt hydroxide can be rapidly converted into a higher-order cobalt oxide with a high electric conductivity by simply adding an oxidizing agent such as aqueous solution of sodium hypochlorite, aqueous solution of hydrogen peroxide, aqueous solution of potassium permanganate, and the like. This reaction being a reaction at a solid-liquid interface, the oxidizing treatment can be performed relatively uniformly. Furthermore, this process can be performed in a batch immediately after the above-described process of coating the surface of nickel hydroxide particles by α-type cobalt hydroxide.
In doing this, it is good to keep the pH of the reaction mixture to be used in rendering α-type cobalt hydroxide adhere on the surface of nickel hydroxide in the range 8 to 10. When the pH of the reaction mixture is too low, it is not possible to produce enough quantity of α-type cobalt hydroxide on the nickel hydroxide particle surface. Also, when the pH is higher than 10, greenish-blue α-type cobalt hydroxide rapidly changes to white-peach colored β type and the subsequent oxidizing treatment with an aqueous solution of sodium hypochlorite is made difficult. Furthermore, when stirring efficiency during subsequent neutralization is poor, the pH locally becomes higher than 10 making it difficult to uniformly produce α-type cobalt hydroxide on the surface of nickel hydroxide particles.
Also, in the above active material of the present invention, the quantity of cobalt oxyhydroxide covering nickel hydroxide surface is chosen to be 0.5 to 10% by weight of nickel hydroxide. When the quantity of α-type cobalt hydroxide covering nickel hydroxide surface is too small, it is not possible to provide a high enough electric conductivity on the surface thus not exhibiting its effect. Conversely, when the quantity is too large, a large quantity of expensive cobalt compound will be consumed thus making the cost high while causing an undesirable decrease in the filling density of the positive active material. The adequate quantity of α-type cobalt hydroxide for covering is 0.5 to 10% by weight of nickel hydroxide, preferably 2 to 5%.
As has been described above, with the present invention, a positive active material having a high rate of utilization and a superior discharge characteristic can be produced more easily by the addition of a smaller quantity of the cobalt compound.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE is a graph showing relationship between discharge rate and capacity.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A practical description of an exemplary embodiment of the present invention will be given in the following together with a description of comparative examples. It will be made clear that the alkaline storage battery described as an example has a high charge-discharge capacity, superior discharge characteristic and superior cycle characteristic.
EXAMPLE 1
[Preparation of Active Material]
A quantity of 100 grams of Ni(OH) 2 powder was added to 500 mL of 0.025 mol CoSO 4 aqueous solution containing a small quantity (1 mL) of hydrazine, into which 0.1 mol NaOH aqueous solution was slowly dropped while violently stirring the CoSO 4 solution to adjust the pH of the resulting reaction mixture to 9.0 and the surface, of Ni(OH) 2 was covered with greenish-blue α-Co(OH) 2 . Stirring was continued until 15 minutes after the addition of the NaOH aqueous solution was finished. Subsequently, 100 mL of NaClO aqueous solution with an effective chlorine concentration of 5% was added to the above suspension, which was stirred for additional 30 minutes. The obtained black suspension was left to stand and washed five times by decantation using 500 mL of ion-exchanged water, after which powder was filtered and dried at 60 degrees C. An inductively-coupled plasma-atomic emission spectroscopy of the quantity of Ni and Co elements in the active material showed that the obtained powder had a weight ratio of Ni(OH) 2 /CoOOH=95.7/4.3. Its specific electric conductivity as measured by 4-probe method was 10 −3 S/cm under a load of 1000 kg/cm 2 .
Nickel foamed metal with a porosity 95% was used as a substrate. Paste was prepared by adding approximately 20 mL of ion-exchange water into 100 grams of the above active material. A positive electrode (35 mm×85 mm×0.85 mm, porosity 35%, weight of the filled material 6.5 gram) was prepared by filling the paste onto the foamed metal, drying and then pressing.
[Preparation of the Negative Electrode]
Hydrogen absorbing alloy was used for the negative electrode. Paste prepared by pulverizing MmNi 3.7 Mn 0.4 Al 0.3 Co 0.6 , being one of MmNi 5 metals, and allowing it to pass a 360 mesh and then adding a CMC aqueous solution with a concentration of 1.5% by weight was coated on a punched metal made of nickel-plated iron. After drying and pressing the product, a water dispersion of 5% fluorine resin was added. It was then cut to the same size as the positive electrode.
[Fabrication of a Battery]
A sealed type prismatic nickel-hydrogen storage battery was fabricated by combining a sheet of the positive electrode and two sheets of the negative electrode and a separator made of nonwoven fabric of polypropylene after hydrophilic treatment. As the liquid electrolyte, adequate quantity of a solution prepared by dissolving 10 grams/L of lithium hydroxide into a KOH aqueous solution with a specific gravity of 1.30 was used.
COMPARATIVE EXAMPLE 1
In preparing the positive active material, the surface of Ni(OH) 2 particles was covered with α-Co(OH) 2 as in the case of Example 1. The positive electrode was prepared in the same manner as in Example 1 with the exception of subsequent treatment with NaClO aqueous solution. Measurement of the quantity of Ni and Co elements in the active material by an inductively-coupled plasma-atomic emission spectroscopy revealed that the positive active material had a weight ratio of Ni(OH) 2 /Co(OH) 2 =95.5/4.5. The specific electric conductivity of the active material as measured by 4-probe method was below the measurable limit (10 −8 S/cm) under a load of 1000 kg/cm 2 .
COMPARATIVE EXAMPLE 2
In preparing the positive active material, though the reaction mixture was neutralized with an alkali as in the above Example 1, the pH of the reaction mixture was adjusted to be alkaline up to 13 and β-type cobalt hydroxide was rendered to precipitate on the surface of nickel hydroxide particles. Subsequently, a positive electrode was prepared in the same manner as in Example 1 with the exception of treatment with a NaClO aqueous solution. Measurement of the quantity of Ni and Co elements in the active material by an inductively-coupled plasma-atomic emission spectroscopy revealed that the obtained powder had a weight ratio of Ni(OH) 2 /Co(OH) 2 =95.8/4.2. The specific electric conductivity of this material as measured by 4-probe method was below the measurable limit (10 −8 S/cm) under a load of 1000 kg/cm 2 .
COMPATATIVE EXAMPLE 3
Nickel hydroxide particles of which the surface had been covered with β-type cobalt hydroxide were prepared in the same manner as in Comparative Example 2. Subsequently, the active material prepared was oxidized in the presence of alkali by heat treatment at 100 degrees C. for 1 hour in the presence of an aqueous solution of 40% by weight NaOH, washed with water and dried to obtain a positive active material. A positive electrode was obtained through the same subsequent process as in Example 1. Measurement of the quantity of Ni and Co elements in the active material by an inductively-coupled plasma-atomic emission spectroscopy revealed that the obtained powder had weight ratio of Ni(OH) 2 /Co(OOH) 2 =95.8/4.2. The specific electric conductivity of this active material as measured by 4-probe method was 10 −4 S/cm under a load of 1000 kg/cm 2 .
COMPARATIVE EXAMPLE 4
Paste was prepared by mixing nickel hydroxide and cobalt oxide of 10% by weight of nickel hydroxide and adding ion-exchange water, which was then filled onto foamed metal to obtain a positive electrode. Subsequent process was the same as in Example 1.
For each of Comparative Examples 1 to 4, a sealed prismatic nickel-hydrogen storage battery was fabricated by using the same negative electrode, separator and liquid electrolyte and through the same process as in Example 1.
Rate of utilization of Active Material and Charge-Discharge Cycle Life of Each Battery:
For each of the batteries fabricated in Example 1 and Comparative Examples 1 to 4, charge-discharge cycle test was conducted in which one cycle consisted of charging to 120% at 25 degrees C. at 0.1C rate and then discharging at 25 degrees C. at 0.2C rate until 0.9 V. The rate of utilization of the active material and the battery capacity at the 10th cycle and charge-discharge cycle life of each battery were obtained. In the cycle life test, the number of cycles reached until the capacity had decreased to 80% of the capacity at the 10th cycle was obtained. Table 1 shows the test results.
TABLE 1
Rate of utilization of
Discharge
Charge-discharge
active material at
capacity at 10th
cycle life
10th cycle (%)
cycle (mAh)
(cycles)
Example 1
100
1702
263
Comparative
73
1122
187
Example 1
Comparative
72
1107
190
Example 2
Comparative
100
1711
224
Example 3
Comparative
105
1644
197
Example 4
It can be seen from Table 1 that Comparative Examples 1 and 2 have a lower rate of utilization and shorter life although the quantity of cobalt hydroxide added was the same as Example 1 of the present invention. Though the surface of nickel hydroxide had been covered with α-type cobalt hydroxide in Comparative Example 1 and with β-type cobalt hydroxide in Comparative Example 2, there was essentially no difference between the two conceivably because α-type cobalt hydroxide had changed to β type by the addition of the liquid electrolyte immediately. In the case of Comparative Example 4 in which CoO had been added, while the initial rate of utilization was superior, the capacity was lower as the filling density of the active material had been rendered lower, and the cycle life was inferior to Example 1. While the rate of utilization and discharge capacity of Comparative Example 3 were similar to Example 1, the cycle life was inferior.
High-Rate Discharge Characteristic of Each Battery:
For each of the batteries fabricated in Example 1 and Comparative Examples 1 to 4, the capacity was compared by charging to 120% at 25 degrees C. at 0.1C rate followed by discharging at 25 degrees C. at 0.1C, 0.2C, 0.5C and 1C rates. The FIGURE shows the result.
While there was essentially no difference between Example 1 and Comparative Example 3, Comparative Example 4 showed a large capacity at lower discharge rates but the capacity decreased with increasing discharge rate. With Comparative Examples 1 and 2, as the quantity of addition of cobalt compound was too small, the discharge characteristic was poor.
As has been described above, it is possible in the present invention to render α-type cobalt hydroxide adhere on the surface of nickel hydroxide particles, and, by subsequent oxidizing treatment with an oxidizing agent, to render high specific electric-conductivity cobalt oxide adhere on the surface of nickel hydroxide with simplicity and stability. As a result, it is possible to achieve a high rate of utilization of the active material, a long cycle life, and a superior discharge characteristic in alkaline batteries employing a nickel positive electrode. | An alkaline storage battery, a positive electrode material for the alkaline storage battery, and a method of preparation for the positive electrode material are disclosed. The positive electrode material is made up of nickel hydroxide particles that have cobalt oxyhydroxide on their surface. The particles may be prepared by a process in which α-cobalt hydroxide adhered to the surface of the nickel hydroxide particles is oxidized to cobalt oxyhydroxide. The battery has a superior rate of utilization of active material, cycle life, and discharge characteristics. | 7 |
SUMMARY OF THE INVENTION
This invention relates to an improvement in the wide stance method of curing a pneumatic tire. The wide stance method is a method of manufacturing a pneumatic tire wherein the distance between the two bead areas of the tire when it is molded (this distance is known as the "curing width") is substantially greater than the distance between the tire bead area when it is operable; that is, mounted and inflated on its recommended rim (this distance is known as the "rim width"). In the standard method of curing pneumatic tires, the curing width of the bead areas in the mold is approximately equal to or slightly greater than the rim width. In the standard methods, a tire which was designed to be mounted on a rim with a 5.5 inch rim width could have a curing width from 5.5 inches to 7 inches. Prior wide stance methods had larger differences in these values. In either the standard method or prior wide stance methods the parting line between the curing bladder and the mold in the bead area has been located at the bead toe. In this invention this parting line is located at a point on the inner periphery of the tire. This location is a significant distance from the bead toe. This means the mold itself extends axially inwardly to at least the center of the wire bundle and preferably beyond.
Even though the wide stance method is known, it has not been commercially exploited to a great extent. Its known advantages are a simpler curing system. In the wide stance system the tire doesn't have to be molded with its lower sidewall and bead area in the reverse curvature that these areas assume in its mounted, operable condition. This system results in the reduction of curing defects due to trapped air during the curing operation and other surface defects; such as cure folds. It also yields an increase in curing bladder life due to the more cylindrical shape of the bladder during the curing operation. This method has also been found to be successful in the manufacture of collapsible spare tires as disclosed in Applicants' copending application, Ser. No. 674,710, filed Apr. 7, 1976.
A primary reason that the commercial exploitation of wide stance molding techniques has been small is the problem of maintaining the wire bead bundles in the proper location during the curing operation. In the prior wide stance molding techniques the wire bead bundles have tended to be displaced axially inwardly from their proper location during the curing operation. As a result of this, the percent of defective tires manufactured by this method was too high to merit commercial exploitation even though the other advantages of these techniques, as set out above, were known. It is believed that this problem is in part the result of bladder pressure on the bead area of the tire which displaced the wire bead bundles.
The method of this invention solves the wire bead bundle displacement problem mentioned above. In the method of this invention the portion of the tire curing mold where each bead area is located (known as the "bead ring") is provided with an annular cavity to accept the tire bead area containing the wire bead bundle during the shaping operation prior to molding. The pressure of the curing bladder during shaping pushes the bead area and wire bead bundle into this cavity and, due to the configuration of this cavity, the bladder pressures employed during the remainder of the curing cycle hold the wire bead bundles in the proper, designed position.
This improvement is attained by the cavity structure in the mold bead ring wherein the bead area containing the wire bead bundle are protected on three sides by the metal bead ring. As a result of this, the only bladder pressures acting upon the bead area containing the wire bead bundle are pressures axially outwardly. The toe of the bead is contained within this cavity and is not in contact with the curing bladder during the curing operation.
In this method the parting line between the mold bead ring and the curing bladder is located on the band ply (innermost layer in the tire) and is removed from the bead toe. This parting line is located at or axially inwardly of the center of the wire bead bundle. In prior methods curing bladder pressures also acted in a radially outwardly and axially inwardly direction on the wire bead bundles.
An object of this invention is to provide a wide stance curing method in which the tire bead areas containing the wire bead bundles are cured in annular cavities in the tire mold to prohibit any axially inward movement of the wire bead bundle during the curing operation.
Other advantages and objectives of this invention will be evident from the detailed description to follow.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a tire in a tire mold utilizing the method in this invention;
FIG. 2 is an enlarged fragmentary cross-sectional view of one of the bead areas of FIG. 1;
FIG. 3 is a view similar to FIG. 2 showing an alternative form of the invention.
DETAILED DESCRIPTION
In FIG. 1 the invention is depicted by a cross-sectional view of a tire and a curing mold with the bead ring having a cavity which is adapted to receive the bead area of the tire. This drawing shows the location of the bead area, wire bead bundle and curing bladder during the method of this invention. In FIG. 1 the bead ring is depicted as 10 and the remainder of the curing mold is 11. These are constructed of any of the known materials which are used in the manufacture of tire curing molds. The curing bladder, 12, is attached to the bead ring at annular cavity, 13. The other end of the curing bladder is attached to another ring, 14. The bladder is constructed of a rubber compound known in the art.
The bead ring, 10, contains an annular cavity, 15. This cavity is located and adapted to accept the bead area, 16, of the pneumatic tire. The bead area contains a wire bead bundle, 17, and has bead toe, 18. The parting line between the curing bladder, 12, and the bead ring, 10, is shown at 19.
In this invention the wire bead bundle, 17, should preferably be of the cable bead type construction. Constructions of this type permit internal rotation of the wires in the bead bundle during the shaping of the uncured tire in the mold or during the shaping of the cured tire in mounting on the rim.
The pneumatic tire construction may be any of the known types (ones with bias cord bodies or radial bodies and stabilizer belt plies in the tread area) that are well known in the art. The rubber compounds utilized in the pneumatic tire are also any of the types that are well known in the art.
The annular cavity, 15, in mold bead ring, 10, has sides 20, 21 and 22. These sides are located radially outwardly, axially outwardly, and radially inwardly, respectively, of the bead area and wire bead bundle when the tire is being cured. The intersection of sides 21 and 22 defines the bead toe 18.
In the method of this invention, the uncured tire is placed in the curing mold between the curing bladder and the mold. The mold is closed and the curing bladder is inflated whereby the bead areas and wire bead bundles of the uncured tire are pushed axially outwardly into the cavity 15 of the mold bead ring. After the mold is completely closed and the curing bladder has its maximum internal pressure, the wire bead bundle is located within the annular cavity in the mold bead ring. During the remainder of the curing operation, the internal pressures of the curing bladder can only act to force the wire bead bundle axially outwardly. No forces can operate on the wire bead bundle to move it in an axially inwardly direction. After the curing operation is complete, the internal pressure in the bladder is released, the mold is opened and the tire is removed.
The tire thus produced has a curing width that is substantially greater than its recommended rim width. No problems are encountered in mounting this tire on the rim and inflating it to its operable condition.
FIG. 2 is an enlarged fragmentary view of the right-hand bead area of FIG. 1 showing this area in greater detail. The reference numbers used in FIG. 1 are also used in FIG. 2.
FIG. 3 is another enlarged fragmentary view of a right-hand bead area according to another embodiment of this invention. It depicts an embodiment of the method of this invention which can be utilized in the manufacture of a collapsible type tire. In a copending application, Ser. No. 674,710, filed Apr. 7, 1976, the Applicants have disclosed and claimed a method of manufacturing this type tire. This tire is designed to be used as a spare tire in automobiles wherein storage space is at a premium. The tire may be mounted on its rim and stored deflated. In this deflated condition the overall diameter of the tire is very small. This is accomplished by an arrangement in which the sidewalls of the tire are folded. The tire is stored in this compact condition. When it is desired to use the tire, the tire is inflated on its rim. During inflation the sidewall folds are removed and the overall diameter of the tire increases greatly.
In the Applicants' method of manufacturing a tire of this type, the tire is molded in a substantially cylindrical shape. After mounting on the rim and while in the stored, uninflated condition, the bead areas of the tire extend axially inwardly in a direction approximately parallel to the axis of rotation of the tire. During inflation the bead area of the tire rotates about the bead bundle so that a bead area of the tire rotates approximately 90° to a position approximately perpendicular to the axis of rotation of the tire, the standard toroidal position of the tire bead area.
In this embodiment the bead area, 16 and the bead bundle, 17, are pushed into the annular cavity, 15, of the bead ring, 10, during the shaping operation prior to curing. This was accomplished by the internal pressure within bladder 12. So situated, as depicted in FIG. 3, the wire bead bundle cannot be displaced axially inwardly during the remainder of the curing operation as the only bladder pressures operating on the bead bundle are in an axially outwardly direction. After the curing cycle is completed, the tire is removed from the mold and mounted in the manner described above.
In FIG. 3 the radially inner wall, 22, of the annular cavity, 15, is shown containing annular ribs, 23, which provide corresponding annular grooves in the cured tire. These annular grooves in the tire define annular ribs, 24, in the cured tire. These annular ribs are located on the bead seat of the tire rim when the tire is in its collapsible condition. During the inflation process on the rim these annular ribs facilitate the retention of air so that the bead area will rotate and proper inflation will be attained. It is understood that the embodiment shown in FIG. 3 may not have these ribs and grooves but may be smooth as shown in FIG. 2.
The location of the wire bead bundles in the Figures depicts an essential feature of the method of this invention. The center of the bead bundles must be axially outwardly of the mold parting line, 19, or at least in the same radial plane as the parting line, when the tire resting in the mold prior to the application of pressure by the bladder. This permits the bead bundles to be maintained in their proper places during curing.
Employing the method of this invention, a D78-14 tire has been constructed having two body plies comprised of nylon reinforcing cords of 1260/2 denier and a tread ply comprised of nylon reinforcing cords of 1260/2 denier. The wire bead bundles were comprised of a cable bead with a solid wire core and eight wires helically wrapped around the core. The tire was built on a standard flat building drum utilizing standard building techniques. The tire was cured with the bead configuration shown in FIG. 3. The bead curing width in the mold was 17.25 inches. In the cured shape, the overall diameter of the tread at its circumferential centerline was 19.01 inches.
This tire was mounted on a standard rim having a 5 inch rim width. In its collapsed position the overall diameter of the tread was 19.29 inches. In its inflated, operable condition the overall diameter of the tread was 25.50 inches. | This disclosure relates to an improvement in the "wide stance" method of manufacturing a pneumatic tire. In this method the space between the two annular wire bead bundles of the tire is substantially greater than the space between the beads in their operable condition, mounted on the recommended rim. The improvement comprises the steps of locating the bead areas of the uncured tire which contain the annular wire bead bundles in annular cavities in the tire mold which are adapted to receive the bead areas. This maintains the wire bead bundles in their proper location during the entire curing operation. | 1 |
BACKGROUND OF THE INVENTION
1.Field of the Invention
The present invention relates to a method and apparatus for handling tools of substantial longitudinal length to insert the tools into and withdraw them from a pressurized container, such as a well bore.
2.Description of the Prior Art
It is necessary to periodically monitor the conditions within a producing well and, for this reason, logging tools are sent downhole on a wireline to gather the necessary data. There are two problems that are involved in accomplishing this data collection, namely, the tools are elongated tubular assemblies of relatively small diameter, in comparison their length, fashioned from short lengths of tubular members to form a single tool of perhaps 20 to 60 feet in length. At this point, it becomes quie evident that the tool will be quite difficult to handle because of its length. The tool is introduced to the well by attaching a lubricator to a blowout preventer at the top of the well casing. The lubricator is a series of large diameter tubular members assembled around the logging tool and contains, at its upper end, a grease injection tube or stuffing box through which the wireline for suspending the tool is passed. The lubricator itself is a major handling problem since it is long, heavy, difficult to manipulate in the rig and make connections, and it also is expensive. After the lubricator and stuffing box have been assembled about the tool, and the tool attached to the wireline, the assembly of the tool and lubricator is hoisted into position on the blowout preventer and secured thereto. Pressure between the borehole and lubricator is equalized by opening a bypass valve around the blowout preventer. The blowout preventer is then opened allowing access to the borehole. After the blowout preventer has been opened, the tool can be lowered into the borehole by the wireline with the grease injection tube or stuffing box providing a seal around the wireline as the tool is lowered.
The tool is extracted from the borehole by drawing it up to a position within the lubricator, closing the blowout preventer, venting the lubricator, and removing the assembly of the tool and lubricator from the blowout preventer and lowering them to a position where they can be subsequently disassembled into the individual components. It will be appreciated from the foregoing description that there are a number of difficulties in such an opertion, including knowing when the tool has been fully withdrawn into the lubricator, not drawing the wireline so taut against the stuffing box that there is a possibility of the wireline being broken with the result being the tool falling downhole before the blowout preventer can be closed and closing the blowout preventer on the tool before it is fully withdrawn into the lubricator. Of course handling the lubricator and tool during the extraction process is equally as difficult as handling them during the insertion process.
SUMMARY OF THE INVENTION
The present invention is intended to overcome the difficulties of the prior art by providing a method and apparatus which aloow relatively short and easily handled sections of a tool, such as a well logging tool, to be sequentially assembled at an enclosure entry and lowered through a pressure lock into the enclosure. The tool of the present invention is formed from a plurality of short tool string sections which are connected by spacer/couplers with the completed tool string being attached to a cable head which is attached to a wireline. Each of the spacer/couplers has an electrical conector on each end thereof, which connectors engage mating connectors on respective ends of the tool string sections. The present invention also includes a tool catcher/pressure control assembly which is mounted on a pressure lock at the entry. The tool catcher opening is generally annular member having an inwardly opening cavity on one side thereof containing a pivotal catch assembly formed by a shaft extending through the catcher cavity transverse to and spaced from the axis of the assembly with a slotted plate attached to the shaft for movement between a horizontal and a vertical position. The slot of the plate is of sufficient width to allow only the passage of a spacer/coupler therethrough so that, in the vertical position, the tool string can pass through the tool catcher and, in the horizontal position, the catcher will engage the lower end of a tool string section and hold the tool in place.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described, by way of example, with reference to the accompanying drawings in which:
FIG. 1 is a schematic side elevation, partly in section, showing the prior art method and apparatus for logging a producing well;
FIG. 2 is a vertical longitudinal section through a portion of a well head incorporating the present invention;
FIG. 3 is an enlarged detail section through a blowout preventer and the present invention;
FIG. 4 is a transverse section taken along line 4--4 of FIG. 3; and
FIG. 5 is a longitudinal section through a spacer/coupler in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The prior art apparatus shown in FIG. 1 is a drilling rig 10 and a platform 12 positioned over a well casing 14 which closed at its upper end by a blowout preventer 16. In this conventional set up, the string tool assembly 18 is suspended by a cable head 20 from a wireline 22 within a lubricator assembly 24. The lubricator assembly 24 is secured at its lower end to the blowout preventer 16 and at its upper end is equipped with a grease junction tube or stuffing box 26 which is supplied with pressurized sealing fluid from a source 28 through a flexible conduit 30.
The prior art requires that the tool assembly 18 and lubricator assembly 24 be formed by joining together individual tool and lubrication members on the platform 12 and then be hoisted to the position shown in FIG. 1 and connected to the blowout preventer 16. It will be appreciated that a tool string 18, such as production log string, or other tool and/or instrument string, can be of substantial length, for example of 20 to 60 feet or even longer, up to the 90 feet of a normal pipe string which is about the maximum length that the standard drill rig 10 can handle. It will be readily appreciated that handling such a long assembly of tool string and lubricator will be a difficult matter requiring many skilled workers in order to prevent damage to the tool string, lubricator, blowout preventer, and rig, as well as injury to the workers.
The present invention will be described with reference to FIGS. 2-5, with FIGS. 2 and 3 showing in somewhat greater detail the blowout preventer 16. This blowout preventer 16 is a standard device known in the well drilling industry and includes a housing 32 having a first coupling means 34 for assembly with the well casing 14 and a second oppositely directed coupling means 36 adapted to receive the tool catcher 38 thereon. The blowout preventer 16 includes a pair of rams 40, 42 having respective inwardly directed mating faces 44, 46 with mating seals 48, 50 on the ends thereof. The rams 40, 42 can be driven by either hydraulic or pneumatic piston means (not shown) or by manual screw threaded members 52, 54 extending through threaded apertures and end caps 56, 58.
The tool catcher 38 is assembled on the second coupling means 36 of the blowout preventer 16 and is a generally cylindrical member having a bore 60 with an inwardly opening cavity 62 on one side thereof. A shaft 64 extends through the cavity in a normally horizontal condition perpendicular to and spaced from the axis of the tool catcher 38. The ends of the shaft 64 are rotatable in sealed bearings 66, 68 the walls of the tool catcher and at least one end extends beyond the tool catcher, as shown in FIG. 4. The shaft 64 is provided with a handle or indicator 70 and can be biased towards the horizontal by a spring 72. Fixed to the shaft 64 is a plate 74 which can move between the illustrated horizontal position substantially closing the bore 60 of the tool catcher and a vertical position, shown in broken lines, in which the bore is completely free of obstruction. The plate has a slot 76 inwardly directed toward the axis of the bore 60. The slot 76 is narrower than a tool string member 78 but wider than a coupler/spacer member 80 so that, in the horizontal position, plate 74 will engage a coupler/spacer member 80, preventing downward movement of the drill string into the borehole. The upper end of the tool catcher 38 is provided with threads 76 which receive the coupling 84 of a lubricating member 86. The coupling 84 can be integral with the lubricating member, as shown in FIG. 2 or a separate rotatable member, as shown in FIG. 3. The upper end of the lubricating member is provided with a stuffing box 88 similar to that described with reference to the prior art.
The coupler/spacer member 80 of the present invention is shown in greater detail in FIG. 5. The coupler/spacer member 80 has an elongated, generally cylindrical body 90 with enlarged male and female coupling heads 92, 94 on the opposite ends thereof forming annular shoulders 96, 98. Male and female electrical connectors 100, 102 are mounted internally of body 90, at the ends thereof, and are joined by cable 104. The electrical connectors 100, 102 have been shown with a single representative terminal for the sake of simplicity. Any member and any patterned array of terminals will, of course, be used as necessary.
The present invention is utilized in the following manner: the tool catcher 38 is mounted on the blowout preventer 16 as shown in FIGS. 2 and 3. The first tool string member 78 is placed in the tool catcher 38 and will be restrained from downward movement by the plate 74. A coupler/spacer member 80 is attached to the upper end of the tool member 78 and the cablehead 20 and wireline 22 attached to the upper end thereof. The lubricating member 86 is then placed on the upper end of the tool catcher 38 and secured in place. Pressure between the wellhead and lubricator is equalized and the blowout preventer 16 and the tool catcher plate 74 opened allowing the first section of the tool be lowered into the borehole by wireline 22. The plate 74 is in a "ready-to-close" condition, biased by spring 72. When the coupler/spacer member 80 arrives in the tool catcher 38, the plate 74 rotates under the action of spring 72 to engage the shoulder 98 of the upper head 94 of the coupler/spacer thereby preventing the first tool section 78 from dropping further into the borehole. The movement of the plate 74 will be noticed by the movement of the handle 70 outside of the tool catcher 38 to give a ready visual indication of when it is time to close the blowout preventer 16. When the blowout preventer 16 is closed, it will grab the coupler/spacer body 90 and seal the well bore. The lubricating member 86 can now be removed, the cable head 20 disconnected and the next section of the tool string connected to the upper end of the coupler/spacer member 80. The lubricating member 86 is then replaced and the same sequence of events followed until the entire tool string is assembled. When the final piece is assembled, and the cable head 20 attached to the top of the tool string, the blowout preventer opened to allow the wireline to feed the tool string down through the borehole taking the necessary measurements. The logging string is removed from the well by reversing the above discussed process.
The present invention has been described with reference to introducing a well logging tool into a producing well, i.e. going into and out of an enclosure or container which is above atmospheric pressure. The invention is equally applicable to the opposite situation and could, for example, be used in a space vehicle, such as the shuttle, to assemble a tool which will be used outside of the vehicle in a zero pressure environment.
The foregoing disclosure and description of the invention is illustrative and explanatory thereof, and various changes in the method steps as well as in the details of the illustrated apparatus may be made within the scope of the appended claims without departing from the spirit of the invention. | A method and apparatus for running long tools into an out of pressurized enclosures includes a tool stop assembled on an access pressure lock of the enclosure and which tool stop cooperates with a segmented tool string to allow sequential assembly, insertion, withdrawal and disassembly of the tool string into and out of the enclosure. The tool string is made up of a number of tool segments interconnected by coupler/spacer members of smaller diameter than the tool sections and of shorter length. The tool catcher acts upon the thinner sections of the coupler/spacer members to fixedly hold the tool string in place for subsequent assembly/disassembly without allowing any significant pressure change in said enclosure. | 4 |
This is a Divisional application of application Ser. No. 09/827,883 filed Apr. 5, 2001, now U.S. Pat. No. 6,523,287.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to electrical contacts and to a method and apparatus for making the contacts. More particularly, the invention concerns a method and apparatus for making four sided electrical contacts of the character having specially configured, spaced apart spring like tines.
2. Discussion of the Invention
Fork like electrical contacts are well known in the art and are widely used in a number of different kinds of electrical applications. Typically, the prior art fork contact includes a pair of inwardly biased sides or tines that extend out from a base so that a member such as a pin contact may be inserted between the pair of sides to make an electrical connection therewith.
Because of the extensive use in industry of electrical contacts of the character described in the previous paragraph, various methods have been suggested in the past for the high volume manufacture of the electrical contacts. In one common prior art method the contact members are stamped or lanced from a suitable piece of sheet material and the contact tongues or tines are then formed or coined as necessary. Exemplary of such electrical contacts is those disclosed in U.S. Pat. No. 3,286,220 issued to Marley et. al. and in U.S. Pat. No. 3,812,452 issued to Sturm.
Another prior art method of making electrical contacts involves the splitting of a bar of electrically conductive metal longitudinally over a portion of its length to form two contact tongues. Such a method is described in U.S. Pat. No. 4,040,177 issued to Beehler et. al. In one form of the Beehler et. al. method, a portion of the bar to be split is to be enclosed between two tools. The tools are then moved, sliding along each other perpendicular to the longitudinal dimension of the bar in mutually opposed directions over a distance which is sufficient to produce the desired splitting. In another method of splitting, the bar to be split is retained over its length such that one end is free to receive a wedge which is longitudinally driven into the bar through this free end.
Experience has shown that, in order to repeatedly produce precision electrical contacts by splitting or shearing the material, it is absolutely essential that the portion of the material immediately adjacent the boundary of the split or shear be rigidly and positively contained. Only in this way can a predictable controlled, precise split of the material be achieved.
An elegantly simple prior art method and apparatus for producing two sided precision electrical contacts by a shearing method is disclosed in U.S. Pat. Nos. 4,909,763 and 4,970,782 issued to the present inventor. In the practice of the methods disclosed in these patents, the starting material from which the electrical contacts are made is closely constrained within the area of the shear boundaries so that predictable and precisely controlled shearing of the material can be repeatably achieved with great accuracy. The present invention comprises an improvement upon the method and apparatus disclosed in U.S. Pat. No. 4,909,763 and in U.S. Pat. No. 4,970,782 and, for this reason, these patents are hereby incorporated by reference as though fully set forth herein.
As will be better understood from the discussion which follows, the thrust of the present invention is to improve on the techniques described in the previously mentioned, incorporated by reference patents and in so doing to provide a method and apparatus for the high volume production of four sided electrical contacts from a starting material which comprises a plurality of spaced apart, pre-cut pins which are precisely split to form four, spaced apart tines or tongue like members. The apparatus of the present invention then forms these four tongue like members into precisely configured, four sided contacts.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method and apparatus for the precise manufacture of high quality, four-sided electrical contacts by means of a closely controlled material skiving or splitting process. More particularly, it is an object of the invention to provide an apparatus of novel design for use in making the precision, four-sided electrical contacts wherein the starting material from which the electrical contacts are made is closely constrained in the area of the shear boundaries so that predictable and precisely controlled shearing of the material can repeatedly be achieved to initially form four precursor sides.
It is another object of the present invention to provide an apparatus for making four-sided electrical contacts of the aforementioned character in which the apparatus includes forming means for forming the precursor sides into a final, end product configuration.
Another object of the invention is to provide an apparatus of the character described in the preceding paragraphs which automatically performs the shearing and forming steps on a progressive basis.
Another object of the invention is to provide an apparatus of the class described which is of simple, straightforward design requiring a minimum amount of maintenance.
Still another object of the invention is to provide a method and apparatus of the character described in the preceding paragraphs which is easy to use by relatively unskilled workmen and has the ability to accomplish very high volume production rates.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a generally perspective view of one form of the four sided electrical contact made in accordance with the method of the present invention.
FIG. 2 is a generally perspective, illustrative view of a greatly simplified form of shearing mechanism.
FIG. 2A is a generally perspective, exemplary view of the general type of precursor article produced using a shearing mechanism of the character depicted in FIG. 2 .
FIG. 3 is a top plan view of the shearing station of the apparatus of the invention and diagrammatically illustrates the initial steps in the method of the invention for shearing the starting work pieces to form the four sides of the precursor of the electrical contact of the general character shown in FIG. 2 A.
FIG. 4 is a cross-sectional view taken along lines 4 — 4 of FIG. 3 showing the shearing tool advanced into one of the die portions of the shearing mechanism provided at the shearing station.
FIG. 5 is a cross-sectional view taken along lines 5 — 5 of FIG. 3 showing the appearance of the outwardly extending tongues of the precursor contact after the starting work piece has been sheared by the forward advance of the shearing tool between the dies of the apparatus of the invention.
FIG. 6 is a fragmentary top plan view showing removal of the shearing tool from the just formed precursor contact.
FIG. 7 is a cross-sectional view taken along lines 7 — 7 of FIG. 6 showing the configuration of the precursor article after formation of the top, bottom and side precursor tongues.
FIG. 8A is a fragmentary, generally diagrammatic top plan view of the tongue spreading station of the apparatus illustrating the first step of the method of the invention for forming the side tongues of the precursor article prior to their being shaped into their final configuration.
FIG. 8B is a fragmentary, generally diagrammatic top plan view similar to FIG. 8A showing the next step in the side forming operation at the forming station, namely the insertion of the spreading tool between two forming dies.
FIG. 8C is a fragmentary generally diagrammatic top plan view similar to FIG. 8B, but showing the spreading tool in a retracted position following spreading of the side tongues.
FIG. 9 is a generally diagrammatic top plan view of the precursor tongue shaping stations showing the sequential steps of the method of the invention for shaping the top and bottom tongues of the precursor contact.
FIG. 10 is a cross-sectional view taken along lines 10 — 10 of FIG. 9 showing the final shaping step for shaping the top and bottom precursor tongues.
FIG. 11 is a generally diagrammatic, top plan view showing the precursor tongue shaping station for shaping the spaced apart, precursor side tongues of the contact into their final shaped configuration.
FIG. 12 is a generally diagrammatic top plan view of the tongue shaping station shown in FIG. 11, illustrating the shaping tool of FIG. 11 in a retracted position relative to the formed contact.
FIG. 13 is a cross sectional view taken along lines 13 — 13 of FIG. 11 .
FIG. 14 is a generally diagrammatic top plan view showing an alternate form of the apparatus of the invention and depicting the steps of an alternate method of the invention for shearing a work piece of a somewhat different construction.
FIG. 15 is a front view of a portion of the apparatus and work piece shown in FIG. 14 illustrating the method of shearing the alternate form of starting work piece.
FIG. 16 is a cross-sectional view taken along lines 16 — 16 of FIG. 14 showing the appearance of the top and bottom tongues following the initial shearing step.
FIG. 17 is a generally diagrammatic top plan view showing still another form of the apparatus of the invention and depicting the steps of the method of the invention for shearing a tapered work piece.
FIG. 18 is a front view of a portion of the apparatus and work piece shown in FIG. 17 illustrating the method of shearing the alternate form of starting work piece.
FIG. 19 is a cross-sectional view taken along lines 19 — 19 of FIG. 17 showing the configuration of the tapered work piece.
FIG. 20 is a cross-sectional view taken along lines 20 — 20 of FIG. 17 showing the appearance of the top and bottom tongues following the initial shearing of the tapered work piece.
FIG. 21 is a cross-sectional view taken along lines 21 — 21 of FIG. 17 showing the appearance of the top and bottom tongues after the initial forming step.
FIG. 22 is a generally diagrammatic, fragmentary top plan view similar to FIG. 17 but showing still another form of the method of the invention for shearing a tapered work piece that also varies in width.
FIG. 23 is a cross-sectional view taken along lines 23 — 23 of FIG. 22 further showing the configuration of the tapered work piece.
FIG. 24 is a cross-sectional view taken along lines 24 — 24 of FIG. 22 showing the appearance of the top and bottom tongues following the initial shearing of the tapered work piece.
DESCRIPTION OF THE INVENTION
Referring to the drawings and particularly to FIG. 1, one type of four sided electrical contact made in accordance with the method of the present invention is there illustrated and generally designated by the numeral 14 . Contact 14 includes a stem portion 16 and four cooperating tongues 18 , 20 , 22 and 24 respectively. After being formed each of the four tongues of the electrical contact is generally arcuate in shape having one end integrally connected to the stem portion and the opposite, or free ends having an outwardly curved portion, generally designated in FIG. 1 by the numeral 30 .
Before discussing the various tongue forming and shaping steps of the method of the present invention that are required to form contact 14 , a brief discussion of the basic shearing techniques of the invention is in order. In this regard, referring particularly to FIG. 2, a very basic type of shearing apparatus is there diagrammatically illustrated. Similarly, FIG. 2A shows a very basic form of precursor, four sided contact made using the apparatus shown in FIG. 2 . As indicated in these figures, during the shearing step the work piece “W” is secured within a clamping means here depicted as first and second cooperating clamping elements 38 and 40 (FIG. 2 ).
As more fully discussed in U.S. Pat. Nos. 4,909,763 and 4,970,762, which patents are incorporated herein by reference, clamping elements of the same general character there described are used to support the work piece “W” as the splitting tool or punch element 42 advances toward the securely clamped work piece. As depicted in FIG. 2, the work piece “W” has a width greater than the width of channels 38 a and 40 a which are formed in elements 38 and 40 in the manner shown in the drawings.
As will be discussed in greater detail hereinafter, by precutting the work piece to some desired width greater than the width of channels 38 a and 40 a , splitting of the work piece by the shearing tool 42 (FIG. 2) will result in the simultaneous formation of the side tongues 35 b and the top and bottom tongues 35 c and 35 d (see FIG. 2 A). Because of the way in which the work piece is split by the skiving tool, if the width of the work piece is properly selected, the thickness of the side tongues will be approximately half the thickness of the starting work piece. More particularly, it is to be appreciated that the width of the work piece “W” must be carefully selected to be about twice the thickness of the work piece “W” if all four contacts are to have the same cross-sectional dimensions. Therefore, by judiciously choosing the width of the work piece in proportion to its thickness, the controlled splitting of the work piece “W” will uniquely produce a precursor contact having four tongues of substantially the same cross-sectional dimensions.
Notwithstanding the foregoing, it is to be appreciated that for some end product applications, having all four tongues the same may not be required, or even desired. By way of example, if the work piece “W” shown in FIG. 2A were to be made somewhat wider than the width “D”, then the thickness of side tongues 35 b would be greater than the thickness of top and bottom tongues 35 c and 35 d . If this were to be done, the stiffer side contacts could be used as locators in the resulting connector. In similar fashion, side tongues 35 b could be formed so that one could compensate for the increased thickness of the side tongues by increasing the length of the lever arm. This would provide the added benefit of reducing the insertion force of the mating male contact.
As is also apparent from a study of FIG. 2A, the thickness of top and bottom tongues 35 c and 35 d is determined by the thickness “T” of the work piece “W”, while the width of the tongues is independent of the thickness of “W”. On the other hand, the width of side tongues 35 b is determined by the thickness of “W”, and the thickness of the tongues and 35 b is independent of the thickness of “W”. Uniquely, the width of the side tongues is substantially equal to the thickness of the work piece. Thus the cross-sectional dimensions of the four tongues are determined quite differently from one pair to the other. For example, on some occasions, it may be desirable to have the side tongues 35 b thicker and longer than the top and bottom tongues. In this instance, the width of the starting work piece would be adjusted accordingly to achieve the desired end result.
As discussed in much greater detail in U.S. Pat. No. 4,909,763, the imposition of the very high shearing on the work piece caused by the shearing tool causes a novel burnishing effect to occur on either side of the apex of the punch. This burnishing action results in the formation of a remarkably fine finish on the sheared surfaces of the precursor electrical contact. In accordance with one form of the method of the present invention, as the shearing tool 42 advances into the channel within which the work piece is clamped, burnished, precursor top and bottom tongues 35 c and 35 d will be precisely formed.
Referring now to FIGS. 3 through 7, one form of the method and apparatus of the present invention for making the electrical contact 14 is there illustrated. In this instance, the starting work piece is provided in the form of an elongated strip of material having a plurality of outwardly extending fingers 44 (FIG. 3.) This starting work piece, which is identified in FIG. 3 as “WP”, is formed by a conventional blanking operation well known to those skilled in the art which produces an indexable work strip having a plurality of outwardly extending fingers 44 . After the starting work piece has been indexably positioned on the work surface of the apparatus using index pins 46 , it is advanced to the shearing station, generally identified by the numeral 48 , where the shearing step is accomplished. During this important shearing step, the fingers 44 are sequentially controllably sheared to produce four sided, precursor contacts 55 of the general configuration illustrated in FIGS. 5 and 7. After the shearing step, each individual precursor contact formed includes a stem portion 55 a , which, at this stage is a part of strip “WP”, spaced apart precursor side tongues 55 b (FIG. 6 ), a precursor top tongue 55 c and a precursor bottom tongue 55 d (FIG. 7 ).
In a manner presently to be described, in using the apparatus of the present invention as generally depicted in FIGS. 3 through 13, the work piece is controllably advanced to the right as seen in FIG. 3, first to the shearing work station 48 and then through several forming and shaping stations where the precursor tongues are strategically formed into their final shape.
At the shearing station, diagrammatically depicted in FIG. 3, a selected finger 44 a is securely clamped in position by cooperating upper and lower clamping elements 58 which comprise a part of the support means of the apparatus of the invention. Each of the clamping elements is provided with a shearing tool receiving channel 58 a which is of a width less than the width of fingers 44 . With finger 44 a securely clamped in place between the clamping elements in the manner shown in the central portion of FIG. 3, shearing means, here shown in the form of a shearing tool or punch 60 , is advanced from the position shown in the central portion of FIG. 3 to a position shown in the right-hand portion in FIG. 3 . As the shearing tool advances it will controllably shear the workpiece in a manner to form the precursor contact which includes precursor side tongues and precursor top and bottom tongues. More particularly after the shearing tool has reached the position shown in FIG. 5, the four precursor tongues comprising a pair of precursor side tongues 55 b , a top precursor tongue 55 c and a bottom precursor tongue 55 d will have been formed. As indicated in FIG. 7, after the shearing step the two precursor side tongues 55 b and the precursor top and bottom tongues 55 c and 55 d respectively will have the general configuration shown. Following retraction of the shearing tool as illustrated in FIG. 6, the work piece “WP” will be advanced to the right in a direction toward the first of several forming stations of the invention wherein the precursor tongues of the precursor contact will be shaped into their final configuration.
It is to be understood that as the precursor contact moves toward the first forming station of the apparatus, another finger 44 of the work piece will automatically be moved into position to be securely clamped between upper and lower clamping elements 58 of the apparatus which are appropriately moved into position above and below on either side of the finger as the finger is moved into position within the shearing work station. Once the finger to be sheared is in position between the clamping elements and spanning the shearing tool receiving channels 58 a , the shearing tool 60 can once again be advanced toward the securely clamped work piece to controllably shear the central portion of the finger and thereby form the next precursor contact which will also have the general configuration shown in FIG. 7 . The means for indexably advancing the workpiece, for positioning the clamping elements and for advancing and retracting the shearing tool are well understood by those skilled in the art and will not be discussed in detail herein.
As best seen by referring to FIG. 5, shearing tool 60 includes a body portion 60 a and a cutter portion 60 b which is integrally formed with body portion 60 a . Cutter portion 60 b includes walls 60 c and 60 d which taper inwardly and terminate in an apex 60 e which defines the shearing edge of the shearing tool. Shearing tool 60 preferably has side walls tapering at an angle of between about 60 and about 80 degrees. The shearing tool functions in much the same manner as the earlier described exemplary shearing tool 42 and, as shown in FIGS. 4 and 5, as it moves inwardly of channel 58 a , precursor top and bottom tongues 55 c and 55 d are simultaneously formed into the general configuration shown in FIG. 7 leaving side tongues 55 b in a spaced-apart configuration. Once again, reference should be made to incorporated by reference U.S. Pat. Nos. 4,909,763 and 4,970,782 for a more detailed discussion of the design requirements for the shearing apparatus shown in FIGS. 3 through 6 and for the details of the shearing step accomplished at the shearing station 48 .
After shearing of the selected finger 44 is completed, the shearing tool is retracted (FIG. 6) and the precursor electrical contact formed during the shearing operation is advanced forwardly of the apparatus to a forming station 63 having the character generally illustrated in FIGS. 8A, 8 B and 8 C. In the manner next to be described, during the forming steps of the method of the invention, first forming means acts on the precursor contact to strategically shape the first and second precursor side tongues thereof to form shaped first and second side tongues. This important first forming means here comprises two separate forming mechanisms, the first of which comprises a spreading means located at station 63 . This spreading means, which here includes a spreading tool 64 and cooperating backing members 66 a and 66 b functions to controllably spread apart and initially shape the precursor side tongues 55 b . Also forming a part of the first forming means of the apparatus of the invention is a second forming mechanism which, as will presently be discussed, functions to finally shape the precursor side tongues after they have been controllably spread apart by the spreading means.
Considering first the important spreading means of the apparatus, this means here comprises first and second backing members 66 a and 66 b which are positioned on either side of a selected precursor electrical contact such as the contact identified in FIG. 8A by the numeral 67 . Also forming a part of the spreading means of the invention is the previously mentioned spreading tool 64 , which in the manner shown in FIG. 8B, can be advanced between the precursor side tongues 67 a and 67 b so as to urge them outwardly to pressural engagement with the inner surfaces of the backing members 66 a and 66 b . After the precursor side members have been acted upon by the spreading tool 64 , the electrical contact will take on the configuration generally shown in FIG. 8C wherein the partially formed contact is identified by the numeral 69 .
Turning next to FIGS. 11, 12 and 13 , another forming station 70 is there shown. Located at station 70 is the previously mentioned second forming mechanism, which shapes the spread-apart side tongues into their end product configuration. As best seen in FIG. 11, the second forming mechanism, which comprises a part of the first shaping means, includes first and second forming members 72 and 74 which are positioned proximate the spaced apart, precursor side tongues 67 a and 67 b of the precursor contact 69 . After members 72 and 74 have been moved into the position shown in the left hand portion of FIG. 11, a first forming mandrel 76 is moved inwardly in the direction of the arrow 77 in FIG. 11 to a location intermediate precursor side tongues 67 a and 67 b . This done, members 72 and 74 are urged inwardly in the direction of arrows 79 shown in the right-hand portion of FIG. 11 into pressural engagement with the precursor side tongues so as to urge the tongues into forming contact with the curved exterior surfaces 76 a provided on mandrel 76 . The means used for moving the members 72 and 74 into pressural engagement with the precursor side tongues can take several forms well known to those skilled in the art including various types of mechanical means or, for example, hydraulically operated rams 79 a which move the members in the direction of arrows 79 and which are diagrammatically illustrated in FIG. 13 .
Following the final shaping of precursor side tongues 67 a and 67 b into their shaped, end product configuration, forming members 72 and 74 are retracted in the direction of arrows 81 of FIG. 12 and forming mandrel 76 is moved outwardly in the direction of the arrow 83 of FIG. 12 . Of course, members 72 and 74 are first retracted, and subsequently mandrel 76 is moved outwardly. This sequence of operation permits the formed tongues 67 a and 67 b to flex while the mandrel is being removed. It is to understood that forming members 72 and 74 can be moved into proximity with the precursor contact by several types of positioning means of a character well known to those skilled in the art
Prior to the final shaping of the precursor side tongues, as described in the preceding paragraph, the top and bottom precursor tongues are shaped by second forming means located at the shaping station 85 , the character of which is shown in FIG. 9 . This important second forming means acts on the precursor contact to strategically shape the top and bottom precursor tongues. Provided at shaping station 85 are third and fourth, or bottom and top forming members 88 and 90 which are positioned proximate top precursor tongue 55 c and bottom precursor tongue 55 d (see also FIGS. 7 and 10 ). As the forming members 88 and 90 move into the position shown in the central portion of FIG. 9, they will be urged inwardly toward a second forming mandrel 92 which has been advanced to a position interiorly of the precursor tongues of the contact. With forming mandrel 92 in the advanced position, forming members 88 and 90 are next urged inwardly in the direction of the arrows 93 of FIG. 10 into a position wherein the top and bottom precursor tongues are urged into pressural engagement with the curved sides of mandrel 92 so as to shape the top and bottom tongues into their shaped configuration shown in FIG. 10 wherein the shaped tongues are identified by the numerals 59 c and 59 d . Once again the means for urging the precursor top and bottom tongues into pressural engagement with the mandrel can take various forms well understood by those skilled in the art and can comprise hydraulic rams 93 a , as diagrammatically illustrated in FIG. 10, for urging the forming members 88 and 90 in the direction of the arrows 93 c.
Referring next to FIGS. 14, 15 and 16 an alternate apparatus of the invention for making four sided electrical contacts is there illustrated. This apparatus is similar in many respects to the apparatus of the invention previously described and is uniquely adapted to shear an alternate form of work piece into a precursor contact having precursor side tongues and precursor top and bottom tongues. The work piece here comprises an elongated, pin-like member 100 having a predetermined width and a predetermined thickness. The work pieces, or pin-like members 100 are affixed to a bandolier strip 102 of a character well known to those skilled in the art which has the configuration generally illustrated in FIG. 14 .
Referring to FIG. 16, it can be seen that the stem portion 100 a of the starting work piece 100 is securely clamped to bandolier strip 102 by a clamping yoke 106 . After the starting pin 100 is securely clamped to the bandolier strip in a manner shown in the drawings, the strip is moved toward the shearing station generally designated by the numeral 108 where the shearing step is accomplished. Shearing station 108 is substantially similar to the previously described shearing station 48 and at this important shearing station a selected pin 100 is controllably sheared to produce a four sided, precursor contact of the general configuration illustrated in FIG. 16 having a stem portion 160 a that is equal in width and thickness to pin 100 . Following the shearing step, the precursor contact thus formed includes a stem portion 100 a , spaced apart precursor side tongues 110 and precursor top and bottom tongues 112 and 114 respectively.
During the shearing step a selected pin 100 is securely clamped between cooperating upper and lower clamping elements 118 which comprise a part of the support means of this alternate form of the apparatus of the invention. As before, clamping elements 118 are each provided with a shearing tool receiving channel 119 which is of a width less than the width of pin 100 .
With the selected pin 100 securely clamped in place between upper and lower support members 118 and shearing tool receiving channels 119 in a manner shown in the center portion of FIG. 14, shearing means. here provided in the form of a shearing tool or punch 120 , is controllably moved toward channels 119 . As the shearing tool enters channels 119 , it will cleanly shear the central portion of the pin in a manner to form the precursor contact, which is of the general configuration illustrated in FIG. 16 . Following the shearing step, shearing tool 120 is retracted and the bandolier strip 102 is moved to the right carrying the precursor contacts 104 with it.
Following the shearing step, the precursor contacts are transported by the bandolier strip toward the first and second forming means of the invention which are of substantially identical construction and operation to those previously described herein.
As was discussed in incorporated by reference U.S. Pat. No. 4,909,763, in some instances the shearing of the starting work pierces WP and 100 causes a “plowing” like effect occurs on the material as the shearing tool advances. This “plowing” like effect can result in the increase in thickness of the tongues and the concomitant shortening thereof. Stated another way, an examination of the top and bottom tongues formed in the shearing process reveals that in some instances they have become thicker than one-half the thickness of the work piece 100 and stem portion 100 a of the contact. Accordingly, if the top and bottom tongues were to be bent inwardly toward one another, their overall length would be less than the length of the unsupported area of the starting work piece. The reasons for this thickening of the tongue walls as well as the foreshortening effect is discussed in detail in columns 9 and 10 of incorporated by reference U.S. Pat. No. 4,909,763 and will not be repeated here. Suffice to say that in some cases the thickness of the upper and lower tongues can vary from between about 50% of the thickness of the work piece “WP” and stem 100 a and about 60% of this thickness. The thickness of the tongues is, of course, at least equal to 50% the thickness of the work piece and stem.
Turning to FIGS. 18 through 21, the steps of still another method for making electrical contacts is there illustrated. The apparatus depicted in these drawings is virtually identical to the apparatus of the invention shown in FIGS. 3 through 13 as previously described herein. However, in this instance, the apparatus is uniquely adapted to shear a tapered finger of a work piece “WT” into a precursor contact having precursor side tongues and precursor top and bottom tongues.
As best seen in FIG. 19, the work piece “WT” here comprises an elongated strip of material 124 having a plurality of outwardly extending fingers 126 which are tapered in cross-section in the manner indicated in FIG. 19 . The advantages of using this novel tapered work piece are discussed in the paragraph that follows:
Experience has shown that, while the prior art, uniform-thickness, beam-type contacts of the character described in U.S. Pat. Nos. 4,909,763 and 4,970,782 issued to the present inventor are well suited for most applications, such contacts exhibit an inherent drawback. More specifically, these types of contacts, that have a uniform thickness beam supported at one end, undesirably exhibit maximum bending stress at the point of support that is proximate the end of the split or shear. By making the starting work piece finger in a tapered configuration in which the finger tapers from a lesser thickness proximate its free distal end to a greater thickness proximate its proximal fixed end, the stress of the fixed end can be markedly reduced and the tendency of the bending stress to propagate the shear considerably lessened.
Referring to FIGS. 17 and 18, the apparatus there depicted is used to form the improved contact as described in the preceding paragraph. As previously mentioned, this apparatus is substantially identical to that shown in FIGS. 3 through 13 and like numerals are used in FIGS. 17 through 21 to identify like components. In using the apparatus to form the improved tapered tongue contacts of the invention, the starting work piece “WT” is first indexably positioned on the work surface of the apparatus in the manner previously described using index pins 46 . This done, the work piece is advanced to the shearing station, generally identified by the numeral 48 , where the shearing step is accomplished in the manner previously described. It should, of course, be noted that blocks 40 must have surfaces in their clamping channels that match the top and bottom surfaces of the fingers.
After the shearing step is completed, each individual precursor contact that is formed includes a stem portion 130 which, at this stage, is a part of a finger 126 of strip “WT”. Extending from stem portion 130 are spaced apart precursor side tongues 132 (FIG. 18 ), a tapered precursor top tongue 134 and a tapered precursor bottom tongue 136 (FIG. 20 ). Each of these top and bottom precursor tongues has a distal, first portion 138 of a first thickness “T-1” and a second, proximal portion 140 of a second thickness “T-2” greater than the first thickness.
As before, in using the apparatus of this latest form of the invention, which is generally depicted in FIGS. 17 and 18, the work piece is sequentially advanced to the right as seen in FIG. 17, first to the shearing work station 48 and then through the several previously described forming and shaping stations where the precursor tongues are strategically formed into their final shape.
After the shearing step has been completed, the two precursor side tongues 132 and the precursor top and bottom tongues 134 and 136 respectively will have the novel tapered configuration shown in FIGS. 20 and 21 wherein the tongues are thicker at their fixed or proximal ends and become thinner in a direction toward their free or distal ends. As earlier discussed, this unique tapered construction will reduce stress at the fixed proximal end thereby lessening the tendency of the shear to propagate.
Referring again to FIGS. 17 and 18, following the initial shearing step at station 48 and the subsequent retraction of the shearing tool, the work piece “WT” will be advanced to the right in a direction toward the spreading means located at station 63 wherein the precursor side tongues of the precursor contact will be shaped in the manner previously described. Next, the work piece will be advanced to the forming station 85 where, in the manner previously described, the top and bottom tongues will be shaped into their end product configuration wherein the product exhibits its novel tapered tongue configuration illustrated in FIGS. 20 and 21.
Referring to FIGS. 22 through 24, the apparatus used to form still another form of improved contact is there illustrated. This apparatus is substantially identical to that shown in FIGS. 17 and 18 and like numerals are used in FIGS. 22 through 24 to identify like components. In using the apparatus to form this latest form of improved contacts of the invention, the starting work piece, here identified as WP- 1 , is first indexably positioned on the work surface of the apparatus in the manner previously described using index pins 46 . This done, the work piece is advanced to the shearing station, where the shearing step is accomplished also in the manner previously described. It is to be noted that in this instance the work piece WP- 1 includes a plurality of spaced apart fingers 150 each of which varies in width from a first width W- 1 , proximate its free end, to a second greater width W- 2 proximate its fixed end (FIG. 22 ). (The variation in width shown in the drawings is somewhat exaggerated for purposes of illustration.) As depicted in FIG. 23, each of the fingers 150 also varies in thickness from a lesser thickness proximate its free end to a greater thickness proximate its fixed end. As in the earlier described embodiments of the invention, in actual operation, the work piece is sequentially advanced to the right as seen in FIG. 22, first to the shearing work station 48 and then through the several previously described forming and shaping stations where the precursor tongues are strategically formed into their final shape.
After the shearing step has been completed, the two precursor side tongues 152 and the precursor top and bottom tongues 154 and 156 not only vary in width, but also, as shown in FIG. 24, vary in thickness with the tongues being thicker at their fixed or proximal ends thinner in a direction toward their free or distal ends. As previously discussed, by making the starting work piece finger in a tapered and variable width configuration as shown in FIGS. 22 and 23, the stresses at the fixed end of the formed contacts can be markedly reduced and the tendency of the bending stress to propagate the shear considerably lessened
Having now described the invention in detail in accordance with the requirements of the patent statutes, those skilled in this art will have no difficulty in making changes and modifications in the individual parts or their relative assembly in order to meet specific requirements or conditions. Such changes and modifications may be made without departing from the scope and spirit of the invention, as set forth in the following claims. | A method and apparatus for the precise manufacture of high quality, four-sided electrical contacts by means of a closely controlled material skiving process. The apparatus is designed so that the starting material from which the four-sided electrical contacts are made is closely constrained in the area of the shear boundaries so that predictable and precisely controlled shearing of the material can repeatedly be achieved to initially form four precursor sides, two of which are arcuate. The apparatus also includes sequentially operating forming mechanisms for precisely forming the precursor sides of the precursor contact into a final end product configuration. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a 371 of International application number PCT/US2014/047674 filed Jul. 22, 2014, which claims the benefit of priority to U.S. Application No. 61/857,189, filed Jul. 22, 2013, and U.S. Application No. 61/858,811, filed Jul. 26, 2013, which are incorporated herein by reference in their entireties
STATEMENT OF INTEREST
This invention was made with government support under grant numbers HD038519 and GM097971 awarded by the National Institutes of Health and grant number DBI1039771 awarded by the National Science Foundation. The government has certain rights in the invention.
FIELD OF THE INVENTION
The invention relates to the field of polymers and olefin polymerization, and more specifically olefin metathesis polymerization.
BACKGROUND
Copolymers are employed in a wide range of materials, ranging from bulk plastics to specialized coatings, pharmaceutical compositions, and biomedical and electronic devices. Among the most commonly used are block copolymers, which often rely on phase separation of the two blocks for their functional properties, for example in drug delivery nanoparticles, and random copolymers, which incorporate two or more functional moieties that act co-operatively, for example in organic light emitting diodes. Regularly alternating polymers allow for controlled positioning of functional substituents, but they are difficult to access synthetically.
Regioregular alternating polymers (for example, SAN, styrene-acrylonitrile, an alternating copolymer used in plastics) are generally synthesized by radical polymerization with kinetic control of alternation in the polymerization reaction. 1,2 Recently, ring opening metathesis polymerization (ROMP) and ring opening insertion metathesis polymerization (ROIMP) 3 have been employed to synthesize alternating polymers: Ilker, M. F.; Coughlin, E. B. Macromolecules 2002, 35, 54-58; Choi, T. L.; Rutenberg, I. M.; Grubbs, R. H. Angewandte Chemie - Intl. Ed., 2002, 41, 3839-3841; PCT publication WO 03/070779.
The existing methods of formation of alternating polymers are limited, and there remains a need for new and more structurally diverse substrates and polymers. The present invention provides substrate and catalyst combinations that can generate a wider range of alternating polymers, having a range of diverse properties.
Herein we address both, the limitation of the NB/COE ROMP, i.e. the formation of COE homoblocks, as well as the intramolecular chain transfer of current AROMP by utilizing CBE/CH monomers containing the DAN-PDI pair to achieve perfectly alternating copolymers. We show that these polymers exhibit a higher intensity charge-transfer absorbance than analogous poly(NB-alt-COE) polymers.
BRIEF DESCRIPTION OF THE INVENTION
The invention provides a method for producing an alternating AB copolymer comprising the repeating unit Ia, Ib, or Ic:
in which the A monomer is derived from a cyclobutene 1-carboxyl or 1-carbonyl derivative III, and the B monomer is derived from a cyclohexene derivative II.
The method comprises contacting the cyclohexene derivative II with the cyclobutene derivative III in the presence of an olefin metathesis catalyst. This polymerization method enables the facile preparation of amphiphilic and bifunctional alternating polymers from simple and readily available starting materials.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows chemical structures of monomers and catalyst (box) used for AROMP.
FIG. 2 shows partial UV-Vis spectra of the charge-transfer region in chloroform. a) Comparison of alternating copolymers. Upper trace=3 mM poly(1-alt-5) 10 , middle trace=100 μM poly(1-alt-5) 10 , lower trace=3 mM poly(NB-alt-COE)-block-poly(COE). b) Plot of charge-transfer absorbance versus concentration of poly(1-alt-5) 10 .
FIG. 3 depicts the 1 H-NMR spectrum of 11-(5-(hexyloxy)naphthalen-1-yloxy)undecyl cyclobut-1-enecarboxylate (1)
FIG. 4 depicts the 13 C-NMR spectrum of 11-(5-(hexyloxy)naphthalen-1-yloxy)undecyl cyclobut-1-enecarboxylate (1)
FIG. 5 depicts the 1 H-NMR spectrum of 2,5-dioxopyrrolidin-1-yl cyclohex-3-enecarboxylate (3).
FIG. 6 depicts the 13 C-NMR spectrum of 2,5-dioxopyrrolidin-1-yl cyclohex-3-enecarboxylate (3).
FIG. 7 depicts the 1 H-NMR spectrum of poly(1-alt-2) 5 .
FIG. 8 depicts the 1 H-NMR spectrum of poly(1-alt-3) 10 .
FIG. 9 depicts the 1 H-NMR spectrum of poly(1-alt-5) 10 .
FIG. 10 depicts a partial 1 H-NMR spectrum of a) 1; b) poly(1-alt-2) 5 ; and c) 2.
FIG. 11 depicts GPC traces of alternating copolymers. a) poly(1-alt-2) 5 ; b) poly(1-alt-5) 10 . Molecular weights and polydispersity indices were measured using UV detection with CH 2 Cl 2 as the eluent and a flow rate of 0.700 mL/min on an American Polymer Standards column (Phenogel 5μ MXL GPC column, Phenomenex). All GPCs were calibrated using poly(styrene) standards and carried out at 30° C.
FIG. 12 depicts fluorescence of the polymers. a) The emission spectra of poly(3′-alt-4-DH) n and poly(3′-Trp-alt-4-DH). (1.2 μM in THF) excited at characteristic wavelengths of tryptophan (284 nm) and dansyl fluorophore (335 nm). b) Plot of charge-transfer absorbance of poly(3′-alt-4-DH) n and poly(3′-Trp-alt-4-DH) n versus concentration ranging from 0.2 μM and 3 μM. c) Concentration dependence of fluorophores without the backbone showed no emission difference between a two fluorophore mixture and dansyl fluorophore alone.
DETAILED DESCRIPTION OF THE INVENTION
The invention provides a method for producing an alternating AB copolymer comprising the repeating unit Ia, Ib or Ic:
which comprises contacting an olefin of structure II with a cyclobutene of structure III
in the presence of an olefin metathesis catalyst. It will be understood that asterisk (*) at the end of a repeating unit can be interpreted as the point of attachment and may be terminated with a functional group as is known in the art. In the above structures, R may be, but is not limited to, H, C 1 -C 20 alkyl, C 2 -C 20 alkenyl, C 3 -C 8 cycloalkyl, heterocyclyl, aryl, C 1 -C 20 alkoxy, C 1 -C 20 alkenyloxy, C 3 -C 6 cycloalkyloxy, aryloxy, heterocyclyloxy, C 1 -C 20 alkylamino, C 1 -C 20 alkenylamino, C 3 -C 8 cycloalkylamino, heterocyclylamino, or arylamino and may be optionally substituted with up to three substituents selected from halo, CN, NO 2 , oxo, alkyl, cycloalkyl, alkenyl, alkynyl, aralkyl, aryl, and a heterocyclic group. In certain embodiments, the repeating unit, n, is between 2 and 20. Each substituent R 1 through R 6 may independently be, but is not limited to, H, aldehyde, C 1 -C 20 alkyl, C 2 -C 20 alkenyl, C 3 -C 6 cycloalkyl, aryl, heterocyclyl, C 1 -C 20 alkoxy, C 1 -C 20 acyloxy, C 2 -C 20 alkenyloxy, C 3 -C 6 cycloalkyloxy, aryloxy, heterocyclyloxy, C 1 -C 20 alkylamino, C 2 -C 20 alkenylamino, C 3 -C 8 cycloalkylamino, heterocyclylamino, arylamino, or halogen; with the proviso that any carbon-carbon double bonds in R or in R 1 through R 6 are essentially unreactive toward metathesis reactions with the catalyst. It will be also understood that adjacent substitutions of R 1 -R 6 may be taken together to form a 5- to 7-membered ring which may be optionally substituted with up to three substituents selected from halo, CN, NO 2 , oxo, alkyl, cycloalkyl, alkenyl, alkynyl, aralkyl, aryl, and a heterocyclic group. In certain embodiments, A may be, but is not limited to C 2 -C 20 alkyl. In another embodiment, A is C 8 -C 12 alkyl. In another embodiment, R 1 through R 6 may be independently be C(O)NH—C 1 -C 20 alkyl-N(R 7 )(R 8 ). Each R 7 and R 8 are independently selected from H, C 2 -C 6 alkyl, cycloalkyl, cycloalkenyl, alkyl-O-alkyl, alkyl-O-aryl, alkenyl, alkynyl, aralkyl, aryl and a heterocyclic group; or R 7 and R 8 may be taken together with the nitrogen to which they are attached form a 5- to 7-membered ring which may optionally contain a further heteroatom and may be optionally substituted with up to three substituents selected from halo, CN, NO 2 , oxo, alkyl, cycloalkyl, alkenyl, alkynyl, aralkyl, aryl, and a heterocyclic group.
By way of example, suitable cyclohexene and cyclobutene species include but are not limited to the following:
It will be understood that olefins in the substituents should be essentially unreactive with the metathesis catalyst under the reaction conditions, so that the metathesis polymerization involves the cyclobutene and cyclohexene double bonds exclusively, or nearly so. Generally, any carbon-carbon double bonds in R or in R 1 through R 6 should be trisubstituted or tetrasubstituted, or otherwise rendered unreactive with the catalyst.
Aryl, as used herein, includes but is not limited to optionally substituted phenyl, naphthyl, anthracenyl, and phenanthryl groups. Heterocycle and heterocyclyl refer to monocyclic and fused polycyclic heteroaromatic and heteroaliphatic ring systems containing at least one N, O, S, or P atom. Aryl and heterocyclic groups may contain from 1 to 60 carbon atoms, and may range from furan, thiophene, and benzene to large chromophores such as phthalocyanines and fullerenes. For some applications, aryl and heterocyclic groups will preferably contain from 1 to 20 carbon atoms.
It will be apparent that alkyl, alkenyl, cycloalkyl, heterocyclyl, acyl, and aryl moieties in the substituents R and R 1 through R 6 may be substituted with functional groups known to be compatible with the catalyst. Examples include, but are not limited to, C 1 -C 4 acyl, acyloxy, acylamino, amido, aryloxy, alkoxy and alkylthio groups; halogens; protected amino groups such as BocNH— and FmocNH—; protected hydroxy groups such as TMSO—, BzO—, and BnO—; and protected carboxyl groups such as —CO 2 -t-Bu and —CO 2 Bn. Accordingly, the terms alkyl, alkenyl, cycloalkyl, acyl, aryl, and heterocyclyl as used herein encompass such substituents.
The method may be used to prepare block copolymers as well, in which one block comprises the repeating units Ia, Ib, or Ic; the proportion of alternating and block copolymer regions in the polymer being dependent upon the catalyst and substrate. The catalyst may be any olefin metathesis catalyst known in the art, such as those disclosed in WO 03/070779. It is preferably an alkylidene ruthenium complex, and more preferably a complex of formula (L)2(L′)X 2 Ru═CHR′, wherein R′ may be, for example, H, C 1 -C 10 alkyl, C 2 -C 10 alkenyl, C 3 -C 6 cycloalkyl, or aryl. The ligand L is typically a trialkyl phosphines, triarylphosphines, tri(cycloalkyl)phosphines, pyridines, aryl, wherein aryl is optionally substituted with a halogen. L′ is a second ligand, and may be a trialkyl phosphine, triarylphosphine, tri(cycloalkyl)phosphine, or a pyridine. L′ may also be an imidazolin-2-ylidine carbene of formula IV:
wherein R 9 may be selected from the group, but is not limited to a C 1 -C 6 alkyl group or aryl. In certain embodiments, X is a halogen or pseudohalogen such as F, Cl, Br, NO 3 , CF 3 , or CF 3 COO − .
In certain embodiments, L is a pyridine, optionally 3-bromopyridine; and L′ is an imidazolin-2-ylidine carbene. In another embodiment, R 9 is preferably mesityl, 2-methylphenyl, 2-ethylphenyl, 2-isopropylphenyl, 2,3-diisopropylphenyl, 2, 6-difluorophenyl, or 3,5-di-t-butylphenyl.
The invention also provides the following polymer comprising the repeating unit Ia, Ib, or Ic.
The polymers of the present invention may be prepared according to the representative Schemes 1 through 3.
The target monomers and catalyst are shown in FIG. 1 . The syntheses of the side-chains are in close analogy to published methods. 4 Based on previous studies, 5 synthetic route 1 (Scheme 1) was first investigated for the alternating copolymerization of the DAN and PDI functionalized CBE and CH monomers, respectively. This route successfully afforded poly(1-alt-2) 5 . However, longer polymerization times were required due to the significant steric hindrance presented by the side-chain units. This resulted in a decrease in the rate of polymerization inhibiting the formation of higher molecular weight polymers.
To minimize steric hindrance and to achieve a higher degree of polymerization, a revised synthetic route was applied using DAN-CBE 1 and a cyclohexene functionalized with N-hydroxysuccinimide (NHS) (compound 3) for AROMP (Scheme 2). The NHS group is less bulky than the PDI, and is not reactive during the polymerization. The PDI ester can then be formed via a post-polymerization functionalization strategy to generate poly(1-alt-5) 10 . This modified route not only allowed for a higher degree of polymerization, but also provided an alternative strategy for the incorporation of the PDI moiety.
Previous studies on poly(CBE-alt-CH) n revealed signals in the 1 H NMR spectrum corresponding to concentration-independent intramolecular backbiting of the enoic ruthenium carbene on the unhindered disubstituted alkenes in the polymer backbone. 5 As a result, polydispersity indices of unfunctionalized poly(CBE-alt-CH) n were larger than 2 and a significant fraction of the polymer was cyclic. In our case, poly(1-alt-2) 10 and poly(1-alt-5) 10 did not show any proton resonance signals due to backbiting, had PDIs lower than 1.3, and displayed a monomodal distribution. We hypothesize that backbiting is inhibited by the increased steric hindrance at the enoic carbene and disubstituted alkene in combination with the restricted flexibility of the polymer backbone upon modification with larger substituents. As a consequence, longer AROMP copolymers were obtained than previously reported.
We designed a new set of cyclobutene derivatives as monomers with bicyclic structures which are very strained and can incorporate rings into the polymeric backbone. 5 Therefore we utilized functional group Br containing bicyclo[4.2.0]oct-7-ene-7-carboxylate and aldehyde containing cyclohexene as the AROMP pair which provides a facile approach to prepare long and completely alternating copolymers with orthogonal functional groups. Post-polymerization modification of Br with an azide group allows click-chemistry while the aldehyde can be coupled to a hydrazide to introduce fluorophores which are not compatible with AROMP reactions.
The alternating copolymers were further modified according to Scheme 4 to crosslink with dansyl hydrazide (DH) and form poly(3′-alt-4-DH) n ; it was coupled with Boc-Trp-alkyn to form poly(3′-Trp-alt-4) n ; both fluorophores were introduced in a one-pot reaction to provide poly(3′-Trp-alt-4-DH) n .
UV-Vis spectroscopy was utilized to investigate the charge-transfer between the side-chains of the alternating copolymers in solution. The UV-Vis spectrum of poly(1-alt-5) 10 (3 mM in chloroform) shows a charge-transfer absorbance at the characteristic wavelength ( FIG. 2 a light blue trace) indicating that the side-chains are able to favorably orient to transfer energy in this system. A concentration study from 3 mM to 100 μM was carried out to determine if these interactions occur inter- or intramolecularly. As shown in FIG. 2 a , the charge-transfer absorbance signal was persistent even at low concentrations. Moreover, the absorbance followed Beer-Lambert behavior based on the concentration of polymer ( FIG. 2 b ), which demonstrated that the charge-transfer is intramolecular. Additionally, the aromatic signals in the 1 H NMR spectrum of poly(1-alt-5) 10 are shifted upfield in comparison to the individual monomers ( FIG. S10 ). These shifts further indicate the pi-pi stacking of the donor-acceptor aromatic units, and are consistent with similar shifts previously reported for partially-folded polymers. 6
We compared the charge-transfer absorbance of the functionalized poly(CBE-alt-CH)s to the previously reported functionalized poly(NB-alt-COE)-b-COE. 4 As shown in FIG. 2 , poly(1-alt-5) 10 exhibits a higher charge-transfer absorbance intensity in comparison to the NB/COE polymers at the same concentration, which indicates that the new poly(1-alt-5) 10 polymers more favorably align the aromatic units of the donor and acceptor moieties.
In conclusion, we have demonstrated the AROMP of CBE and CH monomers containing bulky DAN/PDI side-chains. We attribute inhibition of backbiting to the steric hindrance provided by bulky side-chains around the carbene and the polymer alkenes. UV-Vis spectroscopic analysis shows a charge-transfer absorbance signal for the perfectly alternating copolymers signifying the alignment of the side-chains. The new polymers demonstrate an enhancement of charge-transfer in comparison to previously studied polymers, indicating that the sequence specificity in alternating CBE-CH copolymers provides efficient energy transfer.
Throughout this application, various publications, reference texts, textbooks, technical manuals, patents, and patent applications have been referred to. The teachings and disclosures of these publications, patents, patent applications and other documents in their entireties are hereby incorporated by reference into this application to more fully describe the state of the art to which the present invention pertains. However, the citation of a reference herein should not be construed as an acknowledgement that such reference is prior art to the present invention.
It is to be understood and expected that variations in the principles of invention herein disclosed can be made by one skilled in the art and it is intended that such modifications are to be included within the scope of the present invention. The following Examples further illustrate the invention, but should not be construed to limit the scope of the invention in any way.
EXAMPLES
11-((5-(hexyloxy)naphthalen-1-yl)oxy)undecan-1-ol. 11-((5-(hexyloxy)naphthalen-1-yl)oxy)undecan-1-ol was synthesized from 1,5-dihydroxynapthalene, 1-bromo-hexane, and 11-bromo-1-undecanol in two consecutive steps using a catalytic Williamson ether synthesis. 4
Cyclobut-1-enecarboxylic acid. Cyclobut-1-enecarboxylic acid was prepared according to the procedure for the preparation of 3,3-dimethylcylobutene carboxylic acid as described by Campbell et al. 7 and modified as previously reported. 5 1 H-NMR (400 MHz, CDCl 3 ) δ 10.23 (bs, 1H), 6.94 (t, J=1.2 Hz, 1H), 2.76 (t, J=3.2 Hz, 2H), 2.51 (td, J=3.2 Hz, 1.2 Hz, 2H). 13 C NMR (100 MHz, CDCl 3 ) δ 167.5, 150.1, 138.4, 29.1, 27.5.
11-(5-(hexyloxy)naphthalen-1-yloxy)undecyl cyclobut-1-enecarboxylate (1). To a solution of cyclobut-1-enecarboxylic acid (190 mg, 1.94 mmol) and dicyclohexylcarbodiimide (DCC) (417 mg, 2.04 mmol) in CH 2 Cl 2 (10 mL) stirred at 0° C. for 30 minutes, 11-((5-(hexyloxy)naphthalen-1-yl)oxy)undecan-1-ol (400 mg, 0.97 mmol) and a catalytic amount of dimethylaminopyridine (DMAP) were added. The mixture was allowed to warm to rt over 12 h. CH 2 Cl 2 was evaporated under reduced pressure and the crude product was purified by flash chromatography (1:1/hexanes:CH 2 Cl 2 ) to afford 1 in 35% yield: 1 H NMR (600 MHz, CDCl 3 ) δ 7.86 (d, J=8.2 Hz, 2H), 7.36 (t, J=7.6 Hz, 2H), 6.84 (d, J=7.2 Hz, 2H), 6.80 (s, 1H), 4.10 (m, 6H), 2.74 (s, 1H), 2.47 (s, 1H), 1.93 (d, J=6.3 Hz, 2H), 1.67 (d, J=6.4 Hz, 1H), 1.58 (d, J=5.7 Hz, 2H), 1.36 (d, J=45.9 Hz, 8H), 0.94 (s, 2H). 13 C NMR (126 MHz, CDCl 3 ) δ 162.3, 154.6, 154.6, 146.1, 146.1, 138.8, 126.7, 124.9, 113.9, 113.9, 105.1, 68.0, 64.2, 64.2, 33.9, 32.7, 31.6, 29.5, 29.4, 29.4, 29.4, 29.3, 29.2, 29.0, 28.7, 28.6, 25.9, 25.8, 22.6, 14.0.
Cyclohex-3-en-1-ylmethyl 3-(6-decyl-1,3,5,7-tetraoxo-6,7-dihydropyrrolo[3,4-f] isoindol-2(1H,3H,5H)-yl)propanoate (2). Monomer 2 was prepared from pyromellitic dianhydride and cyclohex-3-en-1-ylmethyl 3-aminopropanoate by methods known in the art. 4
2,5-dioxopyrrolidin-1-yl cyclohex-3-enecarboxylate (3). 3-Cyclohexene-1-carboxylic acid (100 mg, 0.79 mmol), N-hydroxysuccinimide (100 mg, 0.87 mmol), and ethyl, dimethylaminopropyl carbodiimide hydrochloride (EDC.HCl) (182 mg, 0.95 mmol) were dissolved in CH 2 Cl 2 and cooled in an ice bath. Then DIEA was added to adjust the pH to 8-9. The reaction was stirred for 16 h and washed with 5% Na 2 CO 3 (50 mL). The organic phase was dried and condensed, followed by flash chromatography, eluted with 100% CH 2 Cl 2 to yield a white solid in 80% yield: 1 H NMR (600 MHz, CDCl 3 ) δ 5.88-5.44 (m, 2H), 3.01-2.80 (m, 1H), 2.76 (s, 4H), 2.42-2.22 (m, 2H), 2.17-1.92 (m, 3H), 1.90-1.62 (m, 1H). 13 C NMR (100 MHz, CDCl 3 ) δ 170.6, 169.2, 126.6, 124.0, 36.6, 26.9, 25.4, 24.6, 23.6.
2-(6-aminohexyl)-6-decylpyrrolo [3,4-f]isoindole-1,3,5,7(2H,6H)-tetraone (5). Compound 5 was synthesized from pyromellitic dianhydride, decylamine, and N-Boc-1,6-hexanediamine according to methods known in the art. 4
2-Bromoethyl bicyclo[4.2.0]oct-7-ene-7-carboxylate (6). Bicyclo[4.2.0]alkene carboxylic acid was obtained according to the literature with a yield of 62%. 8, 9, 21 The acid (500 mg, 3.3 mmol) was dissolved in 5 mL of CH 2 Cl 2 and was cooled in an ice bath when oxalyl chloride (5 mL) was added. The reaction was stirred for 30 min followed by evaporation to yield bicyclo[4.2.0]oct-7-ene-7-carbonyl chloride as off white oil. 2-Bromoethanol (1.2 mg, 10 mmol), EDC.HCl (630 mg, 3.3 mmol), DIPEA (425 mg, 3.3 mmol) were mixed with the acyl chloride oil in 20 mL of CH 2 Cl 2 . The mixture was stirred for 16 h and was washed with 5% NaHCO 3 (3×), 1N HCl (3×) and brine (2×) sequentially and dried over anhydrous MgSO 4 . The solvent was filtered and removed by evaporation. The crude was subjected to flash silica chromatography (30:70/hexane:CH 2 Cl 2 ) to yield 3 (590 mg, 70%): 1 H NMR (500 MHz, CD 2 Cl 2 ): δ 6.91 (d, J=1.1 Hz, 1H), 4.46 (m, 2H), 3.60 (t, J=6.1 Hz, 2H), 3.04 (dd, J=10.3 Hz, J=5.6 Hz, 1H), 2.77 (td, J=5.6 Hz, J=1.1 Hz, 1H), 1.74 (m, 3H), 1.55-1.38 (m, 5H). 13 C NMR (100 MHz, CDCl 3 ) 161.4, 151.6, 141.0, 63.0, 40.0, 38.4, 28.6, 23.4, 18.8, 18.2. HRMS (ESI) calcd. for C 11 H 15 BrO 2 [M+H] + 258.0255, found 258.0248.
Boc-Trp-OH. Tryptophan (1.00 g, 4.90 mmol) was dissolved in saturated NaHCO 3 aqueous solution and cooled in an ice bath. Boc anhydride (2.14 g, 9.80 mmol) was dissolved THF and added dropwise into the tryptophan solution and the reaction was stirred for 10 h. The organic solvent was removed by evaporation and the remaining aqueous solution was washed with CH 2 Cl 2 (3×20 mL). The water layer was acidified with 1N HCl to pH=2 and was extracted with CH 2 Cl 2 (3×20 mL). The organic layer was dried over MgSO 4 . The solvent was filtered and removed by evaporation to yield Boc-Trp-OH as a white solid. It was recrystallized in ethyl acetate with hexane and used without further purification.
Boc-Trp-alkyn. BocTrp-OH (500 mg, 1.64 mmol), propagyl amine (82.1 mg, 1.49 mmol), EDC.HCl (347 mg, 1.80 mmol) and DIPEA (233 mg, 1.80 mmol) were mixed in THF. The reaction was stirred for 10 h and THF was removed by evaporation. The residue was dissolved in CH 2 Cl 2 and washed sequentially with 5% NaHCO 3 (3×), 1N HCl (3×) and brine (2×) and dried over anhydrous MgSO 4 . The solvent was filtered and removed by evaporation and the crude was subjected to flash silica chromatography (2% MeOH in CH 2 Cl 2 ) to yield Boc-Trp-alkyn (390 mg, 78%). 1 H NMR (700 MHz, CDCl 3 ) 8.28 (s, 1H), 7.66 (d, J=7.5 Hz, 1H), 7.38 (d, J=8.1 Hz, 1H), 7.25-7.20 (m, 1H), 7.18-7.13 (m, 1H), 7.06 (s, 1H), 6.12 (s, 1H), 5.18 (s, 1H), 4.48 (s, 1H), 3.93 (s, 2H), 3.32 (s, 1H), 3.21 (s, 1H), 2.17 (s, 1H), 1.44 (s, 9H). 13 C NMR (176 MHz, CDCl 3 ) 171.5, 155.5, 136.2, 127.5, 123.3, 122.3, 119.8, 118.8, 111.3, 110.4, 80.3 79.16, 71.5, 55.0, 29.1, 28.3. ESI (M/Z) [M+H] + 341.2.
General Procedure for AROMP
The NMR tube was evacuated under high vacuum for 15 min, and then was purged with N 2 gas for another 15 min. Under an N 2 atmosphere, a solution of monomer A in CD 2 Cl 2 (300 μL) was added to the NMR tube. Then a solution of catalyst (H 2 IMes)(3-Br-Py) 2 (Cl) 2 Ru═CHPh in CD 2 Cl 2 (300 μL) was added to the NMR tube. After complete mixing of the solution, the NMR tube was spun for 60 min at an elevated temperature 37° C. until the precatalyst had reacted as can be observed by disappearance of ruthenium alkylidene proton at 19 ppm. Monomer B (cyclohexene derivative) in CD 2 Cl 2 (100 μL) was added to the NMR tube. The reaction was quenched in 8 h with ethyl vinyl ether (50 μL) and the resulting solution was stirred for another 1 h.
poly(1-alt-2) 5 . The reaction was monitored by 1 H NMR. The NMR tube was evacuated under high vacuum for 15 min, and then was purged with N 2 gas for another 15 min. Under an N 2 atmosphere, a solution of monomer 1 (29.6 mg, 0.060 mmol) in CD 2 Cl 2 (300 μL) was added to the NMR tube. Then a solution of catalyst (H 2 IMes)(3-Br-Py) 2 (Cl) 2 Ru═CHPh (4, 5.3 mg, 6.0 μmol) in CD 2 Cl 2 (300 μL) was added to the NMR tube. After complete mixing of the solution, the NMR tube was spun for 60 min at an elevated temperature 37° C. until the precatalyst had reacted as can be observed by disappearance of ruthenium alkylidene proton at 19 ppm. Monomer 2 (19.5 mg, 0.030 mmol) in CD 2 Cl 2 (100 μL) was added to the NMR tube. The reaction was quenched in 8 h with ethyl vinyl ether (50 μL) and the resulting solution was stirred for another 1 h. The mixture was condensed to give a dark brown oil which was further purified by column chromatography (100:1/CH 2 Cl 2 :MeOH (methanol)) to yield an orange solid in 55% yield. 1 H NMR (600 MHz, CDCl 3 ) δ 8.26-7.92 (m, 8H), 7.83-7.74 (m, 10H), 7.42-7.20 (m, 10H), 6.93-6.62 (m, 15H), 5.66-5.17 (m, 8H), 4.30-3.91 (m, 41H), 3.72 (m, 16H), 3.41-3.03 (m, 6H), 2.65-1.02 (m, 382H), 0.99-0.62 (m, 34H). Mn cal =5748, Mn GPC =3291, Mw GPC =4252, PDI=1.29.
poly(1-alt-5) 10 . The reaction was monitored by 1 H NMR. The NMR tube was evacuated under high vacuum for 15 min, and then was purged with N 2 gas for another 15 min. Under an N 2 atmosphere, a solution of monomer 1 (29.6 mg, 0.060 mmol) in CD 2 Cl 2 (300 μL) was added to the NMR tube. Then a solution of catalyst (H 2 IMes)(3-Br-Py) 2 (Cl) 2 Ru═CHPh (4, 5.3 mg, 6.0 μmol) in CD 2 Cl 2 (300 μL) was added to the NMR tube. After complete mixing of the solution, the NMR tube was spun for 60 min at 25° C. until the precatalyst had reacted as can be observed by disappearance of ruthenium alkylidene proton at 19 ppm. Monomer 3 (26.8 mg, 0.120 mmol) in CD 2 Cl 2 (100 μL) was added to the NMR tube. The reaction was quenched in 6 h with ethyl vinyl ether (50 μL) and the resulting solution was stirred for another 1 h. The mixture was condensed to give a dark brown oil which was further purified by column chromatography (100:1/CH 2 Cl 2 :MeOH) to yield an orange solid in 75% yield. 1 H NMR (600 MHz, CDCl 3 ) δ 7.84 (m, 20H), 7.32 (m, 20H), 6.98-6.56 (m, 30H), 5.33 (m, 13H), 4.11 (s, 3H), 292-1.25 (m, 366H), 0.95 (m, 30H). The resulting polymer poly(1-alt-3) 10 (27.2 mg, 3.7 μmol) was dissolved in dry THF and cooled in an ice bath. EDC.HCl (7.1 mg, 37 μmol), DIEA (9.7 mg, 74 μmol), and 2-(6-aminohexyl)-6-decylpyrrolo[3,4-f]isoindole-1,3,5,7(2H,6H)-tetraone (5) (34 mg, 74 μmol) were added. The mixture was stirred for 2 days and then filtered, followed by column chromatography (5:95/acetone/CH 2 Cl 2 ) to yield an orange solid in 20% yield. 1 H NMR (600 MHz, CDCl 3 ) δ 8.26-7.92 (m, 9H), 7.80 (dd, J=14.4, 6.1 Hz, 20H), 7.42-7.18 (m, 20H), 6.93-6.62 (m, 30H), 5.66-5.17 (m, 12H), 4.30-3.91 (m, 59H), 3.72 (dd, J=14.7, 7.1 Hz, 15H), 3.41-3.03 (m, 6H), 2.65-0.99 (m, 545H), 0.99-0.62 (m, 86H). Mn Cal =10948, Mn GPC =7966, Mw GPC =10221, PDI=1.28.
Poly(3-alt-4) n . Under an N 2 atmosphere, 6 (61.8 mg, 0.24 mmol) and G1 (5.3 mg, 0.006 mmol) were mixed in CD 2 Cl 2 (600 μL) in an NMR tube. NMR spectra were acquired at 25° C. until the G1 had completely reacted as determined by the disappearance of its alkylidene α proton signal. Cyclohex-3-enecarbaldehyde 9 (52.7 mg, 0.48 mmol) was added to the NMR tube. When no further propagation occurred, the reaction was quenched with ethyl vinyl ether and stirred for 30 min. The solvent was evaporated, and the alternating copolymer was purified by chromatography on silica gel (97:3/CH 2 Cl 2 :acetone). 1 H NMR (500 MHz, CD 2 Cl 2 ): δ 9.59 (m, 27H), 7.25 (m, 5H), 6.59 (m, 27H), 5.83 (m, 27H), 5.36 (m, 27H), 4.39 (m, 54H), 3.59 (m, 54H), 3.0-1.25 (m, 560H). M n calc =9700, M n GPC =14823, M w GPC =31649, M =2.13.
Post-Polymerization Modification
In the first step of post-polymerization modifications the bromide was converted to an azide by mixing poly(3-alt-4) n and NaN 3 in DMF at 60° C. for 3 hours. Poly(3′-alt-4) n was obtained after workup. 1 H NMR of poly(3′-alt-4) n showed no significant difference from that of poly(3-alt-4) n , so were the GPC traces. Therefore, we obtained IR spectra which showed a distinctive N 3 vibration signal at around 2200 cm −1 .
Poly(3′-alt-4) n . To a solution of poly(3-alt-4) n (44.0 mg, 4.51 μmol) in anhydrous DMF (1 mL) was added NaN 3 (23.0 mg, 353 μmol). The mixture was stirred at 60° C. for 3 h, and water (5 mL) was added and the mixture was extracted with CH 2 Cl 2 (3×5 mL). The combined organic layers were washed with water and dried over MgSO 4 . After filtration, the solvent was evaporated by vacuum to give a yellow oil (31.0 mg, 80%). 1 H NMR (500 MHz, CD 3 OD): δ 9.50 (m, 27H), 7.24 (m, 5H), 6.48 (m, 27H), 5.78 (m, 27H), 5.30 (m, 27H), 4.20 (m, 59H), 3.50 (m, 59H), 3.00-1.35 (m, 863H). IR (KBr): 3418, 2924, 2854, 2718, 2104, 1716, 1633 cm −1 .
Poly(3′-alt-4-DH) n . Poly(3′-alt-4) n (4.7 mg, 0.54 μmol) and dansyl hydrazide (5.5 mg, 21 μmol) were dissolved in THF (2 mL). The mixture was stirred at 65° C. for 2 h and the solution was concentrated under vacuum. The residue was purified by LH-20 with eluting solvent as THF. 1 H NMR (400 MHz, CD 2 Cl 2 ): δ 8.56 (bs, 47H), 8.42 (bs, 39H), 8.28 (bs, 39H), 8.00 (bs, 47H), 7.54 (bs, 87H), 7.20 (bs, 96H), 6.43 (bs, 27H), 5.68 (bs, 29H), 5.13 (bs, 31H), 4.30 (bs, 137H), 3.46 (bs, 131H), 2.94 (bs, 155H), 2.88 (bs, 243H), 2.86 (s, 172H), 2.80-1.01 (m, 1618H). M n calc =16369, M n GPC =19325, M w GPC =34382, M =1.78.
Poly(3′-Trp-alt-4) n . Under an N 2 atmosphere, poly(3′-alt-4) n (5.9 mg, 0.67 μmol), Boc-Trp-alkyn (10.6 mg, 25.6 μmol), CuBr (1.7 mg, 0.20 μmol) and PEDTA (6.7 μL) were mixed in THF (1 mL). After stirring for 12 h, the solution was concentrated and the residue was purified by LH-20 with eluting solvent as THF. M n calc =16715, M n GPC =12472, M w GPC =20226, M =1.62.
Poly(3′-Trp-alt-4-DH) n . Under an N 2 atmosphere, poly(3′-alt-4). (7.0 mg, 0.80 mmol), dansyl hydrazide (8.2 mg, 31 μmol), Boc-Trp-alkyn (12.5 mg, 30.0 mmol), CuBr (2.0 mg, 0.24 mmol) and PEDTA (7.9 μL) were mixed in THF (1 mL). The mixture was stirred at 65° C. for 12 h, the solution was concentrated and the residue was purified by LH-20 with eluting solvent as THF. M n calc =22491, M n GPC =21645, M w GPC =38312, M =1.747. IR (KBr): 3413, 2929, 2854, 1707, 1690 cm −1 .
(1) Hawker, C. J.; Bosman, A. W.; Harth, E. Chemical Reviews 2001, “New polymer synthesis by nitroxide mediated living radical polymerizations,” 101, 3661-3688. (2) Matyjaszewski, K.; Xia, J. H. Chemical Reviews 2001, “Atom transfer radical polymerization,” 101, 2921-2990. (3) Choi, T. L.; Rutenberg, I. M.; Grubbs, R. H. Angewandte Chemie - International Edition 2002, “Synthesis of A,B-alternating copolymers by ring-opening-insertion-metathesis polymerization,” 41, 3839-3841. (4) Romulus, J.; Patel, S.; Weck, M. Macromolecules 2011, “Facile Synthesis of Flexible, Donor-Acceptor Side-Chain Functionalized Copolymers via Ring-Opening Metathesis Polymerization,” 45, 70-77. 10.1021/ma201812x (5) Song, A.; Parker, K. A.; Sampson, N. S. J. Am. Chem. Soc. 2009, “Synthesis of Copolymers by Alternating ROMP (AROMP),” 131, 3444-3445. 10.1021/ja809661k (6) Lokey, R. S.; Iverson, B. L. Nature 1995, “Synthetic molecules that fold into a pleated secondary structure in solution,” 375, 303-305. (7) Campbell, A.; Rydon, H. N. J. Chem. Soc. 1953, “596. The synthesis of caryophyllenic acid,” 0, 3002-3008. (8) Tan, L., Parker, K. A., and Sampson, N. S. (2014) A Bicyclo[4.2.0]octene-derived Monomer Provides Completely Linear Alternating Copolymers via Alternating Ring-Opening Metathesis Polymerization (AROMP). Macromolecules. (9) Tan, L., Parker, K. A., and Sampson, N. S. (2014) Tandem Generation of Tetrasubstituted α,β-Unsaturated Amides and Alternating Copolymers via Alternating Ring-Opening Metathesis Polymerization (AROMP). (10) Song, A., Lee, J., Parker, K. A., and Sampson, N. S. (2010) Scope of the Ring-Opening Metathesis Polymerization (ROMP) Reaction of 1-Substituted Cyclobutenes, J. Am. Chem. Soc. 132, 10513-10520. (11) Tan, L., Parker, K. A., and Sampson, N. S. (2013) A Bicyclo[4.2.0]octene-derived Monomer Provides Completely Linear Alternating Copolymers via Alternating Ring-Opening Metathesis Polymerization (AROMP). Macromolecules. (12) (1999) Why FRET over genomics?, Vol. 1. (13) Rankin, D. A., Schanz, H.-J., and Lowe, A. B. (2007) Effect of the Halide Counterion in the ROMP of exo-Benzyl-[2-(3,5-dioxo-10-oxa-4-aza-tricyclo[5.2.1.02,6]dec-8-en-4-yl)ethyl]dimethyl ammonium Bromide/Chloride, Macromol. Chem. Phys. 208, 2389-2395. (14) Buchowicz, W., Holerca, M. N., and Percec, V. (2001) Self-Inhibition of Propagating Carbenes in ROMP of 7-Oxa-bicyclo[2.2.1]hept-2-ene-5,6-dicarboxylic Acid Dendritic Diesters Initiated with Ru(CHPh)C12(PCy3)(1,3-dimesityl-4,5-dihydroimidazol-2-ylidene), Macromolecules 34, 3842-3848. (15) Haigh, D. M., Kenwright, A. M., and Khosravi, E. (2005) Nature of the Propagating Species in Ring-Opening Metathesis Polymerizations of Oxygen-Containing Monomers Using Well-Defined Ruthenium Initiators, Macromolecules 38, 7571-7579. (16) Johnson, J. A., Lu, Y. Y., Burts, A. O., Lim, Y.-H., Finn, M. G., Koberstein, J. T., Turro, N. J., Tirrell, D. A., and Grubbs, R. H. (2010) Core-Clickable PEG-Branch-Azide Bivalent-Bottle-Brush Polymers by ROMP: Grafting-Through and Clicking-To, J. Am. Chem. Soc. 133, 559-566. (17) Boren, B. C., Narayan, S., Rasmussen, L. K., Zhang, L., Zhao, H., Lin, Z., Jia, G., and Fokin, V. V. (2008) Ruthenium-Catalyzed AzideAlkyne Cycloaddition: Scope and Mechanism, J. Am. Chem. Soc. 130, 8923-8930. (18) Brummelhuis, N., and Weck, M. (2012) Orthogonal Multifunctionalization of Random and Alternating Copolymers, ACS Macro. Lett. 1, 1216-1218. (19) Yang, S. K., and Weck, M. (2007) Modular Covalent Multifunctionalization of Copolymers, Macromolecules 41, 346-351. (20) Love, J. A., Morgan, J. P., Trnka, T. M., and Grubbs, R. H. (2002) A practical and highly active ruthenium-based catalyst that effects the cross metathesis of acrylonitrile, Angew. Chem. Int. Ed. 41, 4035-4037. (21) Snider, B. B., Rodini, D. J., Cionn, R. S. E., and Sealfon, S. (1979) Lewis Acid Catalyzed Reactions of Methyl Propiolate with Unactivated Alkenes, J. Am. Chem. Soc. 101, 5283-5493. | The invention relates to the field of polymers and olefin polymerization, and more specifically olefin metathesis polymerization. The invention provides regioregular alternating polymers and methods of synthesizing such polymers. To demonstrate, polymers were synthesized and modified with a FRET pair (Trp/Dansyl) post-polymerization. | 0 |
This application claims priority from U.S. Provisional Application 60/732,944, for a “Snow Pusher,” filed Nov. 3, 2005 by Michael P. Weagley et al., which is also hereby incorporated by reference in its entirety.
The following disclosure is directed to aspects of an improved snow or material pusher for use with loaders, backhoes, agricultural and larger home and garden tractors and the like for moving snow or other materials on generally flat areas such as parking lots, driveways, feed lots, runways, and loading areas, for example.
BACKGROUND AND SUMMARY OF THE INVENTION
A “pusher” or “pushing apparatus,” as described for example in U.S. Pat. No. 5,724,755 to Weagley (issued Mar. 3, 1998) or the folding material plow of U.S. Pat. No. 6,112,438, to Weagley et al. (issued Sep. 9, 2000), both hereby incorporated by reference in their entirety, generally include sides extending forward from a mold board or central blade to assure material being pushed (e.g., snow, liquids, debris, sludge, etc.) remains in front of the pusher, and is not directed to one or both sides as with conventional plows.
The following disclosure is directed to aspects and embodiments of an improved pusher design, including several aspects that can be employed on traditional pusher designs in order to improve the use and efficiency of such pushers. The disclosed aspects and embodiments, alone and in combination, improve the functionality, reliability, ease of use and/or safety of pushers.
In accordance with an aspect of the embodiments disclosed herein, there is provided a material pushing apparatus, comprising: an upstanding central blade including a first longitudinal edge and a second longitudinal edge along an opposite side of said blade, and left and right ends; a vertical side plate attached to and extending forward at a generally perpendicular angle from each of the ends of the central blade; a first cutting edge attached to the central blade along the first longitudinal edge; and a second cutting edge attached to the central blade along the second longitudinal edge.
In accordance with another aspect disclosed herein, there is provided a reversible coupler for use with a reversible implement, comprising: a first coupler portion suitable for attachment to a vehicle in a first orientation; and a second coupler portion suitable for attachment to the vehicle in a second orientation.
In accordance with another embodiment, there is disclosed a method of using a reversible pusher, comprising: connecting a vehicle to the pusher in a first orientation having a first cutting edge adjacent a surface upon which the pusher rests; advancing the pusher with the first cutting edge adjacent the surface; disconnecting the pusher from the vehicle; reconnecting the vehicle to the pusher in a second orientation having a second cutting edge adjacent the surface; and advancing the pusher with the second cutting edge adjacent the surface.
In accordance with a further aspect, there is provided an improved scraping edge for attachment along a longitudinal edge of a moldboard, comprising: a flexible base, removably attached to the moldboard, along a top portion of the base; a rigid cutting edge extending along and removably attached to said flexible base along a bottom portion of the base, wherein said flexible base flexes to allow the cutting edge to bypass immovable objects it contacts; and a tensioner to bias said flexible base into a partially flexed position.
In accordance with yet another aspect of the invention, there is provided a material pushing apparatus, comprising: an upstanding moldboard including a bottom longitudinal edge, and left and right ends; a vertical side plate attached to and extending forward at a generally perpendicular angle from each of said left and right ends of the moldboard; and a scraping edge attached to the moldboard along said bottom longitudinal edge, said scraping edge including, a flexible base, removably attached to the moldboard, along a top portion of the flexible base using at least one hold-down member; a rigid cutting edge extending along and removably attached to said flexible base along a bottom portion of the base, wherein said flexible base flexes to allow the cutting edge to bypass immovable objects it contacts; and a tensioner to bias said flexible base into a partially flexed position.
In accordance with a further aspect disclosed herein there is provided a material pusher, comprising: an upstanding central blade including a lower longitudinal edge and left and right ends; a vertical side plate extending forward at a right angle from each end of the central blade; and removable wear shoe attached along a bottom edge of each vertical side plate, wherein the removable wear shoe extends from a position adjacent a front edge of the vertical side plate to a position at least 6 inches beyond a rear surface of the moldboard so as to assure that a bottom surface of the wear shoe remains in complete contact with a surface on which the pusher is used.
In accordance with yet a further aspect of the following disclosure there is provided an extended wear shoe for use on a material pusher, comprising: a web for attachment to a side plate of the pusher; a generally horizontal lower surface for sliding contact with the ground, the lower surface transitioning to front and rear ramped surfaces on either end thereof; and a cap, permanently attached to the web and the upper end of the rear ramped surface thereof.
Disclosed in accordance with another embodiment is an improved scraping edge for attachment along a longitudinal edge of a pusher moldboard, comprising: a plurality of rigid sections; said sections being attached along the longitudinal edge using fasteners having a low yield strength and hardness such that one or more sections are dislodged from a normal operating position upon contact with an immovable object to thereby prevent damage to the object.
Also disclosed with respect to yet a further embodiment is a material pushing apparatus, comprising: an upstanding central blade including a lower longitudinal edge and left and right ends; a vertical side plate extending forward at a right angle from each end of the central blade; and a breakaway cutting edge, comprised of a plurality of rigid sections, attached to the central blade along the longitudinal edge, wherein at least one of the sections is dislodged from its normal operating position upon sufficient contact with an immovable object to prevent damage to the object.
In accordance with a further aspect disclosed herein there is provided a material moving apparatus, comprising: an upstanding moldboard including a bottom longitudinal edge, and left and right ends; a vertical side plate attached to and extending forward at a generally perpendicular angle from each of said left and right ends of the moldboard; and a scraping edge attached to the moldboard along said bottom longitudinal edge, said scraping edge including a rigid component and means for assuring that said rigid component yields upon coming in contact with an immovable object.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-4 illustrate various features and aspects of a switchblade, reversible coupling pusher in accordance with one embodiment;
FIGS. 5A-5H illustrate various features and aspects of a switchblade, reversible coupling, pusher in accordance with an alternative embodiment, where FIGS. 5A-5H particularly illustrate steps of using the reversible coupling feature with a skidsteer type vehicle;
FIGS. 6-7 illustrate various embodiments of a flexible trip edge in accordance with another aspect of the invention;
FIGS. 8-10 illustrate various embodiments of a breakaway edge in accordance with another aspect of the invention;
FIGS. 11A and 11B are illustrative side views of alternative embodiments of a snow pushing apparatus employing an extended wear shoe.
DETAILED DESCRIPTION
As used herein the figures are intended to be exemplary in nature, not limiting, and some or all aspects depicted may not be to scale. As will be further contemplated, various aspects of the disclosed embodiments have particular application to alternative snow removal and material moving technologies and while described in accordance with snow pushers and material pushing apparatus, are not intended to be limited to such embodiments. Accordingly, several of the aspects described herein may find particular use in plow, scraper, drag plow and similar applications in the same manner as described relative to snow or other material pushing embodiments.
Referring first to FIGS. 1-5H , various aspects of a switchable/reversible orientation or Switchblade™ pusher configuration will be discussed in detail, along with a reversible coupling mechanism associated therewith. FIGS. 1 and 3 , for example, illustrate a switchable orientation material pushing apparatus 110 . The intent of such a device is to provide two different types of scraping edges (e.g., hard and/or flexible) in a single material pusher so that a user can accommodate many different material conditions. In particular, the apparatus is believed to find practical use in its ability to handle new-fallen snow as well as hard-packed and re-frozen snow and ice that accumulate in parking lots and other heavily traveled areas.
Referring specifically to FIGS. 1-3 , Switchblade pusher 110 includes an upstanding central blade or moldboard 120 having a first longitudinal edge 130 and a second longitudinal edge 140 and left and right ends 150 , 160 , respectively. Also included is a vertical side plate 170 extending forward at a right angle from each of the ends 150 , 160 of the central blade 120 . A first cutting or scraping edge 180 is attached to the central blade or moldboard along the first longitudinal edge 130 , and a second cutting or scraping edge 182 is attached to the central blade along the second longitudinal edge 140 .
In one embodiment the Switchblade™ two-edged pusher has both a flexible polymer or rubber cutting edge 182 attached along a first longitudinal edge and a more rigid or steel cutting edge 180 along a second longitudinal edge. The flexible edge is perfect for wet, heavy snow conditions or jobsites where there are ground obstacles or imperfections in the surface being cleared. The steel edge 180 is ideal for hard packed snow conditions or jobsites that are flat with no ground obstacles. Alternatively, the steel edge 180 may be used on surfaces where some scraping and even removal of the top surface is desirable, for example, cleaning of animal barns and feedlots. Depending upon the situation the Switchblade pusher provides both types of edges on a single device.
One embodiment may include at least one flexible or rubber edge removably fastened to the central blade and extending along a longitudinal edge thereof. In FIG. 3 , a flexible rubber edge is generally depicted as 184 where the edge is reversible (by switching top for bottom), and is held to the face of the moldboard 120 using an elongated steel plate(s) as a hold-down member 185 . Moreover, it is contemplated that at least one cutting or scraping is removably fastened to the central blade along a longitudinal edge. As described above, at least one of the cutting edges comprises a rubber or flexible polymer edge 184 extending along and outward from one of the longitudinal edges of the central blade. As illustrated, such an edge is attached to the central blade 120 using a backing plate and bolts, and in some cases, the position of the edge may be adjusted upward or downward using slotted holes in the edge 184 through which the bolts are connected to nuts (not shown) behind the central blade.
It is further contemplated that one of the cutting edges of the reversible pushing apparatus may be a scraping edge 180 (see also 850 in FIG. 8 ), attached to the moldboard 120 along one longitudinal edge. The scraping edge 180 includes a rigid component and means for assuring that the rigid component yields upon coming in contact with an immovable object. In one embodiment, the scraping edge 180 may be a breakaway edge, wherein at least one of rigid components or sections is dislodged from its normal operating position upon sufficient contact with an immovable object to prevent damage to the object.
As is also shown in the figures, the pusher apparatus 110 further includes a pair of longitudinal wear shoes 190 along at least two edges of the side plate 170 . The wear shoes may be removable, as depicted, or may be permanently attached or mounted to the side plate. The wear shoes may also be extended as depicted, for example, in FIGS. 11A , B described below. The wear shoes 190 comprise inclined front and rear ramp surfaces 192 for sliding contact on the surface. In one embodiment, the front ends of wear shoes 190 and/or the side plates 170 , in conjunction, provide points or define a surface (along lines A-A′) that enables the apparatus to temporarily stand in an upright position, such as depicted in the embodiment of FIGS. 5B and 5C , in order to permit a vehicle to change the direction in which the apparatus is oriented for pushing—thereby changing from a first operating position where the first scraping edge is adjacent to the surface being cleaned to a second operating position whereby the second scraping edge is adjacent to the surface to be cleaned.
Considering FIGS. 1-3 and 5 A- 5 H, it will be apparent that the nature of the vehicle (skidsteer, backhoe or loader) is accommodated by one of several reversible couplers 210 , or similar reversible means for attaching the apparatus to a vehicle. The reversible coupler further enables the pushing vehicle 50 to be suitably attached, from either of two opposite directions. Where the vehicle 50 is a skidsteer-type or similar loader vehicle, the reversible coupler 210 includes a quick-coupling connection for both directions.
The reversible coupler 210 referred to above may be used with a reversible (Switchblade) pusher or with other reversible implements such as those known for use with skidsteer type vehicles. In one embodiment, reversible coupler 210 includes a first coupler assembly 220 , suitable for attachment to a vehicle (loader, skidsteer, etc.) in a first orientation, and a second coupler assembly 230 suitable for attachment to the vehicle in second first orientation. It will be appreciated that the first and second coupler assemblies are essentially mirror image replications of one another and may be contained within a common frame or assembly as depicted in FIGS. 5G and 5H , for example. It is further contemplated that a reversible pusher may have a plurality of non-mirrored couplers on the rear thereof, where one coupler is suitable for receiving a bucket of a loader or backhoe whereas another coupler is suitable for use with a skidsteer-type vehicle, thereby permitting a single pusher to be used with a plurality of vehicle types.
In the embodiment of FIG. 1 , each coupler assembly 220 , 230 includes two rows of parallel posts mounted on the rear of the pusher, the two rows of parallel posts form a slot 224 for receiving the edge of a bucket on the vehicle (not shown in FIG. 1 ). Referring to FIGS. 5C , F and G, for example, each reversible coupler assembly 210 is mounted on the rear of the pusher 110 and includes a pair of generally parallel side rails 250 , and opposed top members (e.g., downward facing flange) 254 , generally spanning between the side rails and providing a downward-facing pocket 256 on the rear of the pusher, the pocket receiving an upper edge or the like of a skidsteer attachment frame, and an angled foot or lower attachment member 258 on opposite ends, also spanning between the side rails, and suitable for receiving a lower wedge, pin or the like of the skidsteer attachment device. FIGS. 5E and 5F are illustrative examples of one method by which the skidsteer attachment device may be connected; first the attachment device of vehicle 50 is inserted into the pocket 256 and then, upon full connection of the attachment device with the coupler, the locking wedge or pin is inserted. It will be appreciated that various alternative means may be employed to interface with the reversible coupler 210 .
As an example of one possible configuration for the coupler assembly, FIGS. 5E-5H are referred to in order to illustrate the manner in which a skidsteer (e.g., Bobcat™) or similar vehicle is attached to the coupler. It will be appreciated that the coupler mechanism is duplicated in a mirrored configuration ( FIGS. 5F , G) to provide the reversible coupling referred to. It will also be appreciated that the coupler foot 258 may further include recesses, apertures 260 or similar features for receiving a locking wedge/detent or similar component or mechanism on the vehicle attachment frame—thereby providing positive attachment to the pusher. Alternatively, the pusher may be connected to the vehicle using well know means such as, hooks, clevises, chains and the like as is well known for connecting pushers to vehicles.
The coupler depicted in FIG. 5C is mounted on the rear of a pusher 110 and employs a common set of side rails such that both of the opposed coupling mechanisms form a single assembly suitable for coupling with a vehicle from opposite or reversible orientations.
Further referring to FIGS. 5A-5D , the sequence of figures illustrates a method for using a reversible pushing apparatus as described herein. The method includes connecting a vehicle 50 to the pusher in a first orientation ( FIG. 5A ), moving the pusher with a first edge adjacent the ground surface ( FIG. 5A ), standing the pusher on its “nose” (for example along the plane defined by line A-A′) as shown in FIG. 5B , disconnecting the vehicle from the pusher while in the “nose-down” position ( FIG. 5C ) and reconnecting the vehicle to the pusher in a second orientation ( FIG. 5D ), in order to subsequently move the pusher with a second edge adjacent the ground surface.
In an alternative method it is simply possible to use the vehicle 50 to roll or flip the pusher from one orientation to the other, thereby avoiding the need to temporarily place the pusher into a nose-down position. As will be appreciated, the vehicle should be disengaged from its respective coupler before flipping so as to enable the pusher to switch or reverse to the opposite orientation.
Referring next to FIGS. 6-7 there is depicted one embodiment of an improved scraping edge for use with the pusher described above, or with other conventional snow pusher designs, including those manufactured by Pro-Tech® and other manufacturers. In general, the improved scraping edge is attached to the central blade or moldboard along a longitudinal edge, and the scraping edge includes a rigid component and means for assuring that said rigid component yields upon coming in contact with an immovable object. In one embodiment, depicted in FIGS. 6-7 , the yielding means may include a flexible base member whereas in an alternative embodiment, depicted in FIGS. 8-10 , the yielding means may include a sacrificial fastener as well as similar components that flex or yield so that the cutting edge does not damage immovable objects it comes in contact with them.
The improved cutting edge of FIGS. 6-7 is designed for attachment along a longitudinal edge of a pusher moldboard 610 , and in a first embodiment comprises a flexible base 630 , removably attached to the moldboard, along a top portion of the base. In one embodiment, the attachment means includes a metal hold-down member 640 applied on the face of the flexible base 630 , wherein the flexible base is sandwiched between the hold-down member 640 and the moldboard 610 . Removably attached to the flexible base 630 , along a bottom portion thereof is a rigid cutting edge 650 , preferably made of steel and alloys thereof that exhibit high hardness and good wear resistance. The use of the flexible base as the means by which the rigid cutting edge is attached to the moldboard flexible permits flexing of the base and allows the cutting edge to bypass an immovable object that it contacts while the pusher moves and then return to a nominal operating position.
The flexible scraping edge base 630 may be made of a polymer (e.g., polyurethane), rubber or similar material, and is approximately 1.5 (1.0-2.0) inches thick. Such materials are available from CUE, Inc. (e.g., Compound No. PO-650) and exhibit approximately the following characteristics: shore durometer (ASTM D2240-64T) of 84A; a compression set of 45% max.; a tensile strength (ASTM D412-61T) of 6000 psi; tensile modulus (ASTM D412-61T) @ 50% elongation of 500 psi; tear strength Trollsera (ASTM D1938)=250, Die C (ASTM D624)=470 and split tear (ASTM D470)=140; compression deflection (ASTM D575-46 Method A)@ 5%=300 psi; and abrasion resistance for Tabor (ASTM D3489-85(90)) of 15% rubber standard or NBS ASTM D1630-83=250.
In an alternative embodiment, the flexible scraping edge may further include a tensioner 660 to bias the flexible base into a partially flexed position. The use of a biasing means to pre-flex the base 630 assures that the base flexes rearward as the cutting edge 650 comes into contact with an immovable object such as a manhole, water-valve cap, curb, raised concrete or asphalt patch or similar objects. As will be appreciated, alternative biasing means including springs, pre-deformation of the base, tabs or stops along the side plates, etc. may be employed to assure that the polymer base 630 flexes rearward when the edge 650 contacts an immovable object. Absent a tensioner or other means for biasing or preflexing the base, the cutting edge may chatter and skip when contacting or moving over surfaces that are uneven yet generally free of immovable obstructions.
As further depicted in FIGS. 6 and 7 , the tensioner is removably attached to the moldboard using the same bolts employed for the metal hold-down member 640 . The tensioner includes an arm 662 that extends downward from where it is attached to the moldboard, and at the end of the arm there is a contact point 664 that applies a force or biasing contact to the metal cutting edge 650 , and the flexible base 630 is biased into the partially flexed (rearward) position as shown in the side view of FIG. 6 . It is also intended that the contact force or amount of bias applied to the cutting edge 650 is adjustable by way of bias adjusting bolt 668 , a threaded bolt at the end of the tensioner arm that establishes the contact point with the cutting edge in the embodiment depicted.
Those knowledgeable in the design of material pushers will appreciate that in an alternative embodiment a material pusher incorporating the improved cutting edge described above, may further include vertically extended or adjustable side plates and/or wear shoes, to provide increased or adjustable clearance between the bottom or the steel cutting edge 650 and the ground surface, thereby providing a region for the installation of the flexible cutting edge—and to provide a sufficient gap below the moldboard in which the edge can flex un an unconstrained fashion.
Turning next to FIGS. 8-11 , there is disclosed yet another embodiment of the breakaway cutting edge for use on a longitudinal edge of a material pusher or similar plow or pushing apparatus. In the design, the breakaway edge provides a cutting surface adequate to remove hard-packed snow or ice from a surface, yet prevents damage to immovable objects (e.g., manholes, sewer covers, curbs, etc.) that come into contact with the edge. The edge design assures that it becomes detached or “breaks away” from the moldboard upon striking such objects with sufficient force.
In one embodiment depicted in FIG. 10 , for example, the pusher comprises an upstanding central blade 810 having a lower longitudinal edge 820 and left ( 832 ) and right ends (not shown). A vertical side plate 840 extends forward generally at a right angle from each end of the central blade. The breakaway cutting edge 850 , comprises a plurality of sections 852 , attached to the central blade 810 along the longitudinal edge. At least one of the sections ( 852 ) may be dislodged from its normal operating position in response to the application of sufficient force resulting from contact with an immovable object, thereby preventing damage to the object.
As depicted in FIGS. 8 and 9 , an applied force Fx 1 is applied to the cutting edge by an immovable object when the pusher is being moved forward along the ground. The force is translated to resulting forces (e.g., Fx 2 ) and relative to opposing force (Fx 3 ) that place the fastener holding the edge 852 to the moldboard 810 , in tension and/or shear. As will be further appreciated, the force applied to the fastener is a function of not only Fx 1 , but also of the relative dimensions of the edge in relation to the moldboard's longitudinal edge, for example, dimensions 811 and 812 . For example, force Fx 1 translates to a significantly “magnified” force Fx 2 as a result of the leverage provided by a wide edge (e.g., dimension 811 ). As depicted, for example, in FIG. 8 , the forces applied to the fasteners holding edge 852 to moldboard 810 are also a function of the angle ( 0 ) of the edge, which results in the addition of a shear stress applied to the fastener as well as a tensile stress.
Preferably, the longitudinal edge 820 of the central blade 810 is made of a material of sufficient strength, or is reinforced, to resist damage when the breakaway edge strikes an object. Moreover, the cutting edge sections 852 are made from ort formed of steel or similar rigid and/or hardened materials, and are attached to the longitudinal edge using attachment hardware or fasteners (e.g., bolts with nuts as depicted in FIGS. 9 and 10 ) that offer less resistance to the applied stress (shear and/or tensile forces are present) than the cutting edge sections 852 , so as to result in the failure of the hardware/fasteners before damage to the object or the pushing apparatus. More specifically, in one embodiment, the edge sections are mounted to the central blade using bolts having a yield strength of less than about 36,000 psi and a tensile strength of less than about 74,000 psi (equivalent of Grade 2 or less). It will be appreciated that SAE-J429 Grade 1 or 2 (also A307 Grades A, B), may be used to assure that the failure of the bolts, by shear or other means, will occur before damage to the pusher components or the immovable object. It will also be appreciated that depending upon the particular application, the dimensions of the components, and/or sensitivity to damage, alternative fasteners sizes, steel alloys/grades, materials and or hardware components may be employed (e.g., aluminum hardware, shear pins, etc.) Although the angle θ is illustrated at approximately 12-degrees from normal, the embodiment depicted in FIG. 9 is believed best operated over a range of angles from about 5-degrees to about 20-degrees from normal, although use over a range of about 0-degrees to about 30-degrees from normal and higher is possible.
As generally depicted in FIG. 9 , the present invention further contemplates the use of a safety attachment mechanism 858 connecting the cutting edge sections 852 to the central blade or moldboard 810 so that in the event that the section is completely dislodged (i.e., all fasteners broken), the section will remain attached to the central blade for later reattachment. Such a mechanism may include a loop or hook welded to the back of the cutting edge and attached by chain, cable, clevis or the like to a similar loop or hook on the rear of the central blade.
Turning now to FIGS. 11A and 11B , there are depicted examples of extended wear shoes for use with a material pusher as previously disclosed. The purpose of the extended shoe is to provide a larger surface on which the pusher rides, with the surface extending rearward from the coupling point, thereby making it easier for a vehicle operator to place the pusher in an orientation where the wear shoes are parallel to the ground or surface on which it is being used. Such a feature significantly decreases the likelihood that a pusher will be operated with only the front or rear edge contacting the surface, and thereby quickly wearing out that portion of the shoe. The improved, extended wear shoe 1210 includes a web 1220 for attachment to a side plate of a pusher, and a generally horizontal lower surface 1230 for sliding contact with the ground, the lower surface transitioning to front and rear ramped surfaces on either end thereof, and a cap, 1240 permanently attached to the exposed or extended portion of web 1220 and the upper end of the rear ramped surface. In other words, the cap covers and reinforces the web over at least part of the region 1250 where the shoe extends beyond the rear of the moldboard (e.g., 120 , 610 , 810 ), and as depicted in FIG. 12A that portion beyond the rear edge of the side plate.
As seen in FIGS. 11A-11B , the wear shoe extends a distance (region 1250 ) of at least about 10 to about 25% of the side plate length beyond the rear of the moldboard 810 , and as mentioned above beyond the coupling contact point between the vehicle and the pusher. Thus, the pusher has a removable wear shoe 1210 attached along a bottom edge of each vertical side plate, where the removable wear shoe extends from a position generally adjacent a front edge of the vertical side plate to a position well beyond the rear of the moldboard to assure that the majority of a bottom surface of the wear shoe remains in contact with the ground surface on which the pusher is used.
The present disclosure contemplates additional improvements to the wear shoe, that include at least a wear shoe lower horizontal surface 1230 made from a steel (e.g., HARDOX 500 (Super Duty) from SSAB Oxelsund AB with 0.26% Cr, 0.49% Si, 1.15% Mn, 0.010% P, 0.002 S, 0.070 Cr, 0.05 Ni, 0.009 Mo and 0.002 B) having a hardness of at least about 300 and more preferably about Brinnell. In such embodiments, a heavy duty shoe having improved wear performance may be fabricated using HARDOX 400 (Heavy Duty) or HARDOX 500 (Super Duty). HARDOX wear plate has a hardness of at least 300 and approximately 400 HB. It combines high wear resistance with toughness and good weldability. HARDOX is manufactured by SSAB Oxelosund AB. Use of the 400 and 500 grades is believed adequate, having a Brinnell hardness from about 300-550, to significantly reduce the wear of the shoes during normal pusher use. It will be further understood that the thickness of the lower horizontal surface of the various wear shoes may also be modified to provide longer shoe life.
It will be appreciated that various of the afore-described improvements and modifications may be applied or adapted to operate in conjunction with or on other types of pushers and material moving or scraping apparatus, including but not limited to, fold-out pushers and other types of snow plows and blades. It will be further appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims. | Disclosed herein are various aspects of an improved snow or material pushers for use with loaders, backhoes, agricultural and larger home and garden tractors and the like for moving snow or other materials on generally flat areas such as parking lots, driveways, feed lots, runways, and loading areas. The improvements include, among others, a reversible design, extended side plates and/or wear shoes as well as improved scraping edge configurations so as to provide added functionality and versatility to pushers. As described the various features may be employed alone or in combination to provide the capability for snow and ice removal while minimizing the potential for damage to surfaces and objects thereon. | 4 |
RELATED APPLICATIONS
[0001] This application claims the benefit of the filing date of a provisional application with Ser. No. 61/305,289 which was filed on Feb. 17, 2010, the disclosure of which is incorporated herein by reference.
TECHNICAL FIELD
[0002] The disclosed subject matter is directed to the production of pre-cast blocks for constructing modular columns.
BACKGROUND
[0003] Decorative stone columns are widely used by homeowners and businesses for a variety of purposes such as the monuments at the entrance of a driveway, as supports between fence sections, as a base for a statue, and as pillars at the entrance to a building to name just a few uses. The construction of decorative stone columns normally requires the services of a skilled mason and the utilization of specialized masonry tools. The average individual does not typically have the necessary tools or requisite skill for constructing appropriate concrete forms or for completing decorative stone column construction. As a result, most decorative stone columns are usually constructed by a skilled mason and at a high cost. Producing a high quality, durable and aesthetically pleasing column at a reasonable cost can be accomplished with the assistance of modular column construction as is outlined below.
SUMMARY
[0004] The present invention pertains to the construction of a decorative column and the method of producing the modular blocks that comprise the decorative column. The column comprises a rigid center post surrounded by a plurality of modular blocks. Each modular block has a hole extending through it so the block can fit onto the rigid center post and remain fixed in place on the post. Each modular block is stackable upon another block of similar construction. The present invention pertains to a method for not only producing the modular blocks with compressible inserts but also the erecting of a decorative column that is capable of accommodating ground heaving due to freezing temperatures and thermal expansion which is particularly important, for example, when the column is utilized to support fence sections.
[0005] The method comprises the steps of producing a flexible mold for forming the modular blocks, positioning a compressible insert into the mold, filling the open area created by the walls of the mold and the exterior surfaces of the compressible insert with a lightweight cementitious material, waiting for the cementitious material to cure and then removing the modular block from the flexible mold.
[0006] Once the modular blocks with the compressible inserts are removed from the mold they are positioned onto the rigid center post so that the compressible insert center opening is aligned with the rigid post and can slide down the post to either the ground or atop another modular block. The process of placing the modular blocks on the center post can be repeated as necessary to produce a decorative column of the desired height.
[0007] The compressible inserts are instrumental in reducing the weight of the modular blocks as the inserts are preferably comprised of materials such as EPS foam or cellular PVC to name but a few available options. In addition, the compressible inserts facilitate placement of the modular blocks on the rigid center post particularly for posts of a substantial height as the compressible and flexible material will not bind against the post as the blocks are lowered into position on the post.
BRIEF DESCRIPTION OF DRAWINGS
[0008] FIG. 1 is a perspective view of a three rail fence constructed with modular columns;
[0009] FIG. 2 is a perspective view of a panel fence constructed with modular columns;
[0010] FIG. 3 is a perspective view of a center post of a modular column being constructed with pre-cast ornamental blocks;
[0011] FIG. 4 is a plan view of an embodiment of a pre-cast block without side slots utilized in a modular column;
[0012] FIG. 5 is a plan view of an embodiment of a pre-cast block with single dimension side slots utilized in a modular column;
[0013] FIG. 6 is a plan view of an embodiment of a block with dual dimension side slots utilized in a modular column;
[0014] FIG. 7 is a plan view of an embodiment of a block with single dimension side slots utilized in a modular column;
[0015] FIG. 8 is a cross sectional view of FIG. 2 revealing the interior features of a modular column;
[0016] FIG. 9 is a perspective view of an empty mold with a center post for forming a block for use in a modular column;
[0017] FIG. 10 is a perspective view of a mold showing a compressible insert surrounding the center post used for forming a block for use in a modular column;
[0018] FIG. 11 is a perspective view of a mold showing the addition of a cementitious material to the open area of the mold for forming a block for use in a modular column; and
[0019] FIG. 12 is a perspective view of a mold showing the cementitious material leveled at the top of the mold for purposes of forming a block for use in a decorative modular column.
DETAILED DESCRIPTION
[0020] Referring now to the drawings wherein like reference numerals refer to similar of identical parts throughout the several views. FIG. 1 reveals a fence section comprised of two modular columns 10 connected by fence rails 54 . FIG. 3 details the process by which a modular block 58 is lowered being lowered into position over a post 12 onto several pre-cast blocks 14 , 16 , 18 already in position. Pre-cast blocks can be used to efficiently and with high aesthetic appeal produce columns 10 for various embodiments of a rail fence such as seen in FIG. 1 as well as for various embodiments of a panel fence such as seen in FIG. 2 . Numerous other embodiments and uses of columns utilizing this modular pre-cast block technology are also contemplated and are only limited by the imagination.
[0021] The production of a pre-cast block 58 begins with the use of a flexible mold 20 such as one produced from silicone and as depicted in FIG. 9 . The mold 20 includes four sides 22 A, B, C and D a center post 24 as well as textured interior walls 26 . The textured interior walls 26 are intended to replicate on the finished modular block a stone face including a desirable and contrasting coloration. Prior to the addition of any cementitious material into the mold 20 the textured interior walls are coated with a coloration mixture of mineral iron oxides, cement, water and an acrylic modifier. The coating is applied consistent with the stone facing molded into the interior walls 26 so as to give the impression that the stone faces are of varying color as might be created by a mason using natural stone. Varying the mineral iron oxides content allows different colors to be formulated to satisfy customer preferences. This coloration mixture may be hand applied to specified portions of the interior wall. Alternatively, automated techniques may also be employed such as the use of robotic systems to apply the coloration mixture.
[0022] Once the subset of the textured interior walls 26 are coated with the above referenced mixture a compressible insert 28 is positioned over the center post 24 as shown in FIG. 10 . The compressible insert 28 is lightweight, and preferably comprised of materials such as EPS foam or cellular PVC. The insert 28 includes an upper surface 32 , and creates an interior space 33 that will prevent the intrusion of cementitious material and also includes a plurality of exterior walls 34 . The insert upper surface 32 is preferably at the same elevation and not above the upper surface 36 of the textured interior walls 26 .
[0023] Once the compressible insert 28 is secured in position over the center post 24 , the open space 38 between the mold walls 26 and the exterior walls 34 of the compressible insert 28 is filled with a cementitious material 40 as seen in FIG. 11 . The cementitious material 40 is preferably a light weight wet cement that readily flows to fill the open space 38 . An exemplary mixture of cementitious material would comprise an expanded slate lightweight concrete, such as Stalite™, a dry pigment, aggregates and water combined to form a flowable, lightweight mixture.
[0024] Once the open space 38 is completely filled the mold 20 is vibrated to remove voids from the cementitious material 40 , allow for settling and to facilitate the movement of the coloration mixture painted onto the mold interior walls 26 into the cementitious material 40 instead of remaining at the surface thereby giving a three dimensional penetration of the coloration mixture into the block and improving the weatherability of the block's surface coloration. In addition, as best seen in FIG. 12 , the cementitious material 40 is leveled at the upper surface 36 to create a smooth even surface that facilitates the stackability of the blocks when the cement is cured.
[0025] In about twelve hours the cementitious material is fully cured and the block, along with the compressible insert, can be removed from the mold 20 . Manipulation of the flexible mold 20 , either manually by overturning the mold and popping out the block as is well known in the art, or by injection of air into an orifice in the mold bottom effectively inverting the silicone mold, will facilitate release of the block from the mold 20 . Because the cementitious material 40 permeates the pores of the exterior walls 34 of the compressible insert 28 , the insert is securely bound to the cementitious material and will not separate during use.
[0026] As seen in FIGS. 4 through 7 , alternative embodiments of the block may be cast in the mold 20 with or without slots. FIG. 4 reveals a standard block 42 without slots that would properly be employed, for example, as shown at the lowermost block 18 in the column in FIG. 3 . This lowermost slotless block 18 would typically be employed in a column utilizing between one and four fence rails, such as exemplified in FIG. 1 .
[0027] An alternative block embodiment as depicted in FIG. 5 reveals a block 50 with slots 52 on opposed sides of the compressible insert 28 . These opposing slots 52 serve to hold rails 54 in position as is best seen in FIG. 1 . FIG. 3 also serves to highlight how the slot 52 of block 58 integrates with the slot and block 14 positioned immediately below it in the column to create an opening for securing the rail 54 in position. It will be readily apparent to one versed in the construction of columns that the placement of the slots 52 in a modular block 10 may be offset by 90 degrees, instead of 180 degrees, should a block be needed for a corner column with fence rails extending outwardly at 90 degrees instead of 180 degrees. In addition, a block may have only a single slot 52 should a column be needed that is adjacent a building or other structure and the rails need only extend in a single direction.
[0028] FIG. 6 depicts a third embodiment of a block 60 that is utilized in the construction of a panel fence such as that shown in FIG. 2 . The narrower and shorter slot 62 serves to secure in place the edge of the entire height of the fence panel 67 . The configuration of this slot 62 can also be viewed in cross section in FIG. 8 which shows four separate blocks 61 A, 61 B, 61 C and 61 D positioned at the top of the column. Block 61 A serves as a capping block and includes no slots since the fence panel does not extend upwardly to that height. Block 61 B includes an upper exterior surface 65 with no slot and a lower portion with a slot 64 . The slot 64 on block 61 B, in conjunction with slot 64 in block 61 C serves to secure one end of the upper rail 66 , as best seen in FIG. 2 , in position within the column. Block 61 C also includes a small slot 62 that is intended to facilitate securing the top portion of the panel 67 in position. Finally, block 61 D includes only a small slot 62 but no larger slot 64 , such as that depicted in FIG. 7 . The configuration of block 61 D is repeated on blocks lower in the column until reaching the lower rail 68 where a similar configuration of blocks is utilized to support the rail 68 and the panel 67 as seen at the top of the column with blocks 61 B and 61 C. The dimensions of the slots 62 , 64 may be tailored to any preferred dimension during production to suit the specific dimensions of the fence rails 66 , 68 and panels 67 that are being utilized. To produce slots of the desired dimension one or more inserts are positioned within the mold prior to introduction of the cementitious material 40 or the molds may have the inserts already included. Whether specifically designed into the mold for purpose of occluding the presence of the cementitious material or removable inserts are positioned within the mold 20 , once the cementitious material 40 has been cured the slots are formed into the finished block and they are ready for column construction.
[0029] The various embodiments of the present invention may be utilized to create a structurally sound and aesthetically pleasing column that can stand alone or be incorporated into a fence of a wide range of configurations including rail fences or panel fences. The use of pre-cast blocks 58 with their aesthetically pleasing exterior surfaces, preconfigured slots and lightweight but structurally rigid material greatly facilitates the construction of the columns. Turning again to FIG. 3 , a rigid center post 12 is placed into the ground or secured by some other means so that it stands in a substantially vertical orientation. The center post 12 is preferably a vinyl composition post because of its resistance to weathering and insects, but may be of any sturdy material such as wood, metal or concrete. Additionally, the center post 12 can be of a wide range of dimensions such as 5 inches square or 3 inches square. Alternatively a rectangular of circular configuration for the rigid center post 12 also may be employed. The center post 12 must, however, be of only slightly lesser dimensions than the hole dimension of the compressible insert 28 so that proper alignment of the pre-cast blocks on the modular column 10 can be accomplished.
[0030] As seen in FIG. 3 , once the center post 12 is secured in a substantially vertical orientation, the central opening 33 of the pre-cast block's 58 compressible insert 28 is aligned over the center post 12 . The first pre-cast block 18 to be installed is then moved onto the lowermost support surface which will either typically be a ground surface or a prepared level surface such as concrete. The process of placing additional pre-cast blocks on the column is greatly simplified with the use of a compressible insert 28 . The compressible insert material is soft and pliable and therefore will not bind against the center post 12 because of interference between the insert 28 and the post 12 . Moreover, as noted above, because of the light weight of the compressible insert and the fact that it occupies a significant percentage of the block interior volume that otherwise would be occupied by cementitious material 40 the pre-cast block weighs far less than a pre-cast block constructed without a compressible insert 28 . The nominal weight of a pre-cast block greatly facilitates the construction of a decorative modular column as placement of a pre-cast block with a compressible insert onto a center post 12 requires lesser physical exertion than installation of blocks comprised entirely of cementitious material 40 .
[0031] As further seen in FIG. 3 , a multitude of modular blocks 14 , 16 , 18 , 58 may be placed onto the rigid center post 12 to create a decorative column of any desired height depending upon how the columns is to be employed, for example, as a fence post, a support column or a mailbox stand. If building a fence rail column then, as previously discussed, slots 52 , 62 , 64 may be configured to satisfy the dimensional requirements of the fence rails and panels. Advantageously, no mortar need be placed between the pre-cast blocks to secure them in position as the blocks simply reside one atop the other creating a seamless textured stone exterior along the entire length of the column. Also advantageously, the compressible insert 28 greatly facilitates the resiliency and longevity of the decorative column 12 in areas where there is heaving of the ground due to the freeze-thaw cycle. Because of these compressible inserts 28 , the pre-cast blocks can float on the center post 12 thereby avoiding the accumulation of tensile and compressive forces that can readily fracture hand crafted stone columns or even those with pre-cast blocks that are mortared and locked into fixed positions. For stone columns, such as those shown in FIG. 1 , that are employed as fence columns, the thermal expansion of the fencing segments can produce significant lateral loads on the stone columns that can be absorbed by the compressible inserts 28 thereby avoiding damage to the stone columns through cracking of the column materials.
[0032] Those skilled in the art appreciate that variations from the specified embodiments disclosed above are contemplated herein and that the described embodiments are not limiting. The description should not be restricted to the above embodiments, but should be measured by the following claims. | A decorative column comprising a rigid center post, a plurality of pre-cast pieces with each piece having a hole extending therethrough so the pre-cast piece slides onto the center post and remains in place on the center post. Each pre-cast piece being stacked upon another pre-cast piece, the pre-cast pieces being of a predefined shape, and a compressible center core liner filling a portion of the hole of the pre-cast piece. The compressible center core including a cutout shape consistent with the cross sectional shape of the rigid center post thereby allowing passage of the center post through the compressible center core. | 4 |
FIELD OF THE INVENTION
The present invention concerns a method for improving the stability of photographic developers with respect to aerial oxidation.
BACKGROUND OF THE INVENTION
The efficacy of the development and of the developer depend on many factors, including the degree to which the developer has been used, or "seasoned". As it is used, the developer gains substances coming from the photographic film being processed, and is oxidized. Oxidation is the cumulative effect of the development (reduction of the silver halides) and contact with the air. The oxidation of the developer, that is, oxidation of the reducing substances which it contains, in particular the developing agents, impairs its efficacy and consequently requires the developer to be regenerated (or renewed) at regular intervals in order to maintain the sensitometric characteristics of the photographic films being processed and to prevent the formation of stain. In order to minimize the effects of aerial oxidation, which occurs even when the developer is not in use, large quantities of sulfite or bisulphite are usually incorporated in the developer (up to 100 g/l or more).
Even with sulfite added, developers suffer the effects of aerial oxidation. Also, this oxidation results in the transformation of the sulfite into sulphate, which must be then eliminated to allow recycling the developer, or discharging it to the drains.
The object of the present invention is a method of solving the aforementioned problem, that is, a method which makes it possible to minimize the aerial oxidation of a photographic developer by reducing the oxygen content in the vicinity of the free surface of the bath of photographic developer.
SUMMARY OF THE INVENTION
A method of treating a photographic bath comprising contacting the atmosphere in the vicinity of the free surface of the photographic bath with a cell comprising electrodes and a solid electrolyte, wherein the solid electrolyte is a substance that is conductive to O 2- ions in the presence of an electric current and at a temperature, such that the electrodes and the electrolyte can dissociate the oxygen into O 2- ions.
DETAILED DESCRIPTION OF THE INVENTION
This method, as shown by the following examples, makes it possible to obtain, in the vicinity of the surface of the bath, an atmosphere which is starved of oxygen, that is, an atmosphere containing less than 5% oxygen and advantageously less than 3% oxygen, instead of the normal oxygen content in atmospheric air, which is 21% (% by volume).
The term "vicinity" in the present specification, is intended to designate the atmosphere which may contribute to the aerial oxidation of the developer. It will be understood that the vicinity may depend on such parameters as the volume, the ventilation or the geometry of the room where the processing equipment is installed.
As mentioned above, the solid electrolyte is a substance which conducts O 2- ions in the presence of an electric current. Substances of this type, associated with electrodes, can extract oxygen from air or from oxygen-containing gaseous mixtures. Such solid electrolytes are described in Abraham et al U.S. Pat. No. 5,227,257 as being derivatives of Bi 4 V 2 O 11 with a gamma phase in which at least one of the elements Bi or V is partially replaced by a substitution element so that the structure of the gamma phase and the equilibrium of the charges are maintained. These derivatives of Bi 4 V 2 O 11 therefore have in particular the following formula:
(Bi.sub.2-x M.sub.x O.sub.2)(V.sub.1-y M'.sub.y O.sub.z)
in which:
M represents one or more metals substituting Bi and having an oxidation number less than or equal to 3;
M' represents one or more elements substituting V and is selected from the class consisting of alkali metals, alkaline earth metals, the transition metals, metals of groups IIIa to Va or IIIb to Vb of the Periodic Table;
the limiting values of x, y and z are functions of the nature of M and M', and x plus y is greater than zero.
Metals can be transition metals such as Zn, Cu, Ni, Co, Fe, Mn, Cd, Sb, In, Al, Ti, Sn, Ru, Nb, Ta, Pb, Cr.
According to one embodiment, the compound has one of the formulae Bi 2 O 2 (V 1-y M' y O z ) or (Bi 2-x M x O z )VO z . where M, M', x, y, z have the aforementioned meaning.
When x is not equal to 0, M preferably represents a rare earth.
When y is not equal to 0, M' preferably represents an alkali metal, an alkaline earth metal or a transition metal, such as Zn, Cu, Ni, Co, Fe, Mn, Cd, Sb, In, Al, Ti, Sn, Ru, Nb, Ta, Pb or Cr.
According to one embodiment, the solid electrolyte has the formula:
Bi.sub.2 V.sub.1-y M'.sub.y O.sub.5.5-1.5y
where M' is a transition metal such as Cu, Zn or Co, and y is a number determined as a function of the metal and the degree of oxidation of the metals. Preferably, y is between 0.05 and 0.5 and advantageously between 0.08 and 0.25.
These substances are designated in the literature under the generic name Bimevox, or depending on the metal associated with bismuth, under the name Bicuvox, Bicovox, Biznvox, etc.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts schematically a device for implementing the method of the invention.
The device comprises a tank 10 containing a photographic developer 11. The free surface of this developer is in contact with atmospheric air. A cell 12 comprising the solid electrolyte is placed in the vicinity of the free surface; each face of the cell 12 is connected to electrodes 14a and 14b, themselves connected to a current source (16); a pipe (13) and a pump (not shown) permits evacuation of the oxygen extracted from the atmospheric air by the solid electrolyte. The cell is placed in a heating source 12b in order it to operate at the desired temperature. A pump 15 circulates the air to be treated.
FIG. 2 depicts another embodiment of the invention, comprising a tank 20 containing a developer 21, a cell 22 containing Bimevox, a circuit 23 for pumping air above the surface of the developer, with a pump 23a, an oxygen gauge 23b and a condenser 23c for cooling the gaseous fluid after it has passed through the cell 22, a pipe 24 for evacuating oxygen and a circuit 25 for the developer with a pump 25b.
FIG. 3 depicts a cell such as 22 in FIG. 2, comprising a heating chamber 30 capable of producing temperatures of up to 700° C. or more, a ceramic or alumina wall 31, a slug 32 consisting of Bimevox, with electrodes 34a and 34b in the form of metallic grids set in the body of the slug but visible on each face of the slug.
The solid electrolyte exhibits O 2- conductivity when its temperature is of at least 250° C., advantageously between 250 and 700° C. and more advantageously between 300 and 600° C., and when it has a voltage across it. A source producing a current density of 100 to 1500 mA/cm 2 at a voltage of 1 to 30 V and advantageously 2 to 15 V is used. Under these conditions, a solid electrolyte slug enables oxygen to be extracted from the atmospheric air above the surface of a developer, at a rate of between 100 and 1000 ml/hour with a slug with a surface area of approximately 2 cm 2 . The oxygen content of the atmosphere in the vicinity of the free surface of the developer can thus be reduced by a factor of 10 until the initial content (21% by volume) is reduced to less than 2% by volume. The risk of aerial oxidation of the developer is therefore reduced accordingly. The cell containing the solid electrolyte is placed with respect to the surface of the bath so as to be able to reduce the oxygen content of the atmosphere likely to be in contact with this surface. The cell can be placed at a greater or lesser distance from the surface depending on whether a suction device is used which forces the ambient atmosphere to circulate throughout the cell. Because the operating temperature of the solid electrolyte is around 250 to 500° C., it is preferred that the cell not be contiguous to the surface of the bath.
According to another embodiment, the polarity of the electrodes of the device depicted in FIG. 1 is reversed so that, instead of reducing the oxygen content of the atmosphere, it is increased so as to oxidize the oxidizable substances contained in the photographic processing bath. It is possible, after a certain period of use, to destroy certain constituents of the bath before discharging it to the drains.
Preparation of the bimevox material
The procedure is in accordance with the operating method described in Abraham U.S. Pat. No. 5,227,257, that is by direct synthesis in solid phase, from Bi 2 O 3 (99% Aldrich), V 2 O 5 (99.6% Aldrich) and CuO (99% Aldrich), or another oxide such as CoO or ZnO, depending on circumstances. The constituents of this mixture are crushed in stoichiometric proportions. Bi 2 O 3 is first heated to 600° C. for 6 hours until all traces of carbonate are eliminated. The crushed mixture is then heated for 12 hours at 700° C. and is left to cool at a rate of 20° C./hour. The structure and formula (Bi 2 V 0 .9 Cu 0 .1 O 5 .35) are checked by X-ray diffraction and pellets of this material are produced by compacting.
EXAMPLE 1A
600 ml of a color developing solution for Kodak Ektachrome E-6® processing was introduced into a closed tank. The developer was maintained at a temperature of 50° C. and stirred vigorously in order to simulate maximum aerial oxidation. By means of a loop and a pump, the conditions of circulation of the developer in the tank, at a rate of 50 ml/minute, were also reproduced. The volume of air in the tank above the surface of the developer was approximately 1000 ml.
In accordance with the arrangement in the diagram in FIG. 1, a cell comprising a solid electrolyte of formula Bi 2 V 1-y Cu y O 0 .5-1.5y with y=0.1 prepared in accordance with the operating method described above was placed above the surface of the developer.
The Bicuvox material was in the form of compacted cylindrical pellets, 16 mm in diameter and 5 mm thick, with two conductive metallic grids inserted in each pellet. The surfaces of the pellet were polished with an abrasive, so as to leave the mesh of the metallic grille showing on each face of the pellet, The assembly was placed in a refractory chamber provided with heating, and was connected to the electrical circuit (current source 16 in FIG. 1).
The cell was raised to a temperature of 500° C. and had a voltage (2 V, 200 mA) across it, enabling an oxygen concentration of approximately 2% to be attained. After 18 hours, the developing agent and sulfite contents of the developer were measured, and its coloration was examined.
The results are set out in Table I.
EXAMPLE 1B
(comparative)
The operating method of Example 1A was repeated, except that a cell was not used and the developer was therefore in contact with atmospheric air.
After 18 hours, a strong brown coloring, and a very marked reduction in the concentration of developing agent and sulfite (see Table I) were noted.
TABLE I______________________________________Example Developing agent g/l Sulfite g/l Coloration______________________________________1A 5.06 (-4%) 5.0 (-15%) clear1B 1.94 (-70%) 0.615 (-59%) brown(comparative)______________________________________
EXAMPLE 2A
The operating method of Example 1A was repeated, except that the E6 color developer was replaced with ascorbic acid black and white developer whose formula was as follows, and was given in Research Disclosure, August 1993, publication No 35249, page 543, "High Potassium Developing Solutions":
______________________________________K.sub.2 CO.sub.3 100 g/lK.sub.2 SO.sub.3 50 g/lBenzotriazole 0.2 g/lHMMP (1) 2.5 g/lKBr 4 g/lAscorbic acid 32 g/lAnti-calcium agent (2) 4.3 g/lpH 10.2 at 20° C.______________________________________ (1) 4methyl-4-hydroxymethyl-1-phenyl-5-pyrazolidinone (2) Diethylenetriaminopentacetic acid
The results obtained are set out in Table II.
EXAMPLE 2B
(comparative)
The operating method of Example 2A was repeated, except that the cell with solid electrolyte was omitted.
The results obtained are set out in Table II.
TABLE II______________________________________Example Developing agent g/l Sulfite g/l Coloration______________________________________2A 37.9 (-0%) 8.9 (-4%) clear2B 29.8 (-20%) 6.0 (-25%) brown(comparative)______________________________________
It can be seen that the reference developer, in the absence of the cell, exhibits a significant reduction in the concentrations of developing agent and sulfite.
The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention. | The invention concerns a method for decreasing the oxygen content of the atmosphere above photographic processing baths. The method comprises using a solid electrolyte which is a compound of bismuth, vanadium or another transition metal. The oxidation in air is thus minimized and the life of the bath is extended. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention.
The present invention relates to a device for bridging over the expansion joints in roadways and the like, especially in bridge roadway.
2. Description of the Prior Art.
Known devices for bridging over expansion joints comprise sliding and rubbing components which render possible the opening and closing of the joint. Deterioration of the mobility under the action of dirt, corrosion and wear can cause these known devices to become useless in time. Moreover such designs require very great precision in production.
Another known device according to Swiss Pat. No. 440,360 consists of thin-walled carrier rods of zig-zag or undulatory form arranged in the direction of movement which are connected with beams extending parallel with the joint edges. Such a device has the disadvantage that it cannot be made watertight, since the two-dimensional movements of the gaps render secure sealing impossible. Moreover the carriers with undulatory or zig-zag course with thin walls must be made easily deformable, which is not possible in the case of wide joints requiring strong rods. The requisite bearing capacity and elasticity can be achieved only limitedly with small joints.
A further device according to U.S. Pat. No. 2,797,952 comprises plates which are supported on trusses of articulated rods connected with the joint edges. Unavoidable forces acting in the transverse direction of the roadway cannot be taken up. The joints, which are heavily stressed under the traffic load, are prone to wear and in time troublesome chattering noises are to be expected. The design requires high production precision. Arrangement of seals in the plate interspaces is possible. A further device according to U.S. Pat. No. 3,904,302 comprises a plurality of rigid strips and elastomeric strips between adjacent rigid strips which extend longitudinally through the gap. Upper ends of the legs are connected to the rigid strips. Lower ends of the legs are interconnected with each other in pairs whereby adjacent legs form a pair and an elastically yielding structure. This design has the disadvantage that the legs and the elastically deformable rigid strips must take up the bending moments from the traffic load. For this reason this system without additional supporting can be used sensibly and economically only to bridge over minor joints.
SUMMARY OF THE INVENTION
The device according to the invention has:
A. a first edge plate extending in the joint longitudinal direction arranged at roadway level and anchored in one joint edge;
B. a second edge plate extending in the joint longitudinal direction, arranged at roadway level and anchored in the other joint edge;
C. at least one intermediate plate arranged between and spaced from said first and second edge plates;
d. elastically deformable seal elements provided between said intermediate plate and said first and second edge plates;
e. first downwardly extending flexible lateral supports supporting said first edge plate;
f. second downwardly extending flexible lateral supports supporting said second edge plate; and
g. downwardly extending intermediate supports supporting the intermediate plate.
The invention is based upon the problem of producing a watertight roadway transition which has no sliding and rubbing parts, is resistant to wear and the operation of which is not impaired by the action of dirt and corrosion, further which renders possible the expansion and contraction of the joint and even in the case of wider joints possesses the requisite bearing capacity without additional supporting constructions; moreover such a roadway transition should be capable of being produced without high production precision. For this purpose in the device according to the invention the intermediate supports are each connected to at least one of the first lateral supports and to at least one of the second lateral supports.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 to 7 show seven different examples of embodiment of expansion joints having three plates, in vertical cross-section;
FIGS. 1a to 7a show the pertinent plan views without the seal elements arranged between the plates;
FIGS. 8 to 10 show three further examples of embodiment of expansion joints with four plates, in vertical cross-section;
FIGS. 8a to 10a show the associated plan views;
FIG. 8b shows the expansion joint as illustrated in FIGS. 8 and 8a without the joint edges and seal elements, in perspective representation;
FIG. 9b shows the expansion joint as illustrated in FIGS. 9 and 9a without the joint edges and seal elements, in perspective representation;
FIG. 11 shows a further example of embodiment of an expansion joint with four plates, without the joint edges and seal elements, in perspective representation;
FIGS. 12 to 25 show various examples of embodiment of the connection of side supports with the edge plates and partly also with the supports; and
FIGS. 26 and 27 show a device for limiting the horizontal movement of the intermediate plates.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the example according to FIGS. 1 and 1a, 1 and 2 designate the two joint edges of the roadway with the roadway flooring 3 and the roadway sub-structure 4. 5 and 6 designate the two edge plates arranged at roadway level, which are anchored in the roadway sub-structure 4 by means of welded-on fins 7 and 8. 9 is an intermediate plate arranged with spacing from the two edge plates 5, 6. The interspaces between the plates are sealed off in known manner by means of elastically deformable seal elements 11 inserted in shape-locking manner into the plates. The intermediate plate 9 is supported on several vertically downwardly extending supports 12 and connected in bending-resistant manner therewith, for example by welding. As may be seen from FIG. 1, the supports 12 are made in inverted T-form in vertical cross-section and merge at the lower end into horizontally protruding legs 27. 28, 29 designate lateral supports formed as flat sections which are elastically flexible in the longitudinal direction of the roadway, are each welded at the upper end with the edge plates 5, 6 and extend like the supports 12 vertically downwards, where they engage with their lower ends on the legs 27 of the supports 12 or are welded or otherwise rigidly connected with these. For the support of the intermediate plate 9 various supports 12 are arranged, namely at intervals A extending in the longitudinal direction B of the joint. Two of these supports may be seen in FIG. 1a.
In the example of embodiment according to FIGS. 2 and 2a, parts formed the same are designated in the same way as in the above-described example of embodiment. 13 designates a support standing on edge an welded in bending-resistant manner to the intermediate plate 9, the lower end of which support is rigidly connected by intermediate pieces 48 arranged at intervals A from one another with the lateral supports 30, 31 of plate form which are elastically flexible in the longitudinal direction of the roadway. Supports 13 and lateral supports can extend over the whole joint length or over only parts thereof.
In the example of embodiment according to FIGS. 3 and 3a, tension cables 32 and 33 serve as lateral supports for the supports 14 of inverted T-form. The ends of these tension cables are connected by means of press-on threaded bushes 49 and 50 (see also FIG. 18) with threaded bolts 51 and 52 which are secured at one end on protruding arms 53 welded to the anchor fins 7, 8 and at the other in the legs 54 of the supports 14. In order to avoid an oblique traction upon the threaded bolts 51, 52, deflector elements 55, 56 serving as guide for the cables 32 and 33 are secured on the one hand to the roadway sub-structure 4 and on the other to the support 14. On a movement of the intermediate plate 9 transversely of the joint the cables incline differently in relation to the roadway surface, so that uniform gap widths occur between the plates.
In the example of embodiment according to FIGS. 4 and 4a the supports 15 have downwardly diverging legs 57, 58 which are connected with one another at the lower end by a cross-piece 59. Thin flat sections 34 and 35 serve as lateral supports for the supports 15.
In the example of embodiment according to FIGS. 5 and 5a the supports 16 are formed as bars of rectangular cross-section and downwardly converging flat sections 36 and 37 which are elastically flexible in the longitudinal direction of the roadway serve as lateral supports.
In the example according to FIGS. 6 and 6a the supports 17 formed as square sections are provided at the lower end each with an elastically flexible flat section 60 placed on edge, which protrudes in the longitudinal direction of the joint to both sides and is connected with the lateral supports 38 and 39 by means of intermediate pieces 61 and 62 arranged at its ends.
In the example of embodiment according to FIGS. 7 and 7a, O-shaped spring elements 63 and 64 which are elastically deformable in the longitudinal direction of the roadway are installed between each support 18 and the two lateral supports 40 and 41, which spring elements render possible an elastic expansion and contraction of the expansion joint.
In the example of embodiment according to FIGS. 8 and 8a each support 19, 20 has legs 65 and 66 of different lengths at the lower end. Correspondingly the lateral supports 42 and 43 have different bending resistance moments, namely the lateral support 43 adjoining the longer leg 66 has the lower moment. This is so that on a movement of the joint in the longitudinal direction of the roadway, apertures or interspaces which always remain the same result between the plates. The same effect can also be achieved if the lateral supports 42, 43 are made with different lengths or act on the supports at different distances from the plates.
FIG. 8b shows a perspective representation of the example of embodiment according to FIGS. 8 and 8a. From this it may be seen that the longer legs 66 of each two successive supports 19, 20 protrude to mutually opposite sides. In this example with four plates again each support 19, 20 is connected through the lateral supports 42 and 43 directly with the edge plates 5 and 6.
The example of embodiment according to FIGS. 9 and 9a corresponds in principle to that according to FIGS. 8 and 8a, with the difference that as in the example according to FIGS. 7 and 7a, O-shaped spring elements 69, 70 are installed between the supports 21, 22 and the lateral supports 44 and 45 and in the legs 67 and 68.
FIG. 9b shows in perspective representation the example of embodiment as illustrated in FIGS. 9 and 9a.
In the example of embodiment according to FIGS. 10 and 10a the supports 23, 24 in vertical section have the form of hollow profiled sections with resiliently elastic side walls and legs 71, 72 of unequal length. The side walls of the supports here have different bending resistance moments, namely the side walls 47 adjoining the longer legs 72 have the smaller moments. In contrast with the example according to FIGS. 8 and 8a the legs 71, 72 are not arranged at the lower ends of the supports but somewhat beneath the middle of the height thereof, in order to increase the spring effect of the hollow supports.
In the example of embodiment according to FIG. 11 with four plates, as lateral supports there serve rods 48 and 49 which are anchored at one end in the legs 65, 66 of the supports 25, 26 and at the other in lateral eyes 73, 74 of the edge plates 5, 6.
FIGS. 12 to 16 show various possiblities of securing rods 75 to 79 serving as lateral supports to the edge plates and partly also to the supports, while FIGS. 17 to 22 show by way of example how cables 32 and 80 to 83 serving as lateral supports can be secured to the edge plates and in part also to the supports, and in fact FIG. 17 shows the securing of a cable 80 by means of straps 84, FIG. 18 the securing of a cable 32 with a press-on threaded sleeve 49, FIG. 19 the anchoring of the upper cable end in a sealing head 85 and FIGS. 20 to 22 the securing of cables 82, 83 with upper end of loop form.
FIGS. 23 and 24 show the possibility of securing a chain 86, serving as lateral support by means of a ring eye 87 and finally FIG. 25 shows the securing of a rod 88, serving as lateral support, with the aid of a ball head 90 seated in a joint socket 89.
In all the examples of embodiment as illustrated and described, each support is connected directly with the two outer plates, while the lateral supports are subjected exclusively to tension stress by the traffic load. The bending stresses upon the lateral supports resulting in the expansion and contraction of the expansion joint are practically insignificant; in any case they are eliminated when cables or chains are used as lateral supports.
When vehicles passing over the expansion joint are braked and accelerated, transverse forces act upon the intermediate plates which can lead to local variations of the gap widths between the plates. However experience has shown that the elastic seal elements 11 arranged between the plates are entirely adequate to take up these transverse forces, so that the plates do not collide nor do gap widths result which are unacceptable for traffic.
FIGS. 26 and 27 show how such transverse forces can be additionally counteracted and the movement of the intermediate plates can be kept under control. For this purpose elements 91, 92 of hook form are secured to the edge plates 5, 6 and engage with clearance each behind the adjacent intermediate plate, while in the case of a plurality of intermediate plates, as illustrated in FIGS. 12 and 13, the intermediate plates are likewise provided with elements 93, 94 and 95, 96 of hook form which each engage with clearance behind the next intermediate plate. | A device for bridging expansion joints in roadways, comprising edge plates anchored in the edges of the roadway to be joined together, an intermediate plate between the edge plates, a resilient seal between the intermediate plate and each edge plate, and flexible lateral supports depending from the intermediate and edge plates and connected together at their ends remote from the plates. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to memory devices and to field programmable gate arrays programmed by loading a bitstream of data stored in one or more memory devices.
2. Description of the Background Art
"The Programmable Logic Data Book" ("Xilinx Data Book"), published by Xilinx, Inc. ("Xilinx") in 1994, describes field programmable gate arrays ("FPGAs") manufactured and sold by Xilinx. These FPGAs are further described in U.S. Pat. No. Re. 34,363, which is incorporated herein by reference. These FPGAs are capable of retrieving configuration data from a Programmable Read-Only Memory ("PROM") or other memory device. Several methods for retrieving configuration data from a single PROM are described in co-pending application Ser. No. 08/500,294 (docket no. M-3416-US), which is incorporated herein by reference.
DESCRIPTION OF BACKGROUND ART FIGURES
One method for retrieving a configuration data stream ("bitstream") from a PROM is represented in FIG. 1. This method is referred to as "master serial configuration mode." Referring to FIG. 1, an FPGA 1 receives an initiating signal on reset line 2, which signal also initializes PROM 4. Alternatively, FPGA 1 may self-initialize in response to the application of a supply voltage. FPGA 1 generates a clock signal on a clock signal line 3. The clock signal is received by PROM 4, which generates in response thereto a bitstream DATA on an output line 5. The bitstream DATA is received by FPGA 1, which becomes configured in response thereto. When FPGA 1 is done configuring itself, it asserts an ENABLEB signal on line 6, indicating that configuration is complete. This signal deselects PROM 4.
Known PROMs generate the bitstream DATA on line 5 in FIG. 1 using a structure shown in FIG. 2. Referring to FIG. 2, an address counter 7 is initialized by a signal on reset line 2. Address counter 7 may be either an up counter or a down counter, but does not function as an up/down counter. The address in the counter is sent via address bus 8 to memory block 9. Memory block 9 places the contents of the memory address specified by address bus 8 onto bitstream line 5. Address counter 7 is updated periodically in response to an input clock signal on clock signal line 3, and sends a new address on address bus 8 to memory block 9. In response thereto, memory block 9 places the next bit of bitstream data onto bitstream line 5. When address counter 7 receives an ENABLEB signal on input signal line 6, address counter 7 ceases to count.
A similar method is known for retrieving a bitstream from a parallel PROM.
The term "self-addressing memory device" will be used herein to refer to any storage device that does not require externally supplied addresses to retrieve the data; the term therefore may include, but is not limited to, serial and parallel Programmable Read-Only Memories ("PROMs"), other Read-Only Memories ("ROMs"), and shift registers. These memory devices may be either volatile or non-volatile. The term "self-addressing" as used herein does not imply the necessity for an addressing scheme; for example, shift registers do not require addressing. The term "ROMs" includes both programmable and non-programmable Read-Only Memories, which may provide either serial or parallel data.
No known self-addressing memory has the capability of setting the initial value in the counter to any of two or more values. No known self-addressing memory has the capability of optionally both incrementing and decrementing the internal counter.
In co-pending application Ser. No. 08/500,294, Leeds also describes a configuration method wherein the system includes first and second FPGAs, as shown in FIG. 3. The FIG. 3 system includes first and second FPGAs 1a and 1b and PROM 4. During configuration, FPGA 1a is in the "master serial configuration mode" and FPGA 1b is in the "slave serial configuration mode." (These configuration modes are described in the Xilinx Data Book on pages 2-32 to 2-35.) FPGA Ia, the master device, provides the signals that control the configuration of both master and slave devices. In response to an initiating signal on reset line 2, which also initializes FPGA 1b and PROM 4, or in response to the application of a supply voltage, FPGA 1a generates a clock signal on a clock signal line 3. This clock signal is input to both PROM 4 and FPGA 1b. PROM 4 responds to the clock signal by providing bitstream data signals to FPGA 1a on line 5. In this example, when FPGA 1a is done configuring itself, FPGA 1a continues to send clock signals to serial PROM 4 and FPGA 1b on signal line 3. Serial PROM 4 thus continues to send bitstream data to FPGA 1a via line 5. This data is passed from FPGA 1a to FPGA 1b via a signal line 10. FPGA 1b takes the bitstream data from line 10 and uses that data to configure itself. FPGAs 1a and 1b include open drain output buffers which drive leads 6a and 6b, respectively. Leads 6a and 6b are "wire-ANDed" together. That is, each of leads 6a and 6b is an open-drain output lead. They are tied to each other and also tied through a resistor 31 to a positive power supply 32. When FPGAs 1a and 1b are both done being configured, the signals on leads 6a and 6b go high, indicating that both FPGAs are done being configured. The high signals on leads 6a and 6b produce a high signal (ENABLEB) which deselects PROM 4.
It is known that the configuration method shown in FIG. 3 can be extended to permit configuration of more than two FPGAs with a single bitstream.
A similar method is known to retrieve a bitstream from a parallel PROM and configure multiple FPGAs. The parallel bitstream data is serialized by the master device, corresponding to FPGA 1a in FIG. 3. When FPGA 1a is done configuring itself, it sends the serialized bitstream to FPGA 1b via a signal line corresponding to signal line 10 in FIG. 3.
It is also known to use multiple PROMs to store a bitstream too large to fit in a single PROM of the size used in a given system. This technique is called "cascading." One example is shown on page 2-32 of the 1994 Xilinx Data Book. This example shows an FPGA in "master serial configuration mode" with first and second cascaded serial PROMs forming a "cascade chain." This method is shown in FIG. 4. Referring to FIG. 4, an FPGA 1 in master serial configuration mode receives an initiating signal on reset line 2, which also initializes PROMs 4a and 4b. Alternatively, FPGA 1 may self-initialize in response to the application of a supply voltage. FPGA 1 generates a clock signal on a clock signal line 3. The clock signal is received by serial PROMs 4a and 4b. PROM 4a generates in response thereto a bitstream on an output line 5. PROM 4b does not generate a bitstream at this time, because PROM 4a also generates a chip enable signal on output line 11, which disables PROM 4b until all of the contents of PROM 4a have been placed on bitstream signal line 5. When all of the contents of PROM 4a have been read, PROM 4a ceases to place data on bitstream signal line 5 and changes the state of chip enable signal 11. Thus PROM 4b begins to generate bitstream data on line 5. The serial data on line 5 is received by FPGA 1, which becomes configured in response thereto. When FPGA 1 is done configuring itself, it asserts an ENABLEB signal on line 6, indicating that configuration is complete. This signal deselects PROM 4a. In response thereto, PROM 4b changes the state of chip enable signal 11, which deselects PROM 4b.
A similar method is known to retrieve a bitstream from multiple parallel PROMs.
DISADVANTAGES OF THE BACKGROUND ART
One advantage of using FPG in a system is the capability of reconfiguring the FPGA or FPGAs to perform a different function without making physical changes to the system. It can be desirable to store multiple bitstreams in a PROM (or in a series of FIROMs as in FIG. 4) to permit such reconfiguration. The known method for storing multiple bitstreams is to store the bitstream data sequentially in the PROM, such that after the FPGA or FPGAs are completely configured, the internal counter in the PROM addresses the first location in the next bitstream. The data at this address is then available if another configuration is initiated.
A disadvantage of this method is that the bitstreams can only be accessed in the same sequential order as they are stored in the PROM. Initializing the PROM counter permits access to the first bitstream at any time, but any further bitstreams can only be accessed sequentially.
Another method for storing multiple bitstreams in a single PROM is to segment the PROM into two or more banks of memory locations ("memory banks"), and to select one of the memory banks based on one or more "bank select" input signal lines to the PROM. This method overcomes the disadvantage of sequential access, but the size of a bitstream is limited to the size of one memory bank of the PROM. As an additional disadvantage, this method is unsuited to the storage of bitstreams of widely varying sizes. Such bitstreams are required in multiple-FPGA systems where it is sometimes desired to configure several FPGAs, and sometimes to configure only one or a few FPGAs. The size of each memory bank must be such that the largest bitstream can be stored in a single memory bank. This structure and method result in wasted memory storage in the memory banks containing the smaller bitstreams.
It is desirable to create a self-addressing memory device which can efficiently store multiple bitstreams of varying sizes, while allowing access to any bitstream at any time.
SUMMARY OF THE INVENTION
A self-addressing memory device in accordance with this invention is capable of reading blocks of data starting from any of two or more initial locations, and may have the option of reading the data in either of two directions from the initial location.
The stored bitstreams can be accessed in any sequence, because the choice of initial values permits more than one starting point for reading the stored data. Each bitstream can be stored with the first data starting at a different initial value.
Bitstreams of different sizes can be efficiently accommodated, because not every initial value need be used. A single bitstream can continue beyond the initial point where a second bitstream could be stored. The initial points do not form barriers to the data. The only limitation on the size of the largest bitstream is that it must be no larger than the data space of the self-addressing memory device, or the total data space of all self-addressing memory devices in the system, if cascaded memory devices are used.
Even more efficient bitstream storage results from the capability to read data in either of two directions from the initial location. This capability permits the storage of two bitstreams of widely varying sizes between any two initial locations, with data read from each location towards the other location. As long as the combined size of the two bitstreams is smaller than the data space, the bitstreams can be stored and used. The relative size of the two bitstreams is immaterial.
In one embodiment, the device is a serial PROM that includes an address counter cap)able of assuming any of two or more initial values, based on the status of one or more external input signals to the PROM. The address counter may be further capable of either incrementing or decrementing, based in one embodiment on the status of an external input signal to the PROM. In one embodiment, a single external input signal selects between "increment from minimum" and "decrement from maximum" for the address counter. A maximum of two bitstreams can be stored in this PROM. The combined size (of the two bitstreams must be no larger than the total data space of the PROM. The bitstreams can be accessed in any sequence.
In a second embodiment, two input signals to a PROM select any of four initial values for the address counter, and determine whether the address counter is to be incremented or decremented. The four selections are: 1) increment from minimum; 2) decrement from a first address value between the minimum and the maximum; 3) increment from a second address value between the minimum and the maximum, typically one memory location higher than the first address value; and 4) decrement from maximum.
This embodiment permits the storage of from one to four bitstreams in a single PROM. A single bitstream may be any size up to the size of the entire PROM data space. First and second bitstreams must have a total size no larger than the entire PROM data space. However, smaller portions of the PROM may be used for smaller bitstreams. For example, the PROM can be partitioned into two data spaces, from initial value (1) to (2), and from initial value (3) to (4). In this example, the first and second bitstreams can have a total size no larger than the data space from the minimum address (1) to the first address (2). The third and fourth hitstreams can have a total size no larger than the data space from the second address (3) to the maximum address (4). This embodiment provides flexibility in combining bitstreams of different sizes. The bitstreams can be accessed in any sequence.
In a third embodiment, PROMs with an input signal selecting between "increment from minimum" and "decrement from maximum" for the address counter are modified to permit cascading of two or more PROMs. Bidirectional chip enable pins are provided. The direction of these pins (input or output) is determined by the same PROM input signal that selects between increment and decrement. This embodiment allows efficient storage of two bitstreams with a total size too large to fit into a single PROM, while allowing access to the bitstreams in any sequence.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically illustrates an FPGA in master serial configuration mode, configuring from a serial PROM.
FIG. 2 schematically illustrates a serial PROM of the prior art.
FIG. 3 schematically illustrates a 3-chip system comprising one FPGA in master serial configuration mode and one FPGA in slave serial configuration mode, configuring from a serial PROM.
FIG. 4 schematically illustrates an FPGA in master serial configuration mode, configuring from first and second cascaded serial PROMs.
FIG. 5 schematically illustrates an FPGA in master serial configuration mode, configuring from a serial PROM that allows increment from minimum or decrement from maximum in accordance with a first embodiment of the invention.
FIG. 5a schematically illustrates a serial PROM with the ability to increment from minimum or decrement from maximum in accordance with a first embodiment of the invention.
FIG. 6 schematically illustrates an FPGA in master serial configuration mode, configuring from a serial PROM that allows immediate access to any of up to four bitstreams in accordance with a second embodiment of the invention.
FIG. 6a schematically illustrates a serial PROM that allows immediate access to any of up to four bitstreams in accordance with a second embodiment of the invention.
FIG. 7 schematically illustrates an FPGA in master serial configuration mode, configuring from a first PROM and a second PROM, each of which allows increment from minimum or decrement from maximum, and further allows a reversible enable chain to permit cascading of this function in accordance with a third embodiment of the invention.
FIG. 7a schematically illustrates a serial PROM that allows increment from minimum or decrement from maximum, and further allows a reversible enable chain to permit cascading of this function in accordance with a third embodiment of the invention.
DETAILED DESCRIPTION OF EMBODIMENTS
The embodiments are described in terms of serial PROMs; obvious variants of the described embodiments include those directed to parallel PROMs, other ROMs, and shift registers.
FIRST EMBODIMENT
In FIG. 5, a system containing a first embodiment of the present invention is shown. This system incorporates an input signal to the PROM that selects between "increment from minimum" (with the minimum address being all zeros in one embodiment) and "decrement from maximum" (with the maximum address being all ones in one embodiment).
Referring to FIG. 5, an FPGA 1 receives an initiating reset signal on input signal line 2. The signal on reset line 2 also initializes PROM 4c to a value dependent on the state of an INC/DECB signal on input signal line 12. Alternatively, FPGA 1 may self-initialize in response to the application of a supply voltage. FPGA 1 generates a clock signal on a clock signal line 3. The clock signal is received by serial PROM 4c, which generates in response thereto a data bitstream on an output line 5. The bitstream is read from the memory block in PROM 4c by either increasing or decreasing an internal address, depending on the state of the INC/DECB signal on signal line 12. The serial data on line 5 is received by FPGA 1, which becomes configured in response thereto. Then FPGA 1 is done configuring itself, it asserts an ENABLEB signal on line 6, indicating that configuration is complete. This signal deselects PROM 4c.
Although FIG. 5 shows a system with one FPGA, it would be obvious to one of ordinary skill in the art to increase the number of FPGAs by means of the known configuration method shown in FIG. 3.
In FIG. 5a, PROM 4c incorporated in FIG. 5 is shown. Referring now to FIG. 5a, an address counter 7a in PROM 4c is initialized by the reset signal on input signal line 2 to either a minimum or a maximum value, depending on the state of the INC/DECB input signal on line 12. Address counter 7a functions as either an up counter or a down counter, depending on the state of the INC/DECB input signal on line 12. In one embodiment, a high value on INC/DECB line 12 sets the counter initialization value to all zeros and configures address counter 7a as an up counter, while a low value on INIC/DECB line 12 sets the counter initialization value to all ones and configures address counter 7a as a down counter. The address in address counter 7a is sent via address bus 8 to memory block 9. Memory block 9 places the contents of the memory address specified by address bus 8 onto data bitstream line 5. Address counter 7a is updated periodically in response to an input clock signal on clock signal line 3, and sends a new address on address bus 8 to memory block 9. In response thereto, memory block 9 places the next bit of bitstream data on output line 5. When address counter 7a receives an ENABLEB signal on input signal line 6, address counter 7a ceases to count.
SECOND EMBODIMENT
In FIG. 6, a system containing a second embodiment of the present invention is shown. This system incorporates two input signals to the PROM that select any of four initial values for the address counter, and determine whether the address counter is to be incremented or decremented. The four selections are: 1) increment from minimum (with the minimum address being all zeros in one embodiment); 2) decrement from d first address value between the minimum and the maximum (the midpoint of the addressable memory in one embodiment); 3) increment from a second address value between the minimum and the maximum (one memory location higher than the first address value in one embodiment); and 4) decrement from maximum (with the maximum address being all ones in one embodiment).
Referring to FIG. 6, FPGA 1 receives an initiating reset signal on input signal line 2. The reset signal on line 2 also initializes PROM 4d to any of four initial values based on the state of the two signals on select input signal lines 13 and 14. Alternatively, FPGA 1 may self-initialize in response to the application of a supply voltage. FPGA 1 generates a clock signal on a clock signal line 3. The clock signal is received by serial PROM 4d, which generates in response thereto a data bitstream on an output line 5. The bitstream is read from PROM 4d by either increasing or decreasing an internal address, depending on the states of the two signals on signal select lines 13 and 14. The serial data on line 5 is received by FPGA 1, which becomes configured in response thereto. When FPGA 1 is done configuring itself, it asserts an ENABLEB signal on line 6, indicating that configuration is complete. This signal deselects PROM 4d.
In FIG. 6a, PROM 4d incorporated in FIG. 6 is shown. Referring now to FIG. 6a, an address counter 7b in PROM 4d is initialized by the reset signal on line 2 to any of four initial values, based on the states of the two select signals on input signal lines 13 and 14. In one embodiment, the initialization value is created by a 4-to-1 multiplexer 15. The select lines of multiplexer 15 are the select input signals on signal lines 13 and 14. The four inputs to multiplexer 15 in this embodiment are: 1) a ground signal bus 16; 2) a value stored in a memory 17 and sent to multiplexer 15 on a bus 18; 3) a value stored in a memory 19 and sent to multiplexer 15 on a bus 20; and 4) a bus 21 driven by the positive power supply. The multiplexer 15 output is sent to address counter 7b via bus 22. Address counter 7b functions as either an up counter or a down counter, depending on the state of the signal on line 14. As shown in the following table, in this embodiment, a high value on line 14 selects a down counter, and a low value on line 14 selects an up counter.
______________________________________13 14 Initial Value Up/Down______________________________________1 1 all ones (21) Down1 0 intermediate point + 1 (20) Up0 1 intermediate point (18) Down0 0 all zeros (16) Up______________________________________
The address in address counter 7b is sent via address bus 8 to memory block 9. Memory block 9 places the contents of the memory address specified by address bus 8 onto bitstream line 5. Address counter 7b is updated periodically in response to an input clock signal on clock signal line 3, and sends a new address on address bus 8 to memory block 9. In response thereto, memory block 9 places the next bit of bitstream data on output line 5. When address counter 7b receives an ENTABLEB signal on input signal line 6, address counter 7b ceases to count.
One embodiment of the present invention implements multiplexer 15 shown in FIG. 6a as a separate multiplexer for each bit of the address counter. Each multiplexer could be implemented as a set/reset flip-flop for the counter bit.
In one embodiment of the invention, memories 17 and 19 are implemented as writable registers, allowing the two initialization values on buses 18 and 20 to be set by the user.
Although FIG. 6a shows an address counter with four possible initial values, it is possible to supply only three initial values, with the fourth option performing an automatic increment or decrement of the intermediate initial value, to create the fourth starting address for the bitstreams.
Based on the description above, it would be obvious to one of ordinary skill in the art to provide more than four initial values for the address counter.
THIRD EMBODIMENT
In FIG. 7, a system containing a third embodiment of the present invention is shown. This system incorporates an input signal to the PROM that selects between "increment from minimum" (with the minimum address being all zeros in one embodiment) and "decrement from maximum" (with the maximum address being all ones for one embodiment) for the address counter, and also includes bidirectional chip enable pins to permit cascading of two or more PROMs.
Referring to FIG. 7, FPCA 1 in master serial configuration mode receives an initiating signal on reset line 2, which also initializes PROMs 4e and 4f to a value dependent on the state of an IN(/DECB signal on signal line 12. Alternatively, FEPGA 1 may self-initialize in response to the application of a supply voltage. FPGA 1 generates a clock signal on a clock signal line 3. The clock signal is received by serial PROMs 4e and 4f.
In the embodiment of FIG. 7, if the INC/DECB signal on signal line 12 is high, PROM 4e generates in response to the clock signal on line 3 a data bitstream on an output line 5. PROM 4f does riot generate a bitstream at this time, because PROM 4e also generates a chip enable signal on input/output line 6e, which disables PROM 4f until all of the contents of PROM 4e have been placed on bitstream signal line 5. When all of the contents of PROM 4e have been read, PROM 4e ceases to place data on bitstream signal line 5, and changes the state of bi-directional chip enable signal 6e. Thus PROM 4f begins to generate bitstream data on line 5. The serial data on line 5 is received by FPGA 1, which becomes configured in response thereto. When FPGA 1 is done configuring itself, it asserts an ENABLEB signal on line 6c, indicating that configuration is complete. This signal deselects PROM 4e. In response thereto, PROM 4e changes the state of chip enable signal 6e, which deselects PROM 4f.
In FIG. 7, if the INC/DECB signal on signal line 12 is low, PROM 4f generates in response to the clock signal on line 3 a bitstream on output line 5. PROM 4e does not generate a bitstream at this time, because PROM 4f also generates a chip enable signal on input/output line 6f, which disables PROM 4e until all of the contents of PROM 4f have been placed on bitstream signal line 5. When all of the contents of PROM 4f have been read, PROM 4f ceases to place data on data bitstream signal line 5, the chip enable signal on line 6f changes state, and PROM 4e begins to generate bitstream data on line 5. The serial data on line 5 is received by FPGA 1, which becomes configured in response thereto. When FPGA 1 is done configuring itself, it asserts an ENABLEB signal on line 6c, indicating that configuration is complete. This signal deselects PROM 4f. In response thereto, chip enable signal 6f changes state and deselects PROM 4e.
In FIG. 7a, PROM 4e incorporated in FIG. 7 is shown. Referring now to FIG. 7a, an address counter 7c in PROM 4e is initialized by the reset signal on line 2 to either a minimum or a maximum value, depending on the state of the INC/DECB input signal on line 12. Address counter 7c functions as either an up counter or a down counter, depending on the state of the IN(/DECB input signal on line 12. In one embodiment, a high value on INC/DECB sets the counter initialization value to all zeros and configures address counter 7c as an up counter, while a low value on INC/DECB sets the counter initialization value to all ones and configures address counter 7c as a down counter. The address in address counter 7c is sent via address bus 8 to memory block 9. Memory block 9 places the contents of the memory address specified by address bus 8 onto bitstream line 5. Address counter 7c is updated periodically in response to an input clock signal on clock signal line 3, and sends a new address on address bus 8 to memory block 9. In response thereto, memory block 9 places the next bit of bitstream data onto output line 5. When address counter 7c receives a disable signal on signal line 23, address counter 7c ceases to count.
In one embodiment, signal line 23 of FIG. 7a is generated from signal lines 6d and 6e and the INC/DECB input signal on line 12. The IMC/DECB signal is inverted by inverter 24 to form the DEC/INCB signal 25. Signal line 6d is bidirectional: signal line 6d provides the input to a 3-state buffer 26 enabled by the INC/DECB signal on line 12, and forms the output of a 3-state buffer 27 enabled by the DEC/INCB signal 25. The output of 3-state buffer 26 is the enable signal on line 23. The input of 3-state buffer 27 is a signal on line 28 that in one embodiment is a terminal count generated by address counter 7c when enabled through signal line 23 and the counting cycle is complete. Signal line 6e is also bidirectional: signal line Ce provides the input to a 3-state buffer 29 enabled by the DEC/INCB signal 25, and forms the output of a 3-state buffer 30 enabled by the INC/DECB signal 12. The output of 3-state buffer 29 is the enable signal on line 23. The input of 3-state buffer 30 is signal 28.
Referring to FIG. 7a, it can be seen that signal lines 6d and 6e form a bidirectional path through PROM 4e, passing through address counter 7c. The directionality of the path is controlled by the INC/DECB signal 12. The one of signal lines 6d and 6e functioning as an input provides an enable/disable signal for address counter 7c. The other signal line functions as an output and provides an enable/disable signal that can be used to control another serial PROM. Signal lines 6d and 6e can, therefore, be tied together in a cascaded chain of chip enable signals that will run (in FIG. 7) from left to right when INC/DECB 12 is high (for incrementing address counter 7c) and from right to left when INC/DECB 12 is low (for decrementing address counter 7c). This embodiment, therefore, allows reading a chain of two or more PROMs from either end.
OTHER EMBODIMENTS
Modifications to the described embodiments, as well as additional embodiments of the invention, will be apparent to those of ordinary skill in the art in light of the foregoing description. Obvious variants of the described embodiments include those directed to parallel PROMs, other ROMs, and shift registers. | A self-addressing memory device is provided that can provide blocks of data starting from more than one initial location in the device, and may have the option of reading in either direction. This memory device can efficiently store multiple bitstreams, which may be of different sizes, that are used to configure one or more configurable logic devices. Each stored bitstream can be accessed in any order. In one embodiment, the configurable logic device is a Field Programmable Gate Array ("FPGA"). In one embodiment, the memory device is a Read-Only Memory ("ROM") that is either read up from all zeros or down from all ones. In one embodiment, the ROM includes a bidirectional chip enable chain that permits cascading multiple ROMs. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application Ser. No. 60/968,628 filed 29 Aug. 2007. The disclosure of this application is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates generally to deuterium-enriched varenicline, pharmaceutical compositions containing the same, and methods of using the same.
BACKGROUND OF THE INVENTION
[0003] Varenicline, shown below, is a well known nicotinic receptor partial agonist.
[0000]
[0000] Since varenicline is a known and useful pharmaceutical, it is desirable to discover novel derivatives thereof. Varenicline is described in U.S. Pat. Nos. 6,890,927, and 6,605,610; the contents of which are incorporated herein by reference.
SUMMARY OF THE INVENTION
[0004] Accordingly, one object of the present invention is to provide deuterium-enriched varenicline or a pharmaceutically acceptable salt thereof.
[0005] It is another object of the present invention to provide pharmaceutical compositions comprising a pharmaceutically acceptable carrier and a therapeutically effective amount of at least one of the deuterium-enriched compounds of the present invention or a pharmaceutically acceptable salt thereof.
[0006] It is another object of the present invention to provide a method for treating smoking addiction, comprising administering to a host in need of such treatment a therapeutically effective amount of at least one of the deuterium-enriched compounds of the present invention or a pharmaceutically acceptable salt thereof.
[0007] It is another object of the present invention to provide a novel deuterium-enriched varenicline or a pharmaceutically acceptable salt thereof for use in therapy.
[0008] It is another object of the present invention to provide the use of a novel deuterium-enriched varenicline or a pharmaceutically acceptable salt thereof for the manufacture of a medicament (e.g., for the treatment of smoking addiction).
[0009] These and other objects, which will become apparent during the following detailed description, have been achieved by the inventor's discovery of the presently claimed deuterium-enriched varenicline.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0010] Deuterium (D or 2 H) is a stable, non-radioactive isotope of hydrogen and has an atomic weight of 2.0144. Hydrogen naturally occurs as a mixture of the isotopes 1 H (hydrogen or protium), D ( 2 H or deuterium), and T ( 3 H or tritium). The natural abundance of deuterium is 0.015%. One of ordinary skill in the art recognizes that in all chemical compounds with a H atom, the H atom actually represents a mixture of H and D, with about 0.015% being D. Thus, compounds with a level of deuterium that has been enriched to be greater than its natural abundance of 0.015%, should be considered unnatural and, as a result, novel over their non-enriched counterparts.
[0011] All percentages given for the amount of deuterium present are mole percentages.
[0012] It can be quite difficult in the laboratory to achieve 100% deuteration at any one site of a lab scale amount of compound (e.g., milligram or greater). When 100% deuteration is recited or a deuterium atom is specifically shown in a structure, it is assumed that a small percentage of hydrogen may still be present. Deuterium-enriched can be achieved by either exchanging protons with deuterium or by synthesizing the molecule with enriched starting materials.
[0013] The present invention provides deuterium-enriched varenicline or a pharmaceutically acceptable salt thereof There are thirteen hydrogen atoms in the varenicline portion of varenicline as show by variables R 1 -R 13 in formula I below.
[0000]
[0014] The hydrogens present on varenicline have different capacities for exchange with deuterium. Hydrogen atom R 1 is easily exchangeable under physiological conditions and, if replaced by a deuterium atom, it is expected that it will readily exchange for a proton after administration to a patient. The remaining hydrogen atoms are not easily exchangeable for deuterium atoms. However, deuterium atoms at the remaining positions may be incorporated by the use of deuterated starting materials or intermediates during the construction of varenicline.
[0015] The present invention is based on increasing the amount of deuterium present in varenicline above its natural abundance. This increasing is called enrichment or deuterium-enrichment. If not specifically noted, the percentage of enrichment refers to the percentage of deuterium present in the compound, mixture of compounds, or composition. Examples of the amount of enrichment include from about 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 16, 21, 25, 29, 33, 37, 42, 46, 50, 54, 58, 63, 67, 71, 75, 79, 84, 88, 92, 96, to about 100 mol %. Since there are 13 hydrogens in varenicline, replacement of a single hydrogen atom with deuterium would result in a molecule with about 8% deuterium enrichment. In order to achieve enrichment less than about 8%, but above the natural abundance, only partial deuteration of one site is required. Thus, less than about 8% enrichment would still refer to deuterium-enriched varenicline.
[0016] With the natural abundance of deuterium being 0.015%, one would expect that for approximately every 6,667 molecules of varenicline (1/0.00015=6,667), there is one naturally occurring molecule with one deuterium present. Since varenicline has 13 positions, one would roughly expect that for approximately every 220,011 molecules of varenicline (13×6,667), all 13 different, naturally occurring, mono-deuterated vareniclines would be present. This approximation is a rough estimate as it doesn't take into account the different exchange rates of the hydrogen atoms on varenicline. For naturally occurring molecules with more than one deuterium, the numbers become vastly larger. In view of this natural abundance, the present invention, in an embodiment, relates to an amount of an deuterium enriched compound, whereby the enrichment recited will be more than naturally occurring deuterated molecules.
[0017] In view of the natural abundance of deuterium-enriched varenicline, the present invention also relates to isolated or purified deuterium-enriched varenicline. The isolated or purified deuterium-enriched varenicline is a group of molecules whose deuterium levels are above the naturally occurring levels (e.g., 8%). The isolated or purified deuterium-enriched varenicline can be obtained by techniques known to those of skill in the art (e.g., see the syntheses described below).
[0018] The present invention also relates to compositions comprising deuterium-enriched varenicline. The compositions require the presence of deuterium-enriched varenicline which is greater than its natural abundance. For example, the compositions of the present invention can comprise (a) a μg of a deuterium-enriched varenicline; (b) a mg of a deuterium-enriched varenicline; and, (c) a gram of a deuterium-enriched varenicline.
[0019] In an embodiment, the present invention provides an amount of a novel deuterium-enriched varenicline.
[0020] Examples of amounts include, but are not limited to (a) at least 0.01, 0.02, 0.03, 0.04, 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, to 1 mole, (b) at least 0.1 moles, and (c) at least 1 mole of the compound. The present amounts also cover lab-scale (e.g., gram scale), kilo-lab scale (e.g., kilogram scale), and industrial or commercial scale (e.g., multi-kilogram or above scale) quantities as these will be more useful in the actual manufacture of a pharmaceutical. Industrial/commercial scale refers to the amount of product that would be produced in a batch that was designed for clinical testing, formulation, sale/distribution to the public, etc.
[0021] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof.
[0000]
[0022] wherein R 1 -R 13 are independently selected from H and D; and the abundance of deuterium in R 1 -R 13 is at least 8%. The abundance can also be (a) at least 15%, (b) at least 23%, (c) at least 31%,(d) at least 38%, (e) at least 46%, (f) at least 54%, (g) at least 62%, (h) at least 69%, (i) at least 77%, () at least 85%, (k) at least 92%, and (1) 100%.
[0023] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 1 is at least 100%.
[0024] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 2 -R 4 and R 11 is at least 25%. The abundance can also be (a) at least 50%, (b) at least 75%, and (c) 100%.
[0025] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 5 -R 13 is at least 11%. The abundance can also be (a) at least 22%, (b) at least 33%, (c) at least 44%,(d) at least 56%, (e) at least 67%, (f) at least 78%, (g) at least 89%, and (h) 100%.
[0026] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof.
[0000]
[0027] wherein R 1 -R 13 are independently selected from H and D; and the abundance of deuterium in R 1 -R 13 is at least 8%. The abundance can also be (a) at least 15%, (b) at least 23%, (c) at least 31%,(d) at least 38%, (e) at least 46%, (f) at least 54%, (g) at least 62%, (h) at least 69%, (i) at least 77%, () at least 85%, (k) at least 92%, and (1) 100%.
[0028] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 1 is at least 100%.
[0029] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 2 -R4 and R 11 is at least 25%. The abundance can also be (a) at least 50%, (b) at least 75%, and (c) 100%.
[0030] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 5 -R 13 is at least 11%. The abundance can also be (a) at least 22%, (b) at least 33%, (c) at least 44%,(d) at least 56%, (e) at least 67%, (f) at least 78%, (g) at least 89%, and (h) 100%.
[0031] In another embodiment, the present invention provides novel mixture of deuterium enriched compounds of formula I or a pharmaceutically acceptable salt thereof.
[0000]
[0032] wherein R 1 -R 13 are independently selected from H and D; and the abundance of deuterium in R 1 -R 13 is at least 8%. The abundance can also be (a) at least 15%, (b) at least 23%, (c) at least 31%,(d) at least 38%, (e) at least 46%, (f) at least 54%, (g) at least 62%, (h) at least 69%, (i) at least 77%, () at least 85%, (k) at least 92%, and (1) 100%.
[0033] In another embodiment, the present invention provides a novel mixture of, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 1 is at least 100%.
[0034] In another embodiment, the present invention provides a novel mixture of, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 2 -R4 and R 11 is at least 25%. The abundance can also be (a) at least 50%, (b) at least 75%, and (c) 100%.
[0035] In another embodiment, the present invention provides a novel mixture of, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 5 -R 13 is at least 11%. The abundance can also be (a) at least 22%, (b) at least 33%, (c) at least 44%,(d) at least 56%, (e) at least 67%, (f) at least 78%, (g) at least 89%, and (h) 100%.
[0036] In another embodiment, the present invention provides novel pharmaceutical compositions, comprising: a pharmaceutically acceptable carrier and a therapeutically effective amount of a deuterium-enriched compound of the present invention.
[0037] In another embodiment, the present invention provides a novel method for treating smoking addiction comprising: administering to a patient in need thereof a therapeutically effective amount of a deuterium-enriched compound of the present invention.
[0038] In another embodiment, the present invention provides an amount of a deuterium-enriched compound of the present invention as described above for use in therapy.
[0039] In another embodiment, the present invention provides the use of an amount of a deuterium-enriched compound of the present invention for the manufacture of a medicament (e.g., for the treatment of smoking addiction).
[0040] The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. This invention encompasses all combinations of preferred aspects of the invention noted herein. It is understood that any and all embodiments of the present invention may be taken in conjunction with any other embodiment or embodiments to describe additional more preferred embodiments. It is also to be understood that each individual element of the preferred embodiments is intended to be taken individually as its own independent preferred embodiment. Furthermore, any element of an embodiment is meant to be combined with any and all other elements from any embodiment to describe an additional embodiment.
DEFINITIONS
[0041] The examples provided in the definitions present in this application are non-inclusive unless otherwise stated. They include but are not limited to the recited examples.
[0042] The compounds of the present invention may have asymmetric centers. Compounds of the present invention containing an asymmetrically substituted atom may be isolated in optically active or racemic forms. It is well known in the art how to prepare optically active forms, such as by resolution of racemic forms or by synthesis from optically active starting materials. All processes used to prepare compounds of the present invention and intermediates made therein are considered to be part of the present invention. All tautomers of shown or described compounds are also considered to be part of the present invention.
[0043] “Host” preferably refers to a human. It also includes other mammals including the equine, porcine, bovine, feline, and canine families.
[0044] “Treating” or “treatment” covers the treatment of a disease-state in a mammal, and includes: (a) preventing the disease-state from occurring in a mammal, in particular, when such mammal is predisposed to the disease-state but has not yet been diagnosed as having it; (b) inhibiting the disease-state, e.g., arresting it development; and/or (c) relieving the disease-state, e.g., causing regression of the disease state until a desired endpoint is reached. Treating also includes the amelioration of a symptom of a disease (e.g., lessen the pain or discomfort), wherein such amelioration may or may not be directly affecting the disease (e.g., cause, transmission, expression, etc.).
[0045] “Therapeutically effective amount” includes an amount of a compound of the present invention that is effective when administered alone or in combination to treat the desired condition or disorder. “Therapeutically effective amount” includes an amount of the combination of compounds claimed that is effective to treat the desired condition or disorder. The combination of compounds is preferably a synergistic combination. Synergy, as described, for example, by Chou and Talalay, Adv. Enzyme Regul. 1984, 22:27-55, occurs when the effect of the compounds when administered in combination is greater than the additive effect of the compounds when administered alone as a single agent. In general, a synergistic effect is most clearly demonstrated at sub-optimal concentrations of the compounds. Synergy can be in terms of lower cytotoxicity, increased antiviral effect, or some other beneficial effect of the combination compared with the individual components.
[0046] “Pharmaceutically acceptable salts” refer to derivatives of the disclosed compounds wherein the parent compound is modified by making acid or base salts thereof. Examples of pharmaceutically acceptable salts include, but are not limited to, mineral or organic acid salts of the basic residues. The pharmaceutically acceptable salts include the conventional quaternary ammonium salts of the parent compound formed, for example, from non-toxic inorganic or organic acids. For example, such conventional non-toxic salts include, but are not limited to, those derived from inorganic and organic acids selected from 1,2-ethanedisulfonic, 2-acetoxybenzoic, 2-hydroxyethanesulfonic, acetic, ascorbic, benzenesulfonic, benzoic, bicarbonic, carbonic, citric, edetic, ethane disulfonic, ethane sulfonic, fumaric, glucoheptonic, gluconic, glutamic, glycolic, glycollyarsanilic, hexylresorcinic, hydrabamic, hydrobromic, hydrochloric, hydroiodide, hydroxymaleic, hydroxynaphthoic, isethionic, lactic, lactobionic, lauryl sulfonic, maleic, malic, mandelic, methanesulfonic, napsylic, nitric, oxalic, pamoic, pantothenic, phenylacetic, phosphoric, polygalacturonic, propionic, salicyclic, stearic, subacetic, succinic, sulfamic, sulfanilic, sulfuric, tannic, tartaric, and toluenesulfonic.
Synthesis
[0047] Scheme 1 shows a route to varenicline (Sorbera, et al., Drugs Fut. 2006, 31, 117
[0000]
[0048] Scheme 2 shows how various deuterated starting materials and intermediates can be used in the chemistry of Scheme 1 to make deuterated varenicline analogs. A person skilled in the art of organic synthesis will recognize that these materials may be used in various combinations to access a variety of other deuterated vareniclines. This Figure is meant to be illustrative and not comprehensive; it should be recognized that a person skilled in the art of organic synthesis will readily derive other chemical reactions and deuterated materials that may be used to make a wide variety of varenicline analogs. The known compound 13, if used in the chemistry of Scheme 1, results in the formation of varenicline with R 4 and R 11 =D. The known perdeuterated cyclopentadiene 14 can be converted to 15 and 16 according to equation (1) of Scheme 2. If 16 is used in place of 6 in the chemistry of Scheme 1, varenicline with R 5 -R 10 and R 12 -R 13 =D results. If the known dialdehyde 17 is used in place of 11 in the chemistry of Scheme 1, varenicline with R 2 -R 3 =D results. Combinations of these strategies are also possible. For example, and not meaning to be comprehensive, the use of 13, 14, NaBD(OAc) 3 , and 17 together results in varenicline with R 2 -R 13 =D.
[0000]
EXAMPLES
[0049] Table 1 provides compounds that are representative examples of the present invention. When one of R 1 -R 13 is present, it is selected from H or D.
[0000]
1
2
3
4
[0050] Table 2 provides compounds that are representative examples of the present invention. Where H is shown, it represents naturally abundant hydrogen.
[0000]
5
6
7
8
[0051] Numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise that as specifically described herein. | The present application describes deuterium-enriched varenicline, pharmaceutically acceptable salt forms thereof, and methods of treating using the same. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a control system for an aerodynamic equipment, such as a wing, for aerodynamically providing vehicular driving stability at various vehicle driving conditions. More specifically, the invention relates to a control system for an aerodynamic equipment, which assists to provide higher cornering stability of the vehicle.
2. Description of the Background Art
Japanese Utility Model First (unexamined) Publication No. 61-101078 discloses a wing control system for an automotive vehicle. The shown system has a vertical wing which is mounted on the vehicular body for pivotal movement about a vertical axis. The control system is responsive to a vehicle speed higher than a predetermined speed and a steering angle greater than a predetermined angle, to cause angular displacement of the vertical wing for utilizing aerodynamic force exerted on the wing for stabilizing the vehicle.
Such prior proposed system is effective for providing stability of the vehicle at a vehicle speed higher than the predetermined speed and at a steering angle greater than a predetermined angle. However, as can be naturally understood, the prior proposed system does not cover overall vehicular driving range.
For example, the aerodynamic force to be generated by the vertical wing is proportional to square of the vehicle speed. Therefore, when the wing angle is set for providing optimal steering characteristics at high vehicle speed, the aerodynamic force to be induced by the vertical wing tends to increase understeer characteristics.
Therefore, it is an object of the present invention to provide a control system for an aerodynamic equipment of an automotive vehicle, which is effective for stabilizing vehicle at any vehicular driving condition.
In order to accomplish aforementioned and other objects, an aerodynamic system for an automotive vehicle, according to the present invention, employs an aerodynamic wing which is pivotable about a vertical axis. A control system is associated with the aerodynamic wing for controlling angular position thereof. The control system is responsive to a vehicle speed and a steering angle for deriving an angular position of the aerodynamic wing as a function of the vehicular speed and the steering angle in such a manner than the angular displacement of the aerodynamic wing from the neutral position is reduced according to increasing of the vehicular speed.
According to one aspect of the invention, an aerodynamics control system for an automotive vehicle comprises:
an aerodynamic wing mounted on a vehicle body, having a vertically extending wing surface and pivotable about a vertical axis within a predetermined angular range across a neutral position;
a drive means for driving the aerodynamic wing for causing angular displacement about the vertical axis;
a vehicle speed sensor for monitoring vehicle speed to produce a vehicle speed indicative signal;
a steering angle sensor for monitoring steering angular position to produce a steering angle indicative signal;
a control unit receiving the vehicle speed indicative signal and the steering angle indicative signal to derive a control signal for controlling driving magnitude of the drive means to place the aerodynamic wing at a desired angular position which is determined on the basis of the vehicular speed indicative signal and the steering angle indicative signal, the control unit deriving a rate of angular displacement of the aerodynamic wing relative to the steering angle indicative signal depending upon the vehicle speed indicative signal so that the rate is decreased according to increasing of the vehicle speed.
The control unit may derive the angular displacement from the neutral position on the basis of the vehicle speed and a steering angular displacement. In the alternative, the control unit derives the angular displacement of the aerodynamic wing from the neutral position with a predetermined primary lag factor. In the later case, it may be preferable that the primary large factor is variable depending upon the vehicle speed.
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. However, it is to be noted that the present invention is not to be limited only to the specific embodiment shown. The present embodiment has been illustrated for purposes of explanation and understanding only.
In the drawings:
FIG. 1 is a schematic block diagram of the preferred embodiment of an aerodynamics control system for an automotive vehicle, according to the present invention;
FIG. 2 is a plan view of an automotive vehicle for which the preferred embodiment of the aerodynamics control system according to the invention is applied;
FIG. 3 is a side elevation of an aerodynamic wing associated with a drive mechanism, which forms the major part of the preferred embodiment of the aerodynamics control system according to the invention;
FIG. 4 is a block diagram of a control circuit in the preferred embodiment of the aerodynamics control system of FIG. 1;
FIG. 5 is an explanatory illustration showing effect of the preferred embodiment of the aerodynamics control system as applied for a two wheel model;
FIG. 6 is a chart showing a relationship between a vehicular speed and yawing rate;
FIG. 7 is a chart showing a relationship between a vehicular speed and a proportional constant;
FIG. 8 is a flowchart showing operation of the aerodynamics control system of FIG. 4;
FIGS. 9(a), 9(b) and 9(c) illustrate variation of steering angle, aerodynamic wing angular position and yawing rate;
FIG. 10 is a flowchart showing another preferred process to be performed by the preferred embodiment of the aerodynamics control system of FIG. 4;
FIG. 11 is a flowchart of a further process to be performed by the aerodynamics control system of FIG. 4; and
FIG. 12 is a fragmentary illustration of the aerodynamics control system which implements the process of FIG. 11.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, particularly to FIG. 1, the preferred embodiment of an aerodynamics control system, according to the present invention, employs a vertical aerodynamic wing 5 mounted on a trunk lid 3 of a vehicle body 1. The vertical aerodynamic wing 5 is pivotable horizontally about a vertical axis. As shown in FIGS. 1 and 3, the vertical aerodynamic wing 5 is supported on a rotary shaft 7 for rotation therewith. The rotary shaft 7 extends through the trunk lid 3 to extend into the interior space of a trunk room or luggage compartment. A driven gear 9 is firmly or fixedly mounted on the lower end of the rotary shaft 7. The driven gear 9 and associated lower end of the rotary shaft 7 are thus oriented within the trunk room. The driven gear 9 meshes with a drive gear 13 which is fixedly mounted on a drive shaft of a stepping motor 11. The stepping motor 11 is a reversible motor for generating driving torques in both rotational direction. The driving torque of the stepping motor 11 is thus transmitted through a gear train constituted by the gears 9 and 13.
As can be seen from FIG. 3, the driven gear 9 has greater diameter than that of the drive gear 13. This establishes a gear ratio in the gear train to provide greater driving torque to be exerted on the rotary shaft 7 with the driven gear 9. The stepping motor 11 and the gear train of the gears 9 and 11 form a drive mechanism for driving the vertical aerodynamic wing 5 in horizontal direction about the vertical axis between a predetermined angular range between θ L and θ R across a neutral position θ M , at which the vertical aerodynamic wing is oriented in alignment with the longitudinal axis of the vehicle and thus generates minimum aerodynamic force.
As shown in FIG. 4, the stepping motor 11 is connected to a control unit 15 which comprises a microprocessor including an input interface 21. An output interface 23, ROM 25, RAM 27, CPU 29 respectively connected via bus line 31. The input interface 21 is connected to a vehicle speed sensor 19 and a steering angle sensor 17 for receiving therefrom a vehicle speed indicative date and a steering angle indicative data. CPU 29 processes the input vehicle speed indicative data and the steering angle indicative data for deriving an angular position of the vertical aerodynamic wing 5. CPU 29 thus derives a control signal representative of the derived angular position of the vertical aerodynamic wing.
The operation of the preferred embodiment of the aerodynamics control system according to the invention will be discussed by utilizing two wheel model shown in FIG. 5. In the following discussion, parameters used in the discussion are as follows:
l: wheel base;
l f : distance between a gravity center Y and a front wheel axle OF;
l r : distance between the gravity center Y and a rear wheel axle RO;
l w : axial distance between the gravity center Y and the vertical aerodynamic wing;
m: vehicular mass weight;
I: inertia moment of the vehicle;
ψ: yawing rate obtained by differentiating a yaw angle ψ;
V: vehicular speed;
y: lateral speed at the gravity center;
p: air density;
C: lateral force coefficient at unit radian of the wing;
S w : surface area of the wing;
θ: steering angle at the front wheel; and
α: angular displacement from the neutral position.
Taking the foregoing parameter, the equation of motion can be expressed as: ##EQU1## The foregoing equation can be transformed by RaPlace transformation as follows: ##EQU2## From the foregoings, the denominator of the solution can be expressed by: ##EQU3## On the other hand, the numerator of the solution can be expressed by: ##EQU4## From the foregoing, the following equation can be derived: ##EQU5## From the above, the numerator can be modified as: ##EQU6## From the above, the absolute value of the static value of the yaw rate ψ(s) can be expressed by: ##EQU7##
Assuming α=kw·θ (kw is constant): that is when the vertical aerodynamic wing 5 is pivotally moved in proportion to the steering angle θ at front wheels, the vertical aerodynamic wing 5 is pivoted in the equal direction to the steering direction of the front wheels if kw is set greater than zero (O). When the vertical aerodynamic wing 5 is pivoted synchronously with the steering of the front wheels in the same direction, the aerodynamic force generated by the wing will serve to stabilize the vehicle. The effect of wing may be demonstrated in the results of simulation as shown in FIG. 6. As can be seen from FIG. 6, the results of simulation shows that by synchronously pivoting the vertical aerodynamic wing 5 by setting the constant kw greater than zero, a yawing rate ψ be reduced significantly.
However, since the aerodynamic force to be generated by the vertical aerodynamic wing 5 is proportional to square of the vehicle speed (V 2 ). Therefore, at relatively high speed as labeled in high speed range, vehicular stability becomes effective to excessively reduce the yawing rate. This results in an excessive understeering to cause difficulty of cornering. In this sense, the aerodynamic force at the medium speed range would be preferred even at the high speed range.
In view of this, the preferred embodiment of the aerodynamics control system, according to the present invention, employs variable kw value which is variable depending upon the vehicle speed as shown in FIG. 7. As can be seen, the kw value is varied to reduce the value according to the increase of the vehicle speed in the vehicle speed range from the medium speed range to he high speed range. Decreasing of the kw value results in reducing of a rate of change in the angular displacement α of the vertical aerodynamic wing 5. In this manner, the yaw rate gain at the high vehicle speed range can be appropriately controlled for providing better drivability of the vehicle.
FIG. 8 is a flowchart shows the operation for controlling angular position of the vertical aerodynamic wing 5. The shown process maybe executed periodically.
Immediately after starting execution, the steering angle data θ i from the steering angle sensor 17 and the vehicle speed data v i from the vehicle speed sensor 19 are read out at a step S1. Based on the vehicle speed data v i , the kw i is derived according to the characteristics of FIG. 7, at a step S2. Then, by multiplying the steering angle data θ i with the kw i value, the angular displacement α i of the vertical aerodynamic wing 5 is derived at a step S3. Then, the control signal representative of the derived angular displacement α i is output to the stepping motor 11 for causing corresponding magnitude of angular displacement in the vertical aerodynamic wing 5.
In the practical control, since the magnitude of angular displacement is appropriately adjusted on the basis of the steering angle and the vehicle speed so as to generate optimal aerodynamic force with the vertical aerodynamic wing 5, vehicular driving stability with appropriate cornering characteristics can be obtained. particularly, since the shown embodiment reduces the rate of change in angular displacement of the vertical aerodynamic wing according to the increase of the vehicle speed in the high vehicle speed range, the aerodynamic force to be generated cannot become excessive.
With the shown construction, the preferred embodiment of the aerodynamic control system, according to the present invention can provide vehicular driving stability without causing degradation of the cornering characteristics over all of the vehicle driving range, as shown in FIG. 9(a).
FIG. 10 shows another preferred process of aerodynamics control to be performed by the preferred embodiment of the aerodynamics control system, according to the invention.
In the shown process, a step S5 is performed in place of the step S3 in the foregoing process. At the step S5, the angular displacement α is derived according to the following equation:
α(s)=kw(V)·(1-τ.sub.f ·s)θ(s)
With the foregoing equation, the angular displacement α of the vertical aerodynamic wing 5 is derived on the basis of the kw value which is variable depending upon the vehicle speed and the steering angular displacement, as shown in FIG. 9(b).
FIG. 11 also shows modification of the preferred process in FIG. 8. In the shown process, the step S3 in FIG. 8 is replaced with a step S6. At the step S6, the angular displacement α is derived according to the following equation: ##EQU8## With the angular displacement α derived through the step S6, the characteristics as shown in FIG. 9(c) can be obtained.
In order to implement the process of FIG. 10, a system as shown in FIG. 12 is employed. The shown construction employs a hydraulic system for driving the vertical aerodynamic wing 5 for causing angular displacement.
The rotary shaft 7 of the vertical aerodynamic wing 5 is connected to a piston rod 37 via a linkage 33. The piston rod 37 carries a piston 57 disposed within a hydraulic cylinder 35. Two fluid chambers defined within the hydraulic cylinder 35 is connected to a hydraulic pump 39. The hydraulic pump 39 is connected to a flow control valve 43 via a supply line 41. The flow control valve 43 is connected to respective of two fluid chambers within the hydraulic cylinder 35 via branch lines 45 and 47. A flow restriction valve 49 is disposed within the supply line 41. The flow restriction valve 49 is connected to the control unit 15 for controlling the flow restriction magnitude, and thereby controlling the line pressure to be supplied to the fluid chambers.
The flow control valve 43 is responsive to the steering operation to switch connection between the hydraulic pump 39 and the fluid chambers via the branch lines 45 and 47, according to the steering direction. The flow control valve 43 is further operable to the neutral position where fluid communication between the supply line 41 and the branch lines 45 and 47 is blocked. Return springs 59 having equal spring forces are respectively disposed within the fluid chambers in the hydraulic cylinder so that the piston 57 can be placed at the neutral position which corresponds to the neutral position of the vertical aerodynamic wing.
In the shown construction, the flow control valve 43 is operated to establish fluid communication between the supply line 41 and one of the branch lines 45 and 47 in response to the steering operation. Then, the pressurized fluid discharged from the hydraulic pump 39 is supplied to one of the fluid chambers to destroy the force balance to cause shifting of the piston from the neutral position. As a result, the vertical aerodynamic wing 5 is driven to cause angular displacement in the corresponding direction. On the other hand, at the same time, the control unit 15 derives the magnitude of angular displacement α of the vertical aerodynamic wing on the basis of the vehicle speed and the steering angular position. The control unit 15 controls the flow restriction valve 49 for adjusting the flow restriction magnitude.
With the construction shown in FIG. 11, since the wing drive mechanism is formed with a hydraulic system, the control characteristics of the vertical aerodynamic wing may have a first-order lag factor. That is, the previously described equation of the angular displacement α(S) of the vertical aerodynamic wing includes a particular term with regard to a coefficient τ d of the first-order lag. Furthermore, as appreciated from the previously described equation of the angular displacement α(S) derived in step 5 of FIG. 10, the equation includes a particular term with regard to a coefficient τ f of the first-order lag. Therefore, in the two embodiments shown in FIGS. 10 and 11, since the angular displacement α(S) is determined with the first-order lag factor depending on a rate of change in the steering angle θ, the aerodynamics control system provides a high steering characteristic and a superior vehicular body attitude control.
While the present invention has been disclosed in terms of the preferred embodiment in order to facilitate better understanding of the invention, it should be appreciated that the invention can be embodied in various ways without departing from the principle of the invention. Therefore, the invention should be understood to include all possible embodiments and modifications to the shown embodiments which can be embodied without departing from the principle of the invention set forth herein. | A control system for an aerodynamic equipment of an automotive vehicle, which is effective to prove higher cornering stability of the vehicle. | 1 |
FIELD OF THE INVENTION
[0001] The invention pertains to food safety devices and methods. More particularly the invention pertains to temperature responsive indicators affixable to food products.
BACKGROUND OF THE INVENTION
[0002] Food products such as frozen foods, dairy products, various types of juices and the like generally must be stored at a temperature below a predetermined value to maintain product freshness and safety. In this regard, it is undesirable to have food products of the type noted above exposed for any significant period of time to temperatures above their safe storage temperature.
[0003] While food product packages including the containers for fluids such as milk or juice, frozen food containers or the like usually contain or carry a date after which the product is preferably not to be sold, such packaging does not usually carry any indicators as to temperatures that the food product might have been subjected to in transit or while at the respective retail outlet.
[0004] From the point of view of consumers, as well as the food product merchandisers, there are benefits to being able to recognize, ahead of time, where one or more food products might have deteriorated due to temperature. For example, if a case of frozen food product was left out of the freezer for an extended period of time, more likely than not the vendor would want to remove those food products from inventory to avoid inadvertent sales or other distribution to retail customers.
[0005] There continues to be a need for food product packaging which would not only carry a “sell by” date but also would carry an indicator of any excessive temperature to which the respective food product had been subjected to subsequent to manufacture and before final sale. Preferably such indicators would be irreversible such that if the food product warmed to a temperature above the storage temperature and then was cooled again, the indicator would not revert to its initial color. It would also be preferable if such indicators could be incorporated into food product packaging with minimal additional cost.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1A is a side elevational view of an exemplary product in accordance with the invention;
[0007] FIG. 1B is a top plan view of a different type of product in accordance with the invention;
[0008] FIG. 2A is a top plan view of a roll of temperature responsive material usable on the product packaging of FIG. 1A or FIG. 1B ; and
[0009] FIG. 2B is a side elevational view of the roll of material of FIG. 2A .
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0010] While this invention is susceptible of embodiment in many different forms, there are shown in the drawing and will be described herein in detail specific embodiments thereof with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the specific embodiments illustrated.
[0011] A material which embodies the present invention makes a one-time change between two readily distinguishable colors when the material experiences a temperature drop below a set point and subsequently the temperature of the material rises back above set point. A coating of the material can be placed directly on product packaging. Alternately, material in accordance with the invention can be deposited on a layer which could also carry a layer of adhesive or directly on a layer of adhesive material.
[0012] In one aspect of the invention, a multilayer product can include a layer of temperature responsive material, deposited onto an inert elongated body layer which also carries a layer of adhesive. This embodiment of the invention can exhibit an elongated tape-like shape which can be wound onto a core forming a dispensing roll.
[0013] FIG. 1A , a side elevational view of a container of a liquid food product 10 , for example milk, juice or the like, carries a dispensing or pouring region of a conventional type 12 . The container 12 also carries product and brand information of a conventional type 14 .
[0014] In accordance with the invention, the container 12 also carries a temperature sensitive material 20 . The material 20 can be deposited directly onto the container 10 . Alternately, the material 20 can be applied to an inert underlying base layer which carries an adhesive layer. The base layer and material 20 can be attached to the container 10 .
[0015] While the material 20 is illustrated with a rectangular shape, neither shape nor position are limitations of the invention. For example, as an alternative, an arbitrarily shaped deposit 20 ′, shown integral with the product and brand information, could be used.
[0016] The material 20 exhibits first and second readily discernible colors. Preferably, material 20 exhibits a first color at room, or processing temperature and retains that color, from normal room or processing temperature, to a lower temperature of a value compatible with the food product carried by the container 10 . For example, the material 20 could exhibit a first color, assuming the food product was milk or juice, throughout the entire time that the container of milk or juice 10 was filled, sealed and was kept at or below a safe storage temperature. Similarly, the material 20 could be applied to other types of non-frozen food products which need to be kept at a relatively low temperature.
[0017] The material 20 irreversibly changes to a second, different color in response to rising above a safe storage temperature for the respective food product, milk or juice in this example. The second color provides an indication to consumers that the product 10 has risen to a temperature above the safe storage temperature. The irreversible nature of the color change continues to inform the consumer even when the temperature of the product 10 has been subsequently reduced to the safe storage region.
[0018] FIG. 1B is a top plan view of another food product package 30 , which, for example could contain a frozen food product such as frozen juice, a frozen dinner, a frozen dessert or the like. The product 30 includes an appropriate form of container 32 which contains the food product as well as product and brand information 34 .
[0019] The container 32 also carries a circular temperature responsive region 40 which exhibits a first color when initially produced and throughout the entire time that the product in package 30 remain at a safe storage temperature, preferably below freezing. If the packaging 30 increases in temperature above a safe storage temperature, for example freezing, the material 40 will permanently change color and exhibit its second color indicative of the product 30 having been exposed to temperatures above the safe storage temperature.
[0020] It will be understood that, as an alternate, the temperature responsive material can be provided in any arbitrary shape or location on container 32 . For example, material 40 can be integrated with product/brand information 34 in a shape compatible therewith.
[0021] Relative to both the products 10 and 30 , the consumer can readily ascertain whether the product has been continuously maintained at or below its safe storage temperature by viewing the respective material 20 , 20 ′ or 40 , 40 ′. Since the material 20 , 20 ′ or 40 , 40 ′ exhibits a one-time color change in response to rising above its predetermined safe storage temperature, the consumer can immediately ascertain which packages of product can be expected to be safe for consumption.
[0022] FIG. 2A is a top plan view of a roll 50 of a representative form of a temperature sensitive material, such as the material 20 . FIG. 2B is a side elevational view of the roll 50 of FIG. 2A .
[0023] The roll 50 is formed with an inert elongated base layer 52 . The layer 52 can be formed of any material, such as paper or resin, acceptable for use in connection with food products. It will be understood that the exact characteristics of the layer 52 are not a limitation of the present invention.
[0024] The layer 52 carries an adhesive layer 54 for attachment to a food product container such as containers 12 or 32 . The layer 54 also carries temperature sensitive material 56 which, as described above, exhibits a first color when manufactured and when exposed to an acceptable food storage temperature, dependent upon the type of food product associated with the material 56 . That material exhibits a second and permanent color in response to the temperature thereof rising above the safe storage temperature of the respective food product.
[0025] Those of skill in the art will also understand that the adhesive 54 and material 56 could be mixed and deposited directly on the container 12 in an alternate embodiment, in a circular shape, corresponding to the shape 40 on the container 32 , or in any other shape. If desired, the material 56 could be applied, whether carried on a layer 52 or directly as described above, in a decorative shape to blend into and be compatible with the product and brand information 14 or 34 .
[0026] The shapes 20 , 40 could be formed spaced apart on a release layer. It will be understood that all such configurations come within the spirit and scope of the present invention.
[0027] In summary, the temperature sensitive material 56 , which could be placed on product packaging in exemplary form 20 , 20 ′ in FIG. 1A or could be placed on product packaging in exemplary form 40 , 40 ′ presents to the consumer a readily ascertainable indicator that the respective food product has been consistently stored at or below its safe storage temperature. Once the temperature sensitive material experiences a temperature in excess of the safe storage temperature of the respective food product it exhibits a permanent color change thereby informing the consumer that the respective package should not be purchased.
[0028] In an alternate embodiment, the temperature sensitive material can be configured to spell out a warning, such as “spoiled”, or “do not use”. In yet another embodiment, the temperature sensitive material can surround letters of a warning word or phrase. In this embodiment, if the temperature sensitive material changes color, the warning word or phrase will appear in the initial color surrounded by the second, temperature responsive color.
[0029] From the foregoing, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the invention. It is to be understood that no limitation with respect to the specific apparatus illustrated herein is intended or should be inferred. It is, of course, intended to cover by the appended claims all such modifications as fall within the scope of the claims. | Food safety can be enhanced by applying a temperature indicating element to packaging for a food product. The element can be applied before or after the food product has been inserted into the packaging. The color of the element indicates if the temperature of the packaged food product has rise to an unsafe level, and/or, has stayed at or above that level for a predetermined time interval. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. patent application Ser. No. 12/799,738, filed Apr. 29, 2010, which is a continuation of U.S. patent application Ser. No. 12/221,986, filed Aug. 8, 2008, now abandoned, which is a continuation of U.S. patent application Ser. No. 10/566,137, filed on Feb. 5, 2007, now abandoned, which is a U.S. National Phase Application under 35 U.S.C.§371 of International Application No. PCT/AU2003/000952, filed on Jul. 30, 2003, where these applications are incorporated herein by reference in their entireties.
BACKGROUND
[0002] 1. Technical Field
[0003] This disclosure is related to hands-free reading devices, including in particular, book rests.
[0004] 2. Description of the Related Art
[0005] Books and other items comprising readable text are typically held in a reader's hands when reading; however, a reader's hands or arms may become fatigued when reading in this manner for extended periods of time.
BRIEF SUMMARY
[0006] According to one embodiment, a book rest may be summarized as including a bag filled with particle matter and an insert structure attached to the bag and defining an alcove to hold a book in a hands-free reading position. The alcove may be configured to receive the book in a generally upright position. The insert structure may include a first section which supports a bottom of the book when the book is supported by the book rest and other sections which support a front and a back of the book when the book is supported by the book rest. Sections of the insert structure may be flat. The insert structure may comprise a plurality of inserts. The particle matter in the bag may comprise foam beads or beans. The bag may be made of a flexible and pliable material, such as, for example, PVC, vinyl or cloth (including woven fabric). The book rest may further include an adjustable page holder to hold the book open. The adjustable page holder may be made of wood, fiber glass, carbon fiber or plastic materials, such as, for example, Perspex™. The page holder may be held in position by a toggle threaded onto elastic which enables the page holder to slide up the elastic to press firmly against the book. Sections or portions of the page holder may slide under the edges of the book, thus ensuring the page holder presses firmly against the pages of the book to keep the book open.
[0007] A method of arranging an item for the purposes of reading from the item may be summarized as including: providing a bag filled with particle matter and positioning the item such that the item is held by an alcove in the bag to be supported in a hands-free reading position. Positioning the item may include positioning a book such that the book is held by the alcove in the hands-free reading position. The particle matter may comprise foam beads or beans. The bag may be made of a flexible and pliable material, such as, for example, PVC, vinyl or cloth (including woven fabric).
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0008] The invention may be better understood with reference to the illustrations of embodiments of the invention in which:
[0009] FIG. 1 is a front perspective view of a hands-free reading device, according to one embodiment, having inserts on which a book or other item comprising readable text may be supported.
[0010] FIG. 2 is another perspective view of the hands-free reading device of FIG. 1 with a page holder.
[0011] FIG. 3 is another perspective view of the hands-free reading device of FIG. 1 with a page holder holding a book in an open position.
DETAILED DESCRIPTION
[0012] The hands-free reading device which is shown in FIG. 1 includes a bag (G) made of a flexible and pliable material, such as, for example, PVC, vinyl or cloth (including woven fabric). The bag (G) contains a suitable particle matter such as foam beads, balls or beans, which enable the flexibility needed to adjust the position of the hands-free reading device and sit the hands-free reading device comfortably on any surface. The bottom of a reader's book or other item comprising readable text may then sit on an insert (I) of the device, as shown in FIG. 3 , while leaning on other inserts (H). The inserts (I), (H) may be flat sections that combine to define an alcove for the book or other item comprising readable text, as shown in FIGS. 1 through 3 .
[0013] FIG. 2 shows a page holder (B) received on the insert (I) of the hands-free reading device to hold a book. The page holder (B) may be made of plastic, such as a Perspex™ material, or a plastic like material. The adjustable page holder may also be made of wood, fiber glass or carbon fiber.
[0014] As shown in FIG. 2 , elastic (C) can be threaded through a hole (F) in the page holder (B) and attached to the hands-free reading device at point (D). A toggle (A) can move along the elastic (C) for easy adjustment of the page holder (B). Page holder edges (E) can slide under each side of a book to keep it in place, as shown in FIG. 3 .
[0015] FIG. 3 shows a book in an open position, resting on the hands-free reading device. To ensure that the pages don't move, and that the reader can indeed read hands-free, the page holder edges (E) can slide under the edges of the book to allow parts (B 1 ) and (B 2 ) of the page holder (B) to press firmly against the pages of the book. The toggle (A) enables a reader to slide up the toggle (A) and tension the elastic (C), to pull and hold the page holder (B) in position against the book. The page holder (B) can also be slid towards the reader and away from the book, whilst still under some tension from the elastic (C).
[0016] In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. | The disclosed hands-free reading device is a particle filled bag having an alcove to support a book or other item comprising readable text in a hands-free reading position. A method of arranging an item for the purposes of reading is also provided. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to radio frequency signal transmission and reception and, more particularly, to methods of and apparatus for transmitting and receiving control information in a digital audio broadcasting signal.
There has been increasing interest in the possibility of broadcasting digitally encoded audio signals to provide improved audio fidelity. Several approaches have been suggested. One such approach, set forth in U.S. Pat. No. 5,588,022, which is hereby incorporated by reference, teaches a method for simultaneously broadcasting analog and digital signals in a standard AM broadcasting channel. An amplitude modulated radio frequency signal having a first frequency spectrum is broadcast. The amplitude modulated radio frequency signal includes a first carrier modulated by an analog program signal. Simultaneously, a plurality of digitally modulated carrier signals are broadcast within a bandwidth that encompasses the first frequency spectrum. Each of the digitally modulated carrier signals is modulated by a portion of a digital program signal. A first group of the digitally modulated carrier signals lies within the first frequency spectrum and is modulated in quadrature to the first carrier signal. Second and third groups of the digitally modulated carrier signals lie outside of the first frequency spectrum and are modulated both in-phase and in-quadrature to the first carrier signal.
The waveform in the AM compatible digital audio broadcasting system described in U.S. Pat. No. 5,588,022, was formulated to provide sufficient data throughput for the digital signal while avoiding crosstalk into the analog AM channel. Multiple carriers are employed by means of orthogonal frequency division multiplexing (OFDM) to bear the communicated information.
In an AM compatible digital audio broadcasting system digitally encoded audio information is transmitted simultaneously with the existing analog AM signal. The digital information is encoded and transmitted using OFDM modulation. Digital audio broadcasting systems can transmit the digital information using various audio encoding and forward error correction rates to allow a broadcaster to trade-off audio quality for coverage area and resistance to channel impairments. The receiver must determine which audio encoding rate is being used for transmission in order to reproduce the digitally encoded signal. Additionally, the receiver must be able to properly synchronize to the interleaver frames in order to have proper error correction and digital signal recovery. There is a need for a method of achieving these goals and for ensuring that the control information is accurately received.
SUMMARY OF THE INVENTION
The present invention provides a method for transmitting control information in a digital audio broadcasting system. The method comprises the steps of transmitting a plurality of control bits in each of a plurality of control frames, wherein a first sequence of the control bits represents a transmission mode, and a second sequence of the control bits represents a control data synchronization word. The plurality of control bits can further include a third sequence of bits representative of an interleaver synchronization word.
The invention also provides a method performed in a radio receiver for determining transmission mode and synchronization for a digital audio broadcasting signal. The method comprises the steps of receiving a plurality interleaver frames containing digital information, wherein each of the interleaver frames includes a plurality control frames. The control frames include a plurality of control bits, wherein a first sequence of the control bits represents a transmission mode, and a second sequence of the control bits represents interleaver synchronization word, and a third sequence of the control bits represents a control data synchronization word. The plurality of control bits can further include a third sequence of bits representative of an interleaver synchronization word. The control bits are processed to identify the control bits representing the control data synchronization word.
The invention also encompasses radio frequency transmitters and receivers that utilize the above method.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more readily apparent to those skilled in the art by reference to the accompanying drawings wherein:
FIG. 1 is a diagrammatic representation of a prior art composite analog AM and digital broadcasting signal which can be utilized when performing the method of the present invention;
FIG. 2 is a block diagram of a transmitter that can perform the signal processing method of this invention;
FIG. 3 is a block diagram of a receiver that can perform the signal processing method of this invention;
FIG. 4 is a more detailed block diagram of a portion of the receiver of FIG. 3; and
FIG. 5 is a schematic representation of a control frame of data that can be processed in accordance with this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention provides a method for determining transmission mode and synchronization for a digital audio broadcasting signal. The technique of broadcasting the digital signal in the same channel as an analog AM signal is called in-band on-channel (IBOC) broadcasting. This broadcasting is accomplished by transmitting a digital waveform by way of a plurality of orthogonal frequency division modulated (OFDM) carriers, some of which are modulated in-quadrature with the analog AM signal and are positioned within the spectral region where the standard AM broadcasting signal has significant energy. The remaining digital carriers are modulated both in-phase and in-quadrature with the analog AM signal and are positioned in the same channel as the analog AM signal, but in spectral regions where the analog AM signal does not have significant energy. In the United States, the emissions of AM broadcasting stations are restricted in accordance with Federal Communications Commission (FCC) regulations to lie within a signal level mask defined such that: emissions 10.2 kHz to 20 kHz removed from the analog carrier must be attenuated at least 25 dB below the unmodulated analog carrier level, emissions 20 kHz to 30 kHz removed from the analog carrier must be attenuated at least 35 dB below the unmodulated analog carrier level, and emissions 30 kHz to 60 kHz removed from the analog carrier must be attenuated at least [35 dB+1 dB/kHz] below the unmodulated analog carrier level.
FIG. 1 shows the spectrum of an AM digital audio broadcasting signal of a type that can utilize the present invention. Curve 10 represents the magnitude spectrum of a standard broadcasting amplitude modulated signal, wherein the carrier has a frequency of f 0 . The FCC emissions mask is represented by item number 12 . The OFDM waveform is composed of a series of data carriers spaced at f 1 =59.535·10 6 /(131072), or about 454 Hz. A first group of twenty four of the digitally modulated carriers are positioned within a frequency band extending from (f 0 −12 f 1 ) to (f 0 +12 f 1 ), as illustrated by the envelope labeled 14 in FIG. 1 . Most of these signals are placed 39.4 dB lower than the level of the unmodulated AM carrier signal in order to minimize crosstalk with the analog AM signal. Crosstalk is further reduced by encoding this digital information in a manner that guarantees orthogonality with the analog AM waveform. This type of encoding is called complementary encoding (i.e. complementary BPSK, complementary QPSK, or complementary 32 QAM) and is more fully described in the previously discussed in U.S. Pat. No. 5,859,876. Complementary BPSK modulation is employed on the innermost digital carrier pair at f 0 ±f 1 to transmit control information. These carriers are set at a level of −28 dBc. All other carriers in this first group have a level of −39.4 dBc and are modulated using complementary 32 QAM for the 48 and 32 kbps encoding rates. Complementary 8 PSK modulation is used on carriers ranging from (f 0 −11 f 1 ) to (f 0 −2 f 1 ) and from (f 0 +2f 1 ) to (f 0 +11 f 1 ) for the 16 kbps encoding rate. For all three encoding rates, the carriers at (f 0 −12 f 1 ) and (f 0 +12 f 1 ) carry supplementary data and may be modulated using complementary 32 QAM.
Additional groups of digital carriers are placed outside the first group. The need for these digital waveforms to be in-quadrature with the analog signal is eliminated by restricting the analog AM signal bandwidth. The carriers in a second and a third group, encompassed by envelopes 16 and 18 respectively, may be modulated using, for example, 32 QAM for the 48 and 32 kbps rates, and 8 PSK for the 16 kbps rate. The carriers are set at levels of −30 dBc for all encoding rates.
FIG. 2 is a block diagram of a transmitter constructed in accordance with this invention. An analog program signal (which in this example includes right and left stereo portions) that is to be transmitted is impressed onto input terminals 28 and 28 ′. The left and right channels are combined in summation point 29 and then fed through an analog audio processor 30 to increase the average analog AM modulation, which extends the coverage region considerably. Such processors are commonplace at analog AM radio stations throughout the world. That signal is passed through a low pass filter 31 having a sharp cutoff characteristic, to produce a filtered monaural analog program signal on line 32 . Filter 31 may, for example, have a cutoff frequency of 5 kHz and 40 dB attenuation beyond 5.5 kHz. Optionally, the effect of filter 31 may be achieved by audio processing within analog audio processor 30 .
For those applications in which the analog and digital portions of the transmitted signal will be used to convey the same program material, a digital source encoder 34 , which may implement the encoding algorithm, converts the right and left analog program signals to a digital signal on line 36 . A forward error correction and interleaver circuit 38 improves data integrity over channels corrupted with impulsive noise and interference, producing a digital signal on line 40 . For those instances where the digital signal to be transmitted is not a digital version of the analog program signal, a data port 42 is provided to receive the digital signal. A supplementary and ancillary data source 44 is also provided for those instances in which the digital version of the analog program signal, or a digital signal supplied to port 42 , is to be supplemented by including additional data. A portion of the ancillary data can be input to the digital source encoder 34 . The source encoder may reserve a portion of its output bits for the transfer of ancillary data. Also, if the audio source does not require the full encoding rate of the source encoder, for instance during non-complex musical passages, the encoder can, on an as available basis, transmit ancillary data. When the source encoder does not require the full encoding rate and can transmit ancillary information in addition to the reserved ancillary data, the source encoder could indicate this condition to the ancillary data source by sending a signal to the ancillary data source, where the signal indicates the amount of additional data that can be transmitted. Ancillary data could be used to transmit signals such as emergency information, stock market quotes, weather forecasts, or information related to the audio program material such as the title of a song.
Data parser 46 receives the digital data and produces a plurality of outputs on lines 48 . Supplementary data that is used on carriers (f 0 −12 f 1 ) and (f 0 +12 f 1 ) is input on line 43 . The signals on pairs of lines 48 from the data parser 46 constitute complex coefficients that are in turn applied to an Inverse Fast Fourier Transform (IFFT) algorithm in block 50 , which generates the baseband in-phase, I, and quadrature, Q, components of the data signal, on lines 52 and 54 respectively. A guard band is applied to the output of the IFFT by processor 53 . When the IFFT output consists of 128 samples per IFFT operation, the guard band consists of 7 samples. The guard band is applied by periodically extending the IFFT output, or in other words, taking samples 1 through 7 and replicating them as samples 129 through 135 , respectively. Following the guard band, a window is applied to the data. The window reduces interference to second and third adjacent stations by reducing the sidelobes in the transmitted spectrum.
Periodically, instead of transmitting encoded program data or ancillary data, a training sequence, also commonly known as pilot information, which is known data, is sent. The training sequence allows processors in the receiver such as the equalizer to acquire the signal rapidly and follow rapidly changing channel conditions. The training sequence can be stored in, or generated by, device 55 and periodically selected as the transmitted waveform, for example, every tenth frame. Alternatively, information for the training sequence could be stored in the frequency domain and applied to the input of the IFFT. However, storing the information in the time domain reduces the required number of IFFT operations. Although known data is sent every tenth frame, the carriers devoted to the transmission of supplementary data, (f 0 −12 f 1 ) and (f 0 +12 f 1 ), may not transmit known data every tenth frame. In this case, the supplementary data to be sent every tenth frame is input to the training sequence waveform generator and the contribution of the carriers devoted to supplementary data is added to the known data. The difference between the supplementary data and ancillary data is that the supplementary data processing is completely independent of the source encoding, FEC, and interleaving operations that are used to process the digitally encoded program information.
The processed baseband analog AM signal is converted to a digital signal by analog-to-digital converter 60 and is delayed by delay device 61 . Delay of the analog signal at the transmitter provides time diversity between the analog and digital signals in the channel. Time diversity leads to the opportunity for robust blending between the analog and digital signals. The delayed analog signal is combined with the in-phase portion of the digital DAB waveform at summation point 62 to produce a composite signal on line 64 . The composite signal on line 64 is converted to an analog signal by digital-to-analog converter 66 , filtered by low pass filter 68 , and passed to a mixer 70 where it is multiplied with a radio frequency signal produced on line 72 by a local oscillator 74 . The quadrature signal on line 57 is converted to an analog signal by digital-to-analog converter 76 and filtered by low pass filter 78 to produce a filtered signal which is multiplied in a second mixer 80 , with a signal on line 82 . The signal on line 72 is phase shifted as illustrated in block 84 to produce the signal on line 82 . The outputs of mixers 70 and 80 are delivered on lines 86 and 88 to a summation point 90 to produce a composite waveform on line 92 . The spurious mixing products are muted by bandpass filter 94 , and the resulting DAB signal is subsequently amplified by a power amplifier 96 for delivery to a transmitting antenna 98 .
The system control information is transmitted on the pair of OFDM carriers that are closest in frequency to the AM carrier. These carriers, one located below the AM carrier frequency and one located the same amount in frequency higher than the AM carrier, are modulated using BPSK modulation. The BPSK carriers form a complementary pair, meaning that when the BPSK carriers are summed the resultant is in quadrature to the AM carrier. The BPSK carriers are made complementary by choosing the modulation on one carrier to be the negative conjugate of the modulation on the other carrier. This means that although there are two BPSK carriers, the information on the carriers is not independent and the carriers transmit a total of only 1 bit of control information per OFDM frame. The symbol rate for a preferred embodiment of the AM compatible digital audio broadcasting system is approximately 430.66 bps, meaning that 430.66 bits of system control information are transmitted per second. The carriers closest to the AM carrier frequency are transmitted at a higher power than the other OFDM carriers. Since they are closest to the center of the channel, the equalizer in the receiver has to adapt less for these carriers than for carriers farther from the center of the channel because the reference phase for the digital signal is normalized to the phase at the center of the channel and the magnitude for the digital signal is normalized by the received power of the BPSK carriers. In addition, since the BPSK carriers are complementary, there is an increase in signal-to-noise ratio that results because the carriers are combined at the receiver. Furthermore, the carriers that are closest to the center of the channel are least sensitive to errors in the symbol timing, or baud recovery, circuits. These factors combine to make the control information very robust.
Further in accordance with the invention, as shown in FIG. 2, the control bits are generated by mode control and data synchronization sequence generator 100 . This generator may consist of a memory device that stores the sequence. A signal on line 102 from the FEC and interleaver processor 38 is used to synchronize the mode control and data synchronization sequence to the retrieval of data from the interleaver. The digital source encoder sends a signal on line 104 to the mode control and data synchronization sequence generator to convey the audio encoding rate that is currently being used. The mode control and data synchronization sequence is provided to the IFFT on line 106 . The IFFT uses the data on line 106 as the input for the digital carriers that convey the mode control and data synchronization sequence. In one preferred embodiment, the FEC and interleaver processor consists of an outer FEC code, followed by an outer interleaver, followed by an inner FEC code, followed by an inner interleaver. The length of the mode control and data synchronization sequence can be set such that the sequence provides data for a number of baud that equals the number of baud that can be transmitted using the data in the inner interleaver. At the receiver, this allows the boundaries of the inner interleaver to be determined by appropriate processing of the mode control and data synchronization sequence.
In one preferred embodiment, there are 400 OFDM frames transmitted per inner interleaver frame, where an inner interleaver frame refers to the data needed to fill the inner interleaver. Since one bit of control information is transmitted per OFDM frame, there are 400 bits of control information transmitted per interleaver frame. Therefore, if the mode control and data synchronization sequence has a length of 400 bits, the sequence will repeat every inner interleaver frame. These 400 bits are divided into 10 segments of 40 bits, where each segment of 40 bits is called a control frame. The format of the 40 bits comprising a control frame 184 is shown in FIG. 5 .
FIG. 3 is a block diagram of a receiver constructed to receive the composite digital and analog signals of FIG. 1 . An antenna 110 receives the composite waveform containing the digital and analog signals and passes the signal to conventional input stages 112 , which may include a radio frequency preselector, an amplifier, a mixer and a local oscillator. An intermediate frequency signal is produced by the input stages on line 114 . This intermediate frequency signal is passed through an automatic gain control circuit 116 to an I/Q signal generator 118 . The I/Q signal generator produces an in-phase signal on line 120 and a quadrature signal on line 122 . The in-phase channel output on line 120 is input to an analog-to-digital converter 124 . Similarly, the quadrature channel output on line 122 is input to another analog-to-digital converter 126 . Feedback signals on lines 120 and 122 are used to control the automatic gain control circuit 116 . The signal on line 120 includes the analog AM signal which is separated out as illustrated by block 140 and passed to an output stage 142 and subsequently to a speaker 144 or other output device.
An optional highpass filter 146 may be used to filter the in-phase components on line 128 to eliminate the energy of the analog AM signal and to provide a filtered signal on line 148 . If the highpass filter is not used, the signal on line 148 is the same as that on line 128 . A demodulator 150 receives the digital signals on lines 148 and 130 , and produces output signals on lines 154 . These output signals are passed to an equalizer 156 , and the equalizer output is passed to a switch 158 . The output of the switch is sent to a deinterleaving circuit and forward error correction decoder 164 in order to improve data integrity. The output of the deinterleaver/forward error correcting circuit is passed to a source decoder 166 . The output of the source decoder is delayed by circuit 168 to compensate for the delay of the analog signal at the transmitter and to time align analog and digital signals at the receiver. The output of delay circuit 168 is converted to an analog signal by a digital-to-analog converter 160 to produce a signal on 162 which goes to the output stage 142 .
FIG. 4 is a more detailed functional block diagram that further illustrates the operation of the invention. Both in-phase (I) and quadrature (Q) signals are provided on lines 148 and 130 as inputs to a windowing and guard interval removal circuit 170 . These signals may be provided by using down converter elements similar to those shown in FIG. 3 . The window should be applied such that the digital carriers remain orthogonal, or at least the lack of orthogonality among the digital carriers is small enough not to impact system performance. The I and Q signals are synchronized to the transmitted baud intervals and each baud is input to an FFT circuit 172 . In some cases it may be advantageous to perform the windowing and guard band removal operations prior to processing by highpass filter 146 . The outputs from the windowing and guard interval removal circuit 170 are input to the FFT 172 . To obtain higher signal-to-noise ratios (SNR) for the complementary carriers, the FFT outputs for pairs of complementary carriers are combined. The output of the FFT is input by way of lines 154 to the coefficient multiplier 174 . The coefficient multiplier adjusts the magnitude and phase of the data for each digital carrier to compensate for channel effects, transmitter and receiver filtering, and other factors that can affect the magnitude and phase of the received digital information. The coefficient multiplier output is used to make symbol decisions, which determines the constellation point that was transmitted. Processor 176 determines which of the frequency domain constellation points was transmitted. These decisions, along with the pre-equalized constellation points and the previous values of the equalizer coefficients are used to update the equalizer coefficients as illustrated by block 178 . Block 178 can utilize a known algorithm such as the least mean squares (LMS) or recursive least squares (RLS) to update the equalizer coefficients.
In order to properly demodulate the data, the receiver must identify when training baud are received. When a training baud is received, the output of the equalizer is not input to the symbol decision processors (including FEC and deinterleavers) because the training baud information is not used to obtain the digitally encoded audio program. Also, the equalizer uses a different convergence factor, or adaptation constant when a training frame is received. Additionally, the data that is input to the noise power estimate is processed differently when a training baud is received. Also, the symbol decisions/a priori data block 176 outputs the ideal data corresponding to the training baud when a training baud is received and the symbol decisions when a normal baud is received. As shown in FIG. 4, the coefficient multiplier output is input to a processor 165 that determines normal training synchronization.
As shown in FIGS. 3 and 4, the data stream from the coefficient multiplier is input to mode control and data synchronization processor 163 . This processor uses only the data from the mode control and data synchronization sequence. Mode control and data synchronization processor 163 processes the control information and determines the audio encoding rate and the boundaries of the inner interleaver. A signal is sent on line 167 to the deinterleaving and FEC circuit 164 to indicate the boundaries of the inner interleaver. This results in synchronization of the data at the receiver with respect to the inner interleaver boundaries and allows proper operation of the deinterleaving and FEC circuit 164 . A signal is also sent to indicate to the source decoder the rate of the encoded audio information.
This invention provides a transmission format and reception method for system control information in an AM compatible digital audio broadcasting system. The transmitted data includes transmission mode, interleaver synchronization, and control data synchronization information. In the preferred embodiment of the invention, the information is transmitted on the OFDM carriers that are closest to the AM carrier. BPSK modulation format is used to provide robust performance in the presence of noise and interference. The synchronization sequences discussed below have been chosen to result in low autocorrelation sidelobe levels.
FIG. 5 illustrates an entire control frame 184 . As shown in FIG. 5, the first 12 bits 186 are to-be-determined and can be used as needed for future system upgrades. The next 4 bits 188 are the transmission mode information bits. These bits indicate the audio encoding rate and the forward error correction rate used in the convolutional encoder. In the currently preferred embodiment of an AM digital audio broadcasting system, there are 3 modes defined for transmission, including audio encoding at 48 kbps with a 3/5 rate for the convolutional encoder, audio encoding at 32 kbps with a 2/5 rate for the convolutional encoder, and audio encoding at 16 kbps with a 1/3 rate for the convolutional encoder. The 4 transmission mode information bit codes were chosen to have the maximum number of different bits.
At the receiver, the transmission mode information is not required until a complete interleaver frame is received. Therefore, it is advantageous for the receiver to use the information from the 10 control frames in the interleaver to determine the transmission mode. One method of determining the transmission mode would be to count the number of transmission mode bits that are received as a 1. With the bit codes illustrated in FIG. 5, the bits should sum to 0, 20, and 40 for the 3/5 code, 2/5 code, and 1/3 codes, respectively. The ideal value closest to the summed value can be used to determine which mode is being transmitted. Simulation of this algorithm for determining the transmission mode has shown it to be practical and reliable because if the mode bits from the BPSK carriers cannot be recovered, it is highly unlikely that the data for the other carriers, which use more complex modulation formats, can be recovered. Alternatively, the transmission mode bits could be correlated with all possible transmission mode codes. The correlation producing the largest output would be chosen as the transmission mode. The result of the correlation could be lowpass filtered and hysteresis could be added to reduce the effects of noise. The correlation could be implemented as a negated exclusive or (XOR) of the received bits with the possible transmission mode codes. The bits resulting from the negated XOR operation for each transmission mode code could be summed to represent the correlation value.
The next four bits 190 are part of the 40 bits that comprise the interleaver synchronization word 194 . The 40 bit interleaver synchronization word is transmitted once per interleaver frame, with 4 of the bits transmitted during each of the 10 control frames that are transmitted during each interleaver frame. The receiver processes the interleaver synchronization information to determine interleaver frame boundaries. The interleaver unique word was chosen to have a high peak-to-sidelobe autocorrelation in order to permit reliable determination of interleaver boundaries. Specifically, the bit pattern used is 1 1 0 0 1 1 1 0 1 0 1 1 1 0 0 0 1 0 1 1 1 1 0 1 0 1 0 0 1 0 0 0 0 0 1 0 0 1 0 0, which has an autocorrelation of 40 when the sequence is aligned and a peak sidelobe level of +/−4 when the sequence is not aligned. Note that the autocorrelation is obtained by correlating the sequence over a periodic extension of itself and these numbers are obtained by using a 1 for a 1 bit and a −1 for a 0 bit. As the interleaver frame is processed by the receiver, the entire interleaver synchronization word can be assembled, by combining the four bit sequences in each of the ten control frames. The received interleaver synchronization word can be correlated with the known transmitted interleaver word to find the interleaver boundaries. Specifically, each time a full control frame is received, the last 40 received interleaver synchronization bits received can be correlated with the known pattern. The result of the correlation can be compared to a threshold to determine interleaver synchronization.
To achieve proper correlation, the synchronization for the BPSK control frame must first be achieved. As shown in FIG. 5, the last 20 bits 192 of a control frame consist of a BPSK synchronization unique word. The purpose of this sequence of bits is to allow the receiver to synchronize to the bit pattern of the control frame so that it can choose the proper bits for the transmission mode and interleaver synchronization information. Like the interleaver synchronization word, this word was chosen to have a high peak-to-sidelobe autocorrelation. Specifically, the bit pattern used is 1 1 1 1 1 0 1 1 0 0 1 0 1 0 1 1 0 0 0 1, which has an autocorrelation of 20 when the sequence is aligned and a peak sidelobe level of +/−4 when the sequence is not aligned. The known transmitted pattern for these bits can be used to correlate the received control word bit pattern at the receiver. Because the other 20 bits of the control word could occasionally produce a high correlation with the BPSK synchronization unique word and to reduce the effects of noise, it may be advantageous to individually low pass filter the correlation output for each of the possible correlation positions within a control frame. The output of the lowpass filters, or of the correlations if a lowpass filter is not used, can be compared to a threshold to determine when BPSK synchronization is achieved.
This invention provides a method and apparatus for transmitting and receiving control information in an amplitude modulated compatible digital audio broadcast signal. In the foregoing specification certain preferred practices and embodiments of this invention have been set out, however, it will be understood that the invention may be otherwise embodied within the scope of the following claims. | A method is provided for transmitting control information in a digital audio broadcasting system. The method comprises the steps of transmitting a plurality of control bits in each of a plurality of control frames, wherein a first sequence of the control bits represents a transmission mode, and a second sequence of the control bits represents a control data synchronization word. The plurality of control bits can further include a third sequence of bits representative of an interleaver synchronization word. A method performed in a radio receiver for determining transmission mode and synchronization for a digital audio broadcasting signal is also provided. The method comprises the steps of receiving a plurality of interleaver frames containing digital information, wherein each of the interleaver frames includes a plurality of control frames. The control frames include a plurality of control bits, wherein a first sequence of the control bits represents a transmission mode, and a second sequence of the control bits represents a control data synchronization word. The plurality of control bits can further include a third sequence of bits representative of an interleaver synchronization word. The first sequence of control bits is processed to determine a transmission mode; the second sequence of control bits is processed to determine control data synchronization; and the third sequence of control bits is processed to determine interleaver boundaries. Radio frequency transmitters and receivers that utilize the above methods are also disclosed. | 7 |
This application claims benefit of U.S. Provisional Application No. 61/064,491 filed Mar. 7, 2008 and entitled, “Trench Drain Filter.” The foregoing application is hereby incorporated herein by reference.
FIELD OF THE INVENTION
A filter for use in a catch basin or trench drain. The filter provides two paths for water to flow through the basin to an outlet. The first path is through a matrix filter and then through a filtering pouch to an outlet. The second path bypasses the matrix filter. A bypass weir helps guide water away from the matrix filter when the matrix filter is clogged.
BACKGROUND OF THE INVENTION
Runoff and drainage from streets, highways, parking lots, and other similar areas is of increasing concern. Often sediment, leaked fluids, rubber, metal particles, dirt, and other debris are washed off of an area by surface water and carried into existing drainage systems or the environment. The tainted water may be carried along existing drainage systems to treatment facilities already strained to capacity or may be expelled directly into natural bodies of water.
In the past, catch basins have been used to capture runoff and waste water from roadways, parking lots, and other areas. These drains often consist of grate-covered basins which collect the runoff and waste water. Runoff and waste water are then channeled into a local drainage system or into a more convenient location or facility which may appropriately deal with the waste water and runoff.
There is a long recognized need to perform some measure of primary treatment of wastewaters. By initially treating the wastewaters and runoff, people may not only help lessen the strain on existing treatment facilities, but may also prevent certain undesirable chemicals and waste from reaching the environment and may aid in the operation of existing water channeling and treatment infrastructure by limiting the amount of debris and waste that enter the infrastructure and either clog or otherwise cause damage to it.
In the past, filters have been added to traditional catch basins. These filters provide a basic filtering capability and generally filter larger debris and other contaminants from waste water and runoff. These filters, however, have several limitations. The first being that the catch basin must be large enough to contain the filtering apparatus. Often catch basins have been built small and/or shallow, either because of the physical requirements of the area being drained or because the trench was dug without consideration of the addition of filtering capacity. In such cases, a conventional catch basin filter is not only inconvenient but impossible for use.
What is needed, then, is an apparatus, method, and system of filtering waste water and runoff without the need for deep or large basins. Moreover, what is needed is an apparatus, method, and system of filtering that removes not only physical debris, but also hydrocarbons from the waste water and runoff.
SUMMARY OF THE INVENTION
A filter for use in a catch basin or trench drain. The filter provides two paths for water to flow through the drain to an outlet. The first path is through a matrix filter and then through a filtering pouch to an outlet. The second path bypasses the matrix filter. A bypass weir helps guide water away from the matrix filter when the matrix filter is clogged.
In one embodiment, a catch basin according to the present invention may include an inlet, an outlet, a filter, an inlet flume configured to direct water towards the filter, a bypass weir substantially surrounding the filter, and a filter pouch. The catch basin may include a first flow route comprising the filter body, filtering pouch and the outlet. A second flow route may comprise the outlet. The bypass weir may direct water towards the second flow route if the filter becomes clogged.
These and other objects and advantages of the invention will be apparent from the following description, the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing out and distinctly claiming the present invention, it is believed the same will be better understood from the following description taken in conjunction with the accompanying drawings, which illustrate, in a non-limiting fashion, the best mode presently contemplated for carrying out the present invention, and in which like reference numerals designate like parts throughout the Figures, wherein:
FIG. 1 shows an angled-view of an embodiment of the present invention.
FIG. 2 shows a side-view of an embodiment of the present invention.
FIG. 3 shows a disassembled-view of an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present disclosure will now be described more fully with reference to the Figures in which various embodiments of the present invention are shown. The subject matter of this disclosure may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein.
FIG. 1 shows an angled-view of an embodiment of the present invention. Shallow concrete catch basin 1 is well-known in the art. Catch basin 1 contains an interior cavity 10 as well as a lip 60 . Catch basin 1 may be any size/shape conducive to run-off and wastewater collection. In some embodiments of the invention, the catch basin 1 has length and width dimensions of 18 inches square; 24 inches square; 36 inches square; 48 inches square; 24 inches by 36 inches; or 36 inches by 48 inches. In at least one embodiment, interior cavity 10 has a minimum depth of 6.5 inches. This allows inlet flume 20 , bypass weir frame 30 , matrix filter 40 , and filter pouch 50 to fit into catch basin 1 's interior cavity 10 while a grate (not pictured) rests on lip 60 .
Inlet flume 20 directs water flowing through a grate (not pictured) towards matrix filter 40 . While inlet flume 20 is preferably made of stainless steel, preferably type 304 or 18/8 stainless steel, it should be noted that inlet flume 20 may be constructed of any suitable material. In some embodiments, inlet flume 20 also includes a rubber gasket 21 . Rubber gasket 21 may seal the space between inlet flume 20 and lip 60 and helps ensure that water flows toward the matrix filter 40 (see FIG. 3 ).
Bypass weir frame 30 may sit along the bottom of interior cavity 10 . Although bypass weir frame 30 is preferably made out of type 304 or 18/8 stainless steel as well, it should be noted that bypass weir frame 30 may be made of any suitable material. Bypass weir frame 30 may be positioned along the bottom of the interior cavity 10 . By virtue of its position, location, and construction bypass weir frame 30 may serve multiple purposes, one of which may be to help secure and position matrix filter 40 .
FIG. 2 shows a side-view of an embodiment of the present invention. Grate 70 is a drain grate as well known in the art. Grate 70 may be made of any suitable material, such as cast iron, aluminum, bronze, or hard plastic. While cast iron, aluminum, bronze, and plastic are specifically mentioned, it should be noted that grate 70 is not limited to these materials. As can be seen in the figure, grate 70 is positioned on top of lip 60 (as indicated by dashed line 71 ). Grate 70 and lip 60 are constructed and arranged such that the top of grate 70 forms the top of the catch basin. Moreover, shallow concrete basin 1 is situated with regards to foundation 80 so that, when placed within the lip 60 , the top of grate 70 is substantially flush with the surrounding ground level.
As can be seen in FIG. 2 , inlet flume 20 sits within concrete basin 1 . As water flows over grate 70 and into the present invention, inlet flume 20 helps collect and direct that water towards the matrix filter 40 for filtering.
Filter pouch 50 preferably contains an absorbent material capable of filtering hydrocarbons, such as oil and greases, from fluid. Filter pouch 50 preferably contains absorbent material capable of absorbing hydrocarbons such as fossil rock, although it should be noted that filter pouch 50 may contain any suitable material. As filter pouch contains absorbent material for the retention and collection of oils and greases, said pouch is preferably configured within the concrete basin 1 so that it is easily replaceable. In some embodiments, filter pouch 50 is configured to clip into the concrete basin via attachment tabs 51 and 52 (see FIG. 1 ). Attachment tabs 51 and 52 allow filter pouch 50 to be securely, yet removably attached so that the filter pouch 50 is easily replaced.
Matrix filter 40 may be constructed of a woven textile surrounding a rigid skeleton. In some embodiments, said woven textile may be a durable polypropylene monofilament geotextile. However, it should be noted that any suitable textile may be used with the present invention. In some embodiments, said rigid skeleton may be formed of polypropylene, however, it should also be noted that any suitably rigid material may be used. The matrix filter may be designed to maximize filtering capabilities while minimizing the physical height or dimension of the matrix filter. Moreover, the matrix filter may be designed to limit the retention of water within the matrix filter.
Along the floor of concrete basin 1 sits bypass weir 30 . Bypass weir 30 is positioned substantially below inlet flume 20 and substantially surrounding matrix filter 40 . Bypass weir 30 and inlet flume 20 are situated so that there is a gap between the overhang of inlet flume 20 and the upper edge of bypass weir 30 . As water flows into the present invention, it enters concrete basin 1 by flowing through grate 70 . The water is then directed by inlet flume 20 down towards matrix filter 40 . Bypass weir 30 helps guide water flow to the matrix filter 40 . If matrix filter 40 should clog or otherwise become impenetrable, gaps between the overhang of inlet flume 20 and the upper edge of bypass weir 30 allow the water to overflow around matrix filter 40 and continue flowing out of outlet 90 (see FIG. 3 ).
FIG. 3 shows a disassembled-view of an embodiment of the present invention. In this figure, dashed lines indicate each part's position and configuration when the present invention is fully assembled. In this figure, inlet flume 20 is shown with rubber gasket 21 . Rubber gasket 21 seals the space between inlet flume 20 and lip 60 to help direct water flow through inlet flume 20 toward matrix filter 40 . Gasket 21 may be formed of any suitable material such as rubber or silicone.
Bypass weir 30 may be located along the bottom of concrete basin 1 . Matrix filter 40 may be located within bypass weir 30 . Filter pouch 50 is positioned such that water flows through filter pouch 50 as it is carried towards outlet 90 . Inlet flume 20 with gasket 21 may be located above bypass weir 30 and matrix filter 40 . Grate 70 may sit above inlet flume 20 on lip 60 . As water is flows through grate 70 , it is directed by inlet flume 20 towards matrix filter 40 . Matrix filter 40 may then filter the water. After an initial filtering by matrix filter 40 , water is directed towards outlet 90 through filter pouch 50 . Filter pouch 50 may then additionally filter the water before it flows out of outlet 90 . As can be seen in the figures, filter pouch 50 , when in an elongated embodiment, may be positioned such that the pouch's longer sides sit substantially perpendicular to the outlet. Moreover, there may be a gap between the upper edge of the filtering pouch and the outlet to allow water to flow over the pouch if necessary.
If matrix filter 40 were to become clogged or otherwise inoperable and incapable of allowing water and fluid to flow through it, bypass weir 30 , in conjunction with inlet flume 20 would allow the water to flow around the matrix filter 40 and into the outlet 90 . In some embodiments, water flowing in such an overflow scenario may bypass filter pouch 50 . In other embodiments, water would be directed to filter pouch 50 even if matrix filter 40 has become clogged. Bypass weir 30 and inlet flume 20 work to provide a bypass for water in such a scenario by virtue of gaps and spacing provided between the two items allowing rising water to flow over the sidewalls of the bypass weir 30 and under the overhang of inlet flume 20 (see FIG. 2 ), and then around matrix filter 40 .
The foregoing description of specific embodiments of the present invention are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obviously, many modifications and variations are possible in view of the above teachings. While the embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, thereby enabling others skilled in the art to best utilize the invention, various embodiments with various modifications as are suited to the particular use are also possible. The scope of the invention is to be defined only by the claims appended hereto, and by their equivalents. | A catch basin configured to filter water by way of a matrix filter and a filter pouch. If the matrix filter should become clogged, a bypass weir provides means of bypassing the matrix filter to prevent the catch basin from clogging. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Patent Application Ser. No. 60/266,854, filed Feb. 7, 2001, under 35 U.S.C. §119(e).
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to computer-based telephony networks and more particularly to software and servers that manage telephony conferencing.
2. Related Art
In today's technological environment, many ways exist for several people in multiple geographic locations to communicate with one another simultaneously. One such way is audio conferencing. Audio conferencing applications serve both the needs of business users and leisure users who are geographically distributed.
Traditional audio conferencing involved a central conferencing server which hosted an audio conference. Participants used their telephones to dial in to the conferencing server over the Public Service Telephone Network (PSTN) (also called the Plain Old Telephone System (POTS)).
Greater availability of low-cost personal computers, networking equipment, telecommunications, and related technology, however, has dramatically changed the way people communicate. One example of such change is the tremendous increase in persons connected to the global Internet. Connectivity achieved by the Internet—connecting numerous, different types of networks—is based upon a common protocol suite utilized by those computers connecting to it. Part of the common protocol suite is the Internet Protocol (IP), defined in Internet Standard (STD) 5, Request for Comments (RFC) 791 (Internet Architecture Board). IP is a network-level, packet (i.e., a unit of transmitted data) switching protocol.
In recent years, technological improvements offer the possibility of transmitting voice data over the worldwide public Internet. Voice over IP (VoIP) began with computer scientists experimenting with exchanging voice using personal computers (PCs) equipped with microphones, speakers, and sound cards.
VoIP further developed when, in March of 1996, the International Telecommunications Union-Telecommunications sector (ITU-T), a United Nations organization, adopted the H.323 Internet Telephony Standard. Among its specifications, H.323 provides the minimum standards that equipment must meet in order to send voice over the IP, and other packet-switched network protocols where quality of sound cannot be guaranteed. Thus, conferencing servers (also called multipoint control units (MCUs)) were developed to host audio conferences where participants connected to a central MCU using PC-based equipment and the Internet, rather than traditional phone equipment.
More recently, several alternatives to H.323 have been developed. One such alternative is the Session Initiation Protocol (SIP) developed within the Internet Engineering Task Force (IETF) Multiparty Multimedia Session Control (MMUSIC) Working Group. SIP, which is well-known in the relevant art(s), is a signaling protocol for Internet conferencing and telephony. SIP addresses users using an e-mail-like address and utilizes a portion of the infrastructure used for Internet e-mail delivery. It handles basic setup functions as well as enhanced services (e.g., call forwarding).
Given the rapid pace of development in the telephony industry—both in protocols and equipment—and the existence of both legacy equipment and protocols (e.g., telephones and switching networks such as the PSTN), audio conferencing service providers need a means to link legacy circuit-switched systems to newer packet-switched systems in order to reach (or service) a broader range of clients and vice versa. Therefore, a method is needed to seamlessly link a combination of MCU architectures for packet based (e.g., IP-based) client and circuit switched (e.g., phone) based client conferencing. The linkage of this combination of MCUs should realize the capabilities of the various participants' equipment and provide the appropriate audio data to each participant.
SUMMARY OF THE INVENTION
The present invention is directed to a method that meets the above-identified needs, whereby packet switched (e.g., Internet Protocol (IP)) based clients (e.g., PC clients) and circuit switched (e.g., phone) clients can simultaneously participate in a single audio conference application.
In an embodiment of the present invention, the method and computer program product of the present invention include the steps of establishing a connection between a packet-switched (e.g., IP-based) conferencing server (also called multipoint control unit (MCU)) and a circuit-switched (e.g., phone-based) conferencing server and designating that connection as continuously active on each server. As used herein, the packet based MCU may be referred to as the “IP MCU,” which is one example of a packet based MCU. Likewise, the circuit switched MCU may be referred to as the “Phone MCU,” which is one example of a circuit switched MCU.
Upon connection, the IP MCU designates the connection as an active speaker (i.e., participant who is actually speaking rather than simply listening), thereby ensuring that the audio data of actively speaking phone-based clients is later distributed to the IP-based clients connected to the IP MCU.
Next, the IP MCU receives a mixed and converted (mix of the audio streams of active speakers connected to the Phone MCU, that has been converted to an audio packet) phone client audio packet from the Phone MCU via the continuously active connection. Upon receipt of this audio packet, the IP MCU treats this packet as an active speaker packet and includes it in the active speaker mix for all its IP clients. Both the IP MCU and the Phone MCU perform an “echo suppression” during the sending of packets so that each client, if they are an active speaker, will not hear themselves speaking.
Next, asynchronously and simultaneously, the IP MCU receives audio packets from the actively speaking IP based clients connected to the IP MCU. The IP MCU forwards the mix of the active speakers to the Phone MCU via the continuously active connection. The Phone MCU treats this connection like just another active speaker Phone client. Because there is echo suppression where each active speaker will get a mix of all active speakers except themselves, the active speaker mix from the Phone MCU will not be forwarded back to itself. Likewise, the active speaker mix from the IP MCU going to the Phone MCU will not be forwarded back to itself because of echo suppression.
Upon completion of the steps above, the process begins again as long as the continuously active connection between the two MCUs remains active. That is, the process continues until either the Phone MCU or the IP MCU ceases hosting the audio conference (i.e., the conference is terminated).
In an alternate embodiment, the method and computer program product of the present invention include the steps of establishing a connection between a Phone MCU and an IP MCU and designating that connection as an active speaker on each server. This embodiment is similar to the embodiment first described above, except that the connection is now initiated by the Phone MCU rather than the IP MCU.
Once the connection is established between the Phone MCU and IP MCU, the Phone MCU designates this connection as continuously active, thereby ensuring that the audio data of actively speaking IP-based clients is later distributed to the phone-based clients connected to the Phone MCU.
Next, asynchronously and simultaneously, the Phone MCU receives a mixed (mix of the audio packets of active speakers connected to the IP MCU) IP-based client audio packet from the IP MCU via the continuously active connection. Upon receipt of this audio packet, the Phone MCU converts this audio packet into an audio stream (i.e., an audio format that phone-based clients can receive) and sends the audio stream to each connected phone-based client connected to the Phone MCU. Again, both the IP MCU and the Phone MCU perform an “echo suppression” during the sending of packets and audio streams so that each client, if they are an active speaker, will not hear themselves speaking.
Next, the Phone MCU receives audio streams from the actively speaking Phone-based clients connected to the Phone MCU. The Phone MCU then converts (i.e., analog to digital conversion) these audio streams into audio packets. Then the Phone MCU forwards these packets to the IP MCU via the continuously active connection.
Upon completion of the steps above, the process begins again as long as the continuously active connection between the two MCUs remains active. Thus, the process continues until either the Phone MCU or the IP MCU ceases hosting the audio conference (i.e., the conference is terminated).
With respect to both embodiments described above, an alternative embodiment of the present invention includes a gateway to bridge the time division multiplexing (TDM) connectivity on the Phone MCU (e.g. PRI lines) to packet connections on the IP MCU. This gateway would be necessary when the transport between the Phone and IP MCUs are different (e.g. H323 ethernet packets for the IP MCU, and a PRI digital phone line for the Phone MCU).
An advantage of the present invention is that it enables simultaneous audio conferencing between clients using multiple types of equipment and protocols.
Another advantage of the present invention is that service providers can continue to support their existing clients using either traditional phone services and IP-based connections, while offering the added convenience of simultaneously linking additional clients using other types of equipment and protocols.
Further features and advantages of the invention as well as the structure and operation of various embodiments of the present invention are described in detail below with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
The features and advantages of the present invention become more apparent from the detailed description set forth below when taken in conjunction with the drawings in which like reference numbers indicate identical or functionally similar elements. Additionally, the left-most digit of a reference number identifies the drawing in which the reference number first appears.
FIG. 1 is a block diagram illustrating the overall system architecture of an embodiment of the present invention, showing connectivity among the various components;
FIG. 2 is a flowchart representing the general operational flow according to an embodiment of the present invention;
FIG. 3 is a flowchart representing the general operational flow according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
I. System Architecture Overview
The present invention is directed to a system and method that enables communication (i.e., audio conferencing) between a linked packet-switched server architecture for Internet Protocol (IP)-based clients and a circuit-switched server architecture for phone-based clients. In a preferred embodiment of the present invention, a service provider supplies the linkage infrastructure (i.e., full duplex dial-up or IP link), agreement terms, and facilities so that clients (i.e., participants) who subscribe to their conferencing services can take part in a multi-party audio conference application. The service provider would also provide customer service, support, and billing as will be apparent to one skilled in the relevant art(s) after reading the description herein. Clients would connect to their respective servers using whatever equipment and protocol they currently have access to, and the invention would provide seamless linkage among the various clients.
Referring to FIG. 1 , a block diagram illustrating the system architecture of an embodiment of the present invention, showing connectivity among the various components, is shown. More specifically, FIG. 1 illustrates a linked multipoint control unit (MCU) architecture 100 for packet-switched (IP-based) personal computer system clients and circuit-switched (phone-based) client conferencing.
Architecture 100 includes a plurality of PC-based clients 102 (shown as clients 102 a - 102 n ) which connect to an IP-based MCU 104 . Architecture 100 also includes a plurality of telephone-based clients 112 (shown as clients 112 a - 112 n ) which connect to a phone-based MCU 110 . The connection between IP MCU 104 and phone MCU 110 is provided by a full-duplex client channel 108 .
Full-duplex client channel 108 enables a service provider to send and receive audio packets from PC-based clients 102 using, for example, the SIP protocol. Full-duplex client channel 108 also enables a service provider to send and receive, for example, H.323 protocol packets from telephone-based clients 112 . The client channel 108 looks like just another active speaker to both the IP MCU 104 and the Phone MCU 110 . In an embodiment of the present invention, because the transport may be different (e.g. H323 ethernet packets for the IP MCU 104 , and a PRI digital phone line for the Phone MCU 110 ), the client channel 108 may go through a protocol converter or gateway.
The present invention is described in terms of the above example. This is for convenience only and is not intended to limit the application of the present invention. In fact, after reading the following description, it will be apparent to one skilled in the relevant art(s) how to implement the following invention in alternative embodiments (e.g., MCUs 104 and 110 handling protocols other than those illustrated herein).
The terms “client,” “subscriber,” “party,” “participant,” and the plural form of these terms may be used interchangeably throughout herein to refer to those who would access, use, and/or benefit from the system and method of the present invention.
II. Operational Flow
Referring to FIG. 2 , a flowchart representing the general operational flow, according to an embodiment of the present invention, is shown. More specifically, FIG. 2 depicts an example control flow 200 involved in providing a linked Internet Protocol (IP)-based client and phone-based client audio conference. In this embodiment, the IP multipoint control unit (MCU) 104 performs the initial steps necessary to establish a link to the Phone MCU 110 .
Control flow 200 begins at step 202 with control passing immediately to step 204 . In step 204 , IP MCU 104 establishes a continuously active connection 108 to Phone MCU 110 . Connection 108 is established as continuously active (i.e., recognized as active speaker by IP MCU 104 ), thereby ensuring that the audio data of actively speaking (e.g., participants who are actually speaking rather than simply listening) phone-based clients 112 is always included in the audio stream later distributed to the connected IP-based clients 102 . IP MCU 104 also keeps an active speaker list so that it can limit the number of actively speaking IP-based clients 102 recognized and added to the stream, thus ensuring that the list does not become too large. If the number of actively speaking IP-based clients 102 becomes too large, the data being sent by the IP MCU 104 to every participant in the audio conference will be unintelligible (i.e., too many participants speaking on top of each other).
Returning to control flow 200 , in step 206 , the IP MCU 104 receives a mixed and converted phone client audio packet from the Phone MCU 110 via the continuously active connection 108 . Upon receipt of this audio packet, in step 208 , the IP MCU 104 sends the mixed and converted phone client audio packet to each connected PC client 102 connected to IP MCU 104 .
In step 210 the IP MCU 104 receives PC client 102 audio packet(s) from each actively speaking PC client 102 connected to IP MCU 104 . Upon receipt of PC audio packet(s), in step 212 , the IP MCU 104 forwards the actively speaking PC client audio packet(s) to the Phone MCU 110 via the continuously active connection 108 .
In step 214 , the process begins again if the continuously active connection 108 is still active. Thus, control flow 200 continues until either the Phone MCU 110 or the IP MCU 104 ceases hosting the audio conference (i.e., the conference is terminated) as indicated by step 216 .
It should be noted, as will be apparent to one skilled in the relevant art(s) after reading the description here, that control flow 200 as presented in FIG. 2 assumes that there is an order to the Phone MCU mixing and the IP MCU forwarding packets. This is done for ease of explanation herein, whereas, in actuality, these events are asynchronous and simultaneous as suggested above. Further, as will also be apparent to one skilled in the relevant art(s), there may some delay between an active speaker becoming active on one MCU, and before that active speaker is heard on the other MCU, but it is symmetric.
Referring to FIG. 3 , a flowchart representing the general operational flow, according to an embodiment of the present invention, is shown. More specifically, FIG. 3 depicts an example control flow 300 involved in providing a linked IP-based client and phone-based client audio conference. In this embodiment, the Phone multipoint control unit (MCU) 110 performs the initial steps necessary to establish a link to the IP MCU 104 .
Control flow 300 begins at step 302 with control passing immediately to step 304 . In step 304 , the Phone MCU 110 establishes a continuously active connection 108 to IP MCU 104 . Connection 108 is established as continuously active (i.e., recognized as active speaker by Phone MCU 110 ), thereby ensuring that the audio data of actively speaking (e.g., participants who are actually speaking rather than simply listening) IP-based clients 102 is always included in the audio mix later distributed to the connected phone-based clients 112 . Phone MCU 110 also keeps an active speaker list so that it can limit the number of actively speaking phone-based clients 112 recognized and added to the mix, thus ensuring that the list does not become too large. If the number of actively speaking phone-based clients 112 becomes too large, the data being sent by the Phone MCU 110 to every participant in the audio conference will be unintelligible (i.e., too many participants speaking on top of each other).
Returning to control flow 300 , in step 306 , the Phone MCU 110 receives a mixed PC client audio packet from the IP MCU 104 via the continuously active connection 108 . In step 308 , the Phone MCU 110 receives an audio packet from each actively speaking phone client 112 connected to Phone MCU 110 . Upon receipt of the actively speaking phone client audio packet, in step 310 , the Phone MCU mixes the mixed PC client audio packet, received in step 306 , with the actively speaking phone client audio packet, received in step 308 , into a combined audio packet.
In step 312 , the Phone MCU 110 forwards the combined audio packet to phone clients 112 connected to Phone MCU 110 . In step 314 the Phone MCU forwards the audio packet, received in step 308 , to the IP MCU 104 via the continuously active connection 108 .
In step 316 , the process begins again if the continuously active connection 108 is still active. Thus, control flow 300 continues until either the Phone MCU 110 or the IP MCU 104 ceases hosting the audio conference (i.e., the conference is terminated) as indicated by step 318 .
It should be noted, as will be apparent to one skilled in the relevant art(s) after reading the description here, that control flow 300 as presented in FIG. 3 assumes that there is an order to the Phone MCU mixing and the IP MCU forwarding packets. This is done for ease of explanation herein, whereas, in actuality, these events are asynchronous and simultaneous as suggested above. Further, as will also be apparent to one skilled in the relevant art(s), there may some delay between an active speaker becoming active on one MCU, and before that active speaker is heard on the other MCU, but it is symmetric.
III. Environment
The present invention (i.e., architecture 100 , control flow 200 , control flow 300 , or any part thereof) may be implemented using hardware, software or a combination thereof and may be implemented in one or more computer systems or other processing systems. In fact, in one embodiment, the invention is directed toward one or more computer systems capable of carrying out the functionality described herein.
An example of a computer system is described. The computer system represents any single or multi-processor computer. The computer system includes one or more processors. The processor is connected to a communication infrastructure (e.g., a communications bus, cross-over bar, or network). Various software embodiments are described in terms of this exemplary computer system. After reading this description, it will become apparent to a person skilled in the relevant art how to implement the invention using other computer systems and/or computer architectures.
The computer system can include a display interface that forwards graphics, text, and other data from the communication infrastructure (or from a frame buffer not shown) for display on the display unit.
The computer system also includes a main memory, preferably random access memory (RAM), and may also include a secondary memory. The secondary memory may include, for example, a hard disk drive and/or a removable storage drive, representing a floppy disk drive, a magnetic tape drive, an optical disk drive, etc. The removable storage drive reads from and/or writes to a removable storage unit in a well-known manner. The removable storage unit, represents a floppy disk, magnetic tape, optical disk, etc. which is read by and written to by the removable storage drive. As will be appreciated, the removable storage unit includes a computer usable storage medium having stored therein computer software and/or data.
In alternative embodiments, secondary memory may include other similar means for allowing computer programs or other instructions to be loaded into the computer system. Such means may include, for example, a removable storage unit and an interface. Examples of such may include a program cartridge and cartridge interface (such as that found in video game devices), a removable memory chip (such as an EPROM, or PROM) and associated socket, and other removable storage units and interfaces which allow software and data to be transferred from the removable storage unit to the computer system.
The computer system may also include a communications interface. The communications interface allows software and data to be transferred between the computer system and external devices. Examples of the communications interface may include a modem, a network interface (such as an Ethernet card), a communications port, a PCMCIA slot and card, etc. Software and data transferred via the communications interface are in the form of signals which may be electronic, electromagnetic, optical or other signals capable of being received by the communications interface. These signals are provided to the communications interface via a communications path (i.e., channel). This channel carries signals and may be implemented using wire or cable, fiber optics, a phone line, a cellular phone link, an RF link and other communications channels.
In this document, the terms “computer program medium” and “computer usable medium” are used to generally refer to media such as a removable storage drive, a hard disk installed in a hard and signals. These computer program products are means for providing software to the computer system. The invention is directed to such computer program products.
Computer programs (also called computer control logic) are stored in main memory and/or secondary memory. Computer programs may also be received via a communications interface. Such computer programs, when executed, enable the computer system to perform the features of the present invention as discussed herein. In particular, the computer programs, when executed, enable the processor to perform the features of the present invention. Accordingly, such computer programs represent controllers of the computer system.
In an embodiment where the invention is implemented using software, the software may be stored in a computer program product and loaded into the computer system using the removable storage drive, hard drive or communications interface. The control logic (software), when executed by the processor, causes the processor to perform the functions of the invention as described herein.
In another embodiment, the invention is implemented primarily in hardware using, for example, hardware components such as application specific integrated circuits (ASICs). Implementation of the hardware state machine so as to perform the functions described herein will be apparent to persons skilled in the relevant art(s).
In yet another embodiment, the invention is implemented using a combination of both hardware and software.
IV. Conclusion
While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example, and not limitation. For example, the operational flows presented in FIGS. 2 AND 3 , are for example purposes only and the present invention is sufficiently flexible and configurable such that it may flow in ways other than that shown.
Further, it will be apparent to persons skilled in the relevant art that various changes in form and detail can be made therein without departing from the spirit and scope of the invention. Thus the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. | A method and computer program product which allows both phone-based and IP-based clients to participate in a single audio conference. The method enables at least two multi-point control units (MCUs) (i.e., conferencing servers) to connect via a standard data linkage (i.e., full-duplex dial-up or IP link). The method and computer program product enables the phone-based MCU to handle the phone clients and the IP-based MCU to handle the IP-based clients, while connecting the two to allow each participating client to hear all other participating clients. | 7 |
BACKGROUND OF THE INVENTION
PAR lamps of the glass sealed beam type commonly employ metal ferrule members that are fusion sealed to a plurality of raised bosses formed on the rear surface of the glass reflector member. Said ferrule members are generally formed as a cylindrical shell having one closed end and various type electrical terminals are commonly soldered to the closed end of the ferrule member. Electrical wire conductors are thereafter joined to said terminals by various means including screw connection, soldering, welding, and frictionally engaged connectors. Since the soldering of these conventional termination means can be labor intensive and further require that some part of the soldering be carried out during assembly of the PAR lamp in the end product, it would be advantageous to eliminate all soldering when joining electrical wire conductors to said lamp. It would be further advantageous to simplify construction of the termination means itself in achieving this objective.
Metal ferrule members having an inverted tapered contour are also known which provide increased mechanical strength when otherwise conventional electrical termination means are soldered thereto. More particularly, said prior art ferrule members are constructed with an inverted, tapered section at the closed or head end for physical engagement with a cap element of the electrical terminal secured thereto and with annular space between said elements being filled with solder. It becomes possible in this manner to reinforce the solder joint by achieving some mechanical interlocking between the joined parts to supplement the adhesive solder bond.
SUMMARY OF THE INVENTION
It has now been discovered that all of the foregoing objectives are provided with ferrule members having an inverted tapered wall section and which simply engage the electrical termination means by a physical gripping action. Specifically, the electrical termination means employed in the improved construction uses a dome-shaped metal contact element having flexible fingers to engage the inverted tapered wall section of the ferrule and dispense with any need for soldering to achieve a satisfactory electrical connection in many low voltage product applications. Said improved termination means further includes a terminal element secured to the dome-shaped metal contact element and which permits a wire conductor to be electrically connected directly thereto by a mechanical crimping action rather than soldering. The present improved sealed beam glass PAR lamp having said metal ferrule members fusion sealed to a plurality of raised bosses formed on the rear surface of the glass reflector member thereby includes each of said ferrule members having an inverted tapered wall section for engagement with electrical termination means solely by a physical gripping action, said electrical termination means comprising a dome-shaped metal contact element having flexible fingers that engage the inverted tapered wall section of the ferrule and further includes a terminal element for a wire conductor electrically connected thereto.
In a preferred embodiment, the ferrule members have a cylindrical body terminating in an inverted tapered head of smaller diameter and with said tapered head being frustoconical in shape. Said preferred lamp embodiment further includes a pair of metal ferrules being employed which are joined together with a strip of electrical insulation serving to physically support the assembled termination means.
In a different preferred embodiment, the ferrule members have a cylindrical body terminating in an inverted tapered head of smaller diameter and with said tapered head having an annular rim joined to the cylindrical body by a recessed wall section. In said preferred embodiment, the terminal element of the termination means may further include means to pierce the insulation of an insulated wire conductor when electrically connected thereto by mechanical crimping action.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 depicts a preferred PAR lamp design in accordance with the present invention.
FIG. 2 depicts a different PAR lamp design also made in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, there is shown an exploded view of a conventional all-glass sealed beam PAR lamp 12 with reflector member 13 being fusion sealed at the sealing rim region 14 to glass lens member 16. Raised bosses 18 and 20 formed on the rear surface of said glass reflector member 13 have metal ferrule members 22 and 24 fusion sealed thereto, respectively, in a conventional manner to provide the electrical connection to a light source located within the hermetically sealed lamp glass envelope. A conventional exhaust tube 25 also emerges from the rear of the glass reflector member in a conventional manner. Each of said ferrule members has a cylindrical body portion 28 terminating in a closed end or head 27 of smaller diameter and which further includes an inverted tapered wall section 28. A pair of dome-shaped metal contact elements 30 and 32 are employed for engagement with the aforementioned ferrule members, each of said metal contact elements having flexible fingers 34 extending from a cylindrical shank portion 36 that terminates in a larger diameter collar 38 for joinder to an electrical insulation strip forming part of said termination means. As can be further noted from the drawing, the flexible fingers 34 residing in the dome-shaped portion of said metal contact elements engage the inverted tapered wall section of the ferrule members to provide the sole means of achieving electrical connection to the light source in the lamp when said termination means has been assembled. The electrical insulation strip 40 employed in said termination means to mechanically reinforce the joinder of a pair of wire conductors (not shown) to the lamp termination includes a pair of openings 42 for conventional attachment of the contact elements in the termination means thereto. A pair of terminal elements 44 and 46 are also conventionally secured to said insulation strip beneath the collars 38 of the contact elements. An opening 48 in each of said terminal elements allows passage of the contact elements therethrough during assembly of the termination means with the collars 38 being thereafter formed during assembly. A pair of ear tabs 50 are located at one end of each contact element in order to secure a wire conductor to the termination means simply by mechanical crimping action.
In FIG. 2 there is shown a different preferred termination means of the present invention in exploded view for cooperative association with the modified ferrule member according to the present invention. More particularly, said modified ferrule member 52 has a cylindrical body portion 54 terminating in an inverted tapered head of smaller diameter 56 and with said tapered head 56 having an annular rim 58 joined to the cylindrical body by a recessed wall section 60. The dome-shaped contact element 62 that engages the inverted tapered head portion of said modified ferrule member by a physical gripping action utilizes flexible fingers 64 and further includes an opening 66 in the dome permitting passage therethrough of a fastener when joining said contact element to the terminal element 68 in said embodiment. Said terminal element 68 includes collar portion 70 that physically engages the contact element when joined thereto with a conventional rivet 72 and which is inserted through the openings 66 and 74 provided in both joined elements. At the opposite end of said terminal element 68, there is located connector means 76 for electrical connection of an insulated wire conductor (not shown) to the termination means depicted in said embodiment. Said connector means 76 includes a pair of semicircular shaped metal tabs 78 which further include barbs or tangs 80 in order to pierce the insulation of said wire conductor when the tabs are mechanically crimped together. It will again be noted that no need exists for soldering to provide said electrical connection according to the present invention.
It will be apparent from the foregoing description that various modifications may be made in the present terminal for a PAR lamp still within the spirit and scope of the present invention. For example, variations in the contact element structure are contemplated to accomodate specific mounting needs for a particular lamp installation or lighting circuit. It is thereby intended to limit the present invention, therefore, only by the scope of the following claims. | An improved sealed beam glass PAR lamp design is disclosed which employs a particular ferrule construction permitting electrical wire conductors to be connected thereto without soldering or screw terminals. The improved termination features physical engagement between the ferrule member and a metal contact element having flexible fingers to grip an inverted tapered wall section of said ferrule member. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 08/112,582, filed Aug. 25, 1993, now U.S. Pat. No. 5,464,563, to be issued Nov. 7, 1995.
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates generally to bleaching cellulosic materials, such as paper pulp, cotton and cotton blends and, more particularly, to a bleaching liquor of sodium hydroxide, optical brighteners and an enhanced hydrogen peroxide composition including a silicate-free stabilizer to produce goods which are soft, absorbent, silicate-free, and have excellent whiteness values.
(2) Description of the Prior Art
Today, the most common type of bleaching process is the oxidation method. This process involves contributing oxygen to the textile material which would result in permanent whiteness. The most common chemicals used in oxidation processes are: (1) Sodium hypochlorite; (2) Hydrogen peroxide; (3) Peracetic acid; and (4) Sodium chlorite.
Of the above four types, hydrogen peroxide is rapidly gaining in popularity because it is nonyellowing, nontoxic, and odorless. In addition, hydrogen peroxide does not have the effluent problem that is associated with chlorine bleaching. For example, during chlorine bleaching, there are chlorinated hydrocarbons that can be formed which are toxic priority pollutants.
Successful bleaching of cellulose which does not change the cellulose occurs when the formation of hydroxyl radicals (--OH) is kept to an absolute minimum. In contrast to the --OOH per anion, the --OH radical is extremely nucleophilic and damaging to the cellulose polymer, therefore, its formation at high temperatures is to be avoided when bleaching is the objective.
A conventional textile bleach bath contains: Sodium hydroxide, surfactant, optical brightener, and stabilizers (silicate or organic). These chemicals are generally mixed in single or multiple head (concentrate) tanks and are automatically diluted before the fabric is saturated.
Alkaline silicates have traditionally been used to stabilize H 2 O 2 under high temperature conditions at pH's 9-13 and in the presence of cotton fiber which carries a variety of inorganic and organic impurities. It is believed that the silicates, such as sodium silicate, potassium silicate, etc., act as a chelating agent to prevent the metals found in water and on the cotton from catalytically decomposing alkaline H 2 O 2 by --OH ion formation.
Because silicate/metal or cation complexes are not very soluble, it is common to see silicate deposits build up on cotton bleaching equipment. There are bleach systems that reduce the silicate levels to a few mg/L, but to date, no chemical system has effectively replaced all of the silicate used in textile bleaching despite the deposit problems and the fabric harshness created by silicate.
The use of organic chemical chelates, such as diethylene triamine pentacetic acid (DPTA), other amine chelates phosphates, and polyphosphonates, have dramatically reduced the amount of silicate necessary to produce finely bleached cotton. The efficiency of these chelates, however, can over stabilize alkaline bleach systems to the point that the H 2 O 2 will not form --OOH bleaching peranion at all. It is known that certain concentrations of bivalent cations, such as calcium or preferably magnesium, will allow for --OOH per anion formation in the presence of silicates and chelates. Therefore, the role of the chelates and silicates as bleach stabilizers is to prevent catalytic destabilization of alkaline H 2 O 2 that form --OH radicals by preferred chelation of transition metals in the presence of an excess of magnesium or calcium ion.
The success of bleaching cellulose with alkaline H 2 O 2 depends on producing, as the major H 2 O 2 decomposition product, perhydroxyl anion or --OOH. The chemical reaction can be shown as follows: ##STR1## The --OOH anion is non-nucleophilic in nature and releases its oxygen for bleaching slowly without reducing the molecular weight of the cellulose polymer, and its oxygen release can be controlled even at high temperatures by preventing transition metals from acting as catalysts.
Simple solutions of hydrogen peroxide are ineffective in bleaching without additives. However, unstabilized alkaline solutions of hydrogen peroxide produce too fast a rate of decomposition and thus must have a stabilizer to control the rate of hydrogen peroxide decomposition to force the predominant --OOH formation. For example, U.S. Pat. No. 4,363,699 teaches bleaching textile fabrics with hydrogen peroxide, sodium hydroxide and an alphahydroxyacrylic acid polymer stabilizer and U.S. Pat. No. 4,496,472 teaches using hydrogen peroxide, an alkali hydroxide and an oligomer of phosphonic acid ester stabilizer.
Prior bleaching solutions also have used sodium hydroxide along with sodium silicate for stabilization of hydrogen peroxide. For example, U.S. Pat. No. 4,337,060 teaches bleaching textile fabrics with potassium orthosilicate, water and hydrogen peroxide and with the reaction products of sodium silicate and potassium hydroxide. However, as discussed above, silicates form insoluble calcium and magnesium complexes and create a harsh hand on textile goods which can interfere with subsequent dyeing and sewing operations.
Thus, there remains a need for a new and improved bleaching process for paper pulp, cotton and cotton blends which rapidly bleaches to produce excellent whiteness while, at the same time, produces goods which are soft, absorbent, and silicate-free.
SUMMARY OF THE INVENTION
The present invention is directed to a bleaching composition for cellulosic materials such as paper pulp, cotton and cotton blends. The chemical system of the present invention includes a mixture of sodium hydroxide, optical brighteners and an enhanced hydrogen peroxide composition that includes a silicate-free stabilizer. In the preferred embodiment, the stabilized, silicate-free hydrogen peroxide composition includes a magnesium salt such as magnesium acetate, an aminoalkylphosphonic acid, dipicolinic acid, and the balance water. The resulting textile goods are soft, absorbent, silicate-free with a Hunter Scale whiteness of greater than about 85. Because a silicate-free stabilizer is used, low levels of fabric extractables are obtained.
Accordingly, one aspect of the present invention is to provide a liquid, silicate-free bleach composition for use in bleaching cellulosic materials including paper pulp, cotton and cotton blends. The composition includes: (a) between about 35 to 50 wt % of hydrogen peroxide; (b) between about 0.05 to 1.0 wt % of a magnesium salt; (c) between about 0.01 to 0.1 wt % an aminoalkylphosphonic acid; and (d) the balance water.
Another aspect of the present invention is to provide a stabilized, silicate-free, hydrogen peroxide composition for use in bleaching cellulosic materials including paper pulp, cotton and cotton blends. The composition includes: (a) between about 35 to 50 wt % of hydrogen peroxide; (b) a magnesium salt; (c) an aminoalkylphosphonic acid; and (d) the balance water.
Another aspect of the present invention is to provide a stabilized, silicate-free, hydrogen peroxide composition including: (a) between about 35 to 50 wt % of hydrogen peroxide; (b) between about 0.05 to 1.0 wt % a magnesium salt; (c) between about 0.01 to 1.0 wt % of an aminoalkylphosphonic acid; and (d) between about 0.01 to 0.1 wt % dipicolinic acid.
Another aspect of the present invention is to provide a liquid composition for use in bleaching cellulosic materials including paper pulp, cotton and cotton blends. The composition includes: (a) about 2 wt % of an alkali hydroxide; (b) about 3 wt % of a stabilized, silicate-free hydrogen peroxide composition including between about 35 to 50 wt % hydrogen peroxide, a magnesium salt and an aminoalkylphosphonic acid; and (c) the balance water.
Still another aspect of the present invention is to provide a method of bleaching cellulosic materials including paper pulp, cotton and cotton blends. The method includes the steps of: (a) providing a bleach liquor including an alkali hydroxide, hydrogen peroxide, a silicate-free stabilizer including a magnesium salt and an aminoalkylphosphonic acid and water; (b) immersing the cellulosic material in the bleach liquor of step (a); and (c) separating the bleach liquor from the cellulosic materials.
These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following description, it is to be understood that such terms as "forward", "rearward", "left", "right", "upwardly", "downwardly", and the like are words of convenience and are not to be construed as limiting terms.
The present invention is a mixture of chelates and a highly purified form of a magnesium salt that is storage stable in commercial strengths of 35% and 50% H 2 O 2 . When the enhanced hydrogen peroxide stabilizer of the present invention is used along with sodium hydroxide and optical brighteners in bleaching, omission of additional stabilizers is possible while producing a satisfactory bleach. The present invention maintains stability of stock grades of H 2 O 2 , i.e. 35% and 50% strengths, in storage without producing decomposition of these high strength H 2 O 2 solutions.
In the stabilized hydrogen peroxide compound of the invention, a variety of magnesium salts may be used to form the silicate-free stabilizer. The anion may selected from a variety of organic or inorganic anions, such as acetate, sulfate, or chloride. In examples 1-51 set forth below, magnesium acetate was used in the stabilizer. In examples 51-68 set forth below, another magnesium salt, magnesium sulfate, was used in the stabilizer. It important that the magnesium salt be very pure and therefore have sufficiently low iron, copper and other multivalent metal levels to be stable to add high strength H 2 O 2 solutions. Even low ppm (mg/L) levels of these multivalent metals can cause explosive decomposition of concentrated H 2 O 2 solutions. The present invention provides good hydrogen peroxide stabilization, even at elevated storage temperatures.
For examples 1-51 shown below, magnesium acetate was prepared by mixing very high grade magnesium oxide (MgOH or MgO) powder and glacial acetic acid with water. One source of magnesium oxide is sold under the tradename Magox 98 HR by Premier Refractories and Chemicals of Cleveland, Ohio. The tank was first charged with water. The organic acid was then added while mixing. The magnesium oxide was then added slowly while mixing. Heat will be generated due to the exothermic reaction. The mixture is continued to be mixed for one hour. After mixing, the mixture is cooled and filtered through a one micron filter. Final pH of the mixtures were in the range of 3.0 to 5.0 depending on the acid concentration.
For examples 52-68 shown below, the magnesium sulfate was a conventional reagent grade. According to the present invention, paper pulp, cotton and cotton blends are bleached in a conventional manner. The bleaching concentrate of the present invention is made using the following chemicals and percentages (percentages based on the weight of the bath (O.W.B.) at a 10:1 ratio of concentrate to bath:
(1) 2% sodium hydroxide-50%
(2) 3% enhanced hydrogen peroxide-35/50%
In addition, the following additional additives may be used:
(3) 2.1% wetter-scour
(4) 0.9% optical brighteners
The specific formulation for the enhanced hydrogen peroxide silicate-free stabilizer was determined by experimental design utilizing various amounts of 50% hydrogen peroxide, a magnesium salt, an aminoalkylphosphonic acid and dipicolinic acid.
In the preferred embodiment, 1-hydroxyethylidene--1, 1-diphosphonic acid--sold under the tradenames Dequest 2010 and Mayoquest 1500--are used as the aminoalkylphosphonic acid. Other derivatives or substituted phosphonic acids which should be suitable include: aminotri (methylenephosphonic acid)--Dequest 2000 and Mayoquest 1320; diethylenetriaminepenta (methylenephosphonic acid)--Dequest 2060 and Mayoquest 1860; N-sulfonic acid--N, N-di(methylenephosphonic acid)--Mayoquest 1100; glycine --N,N-di(methylenephosphonic acid)--Mayoquest 1200; N-(2-hydroxyethyl)-N, N-di(methylenephosphonic acid)--Mayoquest 1352; ethylenediaminetetra (methylenephosphonic acid)--Dequest 2041; and hexamethylenediaminetetra (methylenephosphonic acid)--Dequest 2051.
The present invention can best be understood after a review of the following examples:
EXAMPLES 1-17
Various amounts of 50% hydrogen peroxide, 30% active magnesium acetate, 60% active phosphonic acid and dipicolinic acid were mixed together and tested for hydrogen peroxide retention at 49° C. for up to 37 days.
Table 1 compares the long term stability of the above mixtures by measuring the % retained activity of the solution.
TABLE 1______________________________________Stability Values for Various Additions ofMgAC, Phosphonic, and Dipicolinic AcidsH.sub.2 O.sub.2 -50 MgAC-30 Phosph-60 Dipi % RetainedEx. % % % % Activity______________________________________ 1 98.10 0.150 1.500 0.25 96.0 2 97.00 1.500 1.000 0.50 98.0 3 97.00 1.000 1.500 0.50 106.0 4 98.40 1.500 0.100 0.00 98.0 5 97.00 1.500 1.500 0.00 99.0 6 99.25 0.650 0.100 0.00 92.0 7 98.57 0.825 0.100 0.50 109.0 8 98.10 0.150 1.500 0.25 101.0 9 97.70 1.500 0.800 0.00 103.010 97.00 1.500 1.500 0.00 106.011 99.25 0.150 0.100 0.50 100.012 99.25 0.150 0.100 0.50 96.013 97.67 0.825 1.500 0.00 100.014 99.25 0.150 0.600 0.00 106.015 98.80 0.150 1.050 0.00 107.016 97.90 1.500 0.100 0.50 101.017 98.13 0.825 0.800 0.25 102.0______________________________________
As can be seen, there is a good effect from combinations of MgAC, an aminoalkylphosphonic acid, and dipicolinic acid with the major stabilization effects seen with MgAC and an aminoalkylphosphonic acid.
EXAMPLES 18-34
Various amounts of 50% hydrogen peroxide, 30% active magnesium acetate, 60% active phosphonic acid and dipicolinic acid were mixed together and tested for alkali stability during bleaching. The bleaching bath, sans fabric, contained 2% enhanced peroxide and 4% NAOH-50%. The bath temperature was 190° F. and was held for 30 minutes.
Table 2 compares the alkali stability of the above mixtures.
TABLE 2______________________________________Stability Values for Various Additions ofMgAC, Phosphonic, and Dipicolinic Acids H.sub.2 O.sub.2 -50 MgAC-30 Phosph-60 Dipi Alk-StabEx. % % % % % loss______________________________________18 98.10 0.150 1.500 0.25 28.719 97.00 1.500 1.000 0.50 0.020 97.00 1.000 1.500 0.50 1.021 98.40 1.500 0.100 0.00 0.022 97.00 1.500 1.500 0.00 0.023 99.25 0.650 0.100 0.00 5.324 98.57 0.825 0.100 0.50 3.325 98.10 0.150 1.500 0.25 28.526 97.70 1.500 0.800 0.00 3.127 97.00 1.500 1.500 0.00 1.028 99.25 0.150 0.100 0.50 31.829 99.25 0.150 0.100 0.50 37.830 97.67 0.825 1.500 0.00 14.131 99.25 0.150 0.600 0.00 38.332 98.80 0.150 1.050 0.00 51.633 97.90 1.500 0.100 0.50 43.034 98.13 0.825 0.800 0.25 8.5______________________________________
The less available oxygen loss (AVOX) indicates stable --OOH anion formation and a resistance to --OH radical decomposition of the H 2 O 2 . When zero % AVOX loss is seen, the effect of the stabilizer chemistry is clearly evident.
EXAMPLES 35-51
Test runs were made with a conventional bleaching range under the conditions described below for various dwell times and temperatures. Articles are introduced into the first section of the bleaching range as follows: The water in the range is preheated to 200° F. and the first section is filled with 10 gallons of the above bleaching concentrate per 100 gallons water. The liquor ratio is maintained at approximately 10:1 (10 parts water to 1 part fabric). Enough sections of the bleach range are used to allow the fabric a dwell time of 8 minutes. The treated goods were soft, absorbent, silicate-free, and had excellent whiteness values on a Hunter Scale of greater than about 85.
Table 3 compares the whiteness of the goods measured according to the Hunter Whiteness Scale. The caustic soda-50% and other additives, and the temperature is the same as Table 2.
TABLE 3______________________________________Whiteness Values for Various Additions ofMgAC, Phosphonic, and Dipicolinic AcidsH.sub.2 O.sub.2 -50 MgAC-30 Phosph-60 Dipi WhitenessEx. % % % % Hunter______________________________________35 98.10 0.150 1.500 0.25 86.836 97.00 1.500 1.000 0.50 85.737 97.00 1.000 1.500 0.50 88.138 98.40 1.500 0.100 0.00 87.539 97.00 1.500 1.500 0.00 87.240 99.25 0.650 0.100 0.00 86.941 98.57 0.825 0.100 0.50 85.042 98.10 0.150 1.500 0.25 83.543 97.70 1.500 0.800 0.00 87.544 97.00 1.500 1.500 0.00 75.245 99.25 0.150 0.100 0.50 86.246 99.25 0.150 0.100 0.50 86.947 97.67 0.825 1.500 0.00 88.248 99.25 0.150 0.600 0.00 87.549 98.80 0.150 1.050 0.00 87.350 97.90 1.500 0.100 0.50 87.051 98.13 0.825 0.800 0.25 88.1______________________________________
EXAMPLES 52-68
Various amounts of 50% hydrogen peroxide, 25% active magnesium sulfate (magnesium sulfate is slightly less soluble than magnesium acetate), 60% active phosphonic acid and dipicolinic acid were mixed together and tested for alkali stability during bleaching. The bleaching bath, sans fabric, contained 2% enhanced peroxide and 4% NAOH-50%. The bath temperature was 190° F. and was held for 30 minutes.
Table 4 compares the alkali stability of the above mixtures.
TABLE 4______________________________________Stability Values for Various Additions ofMgSO4, Phosphonic, and Dipicolinic Acids H.sub.2 O.sub.2 -50 MgSO-25 Phosph-60 Dipi Alk-StabEx. % % % % % loss______________________________________52 98.08 0.17 1.50 0.25 0.0053 96.80 1.70 1.00 0.50 0.0054 96.87 1.13 1.50 0.50 0.0055 98.20 1.70 0.10 0.00 0.0056 96.80 1.70 1.50 0.00 0.0057 99.17 0.73 0.10 0.00 0.0058 98.47 0.93 0.10 0.50 0.0059 98.08 0.17 1.50 0.25 4.1760 97.50 1.70 0.80 0.00 0.0061 96.80 1.70 1.50 0.00 0.0062 99.23 0.17 0.10 0.50 0.0063 99.23 0.17 0.10 0.50 0.0064 97.57 0.93 1.50 0.00 0.0065 99.23 0.17 0.60 0.00 0.0066 98.01 0.17 1.05 0.00 0.0067 97.70 1.70 0.10 0.50 0.0068 98.02 0.93 0.80 0.25 0.00______________________________________
The less available oxygen loss (AVOX) indicates stable --OOH anion formation and a resistance to --OH radical decomposition of the H 2 O 2 . When zero % AVOX loss is seen, the effect of the stabilizer chemistry is clearly evident. Compared to the MgAC additions shown in Table 2, the reagent grade MgSO 4 further enhanced peroxide stability.
As can be seen from Tables 1-4, good bleach bath stabilities, good storage stability of the enhanced commercial peroxide solutions, and excellent whiteness values were obtained by enhanced peroxide solutions at 2% owg. and 4% NAOH-50 at 190° F. for 30 minutes.
Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. It should be understood that all such modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the following claims. | A bleaching composition for cellulosic materials such as paper pulp, cotton and cotton blends. The chemical system of the present invention includes a mixture of sodium hydroxide, optical brighteners and an enhanced hydrogen peroxide composition including a silicate-free stabilizer. In the preferred embodiment, the silicate-free stabilizer includes a magnesium salt; an aminoalkylphosphonic acid; dipicolinic acid; and the balance water. The resulting textile goods are soft, absorbent, silicate-free with a Hunter Scale whiteness of greater than about 85. Because a silicate-free stabilizer is used, low levels of extractable solids are obtained. | 3 |
BACKGROUND OF THE INVENTION
This invention relates to optical local area networks, and more particularly to a low cost active node design.
Over the last several years, a number of local area network architectures have evolved to support data communications for a large user population. With the recent emergence of the personal computer, network control cards have been developed to permit these computers to be used as intelligent work stations for local area network applications. Most of these local area network cards employ coaxial cable as the transmission medium. This transmission medium has been used in both the baseband and broadband modes. With the rapid emergence of fiber optic technology, optical fiber has been examined as an alternative to coaxial cable in a number of local area network designs. Recently, several fiber optic components have been developed that can dramatically reduce the cost of integrating this technology into local area network designs.
In U.S. Ser. No. 777,934, filed Sept. 19, 1985, there is disclosed and claimed an active star network node design employing passive optical stars. The teachings of U.S. Ser. No. 777,934 are incorporated herein by reference. Although active star nodes employing optical stars can accommodate high data rate protocols such as Ethernet, these nodes are quite expensive. In addition, the nodes employing passive optical stars are heavy and relatively bulky. Furthermore, the optical star elements suffer splitter losses which degrade system performance.
It is therefore an object of the present invention to provide an optical node which is a fraction of the weight and size of known nodes and having a component cost about one-fifth the known design.
Yet another object of the invention is a low cost node that eliminates the splitter losses associated with nodes employing optical star elements.
SUMMARY OF THE INVENTION
These and other objects of the present invention are achieved by an optical node including a plurality of optical receivers, each receiver connected by fiber optic cables to one of a plurality of user terminals. The electrical outputs of each of the optical receivers are electrically combined. The node also includes a plurality of optical transmitters each of which is connected by fiber optic cables to one of the user terminals. Apparatus is provided for splitting the electrical output of the receivers for driving each of the transmitters. The node may be used both as a head-end or as a repeater.
BRIEF DESCRIPTION OF THE DRAWING
The invention disclosed herein will be understood better with reference to the drawing of which:
FIG. 1 is a block diagram of the active node disclosed herein; and
FIG. 2 is a block diagram of a hardware implementation of the node.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Active optical nodes can be configured to serve both as head-end nodes and repeater nodes. When configured as a head-end, the node receives information from user terminals and rebroadcasts this information to all of the user terminals on the network. When the node is utilized in the repeater or concentrator mode, the information is transmitted to a higher order node. In late 1985, fiber optic components suitable for integration into a local area network implementation were introduced. See, D. W. Tsui, "New Family of Miniature Fiber Optic Components Designed to Save You Money", the 9th International Fiber Optic Communications and Local Area Network Exposition (FOC/LAN 85), pp. 171, September 1985. With the availability of these low cost components, it became evident that a very affordable network node could be produced. In particular, low cost optical receivers and transmitters became available. An active star node 10 using low cost components is shown in FIG. 1. The node 10 includes a plurality of optical receivers 12 and a plurality of optical transmitters 14. In FIG. 1, a single user terminal 16 is connected to the node 10. In particular, a transmitter 18 of the user terminal 16 is connected by a fiber optic cable 20 to a receiver 22. Similarly, a receiver 24 of the user terminal 16 is connected by a fiber optic cable 26 to a transmitter 28. It is to be understood that other user terminals (not shown) would be connected to the remaining receivers 12 and transmitters 14 of the active node 10. Thus, it is seen that in the present implementation, a fiber optic receiver 12 is dedicated to each of the inbound user lines. The outputs of the receivers 12 are electrical signals which are electrically combined in a combiner logic element 30. As shown in FIG. 1, the node 10 is in the head-end configuration so that the combined electrical signal from the combiner logic element 30 is connected to a splitter logic element 32 which distributes the composite electrical signal to the array of optical transmitters 14. The array of optical transmitters 14, such as the optical transmitter 28 broadcasts the signal to each of the attached receivers such as the receiver 24 associated with the user terminal 16. If the node 10 is to be used in a repeater or concentrator mode, the combined electrical signal from the combiner logic element 30 is passed to a dedicated transmitter 34 forming an expansion port by means of a switch 36 so that transmission may proceed toward a higher order node (not shown). Similarly, an expansion port receiver 38 receives signals from a higher order node (not shown) and is converted to electrical format and split by the splitter logic element 32. The array of transmitters 14 then sends an optical signal to each of the users, such as the terminal 16, supported by the node. The low cost node 10 is a fraction of the weight and size of a corresponding node utilizing optical stars, and the component cost is about one-fifth as much. The major advantage of the present design is that the links between the user and the node are now point-point; thus, the system does not suffer the splitter losses attributed to optical star elements. Without these splitter losses, low cost modem to low cost node power margins match almost exactly the power margins that can be obtained from the higher performing modem and node components disclosed in U.S. Ser. No. 777,934. However, the low cost node 10 will support data rates only up to 5 Mb/s. For many applications, this data rate is more than adequate.
A hardware mechanization of the node 10 will now be described in conjunction with FIG. 2. At the left hand side of the logic diagram of FIG. 2 are shown eight receiver units 12. Suitable receivers 12 are manufactured by Hewlett-Packard under the designation HFBR 2402. The only additional components necessary to support each of the receivers are a 2200-ohm pull-up resister 40 and a decoupling capacitor 42. The outputs from each of the receivers 12 are combined in two 7408 quad AND gates 44 and 46. When the head-end/repeater switch 48 is in the head-end position as shown in FIG. 2, the combined receiver signal is sent to a splitter array consisting of two 7404 inverter devices 50 and 52. The inverter devices 50 and 52 invert the signal (compensating for the inversion in the receivers 12) and acts as a driver for the optical transmitters 14. The optical transmitters 14 are driven in a shunt configuration. Suitable transmitters 14 are manufactured by Hewlett-Packard under the designation HFBR 1404. Each of the transmitters 14 is driven by a pair of 74128 line drivers 54 and a resistor/capacitor network 56.
To operate the low cost active star node 10 in the repeater mode, the head-end/repeater switch 48 is set to the EX position. In that position, the receiver information from a ninth receiver 58 associated with an expansion port is used as the drive signal to the eight optical transmitters associated with users' terminal equipment on the node. In a similar manner, the composite information from the eight optical receivers associated with users' equipment on the node is routed to a ninth optical transmitter 60 dedicated to operation on the expansion port. To service this expansion port receiver 58, an additional 74128 logic device 62, and a resistor/capacitor network 64 are required.
A prototype of the node disclosed herein has been constructed at The Mitre Corporation. The logic devices on this prototype model were all mounted on a single wire wrap board and interconnected with standard wire wrap technology. The nine optical transmitters and nine optical receivers were mounted on one wall of the enclosure in transmit/receiver pairs. Only 5 volts were required to power this logic, and this voltage was supplied from a small external supply. The prototype unit was constructed in a cast metal box 71/4 inches long by 43/4 inches wide by 2-inches high.
At present, the bandwidth of the low cost components is restricted to 5 MHz. The fiber optic transmitter described above can perform to 50 MHz, but the receiver design is the limitation. A low cost complementary component is available with just an optical detector and preamplifier that can function at data rates up to 50 MHz. With the availability of such a receiver unit, the technology described in this patent application could be extended to encompass other higher rate protocols such as Ethernet.
It is thus seen that the objects of this invention have been achieved in that there has been disclosed a low cost active node for interconnecting a plurality of user terminals in a fiber optic network. The node uses low cost optical receivers and transmitters and has the advantage that the links between the user and the node are point-point so that the system does not suffer the splitter losses attributed to optical star elements in other node designs. With low cost modems and the active star nodes disclosed herein, the total network cost of fiber optic local area networks becomes attractive when compared with coaxial installations, even at modest data rates. It is recognized that modifications and variations of the present invention will occur to those skilled in the art and it is intended that all such modifications and variations be included within the scope of the appended claims. | The node includes plural optical receivers and transmitters. Each receiver and each transmitter of the node is connected to a user terminal by fiber optic cables. The output of each of the node receivers is electrically combined. Splitting logic is also included for splitting the electrical output of the receivers to serve as an input to the plural optical transmitters. The node may be used as an expansion mode or as a head-end unit. The optical receivers and transmitters have a low cost so that the overall node is approximately one fifth the cost of comparable nodes utilizing passive optical stars. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to a detergent composition containing an organosilane compound. The detergent compositions of this invention are intended for use on hard, i.e. metallic and vitreous surfaces. More particularly, the inclusion of the hereindescribed organosilane compound in detergent compositions provides soil release benefits to surfaces washed with such compositions.
Detergent compositions intended for use on hard surfaces are continually being reformulated in order to improve their performance. Generally, detergent compositions are formulated to obtain optimum cleaning performance. Such endeavors have revolved around the use of different organic detergents as well as the use of detergent builders and various additives, e.g., enzymes, bleaches and pH modifiers. Considerations such as human safety, compatibility of components, and equipment safety have played a part in dictating what components can be used for improving existing detergent compositions.
Other attempts at insuring that hard surfaces are clean have involved the application of various surface coatings to such hard surfaces. For example, cookware which has been coated with Teflon provides a surface which is easier to clean. Thus, while soil continues to deposit upon the surface, its removal is easier by virtue of the coating. Unfortunately, such coatings are relatively expensive. Moreover, such a coating on glassware would be objectionable due to its appearance and/or feel. Since this kind of a coating must be applied by the manufacturer of the cookware or glassware, it must be permanent; this generally involves a relatively heavy coating with the consequent drawback in terms of cost, appearance, and/or feel.
It has been discovered that a very thin layer of a compound possessing soil release benefits can be supplied to metallic and vitreous surfaces by a detergent composition. Thus, when the detergent composition is used for cleaning or washing the hard surface, a thin semi-permanent coating of the compound is deposited. The amount of coating is sufficient to provide a soil release benefit to the surface, while at the same time, is not visible or expensive.
It accordingly is an object of this invention to provide detergent compositions which are capable of imparting a soil release benefit to surfaces contacted therewith.
It is another object of this invention to provide detergent compositions containing an organosilane which are able to efficiently provide soil release benefits to metallic and vitreous surfaces when applied thereto form a dilute wash or rinse solution.
Still another object of this invention is to provide a method for imparting a soil release benefit to hard surfaces.
As used herein, all percentages and ratios are by weight unless otherwise indicated.
SUMMARY OF THE INVENTION
A detergent composition capable of imparting soil release benefits to metallic and vitreous surfaces contacted therewith consisting essentially of:
a. an organosilane having the formula ##STR1## or is siloxane oligomer thereof wherein R 1 is an alkyl group containing 1 to 4 carbon atoms,
(CH.sub.3).sub.3 Si or Z(OC.sub.x H.sub.2x).sub.m
where x is 2 to 4, m is 1 to 20, and Z is hydrogen, an alkyl group containing 1 to 18 carbons or an acyl group containing 1 to 4 carbon atoms; R 2 is an alkyl group containing 1 to 18 carbon atoms; a is 0 to 2; R 3 is hydrogen or an alkyl group containing 1 to 18 carbon atoms; b is 1 to 3; c is 0 or 1; R 4 is an alkyl, aryl or arylalkyl group containing 1 to 12 carbon atoms, a carboxy-substituted alkyl group containing 1 to 4 carbon atoms,
(C.sub.X H.sub.2x O).sub.m Z
where x, m and Z are as defined above, or oxygen provided only one R 4 is oxygen; R 5 is an alkyl, aryl or arylalkyl group containing 1 to 22 carbon atoms; X is halide; and Y is nitrogen, sulfur or phosphorus; and
b. a water-soluble organic detergent selected from the group consisting of nonionic, zwitterionic and ampholytic detergents and mixtures thereof in a weight ratio of organosilane to detergent of from 2:1 to 1:10,000.
DESCRIPTION OF THE INVENTION
The subject invention relates to all manner of detergent compositions. As examples, may be mentioned the following: automatic dishwasher detergent compositions intended for home use, commercial dishwasher detergent compositions, light duty liquid detergent compositions, car wash detergent compositions, rinse aids, window cleaners, toilet bowl cleaners and oven cleaners. The previous listing is merely illustrative and is in no way limiting. Such compositions are further described hereinafter. The compositions may be used on any metallic or vitreous surface where a soil release benefit is desired. Examples of such surfaces are cooking utensils (e.g., metallic pots, pans and skillets), tableware (e.g., china, glasses, ceramic ware, and flatware), oven walls, automobiles, windows, and porcelain surfaces (e.g., bathtubs, sinks and toilet bowls).
The detergent compositions of this invention contain an organosilane and a water-soluble organic nonionic, zwitterionic and/or ampholytic detergent in a ratio of organosilane to detergent of from 2:1 to 1:10,000, preferably 1:1 to 1:500, most preferably 1:3 to 1:60. The organosilane has the following formula: ##STR2## or is a siloxane oligomer thereof wherein R 1 is an alkyl group containing 1 to 4 carbon atoms,
(CH.sub.3).sub.3 Si or Z(OC.sub.x H.sub.2x).sub.m
where x is 2 to 4, m is 1 to 20, and Z is hydrogen, an alkyl group containing 1 to 18 carbon atoms or an acyl group containing 1 to 4 carbon atoms; R 2 is an alkyl group containing 1 to 18 carbon atoms; a is 0 to 2; R 3 is hydrogen or an alkyl group containing 1 to 18 carbon atoms; b is 1 to 3; c is 0 or 1; R 4 is an alkyl, aryl or arylalkyl group containing 1 to 12 carbon atoms, a carboxy-substituted alkyl group containing 1 to 4 carbon atoms,
(C.sub.x H.sub.2x O).sub.m Z
where x, m and Z are as defined above, or oxygen provided only one R 4 is oxygen; R 5 is an alkyl, aryl or arylalkyl group containing 1 to 22 carbon atoms; X is halide; and Y is nitrogen, sulfur or phosphorus. Preferably X is chloride or bromide and b is 1.
It should be understood that the R 4 in the above formula and the formulae to follow may be the same or different. It should further be understood that when Y is S, there will be only one R 4 substituent. Also, when one R 4 is oxygen or, under acidic conditions, the anion of a carboxylic acid substituted alkyl, the counter ion X - is not extant. The 1 to 4 carbon atoms in the carboxy-substituted alkyl group is inclusive of the carboxyl group. The aryl or arylalkyl groups of R 4 and R 5 contain 6 to 12 carbon atoms and 6 to 22 carbon atoms, respectively.
Classes of organosilane compounds and their preparation which fit the above description follow. ##STR3## wherein R 1 is a C 1 -4 alkyl group, b is from 1-3, R 4 is a C 1 -12 alkyl, aryl or arylalkyl group, a carboxy-substituted C 1 -4 alkyl group,
(C.sub.x H.sub.2x O).sub.m Z
where x is 2-4, m is 1-20, and Z is hydrogen, a C 1 -18 alkyl group or a C 1 -4 acyl group, or oxygen provided only one R 4 is oxygen, R 5 is a C 4 -22 alkyl, aryl or arylalkyl group, X is a halide, and Y is N, S or P.
When b is 3 and R 4 is a C 1 -12 alkyl, aryl or arylalkyl group, the class of compounds represented by Formula I is prepared by the following route: ##STR4##
The trihalosilane (where the halogen is chlorine or bromine) is reacted with the allyl chloride at about 100° C. for from 4 to 10 hours in the presence of a catalyst, e.g., chloroplatinic acid or platinum. The resultant gamma-halopropyltrihalosilane is reacted with a lower alcohol to produce the gamma-halopropyltrialkoxysilane. At least three equivalents of alcohol per equivalent of halopropyltrihalosilane are added slowly to the silane. The gamma-halopropyltrihalosilane may be dissolved in an inert solvent, preferably hexane or pentane. (See W. Noll, "Chemistry and Technology of Silanes," Academic Press, New York, 1968, page 81 for the alcoholysis of halosilanes.) One equivalent of the gamma-halopropyltrialkoxysilane is reacted with one equivalent of the tertiary amine, tertiary phosphine, or dialkylsulfide to produce the organosilane. An inert solvent, preferably of high dielectric constant, may be used. The reaction is carried out at temperatures of from 40° C. to 120° C. and a time of 2 to 10 hours for the reaction of the bromopropyltrialkoxysilane and 120° C. to 150° C. for 2 to 20 hours for the reaction of the chloropropyltrialkoxysilane.
The compounds of Formula I when at least one R 4 is a carboxy-substituted C 1 -4 alkyl group are prepared in the same manner except for the last reaction step. Here, a tertiary amine, tertiary phosphine or dialkylsulfide having a carboxy-containing alkyl group(s) is reacted with the alpha, beta or gamma-haloalkyltrialkoxysilane at 50° C. to 200° C. for 2 hours to 20 hours. Such carboxy-substituted tertiary amines, tertiary phosphines, and dialkylsulfides are produced by reacting
R.sub.4 YHR.sub.5 or HYR.sub.5 (where Y is sulfur)
with
X(CH.sub.2).sub.1.sub.-4 COOH
in the presence of base at elevated temperatures, e.g. 50° C. to 150° C.
The compounds of Formula I when at least one R 4 is
(C.sub.x H.sub.2x O).sub.m Z
with X, m and Z as defined above are produced in the manner given above except for the last reaction step. Thus, alpha- beta- and gamma-haloalkyltrialkoxysilane is reacted with a tertiary amine, tertiary phosphine, or dialkylsulfide where at least one substituent is
(C.sub.x H.sub.2x O).sub.m Z
the reaction takes place at a temperature of 50° C. to 200° C. and a time of from 2 to 10 hours.
Compounds of Formula I when one R 4 is oxygen are prepared by following the reactions outlined above up to the last reaction step. At this point, a dialkyl amine, dialkyl phosphine or alkylthiol is reacted with the halosilane at 50° C. to 200° C. for from 4 to 10 hours and then with base to produce an intermediate tertiary amine, phosphine, or dialkyl sulfide. These intermediates are then reacted with H 2 O 2 at 20° C. to 100° C. or preferably O 3 in an inert solvent at -80° C. to 20° C. to yield the organosilane.
When b is 2 in Formula I, a trihalovinylsilane of formula
X.sub.3 SiCH=CH.sub.2
(which is commercially available) is reacted with hydrogen bromide in the presence of peroxide or light to produce a beta-haloethyltrihalosilane. This compound is reacted with an alcohol and thereafter with an appropriate amine, phosphine, or sulfide in the manner discussed above for the preparation of the compounds of Formula I when b is 3.
When b is 1 in Formula I, the starting reactant is a commercially available trihalomethylsilane of formula
X.sub.3 SiCH.sub.3.
this silane is reacted with chlorine or, preferably a half mole of bromine and a half mole of chlorine in the presence of light (such as provided by an ordinary tungsten or fluorescent lamp). The resultant alpha-halomethyltrihalosilane is reacted with an alcohol and thereafter an appropriate amine, phosphine or sulfide in the manner discussed above with the compounds of Formula I when b is 3.
Examples of compounds illustrative of compounds of Formula I follow:
(CH 3 O) 3 SiCH 2 N + (CH 3 ) 2 C 16 H 33 Cl -
(CH 2 H 5 O) 3 SiCH 2 N + (CH 3 ) 2 C 6 H 5 Cl -
(C 2 H 5 O) 3 Si(CH 2 ) 3 N + (C 2 H 5 ) 2 C 10 H 21 Br -
(C 3 H 7 O) 3 SiCH 2 N + (C 3 H 7 ) 2 C 6 H 4 CH 3 Br -
(C 4 H 9 O) 3 Si(CH 2 ) 2 N + (C 2 H 5 )(CH 2 C 6 H 5 ) 2 Cl -
(CH 3 O) 3 SiCH 2 P + (C 2 H 5 ) 2 C 12 H 25 Cl -
(C 2 H 5 O) 3 Si(CH 2 ) 3 P + (C 4 H 9 ) 2 C 6 H 5 Cl -
(C 3 H 7 O) 3 Si(CH 2 ) 2 S + (CH 3 )C 6 H 5 Cl -
(CH 3 O) 3 SiCH 2 CH 2 S + (C 2 H 5 )C 16 H 33 Br -
(CH 3 O) 3 SiCH 2 N + (C 2 H 4 COOH) 2 C 10 H 21 Br -
(C 2 H 5 O) 3 Si(CH 2 ) 3 N + (CH 2 COOH)(CH 3 )C 12 H 25 Cl -
(C 2 H 5 O) 3 Si(CH 2 ) 2 P + (C 3 H 6 COOH)C 2 H 5 )C 10 H 21 Cl -
(C 4 H 9 O) 3 SiCH 2 S + (C 3 H 6 COOH)C 6 H 13 Br -
(CH 3 O) 3 SiCH 2 N + (C 2 H 4 OH) 2 C 18 H 37 Cl -
(C 4 H 9 O) 3 Si(CH 2 ) 3 P + (C 3 H 6 OH) 2 C 6 H 4 CH 3 Cl -
(C 2 H 5 O) 3 SiCH 2 S + (C 3 H 6 OH)C 14 H 29 Cl -
(CH 3 O) 3 SiCH 2 N + (O) - (CH 3 )C 14 H 29
(c 2 h 5 o) 3 si(CH 2 ) 3 P + (O) - (C 2 H 5 )C 12 H 25
(c 2 h 5 o) 3 si(CH 2 ) 2 S + (O) -C 10 H 21
(ch 3 o) 3 siCH 2 N + [(C 2 H 4 O) 3 H](CH 3 )C 8 H 17 Cl -
(CH 3 O) 3 Si(CH 2 ) 2 N + [(C 4 H 8 O) 15 CH 3 ](CH 3 )C 6 H 13
(c 2 h 5 o) 3 si(CH 2 ) 3 N + [(C 2 H 4 O) 6 H] 2 C 10 H 21 Cl -
(CH 3 O) 3 SiCH 2 N + [(C 2 H 4 O) 3 COCH 3 ] 2 C 8 H 17 Cl -
(C 3 H 7 O) 3 SiCH 2 P + [(C 3 H 6 O) 12 H] 2 CH 2 C 6 H 5 Cl -
(C 4 H 9 O) 3 Si(CH 2 ) 3 P + [(C 2 H 4 O) 4 C 4 H 9 ] CH 3 C 4 H 9 Br -
(CH 3 O) 3 Si(CH 2 ) 2 P + [(C 2 H 4 O) 5 COC 2 H 5 ] 2 C 4 H 9 Br -
(CH 3 O) 3 SiCH 2 S + [(C 2 H 4 O) 5 H]C 10 H 21 Cl -
(C 2 H 5 O) 3 Si(CH 2 ) 2 S + [(C 3 H 6 O) 8 C 3 H 7 ]C 4 H 9 Br -
(CH 3 O) 3 Si(CH 2 ) 3 S + [(C 2 H 4 O) 12 COC 4 H 9 ]C 12 H 25 Cl - ##STR5## where R 1 is a C 1 -4 alkyl group, R 2 is a C 1 -18 alkyl group a is 1 or 2, b is 1-3, R 4 is a C 1 -12 alkyl, aryl or arylalkyl group, a carboxy-substituted C 1 -4 alkyl group,
(C.sub.x H.sub.2x O).sub.m Z
where x is 2-4, m is 1-20, and Z is hydrogen, a C 1 -18 alkyl group or a C 1 -4 acyl group, or oxygen provided only one R 4 is oxygen, R 5 is a C 1 -22 alkyl, aryl or arylalkyl group, X is halide, and Y is N, S or P.
The compounds of Formula II are prepared in a manner similar to the preparation of the compounds of Formula I except for the fact that the starting reactants (when b is 1, 2, or 3) all have a C 1 -18 alkyl group or two C 1 -18 alkyl groups attached to the Si atom in place of a halogen atom(s). The starting reactant is commercially available when R 2 is CH 3 . When R 2 is C 2 H 5 or greater, the compound is prepared by reacting a silane with an appropriate olefin. Thus,
X.sub.3.sub.-a SiH.sub.1.sub.+a
is reacted with a C 2 to C 18 olefin to obtain the desired starting reactant. The remaining reaction steps and conditions for producing the desired organosilane of Formula II are essentially the same as for producing the compounds of Formula I.
Examples of compounds of Formula II are:
(CH 3 O) 2 CH 3 SiCH 2 N + (CH 3 ) 2 C 12 H 25 Cl -
(C 2 H 5 O) 2 C 6 H 13 Si(CH 2 ) 2 N + (CH 3 ) 2 C 18 H 37 Cl -
(C 3 H 7 O)(C 3 H 7 ) 2 Si(CH 2 ) 3 N + (C 2 H 5 ) 2 C 10 H 21 Cl -
(CH 3 O)(CH 3 ) 2 SiCH 2 P + (CH 3 ) 2 C 10 H 21 Cl -
(C 3 H 7 O) 2 C 10 H 21 Si(CH 2 ) 2 S + (C 4 H 9 )C 6 H 12 C 6 H 5 Cl -
(CH 3 O) 2 C 16 H 33 Si(CH 2 ) 3 N + (C 2 H 4 COOH)(CH 3 )C 4 H 9 Cl -
(C 2 H 5 O)(CH 3 ) 2 Si(CH 2 ) 2 P + (CH 2 COOH) 2 C 10 H 21 Cl -
(C 3 H 7 O) 2 CH 3 SiCH 2 S + (C 3 H 6 COOH)C 6 H 13 Cl -
(CH 3 O) 2 CH 3 SiCH 2 N + (C 2 H 4 OH) 2 C 18 H 37 Cl -
(C 3 H 7 O)(CH 3 ) 2 SiCH 2 P + (C 3 H 6 OH)(C 4 H 9 ) 2 Br -
(C 4 H 9 O) 2 CH 3 Si(CH 2 ) 3 S + (C 3 H 6 OH)CH 3 Br -
(CH 3 O) 2 CH 3 SiCH 2 N + (O) - (CH 3 )C 16 H 33
(ch 3 o) 2 c 14 h 29 si(CH 2 ) 2 P + (O) - (C 4 H 9 ) 2
(c 4 h 9 o)(ch 3 ) 2 si(CH 2 ) 3 S + (O) -C 14 H 29
(ch 3 o) 2 ch 3 siCH 2 N + [(C 3 H 6 O) 20 H] 2 C 6 H 5 Cl -
(CH 3 O) 2 C 2 H 5 Si(CH 2 ) 2 N + [(C 4 H 8 O) 6 C 2 H 5 ] 2 CH 3 Cl -
(C 2 H 5 O)(CH 3 ) 2 SiCH 2 P + [(C 2 H 4 O) 2 H](C 6 H 5 ) 2 Cl -
(C 2 H 5 O) 2 C 8 H 17 Si(CH 2 ) 3 P + [(C 2 H 4 O) 4 C 6 H 13 ] 2 C 4 H 9 Cl -
(CH 3 O) 2 CH 3 SiCH 2 P + [(C 2 H 4 O) 6 COCH 3 ] 2 C 8 H 17 Cl -
(CH 3 O) 2 CH 3 SiCH 2 S + [(C 3 H 6 O) 2 H]C 14 H 29 Cl -
(C 2 H 5 O)(C 2 H 5 ) 2 Si(CH 2 ) 3 S + [(C 2 H 4 O) 5 CH 3 ]C 8 H 17 Br -
(C 2 H 5 O) 2 C 10 H 21 SiCH 2 N + [(C 2 H 4 O) 2 COC 2 H 5 ](C 4 H 9 ) 2 Cl -
(CH 3 O) 2 C 4 H 9 Si(CH 2 ) 2 S + [(C 2 H 4 O) 2 COCH 3 ]C 12 H 25 Br -
Compounds of Formulas I and II when R 4 is an alkyl, aryl, arylalkyl group or oxygen are disclosed in British Pat. Nos. 686,068 and 882,053 and U.S. Pat. Nos. 2,955,127, 3,557,178, 3,730,701, and 3,817,739. Compounds of Formulas I and II when R 4 is a carboxy-substituted alkyl group or
(C.sub.x H.sub.2x O).sub.m Z
are disclosed in commonly assigned copending patent application "Organosilane Compounds" by Heckert and Watt U.S. Ser. No. 570,532, filed Apr. 22, 1975. (The disclosure of this application is herein incorporated by reference.) ##STR6## wherein R 1 is C 1 -4 alkyl group, a is 0 to 2, R 2 is a C 1 -18 alkyl group, R 3 is a C 1 -18 alkyl group, R 4 is a C 1 -12 alkyl, aryl or arylalkyl group, a carboxy-substituted C 1 -4 alkyl group,
(C.sub.x H.sub.2x O).sub.m Z
where x is 2-4, m is 1-20, and Z is hydrogen, a C 1 -18 alkyl group or a C 1 -4 acyl group, or oxygen provided only one R 4 is oxygen, R 5 is a C 1 -22 alkyl, aryl or arylalkyl group, X is halide, and Y is N, S or P.
The compounds of Formula III when a is 0 and R 4 is an alkyl, aryl or arylalkyl group are prepared by the following route: ##STR7##
The trihalosilane is reacted with an olefin at 100° C. for 4 to 10 hours under a pressure of 50 to 300 psi. in the presence of a chloroplatinic acid or platinum catalyst to produce the trihaloalkylsilane. This reaction is reported by F. P. Mackay, O. W. Steward and P. G. Campbell in "Journal of the American Chemical Society," 79, 2764 (1957) and J. L. Speier, J. A. Webster and S. W. Barnes in Journal of the American Chemical Society, 79, 974 (1957). The trihaloalkylsilane is then halogenated in a known manner by treating it with halogen in the presence of light (such as that provided by ordinary tungsten or fluorescent lamps). Preferably, halogenation is carried out to only partial completion and a distillation is performed to recycle unreacted alkylsilane. The remaining reactions are the same as those described above in connection with the preparation of the compounds of Formula I.
When a is 1 or 2, the preparation of the compounds is essentially the same except for the use of an alkyl substituted silane as the starting reactant.
When R 4 is a carboxy-substituted C 1 -4 alkyl group, oxygen or
(C.sub.x H.sub.2x O).sub.m Z
where x is 2-4, m is 1-20, and Z is hydrogen, a C 1 -18 alkyl group, or a C 1 -4 acyl group, an appropriate amine, phosphine, or sulfide is used in the reaction step as discussed above for the preparation of similarly substituted compounds of Formula I.
The compounds that follow are illustrative of compounds of Formula III.
(c 2 h 5 o) 3 siCH(C 8 H 17 )N + (CH 3 ) 2 C 12 H 25 Cl -
(CH 3 O) 3 SiCH(C 18 H 37 )N + (C 2 H 4 COOH) 2 CH 3 Cl -
(C 3 H 7 O) 2 CH 3 SiCH(C 12 H 25 )N + (C 2 H 4 OH(CH 3 ) 2 Cl -
(C 4 H 9 O) 3 SiCH(C 3 H 7 )N + [(C 2 H 4 O) 10 H] 2 C 6 H 13 Br -
(CH 3 O) 3 SiCH(C 10 H 21 )N + [(C 2 H 4 O) 2 C 4 H 9 ] (CH 3 )C 6 H 5 Br -
(CH 3 O) 3 SiCH(CH 3 )N + [(C 2 H 4 O) 3 COC 2 H 5 ] (C 2 H 5 ) 2 Br -
(C 2 H 5 O) 2 CH 3 SiCH(C 8 H 17 )N + (O) - (CH 3 ) 2
(ch 3 o) 3 siCH(C 8 H 17 )P +CH 3 ) 3 Cl -
(CH 3 O) 2 CH 3 SiCH(CH 3 )P + (C 3 H 6 COOH) 2 C 14 H 28 C 6 H 5 Cl -
(C 2 H 5 O) 3 SiCH(C 10 H 21 )P + (C 2 H 4 OH)C 4 H 9 Cl -
(CH 3 O) 3 SiCH(C 3 H 7 )P + (O) - (CH 3 )C 12 H 25
(ch 3 o) 3 siCH(C 8 H 17 )P + [(C 2 H 4 O) 6 H] 2 CH 3 Cl -
(C 2 H 5 O) 3 SiCH(C 6 H 13 )P + [(C 3 H 6 O) 2 C 18 H 37 ](CH 3 2) 2 Cl -
(CH 3 O) 3 SiCH(CH 3 )S + (CH 3 )C 16 H 33 Br.sup.-
(C 2 H 5 O) 2 CH 3 SiCH(C 12 H 25 )S + (C 2 H 4 COOH)CH 3 Cl -
(CH 3 O) 2 C 16 H 33 SiCH(C 2 H 5 )S + (C 2 H 4 OH)C 2 H 5 Cl -
(CH 3 O) 3 SiCH(C 10 H 21 )S + (O) -C 5 H 11
(c 2 h 5 o) 3 siCH(C 4 H 9 )S + [(C 3 H 6 O) 10 H]C 6 H 5 Cl -
(C 2 H 5 O) 3 SiCH(CH 3 )S + [(C 2 H 4 O) 20 C 2 H 5 ]CH 3 Br -
Commonly assigned copending patent application "Organosilane Compounds" by Heckert and Watt U.S. Ser. No. 570,537, filed Apr. 22, 1975 discloses the preparation of these compounds. (The disclosure of this application is herein incorporated by reference). ##STR8## wherein Z is hydrogen, a C 1 -18 alkyl group or a C 1 -4 acyl group, x is 2-4, m is 1-20, a is 0-2, R 2 is a C 1 -18 alkyl group, b is 1-3, R 4 is a C 1 -12 alkyl, aryl or arylalkyl group, a carboxy-substituted C 1 -4 alkyl group,
(C.sub.x H.sub.2x O).sub.m Z
where x, m and Z are as defined above, or oxygen provided only one R 4 is oxygen, R 5 is a C 1 -22 alkyl, aryl or arylalkyl group, X is a halide, and Y is N, S or P.
The compounds with Formula IV are prepared in substantially the same manner as those of Formula II with the exception that R 1 OH is
Z(OC.sub.x H.sub.2x).sub.m OH
or alternatively the compounds of Formula II are heated in the presence of
Z(OC.sub.x H.sub.2x).sub.m OH
under conditions such that R 1 OH is removed from the system.
Exemplary compounds of Formula IV are as follows:
[CH 3 (OC 2 H 4 )O] 3 SiCH 2 N + (CH 3 ) 2 C 14 H 29 Cl -
[CH 3 (OC 2 H 4 ) 5 O] 2 CH 3 Si(CH 2 ) 3 N + (CH 2 COOH) 2 C 10 H 21 Cl -
[H(OC 3 H 6 ) 3 O] 3 SiCH 2 N + (C 2 H 4 OH)(CH 3 )(C 12 H 25 ) Cl -
[H(OC 2 H 4 ) 18 O] 3 Si(CH 2 ) 2 N + (O) - (CH 3 )C 18 H 37
[ch 3 co(oc 2 h 4 ) 10 o] 3 siCH 2 N + [(C 2 H 4 O) 14 H] 2 C 8 H 16 C 6 H 5 Cl -
[C 16 H 33 (OC 2 H 4 ) 8 O] 2 C 6 H 13 SiCH 2 N + [(C 3 H 6 O)CH 3 ](CH 3 ) 2 Br -
[H(OC 4 H 8 ) 8 O] 3 SiCH 2 N + [(C 2 H 4 O) 4 COCH 3 ] 2 CH 3 Cl -
[C 6 H 13 (OC 2 H 4 ) 2 O] 3 Si(CH 2 ) 2 P + (CH 3 ) 2 C 10 H 21 Br -
[CH 3 (OC 3 H 6 ) 14 O] 3 SiCH 2 P + (C 2 H 4 COOH) (C 6 H 13 ) 2 Cl -
[C 2 H 5 (OC 2 H 4 )O] 2 CH 3 Si(CH 2 ) 2 P + (C 4 H 8 OH)(CH 3 )C 6 H 5 Cl -
[CH 3 (OC 2 H 4 ) 8 O] 3 SiCH 2 P + (O) - (CH 3 )C 8 H 17
[c 2 h 5 co(oc 2 h 4 ) 2 o] 3 si(CH 2 ) 3 P + [C 2 H 4 O) 8 H] 2 C 6 H 13 Cl -
[CH 3 (OC 4 H 8 )O] 3 SiCH 2 P + [(C 3 H 6 O) 2 C 7 H 15 ](C 4 H 9 ) 2 Br -
[C 2 H 5 CO(OC 2 H 4 )O] 3 SiCH 2 S + (CH 3 )C 18 H 37 Cl -
[H(OC 2 H 4 ) 4 O] 3 Si(CH 2 ) 2 S + (C 2 H 4 COOH)C 12 H 25 Br -
[CH 3 (OC 2 H 4 ) 20 O] 3 Si(CH 2 ) 3 S + (C 3 H 6 OH)C 16 H 33 Br -
[H(OC 3 H 6 ) 12 O] 3 Si(CH 2 ) 2 S + (O) -C 5 H 11
[c 12 h 25 (oc 2 h 4 ) 4 o] 3 siCH 2 S + [(C 2 H 4 O) 20 H]CH 3 Br -
[H(OC 2 H 4 ) 12 O] 3 Si(CH 2 ) 3 S + [(C 2 H 4 O)C 14 H 29 [C 6 H 4 CH 3 Cl -
Commonly assigned copending patent application "Organosilane Compounds" by Heckert and Watt U.S. Ser. No. 570,539, filed Apr. 22, 1975 discloses the preparation of these compounds. (The disclosure of this application is herein incorporated by reference.) ##STR9## wherein Z is hydrogen, a C 1 -18 alkyl group or a C 1 -4 acyl group, x is 2-4, m is 1-20, R 2 is a C 1 -18 alkyl group, R 1 is a C 1 -4 alkyl group, a is 0 or 1, d is 1 or 2 provided a+d does not exceed 2, b is 1-3, R 4 is a C 1 -12 alkyl, aryl or arylalkyl group, a carboxy-substituted C 1 -14 alkyl group,
(C.sub.x H.sub.2x O).sub.m Z
where x, m and Z are as defined above, or oxygen provided only one R 4 is oxygen, R 5 is a C 1 -22 alkyl, aryl or aryl alkyl group, X is halide, and Y is N, S or P.
The compounds of Formula V are formed in substantially the same manner as those of Formula II except that a mixture of R 1 OH and
Z(OC.sub.x H.sub.2x).sub.m OH
in the desired ratio is used in place of R 1 OH or, alternatively, the compounds of Formula II are heated with less than 3-a equivalents of
Z(OC.sub.x H.sub.2x).sub.m OH
under conditions such that R 1 OH is removed from the system.
Examples of illustrative compounds follow:
[H(OC 2 H 4 ) 5 O](CH 3 )(C 2 H 5 O)SiCH 2 N + (CH 3 ) 2 C 12 H 25 Cl -
[C 12 H 25 (OC 2 H 4 ) 3 O](CH 3 O) 2 Si(CH 2 ) 3 N + (C 2 H 5 ) 2 C 6 H 5 Cl -
[H(OC 4 H 8 ) 6 O](C 2 H 5 O) 2 Si(CH 2 ) 3 N + [(C 2 H 4 O) 10 H] 2 C 18 H 37 Br -
[CH 3 CO(OC 2 H 4 ) 3 O] 2 (C 2 H 5 O)Si(CH 2 ) 2 N + [(C 2 H 4 O)C 2 H 5 ](C 6 H 5 CH 3 ) 2 Cl -
[H(OC 2 H 4 ) 12 O](C 4 H 8 O) 2 SiCH 2 N + [(C 2 H 4 O) 4 COCH 3 ] 2 C 14 H 29 Cl -
[C 16 H 33 (OC 2 H 4 ) 3 O] (C.sub. 2 H 5 )(CH 3 O)SiCH 2 N + (O) - (CH 3 )C 6 H 13
[h(oc 3 h 6 ) 12 o] (c 2 h 5 o) 2 siCH 2 N + (C 2 H 5 COOH)(CH.sub. 3)C 10 H 21 Cl -
[C 2 H 5 (OC 2 H 4 ) 14 O] 2 (C 4 H 9 O)Si(CH 2 ) 3 N + (C 4 H 8 OH)(CH.sub. 3)C 14 H 29 Cl -
[H(OC 2 H 4 ) 16 O] 2 (CH 3 O)SiCH 2 P + (CH 3 ) 2 C 6 H 4 C 2 H 5 Cl -
[C 3 H 7 (OC 2 H 4 ) 6 O](C 2 H 5 )(CH 3 O)SiCH 2 P + [(C 2 H 4 O) 8 H] 2 C 8 H 17 Br -
[CH 3 CO(OC 2 H 4 ) 2 O] 2 (CH 3 O)Si(CH 2 ) 2 P + [(C 3 H 6 O) 3 C 2 H 5 ] (C 4 H 9 ) 2 Cl -
[H(OC 4 H 8 ) 2 O] (C 12 H 25 )(CH.sub. 3 O)SiCH 2 P + (O) - (CH 3 )C 6 H 5 2
[c 14 h 29 (oc 2 h 4 ) 6 o](ch 3 o) 2 siCH 2 P + (C 3 H 6 COOH) 2 CH 3 Cl -
[H(OC 2 H 4 ) 8 O] 2 (C 4 H 9 O)SiCH 2 P + (C 3 H 6 OH) 2 C 2 H 5 Br -
[H(OC 2 H 4 ) 10 O] 2 (C 3 H 7 O)SiCH 2 S + (CH 3 )C 6 H 12 C 6 H 5 Cl -
[H(OC 4 H 8 ) 2 O] 2 (CH 3 O)Si(CH 2 ) 3 S + [(C 2 H 4 O) 4 H]CH 3 Br -
[C 12 H 25 (OC 2 H 4 ) 6 O](CH 3 )(CH 3 O)SiCH 2 S + [(C 3 H 6 O) 8 CH 3 ]C 3 H 7 Cl -
[CH 3 CO(OC 2 H 4 ) 3 O](C 2 H 5 O) 2 Si(CH 2 ) 2 S + (C 2 H 4 OH)C 12 H 25 Cl -
[CH 3 (OC 3 H 6 ) 12 O](CH 3 O) 2 SiCH 2 S + (C 3 H 6 COOH)CH 2 C 6 H 5 Br -
[H(C 2 H 4 O) 6 O](C 12 H 25 )(CH 3 O)SiCH 2 S + (O) - C 14 H 29
Commonly assigned copending patent application "Organosilane Compounds" by Heckert and Watt U.S. Ser. No. 570,539, filed Apr. 22, 1975 discloses the preparation of these compounds. (The disclosure of this application is herein incorporated by reference.) ##STR10## wherein Z is hydrogen, a C 1 -18 alkyl group or a C 1 -4 acyl group, x is 2- 4, m is 1-20, a is 0-2, R 2 is a C 1 -18 alkyl group, R 3 is a C 1 -18 alkyl group, R 4 is a C 1 -12 alkyl, aryl or arylalkyl group, a carboxy-substituted C 1 -4 alkyl group,
(C.sub.x H.sub.2x O).sub.m Z
where x is 2-4, m is 1-20, and Z is hydrogen, a C 1 -18 alkyl group or a C 1 -4 acyl group, or oxygen provided only one R 4 is oxygen, R 5 is a C 1 -22 alkyl, aryl or arylalkyl group, X is halide and Y is N, S or P.
The compounds of Formula VI are formed in the same manner as those of Formula III with the exception that
Z(OC.sub.x H.sub.2x).sub.m OH
is used in place of
R.sub.1 OH
during the alcoholysis of the halo-silane. Alternatively, preparation may be effected by the heating of compounds of Formula III with
Z(OC.sub.x H.sub.2x).sub.m OH
under conditions such that all of the
R.sub.1 OH
is removed from the system.
The following compounds illustrate the compounds of Formula VI.
[ch 3 (oc 2 h 4 ) 3 o] 3 siCH(CH 3 )N + (CH 3 ) 2 C 18 H 37 Cl -
[C 2 H 5 (OC 2 H 4 )O] 2 CH 3 SiCH(C 2 H 5 )N + (C 2 H 4 OH) 2 C 14 H 29 Cl -
[H(OC 4 H 8 ) 8 O] 3 SiCH(C 4 H 9 )N + (C 2 H 4 COOH)(C 4 H 9 )CH 2 C 6 H 5 Cl -
[CH 3 CO(OC 2 H 4 ) 2 O] 3 SiCH(C 2 H 5 )N + (O) - (CH 3 )C 10 H 21
[h(oc 3 h 6 ) 6 o] 3 siCH(C 12 H 25 )N + [(C 2 H 4 O) 10 H] 2 CH 3 Br -
[C 12 H 25 (OC 2 H 4 )O] 3 SiCH(C 3 H 7 )N + [(C 4 H 8 O) 3 C 5 H 10 ](C 2 H 5 ) 2 Cl -
[C 10 H 21 (OC 2 H 4 ) 4 O] 3 SiCH(C 2 H 5 )N + [(CH 2 H 4 O) 6 COCH 3 ] 2 CH 3 Cl -
[H(OC 2 H 4 ) 16 O] 3 SiCH(C 8 H 17 )P + (C 2 H 5 ) 2 C 6 H 4 C 4 H 9 Cl -
[CH 3 (OC 2 H 4 ) 16 O] 2 C 12 H 25 SiCH(CH 3 )P + (C 2 H 4 COOH) 2 C 10 H 21 Cl -
[C 2 H 5 OC(OC 2 H 4 ) 5 O] 3 SiCH(CH 3 )P + (C 2 H 4 OH)(CH 3 )C 12 H 25 Cl -
[H(OC 2 H 4 ) 2 O] 3 SiCH(C 10 H 25 )P + (O) - (CH 3 )C 16 H 33
[h(oc 2 h 4 ) 2 o] 3 siCH(C 8 H 17 )P + [(C 2 H 4 O) 6 H] 2 C 4 H 9 Br -
[CH 3 (OC 4 H 8 ) 2 O] 3 SiCH(CH 3 )P + [(C 2 H 4 O)C 8 H 17 ](CH 3 ) 2 Cl -
[C 10 H 21 (OC 2 H 4 ) 2 O] 3 SiCH(C 6 H 13 )S + (CH 3 )C 10 H 21 Cl -
[H(OC 2 H 4 ) 14 O] 2 CH 3 SiCH(C 8 H 17 )S + (C 2 H 4 COOH)C 18 H 37 Cl -
[H(OC 3 H 6 ) 4 O] 3 SiCH(C 14 H 29 )S - (C 4 H 8 OH)C 6 H 5 Cl -
[CH 3 CO(OC 2 H 4 ) 3 O] 3 SiCH(C 2 H 5 )S + (O) -C 18 H 37
[c 12 h 25 (oc 2 h 4 )o] 3 siCH(C 3 H 7 )S + [(C 3 H 6 O)H]C 6 H 13 Cl -
[H(OC 4 H 8 ) 4 O] 2 CH 3 SiCH(C 4 H 9 )S + [C 2 H 4 o) 8 C 3 H 7 ]CH 3 Br -
Commonly assigned copending patent application "Organosilane Compounds" by Heckert and Watt U.S. Ser. No. 570,537, filed Apr. 22, 1975 discloses the preparation of these compounds. (The disclosure of this application is herein incorporated by reference.) ##STR11## wherein Z is hydrogen, a C 1 -18 alkyl group or a C 1 -4 acyl group, x is 2-4, m is 1-20, R 2 is a C 1 -18 alkyl group, R 1 is a C 1 -4 alkyl group, a is 0 or 1, d is 1 or 2 provided a+d does not exceed 2, R 3 is a C 1 -18 alkyl group, R 4 is a C 1 -12 alkyl, aryl or arylalkyl group, a carboxy-substituted C 1 -4 alkyl group, (C x H 2x O) m Z where x, m and Z are as defined above, or oxygen provided only one R 4 is oxygen, R 5 is a C 1 -22 alkyl, aryl or arylalkyl group, X is halide and Y is N, S or P.
Compounds having Formula VII are prepared in substantially the same manner as those of Formula III except that a mixture of
R.sub.1 OH
and
Z(OC.sub.x H.sub.2x).sub.m OH
in the desired ratio is used in place of R 1 OH. Alternatively, the compounds of Formula III are heated together with less than 3-a equivalents of
Z(OC.sub.x H.sub.2x).sub.m OH
under conditions such that R 1 OH is removed from the system.
The following compounds are illustrative of the compounds of Formula VII:
[h(oc 2 h 6 ) 6 o](c 2 h 5 o) 2 siCH 12 H 25 N + [(C 2 H 4 O) 10 H] 2 C 18 H 37 Br -
[CH 3 CO(OC 2 H 4 ) 3 O] 2 (C 2 H 5 O)SiCHCH 3 N + [(C 2 H 4 O)C 2 H 5 ] 2 C 6 H 5 CH 3 Cl -
[H(OC 2 H 4 ) 12 O](C 4 H 8 O) 2 SiCHC 2 H 5 N + [(C 2 H 4 O) 4 COCH 3 ] 2 C 14 H 29 Cl -
[C 16 H 33 (OC 2 H 4 ) 3 O](C 2 H 5 ) (CH 3 O)SiCHCH 3 N + (O) - (CH 3 )C 6 H 13
[c 2 h 5 (oc 2 h 4 ) 14 o] 2 (c 4 h 9 o)siCHC 6 H 13 N + (C 6 H 12 OH) (CH 3 )C 14 H 29 Cl -
[H(OC 2 H 4 ) 16 O] 2 (CH 3 O)SiCHC 4 H 9 P + (CH 3 ) 2 C 18 H 37 Cl -
[CH 3 CO(OC 2 H 4 ) 2 O] 2 (CH 3 O)SiCHC 16 H 33 P + [(C 3 H 7 O) 3 C 2 H 5 ](C 4 H 9 ) 2 Cl -
[C 14 H 29 (OC 2 H 4 ) 6 O](CH 3 O) 2 SiCHCH 3 P + (C 3 H 6 COOH) 2 CH 3 Cl -
[H(OC 2 H 4 ) 10 O] 2 (C 3 H 7 O)SiCHC 5 H 11 S + (CH 3 )C 12 H 25 Cl -
[H(OC 4 H 8 ) 2 O] 2 (CH 3 O)SiCHC 8 H 17 S +CH 3 C 6 H 5 Br -
Commonly assigned copending patent application "Organosilane Compounds" by Heckert and Watt U.S. Ser. No. 570,537, filed Apr. 22, 1975 discloses the preparation of the compounds. (The disclosure of this application is herein incorporated by reference). ##STR12## wherein a is 0-2, R 2 is C 1 -18 alkyl group, b is 1-3, R 4 is a C 1 -12 alkyl, aryl or arylalkyl group, a carboxy-substituted C 1 -14 alkyl group,
(C.sub.x H.sub.2x O).sub.m Z
where x is 2-4, m is 1-20, and Z is hydrogen, a C 1 -18 alkyl group or a C 1 -4 acyl group, or oxygen provided only one R 4 is oxygen, R 5 is a C 1 -22 alkyl, aryl or arylalkyl group, X is halide, and Y is N, S or P.
When a is 0, a tris(trimethylsiloxy) silane is used as the starting reactant. Commercially available trihalosilanes and trimethylsilanes are used to produce the starting reactant. Subsequent reaction steps and conditions as discussed in the preparation of compounds of Formula I are used to produce the desired compound of Formula VI.
When a is 1 or 2, a corresponding compound of Formula II is reacted with trimethylchlorosilane at an elevated temperature, e.g., 50° C. to 200° C. to obtain the desired organosilane.
Examples of compounds of Formula VIII are:
[(CH 3 ) 3 SiO] 3 SiCH 2 N + (CH 3 ) 2 C 14 H 29 Cl -
[(CH 3 ) 3 SiO] 2 CH 3 Si(CH 2 ) 3 N + (CH 2 COOH) 2 C 6 H 5 Cl -
[(CH 3 ) 3 SiO] 3 SiCH 2 N + (C 2 H 4 OH) (CH 3 ) (C 12 H 25 ) Cl -
[(CH 3 ) 3 SiO] 3 Si(CH 2 ) 2 N + (O) - (CH 3 )C 8 H 17
[(ch 3 ) 3 siO] 3 SiCH 2 N + [(C 2 H 4 O) 14 H] 2 CH 3 Cl -
[(CH 3 ) 3 SiO] 2 CH 3 SiCH 2 N + [(C 3 H 6 O)CH 3 ](CH 3 ) 2 Br -
[(CH 3 ) 3 SiO] 3 SiCH 2 N + [(C 2 H 4 O) 4 COCH 3 ] 2 CH 3 Cl -
[(CH 3 ) 3 SiO] 3 Si(CH 2 ) 2 P + (CH 3 ) 2 C 10 H 21 Br -
[(CH 3 ) 3 SiO] 3 SiCH 2 P + (C 2 H 4 COOH) (C 6 H 13 ) 2 Cl -
[CH 3 ) 3 SiO] 2 CH 3 Si(CH 2 ) 2 P + (C 4 H 8 OH) (CH 3 )C 10 H 21 Cl -
[(CH 3 ) 3 SiO] 3 SiCH 2 P + (O) - (CH 3 )C 6 H 5
[(ch 3 ) 3 siO] 3 Si(CH 2 ) 3 P + [(C 2 H 4 O) 8 H] 2 C 6 H 13 Cl -
[(CH 3 ) 3 SiO] 3 SiCH 2 P + [(C 3 H 6 O) 2 C 7 H 15 ] (C 4 H 9 ) 2 Br -
[(CH 3 ) 3 SiO] 3 SiCH 2 S + (CH 3 )C 18 H 37 Cl -
[(CH 3 ) 3 SiO] 3 Si(CH 2 ) 2 S + (C 2 H 4 COOH)C 12 H 25 Br -
[(CH 3 ) 3 SiO] 3 Si(CH 2 ) 3 S + (C 3 H 6 OH)C 6 H 4 CH 3 Br -
[(CH 3 ) 3 SiO] 3 Si(CH 2 ) 2 S + (O) -C 14 H 29
[(ch 3 ) 3 siO] 3 SiCH 2 S + [(C 2 H 4 O) 20 H]CH 3 Br -
[(CH 3 ) 3 SiO] 3 Si(CH 2 ) 3 S + [(C 2 H 4 O)C 14 H 29 ]C 2 H 5 Cl -
Commonly assigned copending patent application "Organosilane Compounds" by Heckert and Watt U.S. Ser. No. 570,538, filed Apr. 22, 1975 discloses the preparation of the compounds when R 4 is a carboxy-substituted alkyl group or
(C.sub.x H.sub.2x O).sub.m Z
(the disclosure of this application is herein incorporated by reference.) U.S. Pat. Nos. 2,955,127, 3,624,120 and 3,658,867 discloses the compounds when R 4 is alkyl, aryl, arylalkyl or oxygen. ##STR13## wherein a is 0-2, R 2 is a C 1 -18 alkyl group, R 3 is a C 1 -18 alkyl group, R 4 is a C 1 -12 alkyl, aryl or arylalkyl group, a carboxy-substituted C 1 -4 alkyl group,
(C.sub.x H.sub.2x O).sub.m Z
where x is 2-4, m is 1-20, and Z is hydrogen, a C 1 -18 alkyl group or a C 1 -4 acyl group, or oxygen provided only one R 4 is oxygen, R 5 is a C 1 -22 alkyl, aryl or arylalkyl group, X is halide and Y is N, S or P.
When a is 0, the compounds of Formula IX are prepared following the description given for the preparation of the compounds of Formula III with the exception that a tris(trimethylsiloxy)silane is used as the starting reactant. When a is 1 or 2, a corresponding compound of Formula III is reacted with a trimethylchlorosilane at about 50° C. to 200° C. to produce the desired organosilane.
Illustrative compounds of Formula IX follow:
[(CH 3 ) 3 SiO] 3 SiCH(CH 3 )N + (CH 3 ) 2 C 18 H 37 Cl -
[(CH 3 ) 3 SiO] 2 CH 3 SiCH(C 2 H 5 )N + (C 2 H 4 OH) 2 C 6 H 4 CH 3 Cl -
[(CH 3 ) 3 SiO] 3 SiCH(C 4 H 9 )N + (C 3 H 6 COOH)(C 4 H 9 ) 2 Cl -
[(CH 3 ) 3 SiO] 3 SiCH(C 2 H 5 )N + (O) - (CH 3 )C 10 H 21
[(ch 3 ) 3 siO] 3 SiCH(C 12 H 25 )N + [(C 2 H 4 O) 10 H] 2 CH 3 Br -
[(CH 3 ) 3 SiO] 3 SiCH(C 3 H 7 )N + [(C 4 H 8 O) 3 C 5 H 10 ](C 2 H 5 ) 2 Cl -
[(CH 3 ) 3 SiO] 3 SiCH(C 2 H 5 )N +] (C 2 H 4 O) 6 COCH 3 ] 2 CH 3 Cl -
[(CH 3 ) 3 SiO] 3 SiCH(C 8 H 17 )P + (C 2 H 5 ) 2 C 8 H 17 Cl -
[(CH 3 ) 3 SiO] 2 C 2 H 5 SiCH(CH 3 )P + (C 3 H 6 COOH) 2 C 10 H 21 Cl -
[(CH 3 ) 3 SiO] 3 SiCH(CH 3 )P + (C 2 H 4 OH)(CH 3 )C 12 H 25 Cl -
[(CH 3 ) 3 SiO] 3 SiCH(C 10 H 21 )P + (O) - (CH 3 )C 8 H 17
[(ch 3 ) 3 siO] 3 SiCH(C 8 H 17 )P + [(C 2 H 4 O) 6 H] 2 C 4 H 9 Br -
[(CH 3 ) 3 SiO] 3 SiCH(CH 3 )P + [(C 2 H 4 O)C 8 H 17 ] 2 C 6 H 4 C 2 H 5 Cl -
[(CH 3 ) 3 SiO] 3 SiCH(C 6 H 13 )S + (CH 3 )C 16 H 33 Cl -
[(CH 3 ) 3 SiO] 2 CH 3 SiCH(C 8 H 17 )S + (C 2 H 4 COOH)C 6 H 5 Cl -
[(CH 3 ) 3 SiO] 3 SiCH(C 14 H 29 )S + (C 4 H 8 OH)CH 3 Cl -
[(CH 3 ) 3 SiO] 3 SiCH(C 2 H 5 )S + (O) -C 18 H 37
[(ch 3 ) 3 siO] 3 SiCH(C 3 H 7 )S + [(C 3 H 6 O)H]C 12 H 25 Cl -
[(CH 3 ) 3 SiO] 2 C 18 H 37 SiCH(C 4 H 9 )S + [(C 2 H 4 O) 8 C 3 H 7 ]CH 3 Br -
Commonly assigned copending patent application "Organosilane Compounds" by Heckert and Watt U.S. Ser. No. 570,537, filed Apr. 22, 1975 discloses the preparation of these compounds. (The disclosure of this application is herein incorporated by reference.) ##STR14## wherein R 1 is a C 1 -4 alkyl group, a is 0-2, R 2 is a C 1 -18 alkyl group, b is 1-3, R 4 is a C 1 -12 alkyl, aryl or arylalkyl group, a carboxy-substituted C 1 -4 alkyl group,
(C.sub.x H.sub.2x O).sub.m Z
where x is 2-4, m is 1-20, and Z is hydrogen, a C 1 -18 alkyl group or a C 1 -4 acyl group, or oxygen provided only one R 4 is oxygen, R 5 is a C 1 -22 alkyl, aryl or arylalkyl group, X is halide, and Y is N, S or P.
The compounds of Formula X are prepared by initially reacting (when a is 0 and b is 3) trihalosilane with an alcohol (R 1 OH) at 0° C. to 50° C. for 1 to 10 hours to produce a trialkoxysilane. This silane is then reacted with an allylglycidylether ##STR15## in the presence of 0.01% to 0.1% chloroplatinic acid or platinum at 100° C. for 2 to 10 hours. The resultant product ##STR16## is reacted with a tertiary amine, tertiary phosphine, or dialkylsulfide in the presence of an acid in an inert solvent at 60° C. to 100° C. for 1 to 10 hours to produce the compound of Formula X.
When a is 1 or 2, the preparation of the compounds is essentially the same except for the use of an alkyl substituted silane as the starting reactant.
When b is 2 in Formula X, a trihalovinylsilane of formula
X.sub.3 SiCH=CH.sub.2
(which is commercially available) is reacted with hydrogen bromide in the presence of peroxide or light to produce a beta-haloethyltrihalosilane. This compound is reacted with an alcohol, an allylglycidylether, and finally with an appropriate amine, phosphine, or sulfide in the manner discussed above for the preparation of the compounds of Formula X when b is 3.
When b is 1 in Formula X, the starting reactant is a commercially available trihalomethylsilane of formula
X.sub.3 SiCH.sub.3 .
this silane is reacted with chlorine or, preferably a half mole of bromine and a half mole of chlorine in the presence of light (such as provided by an ordinary tungsten or fluorescent lamp). The resultant alpha-halomethyltrihalosilane is reacted with an alcohol, an allyglycidylether, and finally an appropriate amine, phosphine, or sulfide in the manner discussed above with the compounds of Formula X when b is 3.
The following compounds illustrate the compounds of Formula X.
(ch 3 o) 3 si(CH 2 ) 3 OCH 2 CHOHCH 2 N + (CH 3 ) 2 C 16 H 33 Cl -
(CH 3 O) 2 C 12 H 25 SiCH 2 OCH 2 CHOHCH 2 N + (C 3 H 6 COOH) (C 4 H 9 )C 8 H 17 Cl -
(C 2 H 5 O) 3 Si(CH 2 ) 2 OCH 2 CHOHCH 2 N + (C 2 H 4 OH) 2 C 6 H 5 Br -
(CH 3 O) 3 Si(CH 2 ) 3 OCH 2 CHOHCH 2 N + (O) - (CH 3 )C 8 H 17
(ch 3 o) 3 siCH 2 OCH 2 CHOHCH 2 N + [(C 2 H 4 O)H] 2 C 14 H 29 Br -
(CH 3 O) 2 C 2 H 5 SiCH 2 OCH 2 CHOHCH 2 N + [(C 3 H 6 O) 12 C 2 H 5 ](CH 3 ) 2 Cl -
(C 4 H 9 O) 3 SiCH 2 OCH 2 CHOHCH 2 N + [(C 2 H 4 O) 3 COCH 3 ] 2 CH 3 Br -
(CH 3 O) 3 SiCH 2 OCH 2 CHOHCH 2 P + (C 4 H 9 ) 2 CH 2 C 6 H 5 Br -
(C 4 H 9 O) 3 SiCH 2 OCH 2 CHOHCH 2 P + (C 2 H 4 COOH) 2 C 8 H 17 Cl -
(CH 3 O) 3 Si(CH 2 ) 2 OCH 2 CHOHCH 2 P + (C 2 H 4 OH)(C 2 H 5 )C 10 H 21 Cl -
(CH 3 O) 3 SiCH 2 OCH 2 CHOHCH 2 P + (O) - (CH 3 ) C 18 H 37
(ch 3 o) 3 siCH 2 OCH 2 CHOHCH 2 P + [C 3 H 6 O) 18 H] 2 CH 3 Br -
(C 2 H 5 O) (CH 3 ) 2 SiCH 2 OCH 2 CHOHCH 2 P + [(C 2 H 4 O)CH 3 ] 2 C 6 H 13
(ch 3 o) 3 siCH 2 OCH 2 CHOHCH 2 S + (CH 3 )C 6 H 4 CH 3 Cl -
(CH 3 O) 2 C 16 H 37 SiCH 2 OCH 2 CHOHCH 2 S + (C 2 H 4 COOH)C 8 H 17 Cl -
(CH 3 O) 3 Si(CH 2 ) 2 OCH 2 CHOHCH 2 S + (C 2 H 4 OH)C 6 H 13 Cl -
(C 2 H 5 O) 3 SiCH 2 OCH 2 CHOHCH 2 S + (O) -C 10 H 21
(ch 3 o) 3 siCH 2 OCH 2 CHOHCH 2 S + [(C 2 H 4 O) 12 H]CH 3 Br -
(C 2 H 5 O) 3 SiCH 2 OCH 2 CHOHCH 2 S + [(C 2 H 4 O) 2 C 8 H 17 ]C 2 H 5 Br -
Commonly assigned copending patent application "Organosilane Compounds" by Heckert and Watt U.S. Ser. No. 570,531, filed Apr. 22, 1975 discloses the preparation of these compounds. (The disclosure of this application is herein incorporated by reference.) ##STR17## wherein Z is hydrogen, a C 1 -18 alkyl group or a C 1 -4 acyl group, x is 2-4, m is 1-20, a is 0-2, R 2 is a C 1 -18 alkyl group, b is 1-3, R 4 is a C 1 -12 alkyl, aryl, or arylalkyl group, a carboxy-substituted C 1 -4 alkyl group,
(C.sub.x H.sub.2x O).sub.m Z
where x is 2-4, m is 1-20, and Z is hydrogen, a C 1 -18 alkyl group or a C 1 -4 acyl group, or oxygen provided only one R 4 is oxygen, R 5 is a C 1 -22 alkyl, aryl or arylalkyl group, X is a halide, and Y is N, S or P.
Compounds of Formula XI are prepared in a manner identical with that of Formula X except that R 1 OH is replaced by
HO(C.sub.x H.sub.2x O).sub.m Z.
the following compounds are exemplary of Formula XI compounds.
[H(OC 2 H 4 ) 20 O] 3 SiCH 2 OCH 2 CHOHCH 2 N + (CH 3 ) 2 C 10 H 21 Cl -
[CH 3 (OC 3 H 6 ) 10 O] 2 CH 3 SiCH 2 OCH 2 CHOHCH 2 N + (C 2 H 4 COOH) (C 4 H 9 ) 2 Cl -
[C 2 H 5 (OC 2 H 4 ) 2 O] 3 Si(CH 2 ) 3 OCH 2 CHOHCH 2 N + (C 2 H 4 OH) 2 (C 8 H 17 ) Cl -
[C 8 H 17 (OC 2 H 4 )O] 3 SiCH 2 OCH 2 CHOHCH 2 N + (O) - (C 4 H 9 )C 6 H 5
[ch 3 co(oc 2 h 4 ) 6 o] 3 si(CH 2 ) 2 OCH 2 CHOHCH 2 N + [(C 2 H 4 O) 10 H] 2 CH 3 Cl -
[H(OC 3 H 6 ) 8 O] 2 C 16 H 33 SiCH 2 OCH 2 CHOHCH 2 N + [(C 2 H 4 O) 8 C 4 H 9 ](CH 3 ) 2 Br -
[C 2 H 5 (OC 2 H 4 ) 4 O] 3 SiCH 2 OCH 2 CHOHCH 2 N + [(C 2 H 4 O) 2 COCH 3 ] 2 CH 3 Br -
[C 18 H 39 (OC 2 H 4 ) 3 O] 3 SiCH 2 OCH 2 CHOHCH 2 P + (C 2 H 5 ) 2 C 14 H 29 Cl -
[H(OC 3 H 6 ) 8 ] 3 Si(CH 2 ) 3 OCH 2 CHOHCH 2 P + (C 3 H 6 COOH) 2 C 6 H 13 Cl -
[C 8 H 17 (OC 2 H 4 ) 2 O] 2 CH 3 SiCH 2 OCH 2 CHOHCH 2 P + (C 2 H 4 OH)(CH 3 )C 8 H 17 Cl -
[CH 3 (OC 3 H 6 )O] 3 Si(CH 2 ) 3 OCH 2 CHOHCH 2 P + (O) - (CH 3 )C 10 H 21
[c 2 h 5 (oh 4 c 2 ) 12 o] 3 si(CH 2 ) 2 OCH 2 CHOHCH 2 P + [(C 2 H 4 O) 2 H] 2 C 6 H 4 CH 3 Br -
[CH 3 CO(OC 2 H 4 ) 8 O] 3 SiCH 2 OCH 2 CHOHCH 2 P + [(C 3 H 6 O) 8 C 2 H 5 ](C 4 H 9 ) 2 Cl -
[H(OC 2 H) 4 O] 3 SiCH 2 OCH 2 CHOHCH 2 S + (CH 3 )C 18 H 37 Cl -
[C 16 H 33 (OC 2 H 4 ) 6 O] 2 C 12 H 25 SiCH 2 OCH 2 CHOHCH 2 S + (C 3 H 6 COOH)C 10 H 21 Cl -
[CH 3 (OC 4 H 8 ) 4 O] 3 SiCH 2 OCH 2 CHOHCH 2 S + (C 4 H 8 OH)C 8 H 17 Br -
[H(OC 2 H 4 ) 14 O] 3 Si(CH) 2 OCH 2 CHOHCH 2 S + (O) -C 12 H 14 C 6 H 5
[c 9 h 19 (oc 2 h 4 )o] 3 siCH 2 OCH 2 CHOHCH 2 S + [(C 2 H 4 O) 6 H]C 6 H 13 Cl -
[C 2 H 5 CO(OC 2 H 4 ) 2 O] 3 SiCH 2 OCH 2 CHOHCH 2 S + [(C 4 H 8 O) 12 CH 3 ]C 8 H 17 Cl -
Commonly assigned copending patent application "Organosilane Compounds" by Heckert and Watt U.S. Ser. No. 570,531, filed Apr. 22, 1975 discloses the preparation of these compounds. (The disclosure of this application is herein incorporated by reference.) ##STR18## wherein Z is hydrogen, a C 1 -18 alkyl group or a C 1 -4 acyl group, x is 2-4, m is 1-20, R 2 is a C 1 -18 alkyl group, R 1 is a C 1 -4 alkyl group, a is 0 or 1, d is 1 or 2 provided a+d does not exceed 2, b is 1-3, R 4 is a C 1 -12 alkyl, aryl or arylalkyl group, a carboxy-substituted C 1-14 alkyl group,
(C.sub.x H.sub.2x O).sub.m Z
where x, m and Z are as defined above, or oxygen provided only one R 4 is oxygen, R 5 is a C 1 -22 alkyl, aryl or arylalkyl group, X is halide, and Y is N, S or P.
These compounds are prepared in a manner similar to that described for the compounds of Example XI except that only a part of the R 1 OH is replaced by
HO(C.sub.x H.sub.2x O).sub.m Z.
the following compounds are examples of compounds having the Formula XII.
[ h(oc 2 h 4 ) 12 o](ch 3 o) 2 siCH 2 OCH 2 CHOHCH 2 N + (CH 3 ) 2 C 18 H 37 Cl -
[H(OC 3 H 6 O) 3 O](C 2 H 5 )(CH 3 )Si(CH 2 ) 2 OCH 2 CHOHCH 2 N + (CH 2 COOH)(C 4 H 9 ) 2 Cl -
[C 12 H 25 (OC 2 H 4 ) 9 O](C 2 H 5 O) 2 SiCH 2 OCH 2 CHOHCH 2 N + (C 4 H 8 OH) 2 CH 3 Cl -
[CH 3 (OC 4 H 8 ) 2 O] 2 (C 4 H 9 O)Si(CH 2 ) 3 OCH 2 CHOHCH 2 N + (O) - (CH 3 ) C 16 H 33
[ch 3 co(oc 2 h 4 ) 6 o] 2 (ch 3 o)siCH 2 OCH 2 CHOHCH 2 N + [(C 2 H 4 O) 8 H] 2 CH 3 Br -
[H(OC 2 H 4 ) 18 O](C 2 H 5 O)(C 16 H 33 )SiCH 2 OCH.sub. 2 CHOHCH 2 N + [(C 2 H 4 O)C 12 H 25 ](CH 3 ) 2 Cl -
[H(OC 2 H 4 ) 8 O](C 2 H 5 ) 2 SiCH 2 OCH 2 CHOHCH 2 P + (CH 3 ) 2 C 6 H 5 Cl -
[CH 3 (OC 2 H 4 ) 6 O](C 12 H 25 )(CH 3 O)SiCH 2 OCH 2 CHOHCH 2 P + [(C 2 H 4 O) 6 OCH 3 ] 2 (CH 3 ) Cl -
[ CH 3 CO(OC 3 H 6 ) 4 O] 2 (CH 3 O)Si(CH 2 ) 3 OCH 2 CHOHCH 2 P + (C 4 H 8 OH) 2 CH 3 Cl -
[H(OC 4 H 8 ) 2 O](CH 3 O)(CH 3 )SiCH 2 OCH 2 CHOHCH 2 S + [(C 2 H 4 O) 3 H]C 2 H 5 Cl -
[C 12 H 25 (OC 2 H 4 O](C 4 H 9 O) 2 Si(CH 2 ) 2 OCH 2 CHOHCH 2 S + (C 3 H 6 COOH)CH 3 Br -
[C 2 H 5 CO(OC 2 H 4 ) 10 O] 2 (C 2 H 5 O)SiCH 2 OCH 2 CHOHCH 2 S + (O) -C 12 H 25
Commonly assigned copending patent application "Organosilane Compounds" by Heckert and Watt U.S. Ser. No. 570,531, filed Apr. 22, 1975 of these compounds. (The disclosure of this application is herein incorporated by reference.) ##STR19## wherein a is 0-2, R 2 is a C 1 -18 alkyl group, b is 1-3, R 4 is a C 1 -12 alkyl, aryl or arylalkyl group, a carboxy-substituted C 1 -4 group,
(C.sub.x H.sub.2x O).sub.m Z
where x is 2-4, m is 1-20, and Z is hydrogen, a C 1 -18 alkyl group or a C 1 -4 acyl group, or oxygen provided only one R 4 is oxygen, R 5 is C 1 -22 alkyl, aryl or arylalkyl group, X is halide, and Y is N, S or P.
Tris(trimethylsiloxy)silanes, which are prepared from commercially available trimethylhalosilanes and trihalosilanes, are used as the starting reactants when a is 0. Subsequent reaction steps and conditions as discussed with the preparation of compounds of Formula X are used to produce the desired compound of Formula XIII.
When a is 1 or 2, a compound of Formula X is reacted with trimethylchlorosilane at an elevated temperature, e.g. 50° C. to 200° C. to obtain the desired organosilane.
The following compounds are illustrative of the compounds of Formula XIII.
[(ch 3 ) 3 siO] 3 SiCH 2 OCH 2 CHOHCH 2 N + (CH 3 ) 2 C 10 H 21 Cl -
[(CH 3 ) 3 SiO] 2 CH 3 SiCH 2 OCH 2 CHOHCH 2 N + (C 2 H 4 COOH) (C 4 H 9 ) 2 Cl -
[(CH 3 ) 3 SiO] 3 Si(CH 2 ) 3 OCH 2 CHOHCH 2 N + (C 2 H 4 OH) 2 C 8 H 17 Cl -
[(CH 3 ) 3 SiO] 3 SiCH 2 OCH 2 CHOHCH 2 N + (O) - (C 2 H 5 )C 6 H 4 C 2 H 5
[(ch 3 ) 3 siO] 3 Si(CH 2 ) 2 OCH 2 CHOHCH 2 N + [(C 2 H 4 O) 10 H] 2 CH 3 Cl -
[(CH 3 ) 3 SiO] 2 C 2 H 5 SiCH 2 OCH 2 CHOHCH 2 N + [(C 2 H 4 O) 8 C 4 H 9 ] (CH 3 ) 2 Br -
[(CH 3 ) 3 SiO] 3 SiCH 2 OCH 2 CHOHCH 2 N + [(C 3 H 6 O) 2 COCH 3 ] 2 CH 3 Br -
[(CH 3 ) 3 SiO] 3 SiCH 2 OCH 2 CHOHCH 2 P + (C 2 H 5 ) 2 C 14 H 29 Cl -
[(CH 3 ) 3 SiO] 3 Si(CH 2 ) 2 OCH 2 CHOHCH 2 P + (C 3 H 6 COOH) 2 C 6 H 5 Cl -
[(CH 3 ) 3 SiO] 2 CH 3 SiCH 2 OCH 2 CHOHCH 2 P + (C 2 H 4 OH) (CH 3 )C 8 H 17 Cl -
[(CH 3 ) 3 SiO] 3 Si(CH 2 ) 3 OCH 2 CHOHCH 2 P + (O) - (CH 3 )C 10 H 21
[(ch 3 ) 5 siO] 3 Si(CH 2 ) 2 OCH 2 CHOHCH 2 P + [(C 2 H 4 O) 2 H] 2 C 10 H 21 Br -
[(CH 3 ) 3 SiO] 3 SiCH 2 OCH 2 CHOHCH 2 P + [(C 3 H 6 O) 8 C 2 H 5 ](C 4 H 9 ) 2 Cl -
[(CH 3 ) 3 SiO] 3 SiCH 2 OCH 2 CHOHCH 2 S + (CH 3 )C 18 H 37 Cl -
[(CH 3 ) 3 SiO] 2 C 12 H 25 SiCH 2 OCH 2 CHOHCH 2 S + (C 3 H 6 COOH)C 10 H 21 Cl -
[(CH 3 ) 3 SiO] 3 SiCH 2 OCH 2 CHOHCH 2 S + (C 4 H 8 OH)C 8 H 17 Br -
[(CH 3 ) 3 SiO] 3 Si(CH 2 ) 2 OCH 2 CHOHCH 2 S + (O) -C 16 H 33
[(ch 3 ) 3 siO] 3 SiCH 2 OCH 2 CHOHCH 2 S + [(C 2 H 4 O) 6 H)]C 6 H 4 CH 3 Cl -
[(CH 3 ) 3 SiO] 3 SiCH 2 OCH 2 CHOHCH 2 S + [(C 4 H 8 O) 12 CH 3 ]C 8 H 17 Cl -
U.S. Pat. No. 3,389,160 discloses compounds of Formula XIII when R 4 is an alkyl, aryl, or arylalkyl group. Commonly assigned patent application, "Organosilane Compounds" by Heckert and Watt, U.S. Ser. No. 570,538, filed Apr. 22, 1975 discloses the preparation of the other compounds. (The disclosure of this application is herein incorporated by reference.)
Siloxane oligomers of the above organosilanes are also useful in the present invention. Such oligomers are formed from the monomers by the controlled addition of from 1 to 100 equivalents of water, preferably in an inert solvent such as alcohol, tetrahydrofuran, etc. As used herein, "oligomers" is used to mean a degree of polymerization of from 2 to 100, preferably 2 to 20. A higher degree of polymerization adversely affects the ability of the compound to bond itself to the hard surface and is for this reason avoided. Examples of siloxane oligomers having varying degress of polymerization are readily visualized from the above examples of organosilane monomers.
Water-soluble organic detergents selected from the group consisting of nonionic detergents, zwitterionic detergents, ampholytic detergents and mixtures thereof are used. U.S. Pat. No. 3,579,454 issued May 18, 1971 to Everett J. Collier, Col. 12, line 16 to Col. 13, line 64, (the disclosure of which is herein incorporated by reference) describes suitable detergents which fall within the abovedescribed classes. The nonionic detergents are preferred. The ratio of organosilane to organic detergent is from 2:1 to 1:10,000, preferably 1:1 to 1:500, most preferably 1:3 to 1:60. An amount of organosilane below 1:10,000 does not initially provide a noticeable soil release benefit and is, for this reason, avoided. (A benefit is realized from compositions containing a ratio of organosilane to detergent less than 1:10,000 after repeated washings due to a gradual buildup of deposited organosilane but is, for all practical purposes, too gradual to be of significance.) The upper level of organosilane in the composition is dictated by cost and the absence of any further noticeable soil release benefit. Generally, the amount of organosilane in a composition does not exceed 50% for a rinse aid type product and 10% for other detergent compositions.
When metallic or vitreous surfaces are contacted with a detergent composition containing the above-described organosilanes, a thin coating of the organosilane is attached to the surfaces. It is theorized that the positively charged organosilane is attracted to a negatively charged metallic or vitreous surface. The silicon atom in the organosilane forms a bond with the surface. The presence of the positive charge on the organosilane is necessary to allow the bonding to take place within a reasonable time period when the organosilane is applied from a dilute system such as is normally encountered in detergent compositions. The terminal alkyl groups attached to the positively charged compound provide the soil release benefits. It is believed that the organosilane compound polymerizes on the surface to form a thin coating of the polymer. The coating is responsible for imparting the soil release benefits to the surface. That is, a hard surface having on it the polymeric coating will be soiled; however, the soil is not tenaciously bound to the surface by virtue of the coating and for this reason is easily washed away.
Repeated washings can subsequently remove the polymeric coating. However, the soil release benefit is renewed by using the detergent compositions of this invention. The ability to provide a soil release benefit from a wash or rinse solution is especially beneficial in that it allows the consumer to efficiently and economically impart the benefit to a hard surface without adversely affecting its appearance.
Detergent compositions in which the organosilane compound is included are described in the following paragraphs.
RINSE AID
Rinse aids are intended to be used in automatic dishwashing machines used either in the home or in commercial establishments. At the end of the cleaning cycle, it is desirable that the rinse water which is sprayed onto tableware and cooking utensils drain uniformly. Such uniform draining assures that spots of water do not remain behind. Invariably the water will contain dissolved substances which will leave behind a residue when dried. The inclusion of a rinse aid in the final rinse step insures that very little water is left behind on the dishes. The rinse aids of this invention consist essentially of from 0.1% to 50%, preferably 1% to 10% of the organosilane; from 5% to 99.9%, preferably 10% to 50% of the water-soluble organic nonionic detergent; and the balance water. Optionally from 1% to 30%, preferably 5% to 10% of a sequestering agent, e.g. phosphoric, glycolic, tartaric, succinic, citric, lactic, fumaric, or glyconic acid is included in the composition.
CAR WASH DETERGENT COMPOSITIONS
A composition intended for use in automatic car washes consists essentially of from 0.01% to 10%, preferably 0.1% to 2% of the organosilane; from 20% to 35%, preferably 23% to 28% of the water-soluble nonionic, zwitterionic, and/or ampholytic organic detergent; and the balance water. Optionally, from 1% to 10%, preferably 1% to 3% of magnesium sulfate is included in the composition.
LIGHT DUTY LIQUID DETERGENT COMPOSITION
Light duty liquid detergent compositions are used for hand washing of cooking utensils and tableware. Such compositions consist essentially of from 0.01% to 10%, preferably 0.1% to 2% of the organosilane; from 10% to 90%, preferably 20% to 40% of the water-soluble nonionic, zwitterionic, and/or ampholytic detergent; and the balance water. Optionally, an electrolyte such as potassium chloride or sodium chloride is included in the composition at a level of from 0.5% to 5%, preferably 1% to 2%. Other optional components include a hydrotrope, e.g. toluene sulfonate, cumene sulfonate or xylene sulfonate at a level of from 1% to 20%, preferably 2% to 5%, and a lower alcohol, e.g. a C 1-4 alcohol at a level of from 1% to 20%, preferably 3% to 10%.
AUTOMATIC DISHWASHING DETERGENT COMPOSITION
A detergent composition intended to be used in the home in an automatic dishwashing machine is also encompassed by this invention. Such compositions consist essentially of from 0.01% to 5%, preferably 0.1% to 2% of the organosilane; from 0.1% to 15%, preferably 1% to 5% of the water-soluble nonionic detergent; from 5% to 60%, preferably 30% to 50% of a water-soluble organic or inorganic alkaline builder salt; and the balance inert filler salts. Suitable water-soluble organic and inorganic alkaline builder salts include the following: sodium tripolyphosphate, sodium citrate, sodium carbonate and sodium nitrilotriacetate.
Sodium sulfate and sodium chloride are suitable inert filler salts normally included in detergent compositions of this type.
These compositions can additionally contain from 7% to 35%, preferably 10% to 20%, of an alkali metal silicate having a SiO 2 :M 2 O ratio of from 3.6:1 to 1:2, preferably 2:1 to 3.2:1 wherein M is an alkali metal, e.g. sodium. The composition can optionally also contain a bleach in an amount sufficient to give the product an available chlorine content of from 0.5% to 10%, preferably 1% to 5%. Any suitable chlorine yielding bleach can be used. Examples are as follows: chlorinated trisodium phosphate, dichlorocyanuric acid; salts of chlorine substituted cyanuric acid; 1,3-dichloro-5,5-dimethylhydantoin; paratoluene sulfodichloroamide; trichloromelamine; N-chlorosucinimide; N,N'-dichloroazodicarbonamide; N-chloroacetyl urea; N,N'-dichlorobiuret; chlorinated dicyandiamide; sodium hypochlorite; calcium hypochlorite; and lithium hypochlorite.
COMMERCIAL AUTOMATIC DISHWASHING DETERGENT COMPOSITION
A commercial dishwashing composition consists essentially of from 0.01% to 5%, preferably 0.1% to 2% of the organosilane; from 0.1% to 15%, preferably 1 % to 5 % of the water-soluble nonionic detergent; from 5% to 60%, preferably 30 % to 50 % of a water-soluble organic or inorganic alkaline builder salt; from 10% to 40%, preferably 10% to 30% of an alkali metal base; and the balance inert filler salts.
Suitable water-soluble organic or inorganic alkaline builder salts are described above in connection with the automatic dishwashing detergent composition. Examples of alkali metal bases are sodium hydroxide and potassium hydroxide.
An alkali metal silicate or a chlorine bleach as described above in connection with the automatic dishwashing detergent composition can be added herein at the same levels.
WINDOW CLEANER
Window cleaner compositions contain from 0.001% to 5%, preferably 0.002% to 1% of the organosilane. The remainder of the window cleaner composition consists essentially of from 0.1% to 5%, preferably 0.5% to 3% of the water-soluble nonionic, zwitterionic, and/or ampholytic organic detergent and the balance an organic inert solvent or solvent/water mixture. Suitable organic inert solvents include the following: methanol, ethanol, isopropanol, acetone and methyl ethyl ketone.
ABRASIVE CLEANER
The organosilane of this invention is also used in a detergent composition intended for the cleaning of hard surfaces such as ovens. Such compositions consist essentially of from 0.002% to 5%, preferably 0.01% to 1% of the organosilane, from 0.1% to 10%, preferably 1% to 5% of the water-soluble nonionic, zwitterionic, and/or ampholytic organic detergent; from 50% to 95%, preferably 50% to 75% of a water-insoluble abrasive; and the balance inert filler salts. Suitable abrasives include the following: quartz, pumicite pumice, talc, silica sand, calcium carbonate, china clay, zirconium silicate, bentonite, diatomaceous earth, whiting, feldspar, and aluminum oxide.
IN-TANK TOILET BOWL CLEANERS
The compositions of this invention are useful as an in-tank toilet bowl cleaner. Such compositions consist essentially of from 0.01% to 10%, preferably 0.5% to 2% of the organosilane; from 0.1% to 5%, preferably 0.5% to 2% of sodium bisulfate; from 0.1% to 20%, preferably 1% to 15% of a lower, i.e. C 1-4 alcohol; from 0.5% to 20%, preferably 1% to 15% of the water-soluble organic, nonionic, zwitterionic or ampholytic detergent or mixtures thereof; and the balance water.
The following examples are illustrative of this invention.
EXAMPLE I
The organosilanes of this invention are tested for their ability to provide a soil release benefit to hard surfaces in the manner described immediately below.
A solution of 0.003% organosilane and 0.01% tallow alcohol ethoxylated with 9 moles of ethylene oxide in distilled water is prepared. The solution has a temperature of 55° C. A clean glass slide is dipped into the solution and held there for 10 minutes. The solution is continuously mixed while the glass slide is being treated. After the 10 minute hold time, the glass slide is removed and rinsed with tap water having a temperature of about 15° C. The rinsed slide is dried at 72° C. for 20 minutes.
Next the slide is soiled by dipping it into an oatmeal slurry for 15 seconds and baking it for 20 minutes at 72° C. Thereafter, the slide is washed with distilled water in a Tergotometer for 3 minutes at 55° C. The resultant slide is dyed with a solution of iodide and potassium iodide in water to facilitate its grading.
The slide is graded visually and assigned a number ranging from 0 (equal to an untreated glass slide, i.e., the control) to 4 (a totally clean slide). Intermediate grades of 1 (slightly better than control), 2 (a definite noticeable improvement) and 3 (slide is almost clean) are used.
Each organosilane is tested 5 times in the manner above described and its average is recorded. The individual organosilanes and their grades are reported below.
______________________________________ Grade______________________________________(C.sub.2 H.sub.5 O).sub.3 SiCH.sub.2 N.sup.+(CH.sub.3).sub.2 C.sub.12H.sub.25 Cl.sup.- 4(C.sub.2 H.sub.5 O).sub.3 SiCH.sub.2 P.sup.+(CH.sub.3).sub.2 C.sub.12H.sub.25 Cl.sup.- 4(C.sub.2 H.sub.5 O).sub.3 Si(CH.sub.2).sub.2 N.sup.+(CH.sub.3).sub.2C.sub.12 H.sub.25 Cl.sup.- 4(C.sub.2 H.sub.5 O).sub.3 Si(CH.sub.2).sub.3 N.sup.+(CH.sub.3).sub.2C.sub.12 H.sub.25 Br.sup.- 4(C.sub.2 H.sub.5 O).sub.3 SiCH.sub.2 N.sup.+(CH.sub.3).sub.2 C.sub.6H.sub.13 Cl.sup.- 1(CH.sub.3 O).sub.3 SiCH.sub.2 N.sup.+(CH.sub.3).sub.2 C.sub.6 H.sub.5Cl.sup.- 1(C.sub.2 H.sub.5 O).sub.3 SiCH.sub.2 N.sup.+(CH.sub.3).sub.2 C.sub.18H.sub.37 Cl.sup.- 4(C.sub.2 H.sub.5 O).sub.3 SiCH.sub.2 S.sup.+(CH.sub.3)C.sub.18 H.sub.37Cl.sup.- 4(C.sub.4 H.sub.8 O).sub.3 SiCH.sub.2 N.sup.+(CH.sub.3).sub.2 C.sub.12H.sub.25 C.sub.6 H.sub.5 Cl.sup.- 4(CH.sub.3 O).sub.3 SiCH.sub.2 N.sup.+[(C.sub.3 H.sub.6 O).sub.3 C.sub.2H.sub.5]2 C.sub.8 H.sub.17 Cl.sup.- 1(C.sub.2 H.sub.5 O).sub.3 Si(CH.sub.2).sub.3 N.sup.+(C.sub.2 H.sub.5)[(C.sub.4 H.sub.9 O).sub.8 H]C.sub.4 H.sub.9 Cl.sup.- 1.5(C.sub.2 H.sub.5 O).sub.3 SiCH.sub.2 N.sup.+(C.sub.3 H.sub.7 COOH).sub.2C.sub.8 H.sub.17 Cl.sup.- 1(C.sub.2 H.sub.5 O).sub.3 SiCH.sub.2 N.sup.+[(C.sub.2 H.sub.4 O).sub.4COCH.sub.3]2 C.sub.18 H.sub.37 Cl.sup.- 2.5[(CH.sub.3).sub.3 SiO].sub.3 SiCH.sub.2 N.sup.+(CH.sub.3).sub.2 C.sub.12H.sub.25 Br.sup.- 4(C.sub.2 H.sub.5 O).sub.3 SiCH(C.sub.12 H.sub.25)N.sup.+(C.sub.2 H.sub.5).sub.3 Cl.sup.- 4(C.sub.2 H.sub.5 O).sub.3 SiCH(C.sub.12 H.sub.25)P.sup.+(C.sub.2 H.sub.5).sub.3 Cl.sup.- 4(CH.sub.3 O).sub.2 CH.sub.3 SiCH(C.sub.18 H.sub.37)N.sup.+(CH.sub.3).sub.3 Br.sup.- 4(CH.sub.3 O).sub.2 CH.sub.3 SiCH(C.sub.18 H.sub.37)S.sup.+(CH.sub.3).sub.2 Br.sup.- 4(C.sub.2 H.sub.5 O).sub.3 SiCH.sub.2 N.sup.+(O).sup.-(CH.sub.3)C.sub.14H.sub.29 4(C.sub.2 H.sub.5 O).sub.3 SiCH.sub.2 S.sup.+(O).sup.-C.sub.14 H.sub.29 4(CH.sub.3 O).sub.3 Si(CH.sub.2).sub.3 N.sup.+(CH.sub.3).sub.2 C.sub.6H.sub.4 C.sub.3 H.sub.7 Cl.sup.- 3(CH.sub.3 O).sub.3 SiCH.sub.2 N.sup.+(C.sub.2 H.sub.4 OH)(CH.sub.3)C.sub.12 H.sub.25 Cl.sup.- 4(CH.sub.3 O).sub.3 Si(CH.sub.2).sub.3 OCH.sub.2 CHOHCH.sub.2 N.sup.+ 1.5(CH.sub.3).sub.2 C.sub.8 H.sub.17 Cl.sup.-(C.sub.2 H.sub.5 O).sub.2 C.sub.4 H.sub.9 SiCH.sub.2 N.sup.+(CH.sub.3).sub.2 C.sub.12 H.sub.25 Cl.sup.- 4[H(OC.sub.2 H.sub.4).sub.18 O]].sub.3 SiCH.sub.2 N.sup.+(C.sub.2 H.sub.5).sub.2 C.sub.18 H.sub.37 Cl.sup.- 4[CH.sub.3 (OC.sub.2 H.sub.4).sub.12 O].sub.2 CH.sub.3 SiCH.sub.2 N.sup.+(CH.sub.3).sub.2 C.sub.12 H.sub.25 Br.sup.- 4[CH.sub.3 CO(OC.sub.2 H.sub.4).sub.4]3 Si(CH.sub.2).sub.3 N.sup.+(CH.sub.3).sub.2 C.sub.10 H.sub.21 Cl.sup.- 4[H(OC.sub.2 H.sub.4).sub.8 ](CH.sub.3 O).sub.2 SiCH.sub.2 N.sup.+(CH.sub.3).sub.2 C.sub.12 H.sub.25 Cl.sup.- 4[CH.sub.3 (OC.sub.2 H.sub.4).sub.6 O].sub.3 SiCH(C.sub.12 H.sub.25)N.sup.+(CH.sub.3).sub.3 Br.sup.- 4[H(OC.sub.2 H.sub.4).sub.2 O].sub.2 (CH.sub.3 O)SiCH(C.sub.8 H.sub.17)N.sup.+ 4(CH.sub.3).sub.2 C.sub.6 H.sub.13 Cl.sup.-[(CH.sub.3).sub.3 SiO].sub.3 SiCH(C.sub.16 H.sub.37)N.sup.+(CH.sub.3).sub.2 C.sub.4 H.sub.9 Cl.sup.- 4[H(OC.sub.2 H.sub.4).sub.4 O].sub.3 SiCH.sub.2 OCH.sub.2 CHOHCH.sub.2N.sup.+ 3(CH.sub.3).sub.2 C.sub.12 H.sub.25 Cl.sup.-[CH.sub.3 (OC.sub.2 H.sub.4).sub.8 O].sub.2 (CH.sub.3 O)SiCH.sub.2OCH.sub.2 CHOHCH.sub.2 N.sup.+ 2(C.sub.4 H.sub.9).sub.3 Cl.sup.-[(CH.sub.3).sub.3 SiO].sub.3 SiCH.sub.2 OCH.sub.2 CHOHCH.sub.2 N.sup.+ 4(CH.sub.3).sub.2 C.sub.14 H.sub.29 Br.sup.-[(CH.sub.3).sub.3 SiO].sub.3 SiCH.sub.2 OCH.sub.2 CHOHCH.sub.2 P.sup.+ 4(CH.sub.3).sub.2 C.sub.14 H.sub.29 Br.sup.-Siloxane dimer of (C.sub.2 H.sub.5 O).sub.3 SiCH.sub.2 N.sup.+ 4(CH.sub.3).sub.2 C.sub.12 H.sub.25 Cl.sup.-Siloxane dimer of (C.sub.2 H.sub.5 O).sub.2 (CH.sub.3)SiCH.sub.2 N.sup.+ 3(CH.sub.3).sub.2 C.sub.16 H.sub.33 Cl.sup.-Siloxane trimer of (CH.sub.3 O).sub.3 Si(CH.sub.2).sub.3 P.sup.+ 4(CH.sub.3).sub.2 C.sub.12 H.sub.25 Cl.sup.-Siloxane dimer of (CH.sub.3 O).sub.3 SiCH.sub.2 S.sup.+ 4(CH.sub.3)C.sub.12 H.sub.25 Cl.sup.-______________________________________
The addition of different water-soluble organic detergents as hereinbefore described to the solution at levels of 2:1 to 1:10,000 organosilane to detergent does not alter the relative grades of above. That is, such solutions still impart a noticeable soil release benefit to the glass slides. In particular, sodium 3-dodecylaminopropionate or 3-(N,N-dimethyl-N hexadecylammonio)propane-1-sulfonate and the organosilane when tested as above give the same relative grades as above reported for the nonionic detergent.
The following examples are illustrative of detergent compositions containing the organosilanes of this invention. All impart a noticeable solid release benefit to metallic and vitreous surfaces washed or rinsed therewith.
______________________________________EXAMPLE IIRinse aid______________________________________(CH.sub.3 O).sub.2 C.sub.12 H.sub.25 SiCH.sub.2 N.sup.+(CH.sub.3).sub.2C.sub.10 H.sub.21 Cl.sup.- 2.0%Tallow alcohol ethoxylated with 9 moles 15.0% of ethylene oxideWater balance______________________________________
when
(CH.sub.3 O).sub.2 C.sub.12 H.sub.25 SICH.sub.2 P.sup.+(CH.sub.3).sub.2 C.sub.10 H.sub.21 Cl.sup.-
or
(CH.sub.3 O).sub.2 C.sub.12 H.sub.25 SiCH.sub.2 S.sup.+(CH.sub.3)C.sub.10 H.sub.21 Cl.sup.-
is substituted for the organosilane of Example II, substantially the same results are obtained.
______________________________________EXAMPLE IIIRinse Aid______________________________________(C.sub.2 H.sub.5 O).sub.3 SiCH.sub.2 N.sup.+(CH.sub.3).sub.2 C.sub.12H.sub.25 Cl.sup.- 5.0%50:50 mixture of C.sub.14 and C.sub.15 alcohols 40.0% ethoxylated with 4 moles of ethylene oxideCitric Acid 8.0%Water balance______________________________________
Substantially the same results are obtained from the above composition when the organosilane is replaced by a similar compound having a phosphorous atom or a sulfur atom (and only one methyl group) in place of the nitrogen atom.
______________________________________EXAMPLE IVCar Wash Detergent Composition______________________________________(CH.sub.3 O).sub.3 Si(CH.sub.2).sub.3 N.sup.+(CH.sub.3).sub.2 C.sub.18H.sub.37 5.0%Poly(oxyalkylene)nonionic detergent 26.0% (Pluradot HA430 supplied by Wyandotte Corp.)Magnesium Sulfate 2.0%Water balance______________________________________
When the above organosilane is replaced with
(CH.sub.3 O).sub.3 Si(CH.sub.2).sub.3 P.sup.+(CH.sub.3).sub.2 C.sub.18 H.sub.37 Cl
or
(CH.sub.3 O).sub.3 Si(CH.sub.2).sub.3 S.sup.+(CH.sub.3)C.sub.18 H.sub.37 Cl.sup.-,
substantially the same results are obtained.
______________________________________EXAMPLE VLight Duty Liquid Detergent Composition______________________________________(C.sub.2 H.sub.5 O).sub.3 Si(CH.sub.2).sub.3 .sup.+(CH.sub.3).sub.2C.sub.18 H.sub.37 Cl.sup.- 0.05%Nonyl phenol ethoxylated with 6 moles 30.0 % of ethylene oxideWater balance______________________________________
______________________________________EXAMPLE VILight Duty Liquid Detergent Composition______________________________________(C.sub.3 H.sub.7 O).sub.3 Si(CH.sub.2).sub.2 N.sup.+(C.sub.2 H.sub.5).sub.2 C.sub.10 H.sub.21 Br.sup.- 1.0%Coconut alcohol ethoxylated with 6 moles 25.0% of ethylene oxidePotassium chloride 2.0%Sodium toluene sulfonate 2.0%Ethanol 5.0%Water balance______________________________________
Replacement of the above organosilane with similar compounds having a phosphorous atom and a sulfur atom (and only one ethyl group) in place of the nitrogen atom gives substantially the same results.
______________________________________EXAMPLE VIIAutomatic Dishwashing Machine Detergent Composition______________________________________(C.sub.2 H.sub.5 O).sub.2 C.sub.8 H.sub.17 SiCH.sub.2 N.sup.+(CH.sub.3).sub.2 C.sub.6 H.sub.13 Cl.sup.- 1.0%Tallow alcohol ethoxylated with 9 moles 3.0% of ethylene oxideSodium Citrate 50.0%Sodium Sulfate 43.0%Misc. (water, perfume and dyes) balance______________________________________
When
(C.sub.2 H.sub.5 O).sub.2 C.sub.8 H.sub.17 SiCH.sub.2 P.sup.+(CH.sub.3).sub.2 C.sub.6 H.sub.13 Cl.sup.-
or
(C.sub.2 H.sub.5 O).sub.2 C.sub.8 H.sub.17 SiCH.sub.2 S.sup.+(CH.sub.3)C.sub.6 H.sub.13 Cl.sup.-
is substituted for the organosilane of Example VII, substantially the same results are obtained.
______________________________________EXAMPLE VIIIAutomatic Dishwashing MachineDetergent Composition______________________________________(CH.sub.3 O).sub.2 CH.sub.3 Si(CH.sub.2).sub.2 N.sup.+(C.sub.2 H.sub.5).sub.2 C.sub.16 H.sub.33 Cl.sup.- 0.05%Sodium tripolyphosphate 35.0%Chlorinated trisodium phosphate 21.0%Poly(oxyalkylene) nonionic detergent 4.0% (Pluradot HA433 supplied by Wyandotte Corp.)Sodium silicate (SiO.sub.2 :Na.sub.2 O) 17.5%Sodium Sulfate 21.0%Miscellaneous (water, perfume, dyes, suds, suppressors, etc.) Balance______________________________________
The use of similar organosilanes having a phosphorous or sulfur atom (and only one ethyl group) in place of the nitrogen atom results in satisfactory soil release benefits.
______________________________________EXAMPLE IXCommercial Automatic DishwashingDetergent Composition______________________________________(C.sub.4 H.sub.9 O).sub.3 SiCH.sub.2 N.sup.+(CH.sub.3).sub.2 C.sub.10H.sub.21 Cl.sup.- 2.0%Tallow alcohol ethoxylated with 5.0% 6 moles of ethylene oxideSodium tripolyphosphate 50.0%Sodium hydroxide 15.0%Sodium Sulfate 25.0%Misc. (water, perfume and dyes) balance______________________________________
Substantially the same results are obtained from the above composition when the organosilane is replaced by a similar compound having a phosphorous atom or a sulfur atom (and only one methyl group) in place of the nitrogen atom.
______________________________________EXAMPLE XCommercial Automatic DishwashingDetergent Composition______________________________________(C.sub.4 H.sub.9 O).sub.3 SiCH.sub.2 N.sup.+(CH.sub.3).sub.2 C.sub.6H.sub.13 Cl.sup.- 0.5%Sodium tripolyphosphate 40.0%Tallow alcohol ethoxylated with 9 moles of ethylene oxide 3.0%Sodium hydroxide 22.0%Sodium silicate 10.0%Chlorinated trisodium phosphate 12.0%Sodium sulfate 10.0%Miscellaneous (perfume, dyes, water) Balance______________________________________
______________________________________EXAMPLE XIWindow Cleaner______________________________________(C.sub.2 H.sub.5 O).sub.3 Si(CH.sub.2).sub.2 N.sup.+(C.sub.3 H.sub.7).sub.2 CH.sub.2 C.sub.6 H.sub.5 Cl.sup.- 0.01%C.sub.12 alcohol ethoxylated with 8 moles of ethylene oxide 2.0%Isopropanol 97.99%______________________________________
The use of organosilane compounds having a phosphorous atom or a sulfur atom (and only one propyl group) in place of the nitrogen atom results in satisfactory products.
______________________________________EXAMPLE XIIAbrasive Cleaner______________________________________(CH.sub.3 O) (CH.sub.3).sub.2 Si(CH.sub.2).sub.3 N.sup.+(C.sub.2 H.sub.5).sub.2 C.sub.12 H.sub.25 Br.sup.- 1.0%Coconut alcohol ethoxylated with 5 moles of ethylene oxide 2.0%Silica 70.0%Sodium sulfate 23.0%Miscellaneous (water, perfume, dyes) Balance______________________________________
when
(CH.sub.3 O) (CH.sub.3).sub.2 Si(CH.sub.2).sub.3 P.sup.+(C.sub.2 H.sub.5).sub.2 C.sub.12 H.sub.25 Br.sup.-
or
(CH.sub.3 O) (CH.sub.3).sub.2 Si(CH.sub.2).sub.3 S.sup.+(C.sub.2 H.sub.5)C.sub.12 H.sub.25 Br.sup.-
is substituted for the organosilane of Example XII, substantially the same results are obtained.
______________________________________EXAMPLE XIIIIn-Tank Toilet Bowl Cleaner______________________________________(CH.sub.3 O).sub.3 SiCH.sub.2 N.sup.+(CH.sub.3).sub.2 C.sub.10 H.sub.21Cl.sup.- 0.5%Sodium salt of sulfated coconut alcohol 10.0%Sodium bisulfate 1.0%Ethanol 5.0%Water balance______________________________________
Substitution of
(CH.sub.3 O).sub.3 SiCH.sub.2 P.sup.+(CH.sub.3).sub.2 C.sub.10 H.sub.21 Cl.sup.-
or
(CH.sub.3 O).sub.3 SiCH.sub.2 S.sup.+(CH.sub.3)C.sub.10 H.sub.21 Cl.sup.-
for the above organosilane gives substantially the same results.
______________________________________EXAMPLE XIVLight Duty Liquid Detergent Composition______________________________________(C.sub.2 H.sub.5 O).sub.3 Si(CH.sub.2).sub.3 N.sup.+(CH.sub.3).sub.2C.sub.18 H.sub.37 Cl.sup.- 1.0%Coconut alcohol ethoxylated with 22.0% 6 moles of ethylene oxideDimethyldodecylamine oxide 12.0%Ethanol 5.4%Water balance______________________________________
Satisfactory results are obtained when the organosilanes of Examples II - XIV are replaced by any of the organosilanes of Example I. Siloxane oligomers of the organosilanes of Examples I - XIV having a degree of polymerization of from 2 to 100 when substituted in the above examples for the organosilane monomer also give a noticeable soil release benefit to surface washed or rinsed therewith.
The compositions of this invention are generally diluted with water during usage. Under normal usage conditions, from 0.2 to 20 p.p.m. of organosilane is found in the wash or rinse solution. Surprisingly, even from such a low concentration, the organosilane molecule of this invention deposits itself upon hard surfaces in an amount sufficient to provide a noticeable soil release benefit. As previously discussed, it is believed the positively charged atom in the molecule is largely responsible for the necessary deposition to take place under such dilute conditions.
In another aspect of this invention, the organosilane is used in a commercial dishwashing machine as part of the final rinse cycle and free of any organic detergent. Thus, the organosilane is metered into the rinse water at a level sufficient to provide a soil release benefit (i.e. about 0.2 to 20 p.p.m. organosilane) and applied to the previously washed cooking utensils and tableware. | A detergent composition containing an organosilane is capable of imparting soil release benefits to hard surfaces washed therewith. Soil adheres to such surfaces less strongly thereby making them easier to clean. The detergent composition can be formulated for use in a wide range of applications, e.g., as a light duty liquid composition, rinse aid, oven cleaner, window cleaner, automatic dishwasher composition, car wash detergent composition or toilet bowl cleaner. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to a method of measuring the rotor flux of a dynamoelectric machine by measuring the terminal voltage of the machine.
Many synchronous and induction motor control schemes such as vector control and sin θ controls use an estimate of the phase and amplitude of the rotor flux in determining motor torque and to generate frequency and current commands for the machine. In motor controls such as vector controls, the phase and magnitude of the flux must be accurately known since flux is produced by providing current in phase with the motor flux and torque is produced when flux and current are ninety degrees out of phase.
One method of measuring rotor flux is to use flux coils embedded in each phase of the motor stator as described in Franz et al, U.S. Pat. No. 4,011,489. However, this method is only available for motors specially constructed for flux control. It is desireable, therefore, to provide a method of flux control which can be applied to a standard alternating current motor.
If the voltage across the magnetizing reactance of a motor is integrated by an ideal integrator, the rotor flux is obtained. The voltage across the magnetizing reactance in a motor, however, cannot be measured directly. What can be measured is the total terminal voltage of the motor which can be represented as the sum of voltages due to stator resistance and leakage reactance in series with the induced CEMF (counterelectromotive force). The stator resistance cannot be easily compensated for since it varies as a function of temperature. Furthermore, the terminal voltage measurement is not exact due to minor voltage offsets in the voltage measuring circuits.
One approach for generating a flux signal from motor terminal voltage is to use a low pass filter as an integrator. At low frequencies, the low pass filter has a finite gain. The rotor flux is a sinusoidal varying signal which ideally has a long term average value of zero. If the voltage measuring circuit including the filter introduces any offset, the integrated signal will have a non-zero average value producing inaccurate results. When a low pass filter is used, precision voltage sensors with an accuracy greater than 0.1 percent are usually required.
Another approach to flux reconstruction, disclosed in Blaschke's German Pat. No. 1806769, is to use an integrator with a proportional plus integral feedback loop to generate a signal with a zero time average. The time constant of the proportional plus integral feedback has to be sufficiently large to provide averaging at low frequencies which in turn provides low gain and sluggish response. Distortion of the flux phase information occurs at low frequencies since the circuit is not an ideal integrator.
Yet another approach, disclosed in Dreiseitl et al, U.S. Pat. No. 4,282,473, is to use an adaptive notch filter to perform machine terminal voltage integration to avoid deterioration in performance at low frequencies. However, such technique introduces additional filter elements which may give rise to other offset problems. Furthermore, the motors are operated over a wide frequency range in which the notch filter is not utilized.
It is an object of the present invention to provide an improved method of obtaining flux information from motor terminal voltage.
It is an object of the present invention to generate a flux signal from the motor terminal voltage that provides DC elimination synchronous to the flux wave.
It is a further object of the present invention to generate a flux signal from terminal voltage that provides accurate phase information from low precision sensors.
It is a further object of the present invention to generate a flux signal from terminal voltage that provides DC elimination during rapidly changing rotor speeds.
SUMMARY OF THE INVENTION
In one aspect of the present invention a method of developing a flux signal indicative of flux in a dynamoelectric machine is provided. A machine voltage at the machine terminals is measured and a signal proportional to the machine voltage is integrated to generate a flux signal. The local maxima and minima of the flux signal are detected and the drift of the actual waveform from the desired zero axis of the flux signal is determined each half cycle from the last maxima and minima detected. The DC component found in the flux signal is subtracted from the signal proportional to terminal voltage, prior to integrating the signal proportional to terminal voltage, thereby providing a reconstructed flux signal with the DC component eliminated.
BRIEF DESCRIPTION OF THE DRAWING
While the specification concludes with claims particularly pointing out and distinctly claiming the present invention, the objects and advantages of the invention can be more readily ascertained from the following description of a preferred embodiment, taken in conjunction with the accompanying drawing in which:
FIG. 1 is a part block diagram, part schematic representation of hardware used in the digital flux reconstruction method in accordance with the present invention;
FIG. 2 is a vector diagram showing the relationship between a three phase representation of stator voltages and a two phase representation stator voltages;
FIG. 3 is a block diagram representation of the discrete data flow occurring in the microcomputer of FIG. 1 according to the present invention;
FIGS. 4A, 4B and 4C show waveform diagrams on a common time scale without drift correction, with instantaneous drift correction and with long-term drift correction, respectively, helpful in explaining the operation of the present invention; and
FIG. 5 is a pseudo code representation of the detection of drift of the actual waveform from the desired zero axis in the flux signal and its correction in accordance with the present invention.
FIG. 6 is a simplified block diagram of a phase lock loop circuit of a type which might be used in the implementation of a flux control motor system;
FIG. 7 is a flux diagram illustrating the relationships of the flux vectors referenced in FIG. 6;
FIG. 8 is a four quadrant diagram illustrating the orientation of flux vectors; and
FIG. 9 is a first and second table which identify conditions and a corresponding action required to implement initialization of the peak detect and DC correct logic associated with the flux integrators.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the Figures and particularly FIG. 1 thereof, three phase voltages A, B and C are coupled to a dynamoelectric machine shown in the present embodiment as an induction motor 5. The three phase voltages are also coupled through high impedance voltage feedback resistors 7, 9 and 11, to analog hardware 13 which provides a two phase representation of the stator voltage. The two phases in the two phase representation are designated ALPHA and BETA. ALPHA is in phase with motor phase A and BETA is displaced ninety degrees from ALPHA in the direction of the three phase ABC rotation. A vector diagram showing the relationship between the two coordinate systems is shown in FIG. 2. No information is lost in this coordinate system change since the three phases A, B and C contain redundant information in the representation of a vector in two dimensional space. The ALPHA and BETA axes may be thought of as abscissa and ordinate axes mounted on the stator with the origin of the coordinate systems situated on the shaft of the motor. The ALPHA and BETA voltage feedback signals provided by the analog hardware represent the components of the stator voltage in phase with the ALPHA and BETA axis, respectively.
The ALPHA and BETA analog voltage feedback signals from the analog hardware 13 are coupled to voltage controlled oscillators (VCO) 15 and 17, respectively, which provide digital pulse train signals to two internal counters of a microcomputer 19, such as Intel 8051.
Referring now to FIG. 3 a block diagram showing discrete data flow in the microcomputer 19 is shown for the ALPHA signal. Although the following discussion will refer to discrete devices for performing the described functions, it should be understood that the devices are identified only for ease of illustration and may not have a fixed counterpart within the structure of the microcomputer. One of the internal counters in the microcomputer is shown as a free running 8 bit counter 21. The counter 21 is sampled and a difference in the count since the last sample provides a representation of the average voltage during the last sampling interval for the ALPHA component.
The sampling is accomplished using a delay element 23 which delays the signal V -- NEW until the next time the 8 bit counter is sampled. At that time, the most recently sampled signal V -- NEW is compared to the previously sampled signal V -- OLD in summing device 25. The delay element 23 and summing device 25 are configured as a differentiator with the difference determination performed every sampling interval. A typical sampling interval may be 1.5 milliseconds.
The average voltage signal from the differentiator is summed with a voltage offset signal in a summing device 27 to correct for a voltage offset in the voltage controlled oscillator. The VCO offset is introduced to provide a counting range which is not centered about zero since the counter 21 cannot recognize the concept of negative counts. A scale factor is applied to the signal from device 27 in block 29 and the scaled V DIFF signal is coupled to a multiplying device 31.
A variable HV, which is a normalizing scale factor, can be utilized when the reconstructed flux signal is used as a feedback signal in a flux regulator having a constant command value. Varying HV varies the command flux value. Below motor base speed, HV is adjusted so that the flux in the motor is correct. Above base speed, field weakening is accomplished by increasing HV according to the ratio of excitation frequency to base frequency.
The VCO 15 and counter 21 will be recognized to form an integrator which integrates the motor voltage signals (ALPHA and BETA in identical circuits). The V DIFF signal is a differentiated signal so that the net result of the processing is to provide a reproduction in digital form of the input analog voltage. During motor operation, the signal from multiplier 31 is passed through to summing junction 39. A summing junction 37 is used prior to startup to couple a synthesized flux signal from a square wave generator 35 through a switch 33 to the flux control apparatus for the purpose of nulling measurement offsets.
The signal from multiplier 31 is corrected by a long term DC offset, to be discussed hereinafter, in summing junction 39. The corrected signal is next integrated in integrator 41. Integrator 41 comprises digital delay block 43 which adds the sum of all the previously sampled, corrected voltages, i.e., an output flux signal, to the presently sampled voltage in summing junction 45 to generate the flux signal. Since block 43 adds the old value of flux to the new volts signal, the output signal of block 41 is the integral of the motor voltage, i.e., the motor flux. A limit device 47 clamps the upper and lower permissable values of the flux signal. The flux signal, which is sinusoidal with a DC offset, is coupled to a peak detect circuit 49 where the minima and maxima of the flux signal are determined. When a peak is detected, the value of the peak is added to the previously detected peak in order to obtain the DC component which is equal to one half of the sum of the maximum and minimum flux values. The DC component is immediately injected through a summing junction 45 where it is subtracted from the flux signal to provide an instantaneous DC correction to prevent the integrator 41 from saturating and to correct the value of the flux signal.
Referring now to FIGS. 4A, B and C, FIG. 4A shows the waveform of the flux signal obtained by integrating stator voltage without correction for DC offset, i.e., drift of the actual waveform from the desired zero axis. An integrator receiving this signal will saturate, due to the DC component resulting from the inaccuracies of the sensors that measure the voltage and other voltage shifts due to factors and offsets. FIG. 4B shows the effect of an instantaneous correction performed every half cycle to remove the DC offset determined from the detected maxima and minima. This correction is indicative of the correction implemented periodically by detector 49 through junction 45.
A further improvement in the flux signal can be made by using a long term offset in addition to the correction made every one half cycle. Each half cycle when a peak is detected, the correction signal is also coupled through a gain block 51 to an integrator 53. Integrator 53 comprises a delay element 54 which provides the sum of all the previous long term DC corrections to a summing junction 55 where the value of the latest gain adjusted DC correction is added. The output of junction 55 passes through a limit block 57 which ensures that the long term DC correction signal is limited to predetermined upper and lower bounds. The DC correction signal is integrated in integrator 53 to provide a long term DC correction signal which is subtracted from each voltage signal in junction 39, reducing the DC offset found by the peak detector during steady state conditions. The peak detector continues to provide instantaneous corrections after a peak is found and the long term correction signal is modified as needed after each peak is found. Typically, the gain of block 51 is much less than one so that the long term correction tends to compensate for offsets without overshooting the desired value, i.e., it tends to be a stabilizing function. FIG. 4C illustrates the effects of both instantaneous correction and long-term correction. It should be noted that the effects of long-term correction through block 53 is to reduce the degree of subsequent instantaneous corrections. The operation of the peak detector together with the instantaneous and long term corrections is shown in detail in the pseudo code of FIG. 5.
The outputs of the block diagram of FIG. 3 are an ALPHA flux component from integrator 41 which is generally sinusoidal and a flux magnitude signal (FMAG) equal to the absolute value of the most recently detected peak. The BETA component of the flux and the BETA flux magnitude are developed in the same way as the ALPHA components. The BETA component is determined from the output of voltage controlled oscillator 17. Note that the variable FMAG is common to both ALPHA and BETA phases.
The pseudo code is shown having a main routine DC DETECT AND CORRECT and four subroutines CHECK -- MIN, CHECK -- MAX, INCORPORATE -- PEAK, AND LONG -- TERM. The four subroutines are called as needed. Initially, the DC -- CORRECT -- BIT is zero and the PEAK -- FOUND -- BIT is zero. The DC -- CORRECT -- BIT is defined as the value of the DC -- CORRECT -- BIT combined in logic OR operation with the PEAK -- FOUND -- BIT flag. In this first pass, this sets DC -- CORRECT -- BIT to zero. If the DC DETECT and CORRECT routine is looking for a minima, the CHECK -- MIN subroutine is called. The subroutine ckecks for decreasing values of sampled flux and, if the flux is decreasing, the variable MIN is set equal to the reduced value of the detected flux. The subroutine then is completed and operation returns to the main routine where the BOOLEAN combination of DC -- CORRECT BIT*/PEAK -- FOUND -- BIT is evaluated. Since the DC -- CORRECT.sub. -- BIT is zero, the expression is not true and the main routine begins again. The CHECK -- MIN subroutine is again called to determined when the flux stops decreasing and begins to increase above the minimum value by a predetermined threshold. On the pass through the subroutine when this occurs, a different subroutine is called, namely INCORPORATE -- PEAK, to determine the instantaneous DC correction. Each time the main routine begins, a new value of flux from the most recently sampled voltage is used.
In the INCORPORATE PEAK subroutine, the DC correction is determined as 1/2 (MAX+MIN) where MAX is the last maximum detected and MIN is the last minimum detected. The minimum value is set equal to the minimum value less the DC correction to determine the true minimum flux. Similarly, the MAX variable is set equal to the maximum less the DC correction to obtain the true maximum flux. The flux magnitude is equal to the corrected maximum flux since the corrected maximum flux is equal to the negative of the corrected minimum flux. At the end of the INCORPORATE PEAK subroutine, operation returns to the CHECK MIN subroutine where the peak found bit is set equal to one. The -- LOOKING -- FOR -- MAX bit is set indicating that a CHECK MIN subroutine has just been completed. The maximum flux variable is set equal to the latest value of the sampled flux.
Returning to the main routine, the Boolean expression DC -- CORRECT BIT */PEAK -- FOUND -- BIT is evaluated. The Boolean expression is true if the DC CORRECT -- BIT combined by an AND operator with the complimented PEAK -- FOUND -- BIT (the "/" means NOT in the expression /PEAK -- FOUND -- BIT -- ) is a logical one. Since the DC -- CORRECT -- BIT is a zero and the PEAK -- FOUND -- BIT is a one, ANDing zero and not one is a zero. Since the expression is false the main routine is run again from the beginning.
The DC -- CORRECT -- BIT is set equal to one, the PEAK -- FOUND -- BIT is set equal to zero and the CHECK -- MAX subroutine is run. The most recent value of flux is sampled and if greater than the previously measured value of flux, the max routine is returned to the main routine and the expression DC -- CORRECT -- BIT */PEAK -- FOUND -- BIT is again evaluated. Since DC -- CORRECT -- BIT is one and PEAK -- FOUND -- BIT is zero, this time the expression DC -- CORRECT BIT */PEAK -- FOUND -- BIT is true and a LONG -- TERM correction subroutine is called. A variable VOF is set equal to its previous value plus K 2 times the DC correction factor. The gain K 2 is less than one and represents the gain of the block 51. The value of VOF is checked not to exceed a predetermined upper or lower limit and the DC correct bit is set equal to zero.
It can be seen that the LONG -- TERM correction subroutine will not be called in the same pass through the main routine in which an INCORPORATE -- PEAK subroutine is called. This controls the maximum time required for each complete running of the main routine and permits the main routine to be run each time a new flux value is determined from the latest voltage sample. The main subroutine begins again from the beginning and calls the CHECK -- MAX subroutine which is repeated until the sampled flux is found to have passed the maximum by a predetermined threshold. The INCORPORATE -- PEAK subroutine is again called and the DC correction value determined.
When the DC DETECT & CORRECT routine is first initialized the phase of the flux is not known. Whether a CHECK -- MIN or a CHECK -- MAX is to be performed first is not known. One way to solve this dilemma is to allow two peaks to be detected and ignore the flux signals and peak values detected. Subsequent flux information will be valid. If the CHECK -- MIN subroutine is first called and the flux signal is decreasing the correct minimum will be found. However, if the CHECK -- MIN subroutine is first called and the flux signal is increasing an incorrect minimum will be found since the first sample will be set equal to a minimum and a subsequent sample will be found to be greater than the last found minimum by a predetermined value. A maximum will then be checked for and since the flux signal is increasing a true maximum will be found. As can be seen the output of the DC DETECT & CORRECT will be working properly after two half cycles.
As will be appreciated from the above description of the implementation of FIG. 5, the system looks for maximum and minimum values in establishing offset corrections. Prior to startup, it is important to provide offset compensation for DC values that exist at very low startup frequencies. One method of doing this is to introduce a square wave signal which is symetrical about zero at summing junction 37 in FIG. 3. This signal will carry the DC signal up and down at a periodic rate which the peak detector 49 can operate on to establish a long term offset at a steady state value for when the AC drive is enabled. As soon as the drive is enabled, the switch 33 is actuated to block the signal from generator 35 and the system operates as described above.
When it is desired to start the AC motor, an initial pre-flux condition is established by applying DC current to the motor stator. This current is applied at a known orientation for a period sufficient to build flux in the motor in a predetermined orientation. That orientation may be the orientation of flux at the position at which the motor was last stopped or may be some other selected orientation. The essential criteria is that flux orientation be known at the time that the motor drive is enabled. It should be noted that for pre-flux set-up, the signals generated by the flux integrators are ignored. Once the pre-flux condition is established in the motor, the flux integrators are initialized to a state in which their signals correspond to the state of the pre-flux orientation. Based upon that initialization from prior knowledge of flux orientation, the motor can then be excited by applying a current having an orientation that will produce torque immediately rather than merely supporting or producing more flux. The time during which the pre-flux current is applied will vary with the motor rotor time constant and will generally be only a few (2 to 5) time constants to allow flux time to build in the motor rotor. Typical rotor time constants for a motor are in the range of three hundred milliseconds although very large motors may have time constants of one to two seconds.
The primary purpose of pre-flux is to provide a known flux orientation in the motor so that torque can be produced. When a motor has been running and is brought to a stop, it is also advantageous to leave a DC flux producing component on the motor so that in the event it is desireable to start the motor again after only a very short off period, flux will be retained at a known orientation to assist in starting. The time to start may be reduced for short off times by such a practice since it will then not be necessary to preflux the motor and the regulator can be implemented based upon the last known orientation.
Referring now to FIG. 6, there is shown a functional block diagram of a phase lock loop which utilizes the flux ALPHA and flux BETA signals for generating phase A, B and C current commands for controlling operation of an AC motor. Before describing FIG. 6, reference is made to FIG. 7 which shows a vector diagram of the quantities being controlled by the phase lock loop. The vector ψ 2 represents rotor flux. The vector ψ L is a leakage flux perpendicular to vector ψ 2 . The net vector ψ 1 , is the sum of ψ 2 and ψ L and represents the stator flux. The direction of the rotor flux is considered to be the Y direction and is the direction in which the flux producing current is applied. The direction perpendicular to that is the X-direction and is the direction in which the torque producing current is applied. Flux ALPHA and flux BETA provide the orientation to the vector ψ 1 . However, it is desireable to develop the excitation voltages by reference to vector ψ 2 , i.e., at an angle which is oriented to the rotor flux vector ψ 2 . The vector difference between vectors ψ 1 and ψ 2 is vector ψ L which displaces the stator and rotor vectors by an angle ΦL. Thus, the phase lock loop is required to lock on vector ψ 2 and this is accomplished by introducing a compensating value into the loop.
Turning now to FIG. 6, the flux ALPHA (ψα) and flux BETA (ψβ) values are input to a two-phase discriminator circuit 60 of a type well known in the art. Sine and cosine values are also supplied to circuit 60. The output of circuit 60 is a phase error signal. The correction factor for ψ L is summed with the phase error signal and the result is applied to a proportional plus integral (PI) circuit 62. The signal from PI circuit 62 is then integrated to create a γPLL signal which drives a rotator 64 of a type well known in the art to derive the I A , I B and I C current command signals for controlling motor operation. The sine and cosine values are easily obtained from a look-up table 68 for application to circuit 60. The ψL correction factor is obtained from the product of the real component of current, Ireal, and a leakage value L94. By injecting the -ψL factor, the phase lock loop locks on a frequency a selected value displaced from rotor flux. It should be noted that the amount of displacement varies with load and is automatically adjusted by use of the Ireal value in computing ψL.
A circuit block 66 computes the Ireal by demodulating the I ALPHA and I BETA values obtained by three-phase to two-phase conversion of the values of Ia, Ib and Ic currents in the motor. The demodulated Ireal value is a DC component in steady state. The operation is a typical coordinate transformation which uses the phase lock loop output, γ PLL , to demodulate measured current feedback signals, I ALPHA and I BETA , to produce an Ireal, a real component of current, where Ireal represents current in the X-direction in the motor. The γ PLL value is an angle obtained from integration of the rotation frequency, ω PLL , which is the output of the PI block 62.
During continuous uni-directional operation of the drive, the flux integrators and the PEAK -- DETECT and DC -- CORRECT logic function properly since their state information accurately reflects recent history. In other words, the integrators contain valid quadrature components of flux, appropriately lagging the voltage inputs, and the peak detector logic for each phase is anticipating the proper peak (minimum or maximum) with accurate knowledge of the value of the previous peak. However, upon conditions of start-up, frequency reversal, or any transition to the voltage model without accurate history, this state information is generally incorrect. Thus, some means of establishing proper initial conditions of state information is necessary.
Certain conditions require initialization of the peak detector logic only, and other conditions require complete initialization of the flux integrators as well as the peak detector logic. Therefore, two initialization procedures are defined: INIT -- PEAK -- DETECTOR, and INIT -- VOLTAGE -- MODEL. The INIT -- PEAK -- DETECTOR procedure is called by the INIT -- VOLTAGE -- MODEL procedure. For example, upon start-up, the INIT -- VOLTAGE -- MODEL procedure is called while on reversal, only the INIT -- PEAK -- DETECTOR procedure is called.
Turning first to the INIT -- PEAK -- DETECTOR procedure and referring to FIG. 8, one can see that if the quadrant of the net flux vector is known, along with an indication of the direction of its net rotation, then the sense (MAX or MIN) of the next expected peak for each phase (ALPHA and BETA) is defined. This information is necessary and sufficient to define the values to which the following variables should be initialized (see FIG. 5): LOOKING -- FOR -- MAX (bit), MAX (multi-bit), MIN (multi-bit). LOOKING -- FOR -- MAX is initialized True or False, and MAX and MIN are set to either the instantaneous value of FLUX or to plus or minus FMAG, as given by the table of FIG. 9. There are eight different combinations of quadrant and direction, each calling for one of four different sets of initialization actions. The first table of FIG. 9 identifies a condition and a corresponding action. The second table describes the corresponding action by defining the actual variable values. Additionally, the PEAK -- FOUND and DC -- CORRECT bits for each phase should be cleared to indicate that thee is no need for an instantaneous DC correction or adjustment to the long-term correction term until the next peak is found.
Determination of the locus and direction of motion of the flux can be accomplished by various means. A convenient source of this information is provided by the phaselock loop of FIG. 6. Quadrant information can be derived from the output angle γPLL of the loop, taking into account phase shifts defined by the phase discriminator 60. Direction of rotation is best represented by the sign of the integral term in the PI loop filter 62, which provides a relatively smooth measure of PLL frequency. A refinement to the determination of locus would take into account the additional load-dependent phase shift between the flux vector and the angle of the PLL due to the compensation for leakage inductance introduced into the PLL.
Considering now the INIT -- VOLTAGE -- MODEL procedure, it will be appreciated that initialization of the entire voltage model involves initialization of the flux integrators to nominal values at proper phase, and subsequent initialization of the PEAK -- DETECT and DC -- CORRECT logic. In a system with phaselock loop 60, the angle is easily defined by using the output angle γPLL of the PLL 60. Again, a refinement to the determination of locus would take into account the additional LOAD -- DEPENDENT phase shift between the flux vector and the output angle γPLL of PLL 60 due to the compensation for leakage inductance introduced into the PLL 60. The initialization action to be performed requires setting values and the following steps:
(1) FAMG=NOMINAL
(2) FLUX -- ALPHA=ALPHA projection of FMAG at angle defined by γ -- PLL;
(3) FLUX -- BETA=BETA projection of FMAG at angle defined by γ -- PLL;
(4) Call INIT -- PEAK -- DETECTOR procedure.
As will be seen from the previous description of INIT -- PEAK -- DETECTOR procedure, this last procedure merely adds the further steps of setting FMAG, i.e., flux magnitude, at a nominal value and establishing ALPHA and BETA flux components in accordance with the output of PLL 60.
While the principles of the invention have now been made clear in an illustrative embodiment, there will become obvious to those skilled in the art many modifications in structure, arrangement, and components used in the practice of the invention and otherwise which are particularly adapted for specific operating requirements without departing from those principles. The appended claims are therefore intended to cover and embrace any such modifications, within the limits only of the true spirit and scope of the invention. | A method for developing current control signals from motor terminal voltage in the control of alternating current electric motors which utilize electric current control signals oriented to the phase of a flux component in a rotating field for applying current so as to control the flux and torque in the motor. The method includes developing flux signals from measurement of motor terminal voltage and integrating those signals to develop corresponding flux signals. In one form, the method eliminates DC components occuring in the resultant flux signals by locating local maxima and minima of the resultant flux signal and correcting the value of the flux integrator so as to provide maxima and minima flux signals having equal absolute values. The method also includes establishing an initial flux in the motor prior to startup which is oriented in a predetermined manner such that initial current applied to the motor can be applied so as to immediately develop torque, if required. The method further provides for initializing the flux integrators and associated logic such that discontinuities attributable to events such as frequency reversals are avoided. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to specific binding assays in which binding proteins specific for a sample analyte are bound by antibodies. The antibodies are specific for different epitopes of the binding protein and can be attached to either soluble or insoluble materials which facilitate separation procedures.
2. Description of the Prior Art
This invention relates to methods and means for determining the presence of a ligand in a liquid medium based on the affinity of the ligand for a specific binding partner. In particular, this invention relates to methods and means for use in specific binding assays which do not employ radioactive materials.
Folate deficiences in the human body are a common cause of megaloblastic anemia. In humans, folic acid is metabolized to tetrahydrofolic acid and subsequently to 5-methyltetrahydrofolic acid (5'-mTHF). Often, the concentration of 5'-mTHF is measured using a competitive binding assay. It would be useful to include 5'-mTHF used in the standard reagents as a calibrator. Unfortunately, 5'-mTHF is very unstable and its use can require sealing the material in lyopholized form.
U.S. Pat. No. 4,350,659 to Riceberg of Corning Glass Works disclosed a process for stabilizing 5'-mTHF by complexing it with a binding protein such as folate binding protein (FBP). The complex is then frozen and lyophilized to yield a dry powder. Recommended storage of the powder includes air tight and light resistant containers. Lypholization permits storage of 5'-mTHF in a stable form until it is needed. Such techniques are impractical in the manufacture of assay kits and make it difficult to use in clinical laboratory settings. Moreover, after reconstituting the lypholized material, instability problems can reappear.
Deficiencies in vitamin B 12 may result in neurological damage. Futhermore, as this vitamin is necessary for proper folic acid metabolism, its absence also results in megaloblastic anemias. Since megaloblastosis may also be produced by folate deficiency due to other causes, it is necessary to determine if the megaloblastosis is caused by a deficiency of either or both vitamins.
U.S. Pat. No. 4,399,228 to Riceberg of Corning Glass Works discloses a folate and vitamin B 2 competitive protein binding assay. Radioactive 57 Co or 125 I tracer is added to patient samples and counted with a gamma counter. In the assay, the binding protein is covalently bound to porous glass. The endogenous binding proteins in the patient sample are destroyed by boiling the reaction tube. Because of the hazard and difficulty of handling radioactive materials, there have been many attempts to devise convenient specific binding assay systems which are as sensitive and rapid as radioimmunoassays but which utilize features other than radioactivity as the means for monitoring the binding reaction.
U.S. Pat. No. 4,028,465 to Lewin et al., of Bio-Rad Laboratories discloses a radioactive competitive assay procedure where sample serum folate is measured. The serum folate binding proteins are inactivated by heat. The invention discloses the use of a sulfhydryl such as dithiothreitol in buffer which can be used to stabilize folate prior to the heating process. The use of this stabilizer was advantageous over methods utilizing mercaptoethanol because it is an easily weighed solid with only a mild odor.
Folate and vitamin B 12 assays typically employed heating or boiling steps prior to testing in order to liberate folate in the sample from endogenous binding proteins. The heating or boiling steps are difficult to accurately control and are time consuming. More recent assays denature samples by chemical means without boiling. One can achieve denaturation by using a strong base with or without other chemicals.
U.S. Pat. No. 4,418,151 to Forand et al., of Rohm and Haas Company also relates to a radioassay for serum folate. A measured amount of serum is mixed with a constant amount of radioactively tagged vitamin B12 and/or folate tracer. The solution is exposed to a mercaptan denaturing agent in the presence of a conversion agent such as potassium cyanide in a highly alkaline environment. The use of mercaptan solutions allows stabilization in the protecting buffer while high pH causes inactivation of the endogenous binding proteins.
U.S. Pat. No. 4,451,571 to Allen of University Patents teaches the use of strong base with a sulfhydral compound, such as betamercaptoethanol (BME), thioglycolate, thioglycerol or dithiothreitol (DTT). The sulfhydral compounds destroy endogenous binding proteins thereby liberating the sample vitamin B 12 or folate to be measured. Although the strong base releases analyte from its binding protein, it does not substantially denature all endogenous binding protein. Therefore it is helpful to have another compound such as a sulfhydral to help liberate analyte from binding protein and also eliminate blocking antibodies which may interfere in the assay. The blocking antibodies can be troublesome to the assay because they react with binding factors.
U.S. Pat. No. 4,828,985 to Self of Cambridge Patent Developments teaches a method where secondary antibodies are raised against complexes of nonimmunogenic materials and primary antibodies against the nonimmunogenic materials. The secondary antibodies are not antibodies against either the nonimmunogenic materials nor the primary antibodies. Detection is accomplished by labelling the secondary antibodies with enzyme or some other detectable means.
The present invention is an improvement over existing technology in that it discloses a method that enables more coupling of specific binding proteins. This invention discloses a method whereby a mixture of two monoclonal or polyclonal antibodies or a mixture thereof against different epitopes of a binding protein gives increased coupling. This method can be utilized for several different assays in which analyte is detected. Another advantage of the present invention is that this multiclonal format allows the use of pteryolglutamic acid (PGA) as a calibrator in a folate assay instead of the unstable 5'-mTHF.
SUMMARY OF THE INVENTION
The present invention relates to a method of a heterogenous assay whereby the ability to bind specific binding proteins is enhanced with a multiclonal antibody format. The multiclonal format couples binding proteins up to ten times the efficiency of a singular antibody format. The improved method generally comprises directly or indirectly binding a specific binding pair member to a capturable material by utilizing a mixture of antibodies. The specific binding pair member contains binding sites which will then be occupied by either the sample analyte of interest or a labelled analyte analog. A capturable material, one in which the antibodies, specific binding pair members and sample analyte or analyte analog are attached, can then be isolated by ionic interactions with a matrix material where detection can take place.
This invention can be utilized for any assay employing binding proteins which can couple specific ligands. Another advantage of the present invention is the use of PGA as a calibrator in a folate assay instead of 5'-mTHF. Traditional use of 5'-mTHF in folate assays has proved it to be an unstable compound. The use of the present invention allows PGA to be used as a calibrator whereas a monoclonal or polyclonal format alone exhibited differential performance between PGA and 5'-mTHF.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows folate binding protein binding PGA similarly to 5'-mTHF in the multiclonal format.
FIG. 2A shows the effects of not adding citrate
FIG. 2B shows the effects of adding citrate for increased PGA stability.
DETAILED DESCRIPTION OF THE INVENTION
Multiclonal Format
This invention relates to methods and means for determining the presence of a ligand in a liquid medium based on the affinity of the ligand for a specific binding protein.
The present invention discloses a method of a heterogenous assay for measuring analytes in patient samples. There are two separate phases to this procedure. The first phase is the coupling of a polyanionic substance to antibodies with different binding specificities for a particular binding protein. The binding protein is then added to the antibodies creating a polyanion:anti-binding protein antibody:binding protein complex. This complex is referred to as a capture reagent. The second phase is the reaction of particular reagents with the patient sample. The binding protein in the complex captures its particular analyte in the patient sample. The reaction mixture is transferred to a polycation matrix where the polyanion is caught. A reagent containing an analyte analog coupled to an enzyme is added to bind to any unoccupied binding proteins. Non-bound materials are washed away from the matrix and after addition of a standard fluorescent substrate for the enzyme, analyte concentration can be determined from fluorescent intensity.
The present invention also employs a method in which a mixture of two or more anti-binding protein monoclonal or a mixture of monoclonal and polyclonal antibodies works better than a single antibody alone. One example of how this method can work is folate binding protein (FBP). The two or more antibodies (two or more monclonal or a mixture of monoclonal and polyclonal antibodies) are attached to a polyanion such as carboxymethylamylose (CMA) through covalent linkage. FBP is then added to the mixture and the FBP is coupled non-covalently to the antibodies. In effect, the antibodies act as a linker between the FBP and the polyanion. This method prevents having to directly link the binding protein to the polyanion. Direct linkage of the binding protein to the polyanion could conformationally change the binding protein thereby affecting its ability to bind test sample analyte. To show the marked difference when two antibodies are used as opposed to a single monoclonal, two individual monoclonal antibodies were tested against a 1:1 mixture of the two antibodies. In the competitive assay described above, the FBP was linked to the CMA by one or both monoclonal antibodies. The 1:1 mixture of the two anti-FBP monoclonals works better than either monoclonal alone. Table 1 gives an indication as to how effective the multiclonal format is. The numbers in Table 1 refer to the substrate turnover rate. It is important to note that this format uses antibodies that have different affinities to the same protein.
TABLE 1______________________________________ CLONE CLONE 1:1[FLOATE] A (c/s/s) B (c/s/s) MIXTURE______________________________________ 0 ng/ml 370 687 2342 4 ng/ml 206 337 141230 ng/ml 32 48 141______________________________________
The 1:1 mixture of the two antibodies gave a dramatically increased signal. This indicates that there is more folate binding protein bound by the antibodies in the 1:1 mixture. This in turn means more coupling of analyte analog and hence more signal.
The coupling of antibody to the polyanion can be achieved in one of two ways. First, the individual monoclonals or mixture of monoclonal and polyclonals can be coupled at separate times. Therefore, each of the antibodies is coupled to the polyanion in a separate incubation step before being mixed in a 1:1 fashion. The second method is to mix both antibodies together (using appropriate ratios of antibodies) and then couple the mixture to the polyanion in a single incubation step. The second method is useful when working with large quantities of antibody because of the single incubation time.
Different ratios of monoclonal antibodies give better results with the multiclonal format than the individual clones alone. Apparently, even minor additions of a multiclonal format yield increased anti-binding protein antibody:binding protein capabilities. Results of experiments utilizing the monoclonal versus multiclonal format and varying ratios of the multiclonal format are presented in Table 2. Once again, values presented are substrate turnover rate due to detectable label binding to unoccupied binding protein sites.
TABLE 2______________________________________% of % ofClone Clone 0 ng/ml 4 ng/ml 20 ng/mlA B Folate Folate Folate______________________________________100 0 447 245 4380 20 2479 1581 17070 30 2551 1640 17850 50 2461 1571 17230 70 2403 1487 168 0 100 640 360 50______________________________________
Characterization of Folate Binding Protein Antigen
FBP antigen was isolated from bovine whey by PGA affinity chromatography. Silver-stained polyacrylamide gel electrophoresis (PAGE) and isoelectric focusing verified the homogeneity of the protein. Two bands visible by PAGE corresponded to the published molecular weights of bovine FBP with and without glycosylation. Cation and anion exchange chromatography, as well as reverse phase high performance chromatography methods, showed no more than two entities in the FBP preparation. Chemical deglycosylation with trifluoromethanesulfonic acid converted the higher molecular weight component into a single entity with an electrophoretic mobility identical to the lower molecular weight band. These data support the conclusion that the two components represent FBP with different degrees of glycosylation.
Additional verification that the protein was FBP was provided by the following: 1) the protein exhibited specific, high affinity binding of radioactive folate, 2) N-terminal amino acid sequence analysis of the first twenty three amino acids provided an unambiguous sequence in perfect agreement with the amino acid sequence published for bovine FBP (Svendsen, I., Hansen, S. I., Holm, J., and Lyngbye, J., Carlsberg Research Communications, 49:12-31, 1984), and 3) gas chromatography mass-spectroscopy analysis showed two components with molecular masses of 30,850 and 25,968 consistent with the expected mass of the FBP polypeptide with and without carbohydrate side chains.
FBP Monoclonal Antibody Development
Immunogen Preparation
Purified folate binding protein (FBP) was used as the immunogen for animal immunizations and the antigen for reactivity screening.
Immunization Strategy
Two female 6-8 week old BALB/c mice (Charles River, Wilmington, Mass.) were immunized with purified folate binding protein (FBP). The dose level was 200 μg in 100 μl of a 1:1 ratio of the FBP solution in Freund's Complete Adjuvant (Difco Laboratories, Detroit, Mich.). The adjuvant emulsion route of injection was equally distributed interperitoneally and subcutaneous. The animals were allowed a 3 week rest period before a 100 μg FBP intravenous prefusion boost was administered in 100 μl, 3 days prior to fusion.
Fusion
On the day of the fusion, the 2 mice were sacrificed by cervical dislocation and the spleen was removed. The splenocytes were washed one time in Iscove's Modified Dulbecco's Medium (IMDM) (GIBGO, Grand Island, N.Y.) and centrifuged 1000 RPM for 10 minutes. The pelleted splenocytes were combined with SP2/O myeloma cells (from the laboratory of Dr. Milsrein, Cambridge, U. K.) at a 1:1 ratio, washed in IMDM, and centrifuged. The supernatant was removed and 1 ml of 50% polyethylene glycol (PEG) (American Type Culture Collection, Rockville, Md.) was added to the pellet for 1 minute as the pellet was gently being dispersed by tapping and swirling. Thirty mls of IMDM were added to the mixture and centrifuged as previously described. The supernate was decanted and the pellet resuspended in IMDM with HAT (hypoxanthine, aminopterin, and thymidine) (Gibco, Gaithersburg, Md.), 10% Fetal Bovine Serum (FBS) (Hyclone Laboratories, Logan, UT.) and Salmonella typhimurium mitogen (STM) (1% v/v) (RIBI Immunochem Research, Inc., Hamilton, Mont.). STM is a B-cell specific mitogen, and is used to enhance fusion frequency. The fusion cell suspension was plated into 96-well tissue culture plates.
Primary Fusion Screening
The primary screening of the fusion occurred on day 10 at which time the cultures were confluent. An enzyme immunoassay (EIA) was used to detect anti-FBP reactivity in the supernate samples. Microtiter wells were coated with 100 μl of a 5 μg/ml FBP in phosphate buffered saline (PBS) and incubated at room temperature overnight. The following day the plates were blocked for 30 minutes with 200 ILl per well of 3% bovine serum albumin (BSA) in PBS. After washing the plates 3 times with distilled water, 50 μl of culture supernate was added per well and incubated 1 hour. The plates were washed 3 times and 50 μl per well of diluted goat anti-mouse IgG+IgM-HRPO (horseradish peroxidase) conjugate (Kirkegaard Perry Laboratories, Gaithersburg, Md.) was added to the plate for a 30 minute incubation period. The plate was washed a final time and the color development utilized O-phenylenediamine:2HCI (OPD) (Abbott Laboratories, Abbott Park, Ill.). The relative intensity of optical density readings identified hybrids #1-279 and #1-641 as 3 times that of the negative control, normal mouse serum (NMS) (Organon Teknika-Cappel, Malvern, Pa.) and the hybrids were selected as candidates for cloning and further evaluation.
Hybrid Cloning
Hybrids #1-279 and #1-641 were cloned by limiting dilutions. 1 to 10 dilutions were done starting at 1×10 2 up to 1×10 6 . The cloning media used was IMDM with 10% v/v FBS and 1% v/v HT (hypoxanthine and thymidine)Supplement (Gibco, Gaithersburg, Md.). A 100 μl cell suspension was added to each of the 96 well in the TC plate. On day 7 the plates are fed with 200 μl/well of cloning media.
Clone Selection
Clones #1-279-176 and #1-641-101 were selected from the 1×10 6 dilution wells for further evaluation based on additional EIA screening of the clone supernate of confluent cultures. The EIA screening protocol used is described previously.
Subclone Selection
For purposes of reagent reproducibility it was necessary to ensure that a single cell line of 1-279-176 was obtained. To do so, the cell line was cloned one more time as described above. EIA screening as described above was used for subclone selection of #1-279-866.
Western Blot Evaluation
The FBP antigen, 10 μg, either reduced with 2-mercaptoethanol (Bio-Rad, Richmond, Calif.) or non-reduced was run on an 8-16%, 1.0 mm, mini-polyacrylamide gel (Novex, San Diego, Calif.) on a mini electrophoresis and transfer system (Profile™System, Schleicher & Schuell, Keene, N.H.) according to manufacturer's instructions. The protein was next transferred from the gel onto nitrocellulose. The nitrocellulose was cut into strips and antibody was incubated on the strips for several hours. The antibody binding capability to the reduced and non-reduced antigen was detected using the goat anti-mouse IgG+M-HRPO conjugate mentioned above with the color development driven by 4-chloro-napthol (Sigma, St. Louis, Mo.). Antibody from 1-279-866 was found reactive to the 32kD MW FBP in reduced and non-reduced conditions. Antibody from 1-641-101 was not found reactive to FBP antigen in the Western blot test. Based on these data, the monoclonal antibody produced by the hybrid cell lines were determined to be directed against two distinct epitope binding sites.
Isotype
The isotypes of the monoclonal antibody secreted from the cell lines identified as 1-279-866 and 1-641-101 were determined on an EIA clonotyping kit (Southern Biotech, Birmingham, Ala.). The assay is performed according to the vendor recommendations and the results indicate that both were IgG1, kappa.
Isoelectric Focusing
Electrophoretic evaluation of the 1-279-866 and 1-641-101 antibodies was performed on the PhastSystem (Pharmacia-LKB, Piscataway, N.J.). Coomassie staining of the sodium dodecyl sulfate polyacrylamide gel electrophoresis (SDS-PAGE) profile identified the typical antibody banding pattern of a single light chain band at 25 kD and a single heavy chain band at 55 kD for each antibody. The silver stained IEF profile identified a pl of 6.8±0.2 for 1-279-866 and a pl of 6.6±0.2 for 1-641-101.
Deposit
Cell lines 1-279-866 and 1-641-101 have been deposited with the American Tissue Culture Collection (A.T.T.C on Jan 26, 1993) (16301 Parklawn Drive Rockville, Maryland). Cell line 1-279-866 has been designated A.T.C.C No. HB 11249 and cell line 1-641-101 has been designated A.T.C.C No. HB 11250.
Methods and Reagents
The current invention teaches a method wherein a mixture of two or more anti-binding protein monoclonal or a mixture of monoclonal and polyclonal antibodies gives a better reaction rate than either monoclonal or polyclonal alone. This method of assay is applicable for many proteins and their binders including folate and vitamin B 12 but is not limited to them.
The sample to be tested for the presence of analyte can be subject to various steps that denature endogenous proteins which may interfere with the assay. The present invention preferably employs a pretreatment of the sample with the DTT mixed with acetic acid, sodium chloride, and ethyldiaminetetraacetic acid (EDTA). The DTT not only denatures protein but also preserves the reduced form of 5'-mTHF. Other general denaturing agents may substitute for DTT depending on the analyte.
A second denaturing step is preferably the addition of 0.75M potassium hydroxide to the sample. This addition creates a highly basic environment that further denatures the endogenous folate binders in the sample thereby releasing the folate for measurement. Other strong bases such as NaOH, LiOH and NH 4 OH can be used.
The capture technique employed utilizes a polyanion such as CMA. Coupled to the polyanion is a mixture of anti-folate binding protein antibodies complexed with folate binding protein. The antibodies act as linkers between the polyanion and the folate binding protein. The folate binding protein binds non-covalently to the antibodies associated with the polyanion. It is important that the denatured sample be neutralized by buffer before or at the time of addition of FBP. In the present invention, the neutralizing is preferably done at the time of FBP addition. The capture reagent may be diluted into a buffer of 50 mM borate, pH 8.1; 0.2% human serum albumin (HSA); 0.1% tween-20; 0.1% sodium azide; 0.003% dextran sulfate; and 1 mM EDTA. The HSA component contains no endogenous folate binding protein. Sodium azide is a preservative commonly used in laboratory reagents which can provide some antibacterial action. Dextran sulfate in the capture reagent binds to stray cations (i.e. cation dust from the matrix) which could interfere in the accuracy of the assay.
The addition of the capture reagent, which contains borate buffer, to the reaction well neutralizes the denaturants and allows the folate in the samples to bind to the folate binding protein. After an incubation, the reaction mixture is transferred to the matrix where the polyanion adheres to a polycation material.
There are various ways that the polycation can be added. The polycation material can be added directly to the capture reagent where it will adhere to the polyanion. Another method is to add the polycation to the reaction mixture one step prior to the reaction mixture being added to the matrix. The preferred method is to precoat the matrix with polycation and then add the reaction mixture.
The conjugate reagent contains the enzyme alkaline phosphatase conjugated to pteroic acid and diluted into 50mM Tris(hydroxymethyl)aminomethane (TRIS), pH 7.4; 0.5% HSA; 0.1M sodium chloride; 1 mM magnesium chloride; 0.1 ram zinc chloride; 0.1% dextran sulfate; and 0.1% sodium azide. The conjugate binds to the unoccupied folate binding protein sites. The conjugate reagent is not limited to the use of pteroic acid. Other folate analogs including PGA can be used in the conjugate reagent.
The standard IMx® (Abbott Laboratories, North Chicago, Ill., 60064) methylumbelliferyl phosphate substrate is used in the present invention.
As mentioned earlier, there have been problems in using 5'- mTHF as a standard or calibrator. It is unstable once exposed to light, temperature and atmosphere. Its instability negates its usefulness as a calibrator. Moreover, 5'-mTHF may necessitate using human serum in the calibration matrix. Also necessary when using 5'-mTHF is the addition of ascorbate and citrate. The addition of these increases the stability of 5'-mTHF during usage but ascorbate was found to interfere in the assay.
The present invention uses PGA as its calibration reagent. The advantages of using PGA are several. First, PGA is more stable than 5'-mTHF; second,there is better reproducibility of results with PGA calibrating the assay over 5'-mTHF; and third, ascorbate is not needed to stabilize PGA. Additionally, PGA as a calibrator allows the use of bovine serum albumin (BSA) instead of human serum as the calibrator diluent. This lessens the hazards, cost and availability problems associated with human serum.
5'-mTHF is the metabolic form of folic acid that is actually measured in patient samples. Accordingly, calibrators other than 5'mTHF must be sufficiently bound by the appropriate binding proteins to give good correlation to sample 5'-mTHF levels. Although the mechanism by which it works is unknown, the multiclonal format allows FBP to bind PGA in a similar fashion to that of 5'-mTHF. Therefore, the multiclonal format allows calibration with PGA and gives a good indication of test sample 5'-mTHF. An example of the comparison is given in FIG. 1.
Another improvement of the present invention is the finding that addition of citrate improved PGA stability of day zero values to several months. PGA day zero value stability was evaluated in the BSA diluent with and without citrate (100 mM). With citrate, PGA day zero value stability is improved over time at -20° C., 4° C., 45° C., and room temperatures. FIG. 2B shows the effects of citrate enhanced PGA day zero value stability over no citrate addition (FIG. 2A). Test points were run the IMx® instrument and MUP turnover rates were measured on the days indicated. The rates obtained were compared to the baseline runs of day zero.
The same methodology can be used to assay for vitamin B12. Vitamin B 12 is preferably separated from its endogenous intrinsic 5 factor with the use of alpha-methyl thioglycerol and subsequent high alkaline enviroment. This allows the released vitamin B 12 to couple to the capture reagent complex, thereby facilitating the detection process.
Patient samples were analyzed and individual folate concentrations were measured using two commonly used assays. Patient samples were analyzed by the IMx® against Bio-Rad® (Bio-Rad Chemical Div. Richmond, Calif., 94804) and Corning® (Corning Inc., Science Products Division, Corning, N.Y., 14831) assays with both the multiclonal and polyclonal format. As can be seen in Table 3, there was good agreement between the two methods. The designation "N" refers to the number of patient samples tested.
TABLE 3______________________________________ Mutliclonal Polyclonal______________________________________IMx ® v. Bio-Rad ®Intercept 0.84 1.14Slope 0.67 0.57R value 0.98 0.98N 47 47IMx ® v. Corning ®Intercept 0.87 1.40Slope 0.61 0.50R value 0.94 0.92N 46 46______________________________________
Also significant is the fact that the multiclonal reagent showed good stability after 3 days at 45° C. Two individual monoclonals, a 1:1 mix of the two monoclonals, and a polyclonal sample were tested at the different temperatures. The multiclonal reagent (1:1 mix) lost only 10% of its 4° C. activity after 3 days at 45° C. As shown in Table 4, the multiclonal format shows good ability to bind more binding protein as indicated by higher substrate turnover rates after storage at higher temperatures.
TABLE 4______________________________________[Folate] Clone A Clone B 1:1 Mix Polyclonal______________________________________Day 3-4 Degree0 ng/ml 906 1274 2245 9824 ng/ml 646 835 1184 567R4/R0 0.71 0.66 0.53 0.58Day 3-45 Degrees0 ng/ml 785 1025 2020 9034 ng/ml 565 686 1061 509R4/R0 0.72 0.67 0.53 0.56% activity 87 80 90 92remaining______________________________________
The present invention's methodology can be used to adapt it to several analytes. The antibodies used were developed to aide in eliminating reagent performance variability. The multiclonal format was initially prepared by mixing two of the CMA-antibody conjugates together in the capture reagent. This was later simplified by mixing the two antibodies together and then coupling the mixture to CMA to generate a multiclonal. The antibody mixture can be two separate monoclonal or a combination of monoclonal and polyclonal antibodies.
DTT reagent is added to samples at the beginning of the assay to maintain a reducing environment for preserving sample 5'-mTHF. DTT can also function as a protein denaturant by reducing disulfide bonds and making other proteins more susceptible to alkaline denaturation. Published articles have indicated that folate binding proteins are irreversibly denatured at a pH of 12 or greater. The present invention preferably uses a potassium hydroxide reagent to denature patient samples by destroying endogenous folate binding proteins. This allows the CMA-multiclonaI-FBP complex to bind with the released patient sample folate. Thus, the assay must reproducibly raise the pH for denaturation and then neutralize the base with the capture diluent. Current literature and our experience suggests that a pH of approximately 9.3 gives optimum binding of PGA in the calibrators and the 5'-mTHF in the samples. In the present invention, not only must the diluent be appropriate for the CMA-multiclonaI-FBP capture reagent to 0 function and remain stable but it must also neutralize the KOH. The capture reagent therefore buffers the reaction pH for appropriate PGA and 5'-mTHF performance. Borate is a preferable buffer with a pKA near 9.3 and is conducive for FBP binding ability. Addition of 4% sucrose increases the solubility of borate. The ability of sucrose to 5 perform this function is due to the cis-hydroxy groups which combine with the borate. Sucrose prevents the occasional precipitation of borate from capture diluent stored at 4° C.
Folate Assay
1. Procedure
a. Load the IMx® (Abbott Laboratories, Abbott Park, Ill., 60064) carousel with the calibrators and/or controls and test samples (minimum of 100 ul each). Then 0.4 ml of dithiothreitol (DTT) is placed into the predilute well of the first reaction cell in the carousel.
b. The assay begins with each reaction well receiving 0.015 ml of the DTT from the first reaction cell's predilute well and 0.018 ml of the calibrator, control, or sample. The DTT denatures proteins and preserves the reduced form of 5'-mTHF in the samples. Each well is incubated for 8 minutes.
c. Add 0.028 ml of the 0.75M potassium hydroxide (KOH) into each reaction well and incubate 8 minutes.
d. Add 0.15 ml of capture reagent (polyanion-anti-FBP antibody complexed with FBP in borate buffer) to the reaction well. The borate buffer in the capture reagent neutralizes the denaturants (final pH near 9.3) and allows the folate in the samples to bind to the FBP. The dextran sulfate in the capture reagent binds to stray cations (i.e. cation dust from the matrix) and reduces assay variability. Incubate the wells for 12.5 minutes.
Transfer 0.22 ml of the reaction mixture to the ion capture reaction cell matrix where the polyanion (connected to the FBP through the antibodies) adheres through ionic interactions to the polycation on the reaction cell matrix.
f. Two diluent washes of the matrix remove unbound materials and then are followed by the addition of 0.06 ml of conjugate reagent. The conjugate reagent used is calf intestine alkaline phosphatase conjugated to pteroic acid. The conjugate binds to sites on the captured FBP unoccupied by folate.
g. Unbound conjugate is then washed from the surface of the matrix, 0.06 ml of methylumbelliferyl phosphate (MUP) reagent is added, and the fluorescence of the liberated MU is read. The fluorescence intensity is inversely proportional to the amount of folate in the calibrators or patient samples.
Vitamin B 12 Assay
1. Procedure
a. Load the carousel with the calibrators and/or controls and test samples (minimum 100 ul each). Then 0.4 ml of alpha monothioglycerol is placed into the predilute well of the first reaction cell in the carousel.
b. The assay begins with each reaction well receiving 0.01 ml of alpha monothioglycerol and 0.06 ml of the calibrator, control, or sample. The reducing agent denatures proteins. Incubate for 8 minutes.
c. Add 0.08 ml of the KOH into each reaction well and incubate for eight minutes.
d. The addition of 0.15 ml of capture reagent (polyanion-anti-intrinsic factor antibody complexed with intrinsic factor in borate buffer) to the reaction well then neutralizes the denaturants (final pH near 9.3) and allows the vitamin B 12 in the samples to bind to the intrinsic factor. The dextran sulfate in the capture reagent binds to stray cations (i.e. cation dust from the matrix) and reduces assay variability. Incubate for 12.5 minutes,
e. 0.15 ml of the reaction mixture is transferred to the ion e. capture reaction cell matrix where the polyanion (connected to the intrinsic factor through the anti-intrinsic factor antibody) adheres through ionic interactions to the polycation coated on the matrix.
f. Two diluent washes of the matrix are followed by the addition of 0.05 ml of conjugate reagent. The conjugate reagent used is calf intestine alkaline phosphatase conjugated to vitamin B 12 or vitamin B 12 analog. The conjugate binds to sites on the captured intrinsic factor unoccupied by vitamin B 12 .
g. Unbound conjugate is then washed from the surface of the matrix, 0.06 ml of methylumbelliferyl phosphate (MUP) reagent is added, and the fluorescence of the liberated MU is read. The fluorescence intensity is inversely proportional to the amount of vitamin B 12 in the calibrators or patient samples. | An improved method for performing immunoassays whereby specific binding proteins for vitamin B12, folate and other target analytes are utilized with antibodies with different specificities for the binding proteins. Antibodies bridge the specific binding protein directly or indirectly to a capturable material. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates to chemical compounds, their use as intermediates in the preparation of pharmaceutical agents, and to processes for their preparation.
BACKGROUND OF THE INVENTION
[0002] International Patent Publication No. WO 00/72801 discloses a series of 3-substituted nonanoic acid derivatives of use as avp3 receptor antagonists, including compounds of the formula (A):
wherein n is 2 or 3.
[0003] The synthetic methods given in that application work well on a small scale, but the process is linear and requires a chiral HPLC separation of enantiomers of a penultimate intermediate. The δ-keto-acid moiety within the compound of formula (A) contains the only stereogenic carbon. There is therefore a need for an enantioselective and more efficient synthetic route to the compound of formula (A).
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is an x-ray powder diffraction (XRPD) pattern for the Form A polymorph of the product of Example 5 containing all observed XRPD reflections between 3° and 40° 2-theta. The ordinate or Y-axis is x-ray intensity (counts) and the abscissa or X-axis is the angle two-theta (2θ) in degrees.
[0005] FIG. 2 is an x-ray powder diffraction (XRPD) pattern for the Form B polymorph of the product of Example 5 containing all observed XRPD reflections between 3° and 40° 2-theta. The ordinate or Y-axis is x-ray intensity (counts) and the abscissa or X-axis is the angle two-theta (2θ) in degrees.
[0006] FIG. 3 is an x-ray powder diffraction (XRPD) pattern for the crystalline zwitterion of the compound of formula (A) where n=3 containing all observed XRPD reflections between 3° and 40° 2-theta. The ordinate or Y-axis is x-ray intensity (counts) and the abscissa or X-axis is the angle two-theta (2θ) in degrees.
[0007] FIG. 4 is an x-ray powder diffraction (XRPD) pattern for the crystalline TRIS salt of the compound of formula (A) where n=3 containing all observed XRPD reflections between 3° and 40° 2-theta. The ordinate or Y-axis is x-ray intensity (counts) and the abscissa or X-axis is the angle two-theta (2θ) in degrees.
DETAILED DESCRIPTION OF THE INVENTION
[0008] The present invention provides compounds of general formula (I):
wherein n is 2 or 3, P is an amino protecting group and R 1 is hydrogen, chlorine, bromine or C 1 to C 6 straight or branched alkyl, are useful intermediates.
[0009] The present invention also provides a method of preparing a compound of formula (1) which comprises the ring closure of a compound of the formula (II):
wherein R 1 , P and n are as defined in relation to formula (I) and Y is a chlorine, bromine or iodine atom or a mesylate, tosylate, brosylate, nosylate or triflate group.
[0010] Preferably this reaction is carried out in the presence of a copper catalyst such as CuCl, CuBr, CuBr.Me 2 S, CuI, and the like.
[0011] The compounds of formula (II) may be prepared by the reaction of a compound of the formula (III):
wherein R 1 and P are as defined in relation to formula (II) and R 3 is hydrogen or methyl with a C 1-6 -alkyl lithium, such as hexyllithium, n-butyllithium and sec-butyllithium, followed by reaction with a compound of the formula (IV):
X—(CH 3 ) m —Y (IV)
wherein Y is defined as in relation to formula (II), X is a chlorine, bromine or iodine atom or a mesylate, tosylate, brosylate, nosylate or triflate group, and m is 3 or 4 when R 3 is hydrogen, or m is 2 or 3 when R 3 is methyl.
[0012] It is a great advantage of the present invention that the above reactions may be performed as a “one pot” or single stage reaction.
[0013] In formulae (I), (II) and (III), R 1 is preferably a chlorine atom.
[0014] In formulae (I) and (II), n is most aptly 3.
[0015] In formulae (I), (II) and (III), suitable examples of the amino protecting group P include a group selected from: tert-butylmethoxyphenylsilyl, tert-butoxydiphenylsilyl, trimethylsilyl, triethylsilyl, acetyl, pivaloyl (2,2-dimethyl-1-oxopropyl), o-nitrobenzyloxycarbonyl, p-nitrobenzyloxycarbonyl, benzyloxycarbonyl, tert-butyloxycarbonyl (t-BOC), 2,2,2-trichloroethyloxycarbonyl, benzhydryl, o-nitrobenzyl, p-nitrobenzyl, 2-naphthylmethyl, benzyl, 2,2,2-trichloroethyl, tert-butyldimethylsilyl, tert-butyldiphenylsilyl, 2-(trimethylsilyl)ethyl, p-methoxybenzyl, p-methoxyphenyl, 4-pyridylmethyl, tert-butyl, allyloxycarbonyl, di-C 1-10 alkylphosphoryl, diarylphosphoryl and di-ar-C 1-10 alkylphosphoryl.
[0016] More particularly, P represents a protecting group which is selected from the group consisting of: an alkoxycarbonyl group (especially t-BOC), diisopropylphosphoryl and pivaloyl (2,2-dimethyl-1-oxopropyl).
[0017] Most suitably, P is a tert-butoxycarbonyl (t-BOC) group.
[0018] Hence, in a favoured embodiment, the present invention provides a process for the preparation of the compounds of the formulae (V) and (VI):
which comprises the reaction of a compound of the formula (IV) as defined above with the compound of the formula (VII)
to yield a compound of the formula (VIII)
wherein Y is as defined in relation to formula (II) and p is 3 or 4, and which is cyclised, without isolation, to the compounds of formulae (V) and (VI), respectively.
[0019] In compounds of formula (IV), X and Y are suitably both halogen, for example X may be bromo or iodo and Y may be chloro. Apt compounds include Cl(CH 2 ) 4 I, Cl(CH 2 ) 3 I, Cl(CH 2 ) 2 I, Cl(CH 2 ) 4 Br, Cl(CH 2 ) 3 Br and Cl(CH 2 ) 2 Br.
[0020] The compounds of the formulae (III) and (VII) may be prepared from the corresponding carbamates of formulae (IX) and (X), wherein BOC is CO 2 t Bu:
by reaction with a lithium alkyl such as a slight excess of n-BuLi or s-BuLi preferably in the presence of equimolar amount of tetramethylethylenediamine.
[0021] The compounds of formula (I) may be converted into compounds of International Patent Publication No. WO 00/72801 by the synthetic methods described therein and by other conventional chemical synthetic methods.
[0022] The compounds of formula (I) are also useful intermediates in the preparation of compounds of U.S. Pat. No. 3,960,876 and can be used as described therein.
[0023] The present invention further describes a practical method to prepare enantiopure compounds of the formula (XI):
and salts thereof wherein R is an esterifying group. Most suitably, R is a C 1-6 alkyl group such as methyl, ethyl or propyl group and is preferably a methyl group.
[0024] Compounds of formula (XI) may be prepared by the asymmetric solvolysis of the anhydride of the formula (XII):
[0025] This reaction may be performed using lower alkanols such as methanol, ethanol, 2,2,2-trifluoroethanol, 1-propanol, benzyl alcohol, 2-propanol and 1,1,1,3,3,3-hexafluoro-2-propanol at a temperature between −70° C. and ambient temperature. Preferably, the reaction is carried out with methanol at about −30° C. The reaction will use a solvent which can be an excess of the lower alkanol but which is preferably an inert solvent such as THF, DMF, dichloromethane or toluene. Generally about 10 equivalents of the alkanol will be used and the reaction adjusted to a concentration of about 0.2-0.4 M. The reaction is performed in the presence of a catalytic or stoichiometric amount of an optically active amine. The amine is typically a naturally occurring Cinchona alkaloid or one of its derivatives and is most suitably present in an equimolar amount. Preferred amines include quinidine and quinine. Hence the compound of formula (XIa) is favourably formed as the quinidine salt. On the other hand, the compound of formula (XIb) can be obtained with quinine. It is an important advantage of the current invention that the diastereomeric purity of the amine salts can in principle be conveniently increased via a recrystallization.
[0026] This invention also provides a practical procedure to prepare the compound of formula (m as well as methods to convert compounds of the formula (XIa) or (XIb) into compounds of the formula (XIII):
wherein R is as defined in relation to formula (XI) and X is (a) a —CH 2 P(O)(OR′) 2 group, wherein R′ is defined as a C 1-6 alkyl group such as methyl, ethyl, propyl, isopropyl, etc. or (b) a Ph 3 P═CH— group.
[0027] The compounds of formula (XIIIa) wherein X is —CH 2 P(O)(OR′) 2 may be prepared from the compounds of formula (XIa) by an activation reaction with pivaloyl chloride and triethylamine in dry THF at −5° C., yielding a compound of formula (XIII) wherein X is —O.CO.C(CH 3 ) 3 , followed by a reaction with an excess of lithiated dialkylmethylphosphonate at low temperature. Alternatively, compounds of formula (XIIIa) can be prepared by a reaction of compounds of the formula (XIb) with an excess of lithiated dialkylmethylphosphonate at low temperature followed by an esterification.
[0028] The compound of formula (XIIIb) wherein X is Ph 3 P═CH— may be prepared from the compounds of formula (XIa) by an activation reaction with either pivaloyl chloride or isobutylchloroformate and a suitable base (triethylamine, diisopropylethylamine, etc.) in dry THF at about −5° C., yielding compounds of formula (XIII) wherein X is —O.CO.C(CH 3 ) 3 and —OCO 2 i Bu, respectively, followed by a reaction with an excess of lithiated Ph 3 P ⊕ CH 3 .Br ⊖ in THF at about −70° C. and then allowing the reaction to warm to ambient temperature. The excess lithiated Ph 3 P ⊕ CH 3 .Br ⊖ can range from 2.2 to 3.5 equivalents depending on whether or not the triethylamine hydrochloride salt which is formed in the activation step is removed (via filtration or extraction).
[0029] The compounds of formulae (XI) and (XIII) are at least 60% enantiomerically pure, more suitably at least 80% enantiomerically pure, preferably at least 90% enantiomerically pure and most preferably at least 98% enantiomerically pure.
[0030] The compound of formula (XII) may be prepared by treating the corresponding diacid of formula (XIV)
with trifluoroacetic anhydride in a suitable inert solvent, such as THF at an elevated temperature, such as between 50 and 55° C. Crystallisation by slow addition of an antisolvent, such as heptane followed by cooling, for instance to ambient temperature, results in good yield.
[0031] The diacid of formula (XIV) may be prepared by reacting 2-methoxypyrimidine-5-carbaldehyde with ethylacetoacetate in the presence of piperidine in a suitable solvent, such as an alcohol, for example, propan-2-ol, at a temperature in the range of 10-80° C., preferably at 50° C. The reaction is followed by a hydrolysis with, for instance, aqueous sodium hydroxide at 0° C., phase separation of the resulting mixture, acidification of the aqueous layer with, for instance, concentrated hydrochloric acid to pH 2-3 and crystallization of the product.
[0032] The compounds of the formulae (XIIIa) and (XIIIb) are useful intermediates to prepare the compound of formula (A) via a reaction with the compound of formula (XV)
and further elaboration of the resulting product to give the desired active pharmaceutical ingredient.
[0033] The present invention further describes a practical method to prepare enantiopure compounds of the formula (A) which comprises reacting a compound of formula (XVI) with a compound of formula (XIII):
wherein n is 2 or 3, P is an amino protecting group, and R and X are as hereinbefore defined for the compound of formula (XIII); followed by enone reduction and deprotection of the carboxyl and amino groups.
[0034] Preferably n is 3.
[0035] Suitable examples of the amino protecting group P include a group selected from: tert-butylmethoxyphenylsilyl, tert-butoxydiphenylsilyl, trimethylsilyl, triethylsilyl, acetyl, pivaloyl (2,2-dimethyl-1-oxopropyl), o-nitrobenzyloxycarbonyl, p-nitrobenzyloxycarbonyl, benzyloxycarbonyl, tert-butyloxycarbonyl (t-BOC), 2,2,2-trichloroethyloxycarbonyl, benzhydryl, o-nitrobenzyl, p-nitrobenzyl, 2-naphthylmethyl, benzyl, 2,2,2-trichloroethyl, tert-butyldimethylsilyl, tert-butyldiphenylsilyl, 2-(trimethylsilyl)ethyl, p-methoxybenzyl, p-methoxyphenyl, 4-pyridylmethyl, tert-butyl, allyloxycarbonyl, di-C 1-10 alkylphosphoryl, diarylphosphoryl and di-ar-C 1-10 alkylphosphoryl.
[0036] More particularly, P represents a protecting group which is selected from the group consisting of: an alkoxycarbonyl group (especially t-BOC), diisopropylphosphoryl and pivaloyl (2,2-dimethyl-1-oxopropyl).
[0037] Most suitably, P is a tert-butoxycarbonyl (t-BOC) group.
[0038] Most suitably, R is a C 1-6 alkyl group such as methyl, ethyl or propyl group and is preferably a methyl group.
[0039] Preferably, X is —CH═PPh 3 .
[0040] The reaction is conveniently effected as a single solvent through-process. Suitable solvents include toluene, isopropyl acetate, acetonitrile, ethanol and isopropyl alcohol (2-propanol), the latter being most preferred.
[0041] Conveniently, the intermediate enone of formula (XVII)
is not isolated. Enone reduction is conveniently effected by hydrogenation in the presence of a palladium metal catalyst, aptly palladium on carbon. After filtration of the catalyst, a saponification step using aqueous hydroxide, for example, sodium hydroxide, removes the carboxyl protecting group to give the compound of formula (XVIII)
[0042] Deprotection of compound (XIII) can be effected in a conventional manner. Preferably, when P is a tert-butoxycarbonyl (BOC) group, acids are used. Most preferably, a treatment with an excess of trifluoroacetic acid (preferably about 15 equivalents) is used. The reaction is effected in a suitable solvent. Preferably, a halogenated hydrocarbon, for example, dichloromethane, at a temperature between 20° C. and 40° C. is used.
[0043] After neutralizing the reaction mixture with aqueous hydroxide, for example, sodium hydroxide, and, if necessary, adjusting the pH of the separated aqueous layer to about 6.0 using a mineral acid, such as hydrochloric acid, the compound of formula (A) is extracted as the zwitterion using a suitable solvent, preferably dichloromethane.
[0044] Before or after deprotection of the amino moiety, the reaction mixture may undergo a carbon treatment to reduce the level of residual palladium.
[0045] The compound of formula (A) may be crystallized from a lower alkanol solvent. Ethanol and 2-propanol are the preferred solvents; 2-propanol is the most preferred solvent.
[0046] The novel, crystalline zwitterion of the compound of formula (A) is unexpectedly stable and non-hygroscopic, and has a desirable water solubility making it particularly advantageous for pharmaceutical formulation. The crystalline zwitterion of the compound of formula (A) where n=3 is characterised by the X-ray powder diffraction (XRPD) data shown in FIG. 3 , which has the significant peaks listed in Table 1:
TABLE 1 Angle d value Intensity 2-Theta ° Angstrom Count 9.8 8.98 408 15.1 5.86 439 15.5 5.73 331 16.4 5.40 151 17.3 5.13 160 18.1 4.89 138 19.8 4.48 278 22.1 4.01 965 23.5 3.78 247 24.6 3.61 202 27.3 3.27 176
[0047] Although crystalline zwitterion of the compound of formula (A) where n=3 is characterized by the complete group of angle 2 theta values listed in Table 1, all the values are not required for such identification. The crystalline zwitterion of the compound of formula (A) where n=3 can be identified by the most significant angle 2 theta values: 9.8°, 15.1°, 15.5°, 19.8°, 22.1°, 23.5° and 24.6°.
[0048] The compound of formula (A) may also be crystallized as the tris(hydroxymethyl)aminomethane (TRIS) salt by treating a solution of the zwitterion (for instance, in 2-propanol) with tris(hydroxymethyl)aminomethane and then crystallizing the TRIS salt from either ethanol or, more preferably, 2-propanol. The crystallization solvent may be “wet” or “dry”, i.e. containing a water content of between about 6% and less than 0.1%, preferably about 4%.
[0049] The novel, crystalline TRIS salt of the compound of formula (A) where n=3 is characterised by the XRPD data shown in FIG. 4 , which has the significant peaks listed in Table 2:
TABLE 2 Angle d value Intensity 2-Theta ° Angstrom Count 5.3 16.56 422 15.4 5.76 102 16.1 5.51 259 20.2 4.39 227 21.5 4.13 633 22.1 4.01 147
[0050] Although crystalline TRIS salt of the compound of formula (A) where n=3 is characterized by the complete group of angle 2 theta values listed in Table 2, all the values are not required for such identification. The crystalline TRIS salt of the compound of formula (A) where n=3 can be identified by the most significant angle 2 theta values: 5.3°, 16.1°, 20.2° and 21.5°.
[0051] If desired, the crystallization of the TRIS salt of the compound of formula (A) may be utilised in a method of purifying the zwitterion of the compound of formula (A). Thus, the zwitterion is prepared as previously described, and is converted to the TRIS salt as described above. After recovery of the crystalline TRIS salt, the salt is broken by dissolving the TRIS salt in de-ionized water. The pH is adjusted to about 6.0 using, for example, hydrochloric acid, and the solution extracted with dichloromethane. After washing with further de-ionized water, the solvent is switched and the product crystallized as described above.
[0052] If desired, a carbon treatment stage may be incorporated into the zwitterion recrystallization using a suitable carbon.
[0053] The crystalline zwitterion compound of formula (A) prepared in the above method has a very high enantiopurity, with an enantiomeric excess of ≧98%, preferably ≧99%, and more preferably ≧99.5%.
[0054] According to a further aspect of the present invention, compounds of formula (XVI) may be prepared by a Suzuki coupling of the compounds of formulae (I) and (XIX), wherein R 1 is a chlorine atom and each R a is independently C 1 to C 6 straight or branched alkyl, preferably methyl or ethyl and P is defined as above,
followed by acetal hydrolysis to yield the compound of formula (XVI).
[0055] Conditions suitable for a Suzuki coupling reaction are well known in the art (for review, see for instance A. Suzuki, in “Metal-catalyzed Cross-coupling Reactions”, F. Diederich and P. J. Stang (Eds.), Wiley-VCH; Weinheim (1998), pp 49-89), using a catalyst formed in situ from a suitable palladium salt and a ligand. Suitable catalysts include tetrakis(triphenylphosphine)palladium (0), the combination of palladium(II) acetate and 1,1′-bis(diphenylphosphanyl)ferrocene (DPPF) or the related dichloro[1,1′-bis(diphenylphosphino)ferrocene]palladium (II) dichloromethane adduct, or the combination of palladium(II) acetate and tricyclohexylphosphine (Cy 3 P), or the related bis(tricyclohexylphosphine)-palladium (0) or trans-dichlorobis(tricyclohexylphosphine)palladium (II).
[0056] A particularly preferred catalyst is that formed in situ from a combination of palladium(II) acetate and 1,1′-bis(diphenylphosphanyl)ferrocene (DPPF).
[0057] The reaction is effected in the presence of a base, for example, potassium carbonate, sodium tert-butoxide or aqueous sodium hydroxide, in a suitable solvent such as an ether, for example, tetrahydrofuran, dimethoxyethane or dioxane or an aromatic hydrocarbon, for example toluene, and at an elevated temperature, for example, between 65° C. and the reflux temperature of the solvent.
[0058] A particularly preferred base is potassium carbonate.
[0059] Immediately following the coupling reaction acetal hydrolysis can be effected in high yield using conventional procedures, for example, by extracting the diethyl acetal intermediate into isopropyl acetate and treating with a strong acid such as hydrochloric acid, at a reduced temperature, for example, between 0° C. and 10° C.
[0060] The compound of formula (XIX) can be prepared from the commercially available acrolein dialkyl acetal, preferably the diethyl or dimethyl acetal, and 9-borabicyclo[3.3.1]nonane (9-BBN) following a standard hydroboration protocol at 0 to 30° C. in an ether solvent, preferably tetrahydrofuran.
[0061] The compound of the formula (III) where R 1 is a chlorine atom may also be prepared from the corresponding protected amine of formula (XX)
by reaction with a lithium alkyl such as a slight excess of n-BuLi or s-BuLi, preferably in the presence of an equimolar amount of tetramethylethylenediamine.
[0062] The following non-limiting examples are provided to illustrate the present invention.
EXAMPLE 1
1,1-Dimethylethyl 2-chloro-5,6,7,8-tetrahydro-9H-pyrido[2,3-b]azepine-9-carboxylate
[0063]
[0064] Tetramethylethylenediamine (5.85 kg) was dissolved in THF (54.5 L) and degassed. The bath was cooled to −20° C. and then hexyllithium (˜2.5 M, 22 L) was charged over 35 minutes maintaining the internal temperature between −10° C. and −20° C. The batch was aged for 30 minutes between −18° C. to −16° C. and then cooled further to −75° C. A solution of 1,1-dimethylethyl [6-chloro-2-pyridinyl]carbamate (5.23 kg) in THF (16 L) was added to the above solution, maintaining the temperature below −65° C. The red/brown dianion solution was aged for 1 hour at −70° C. and then a solution of 1-chloro-4-iodobutane (7.57 kg) in THF (5 L) was added, maintaining the internal temperature below −65° C. After the addition, the reaction was allowed to warm slowly to ambient temperature and then heated to reflux for 9 hours. The solution was then cooled to 60° C. and water (54.5 kg) added, maintaining the internal temperature above 40° C. The aqueous layer was cut and extracted with isopropyl acetate (IPAc) (54.4 L). The combined organic layers were washed with water (27 L), azeotropically distilled iin vacuo to a volume of 26 L, and then solvent switched to heptane to a final volume of 26 L. The resulting slurry of crystals was cooled to 5° C., aged for 1 hour and then isolated by filtration. A wash with cold heptane (10 L) and overnight drying iin vacuo at 40° C. furnished the title compound (5.05 kg) in 78% yield. Recrystallisation from ethyl acetate furnished an analytically pure sample; m.p. 166-168° C.
[0065] 1 H NMR (400 MHz, d 6 -DMSO, 343 K): δ 7.62 (d, J=7.9 Hz, 1H), 7.17 (d, J=7.9 Hz, 1H), 3.35 (m, 2H), 2.58 (m, 2H), 1.62 (m, 2H), 1.51 (m, 2H), 1.22 (s, 9H); 13 C NMR (100 MHz, d 6 -DMSO, 343 K): δ 155.7, 153.8, 146.7, 142.8, 134.0, 123.3, 80.6, 47.1, 32.6, 29.5, 28.8, 25.7.
Example 2
[0066] In all of the following reactions high yielding lithiation could be achieved by the addition of 1b to a slight excess (2.2 eq) of an equimolar TMEDA/n-BuLi solution, whereas the lithiation of 1a required more forcing conditions (TMEDA/n-BuLi at −10° C. or TMEDA/s-BuLi at −78° C.). The TMEDA/BuLi mixtures were aged for about 30 minutes at −20° C. prior to addition of substrate 1. The dianion is then quenched with the α,ω-dihalide to form the intermediate. Warming the reaction mixture to reflux effected ring closure to give the product 2. The results of a series of experiments were as follows:
TABLE 3 1a, X = H, R = H 1b, X = Cl, R = H 1c, X = H, R = Me 1d, X = Cl, R = Me 2a, X = H, n = 1; 2b, X = Cl, n = 1 2c, X = H, n = 2, 2d, X = Cl, n = 2 2e, X = H, n = 3, 2f, X = Cl, n = 3 Copper (I) Yield Entry Substrate 1 R—Li Additive Halide Electrophile Product 2 % a 1 1a s-BuLi TMEDA — Cl(CH 2 ) 2 I 2a 0 2 1a s-BuLi TMEDA — Cl(CH 2 ) 3 I 2c 54 3 1a s-BuLi TMEDA — Cl(CH 2 ) 4 I 2e 55 4 1d n-BuLi — — Cl(CH 2 ) 2 I 2d 0 5 1c n-BuLi — — Cl(CH 2 ) 3 I 2e 86 6 1c n-BuLi — — Cl(CH 2 ) 2 Br 2c 0 7 1b n-BuLi TMEDA — Cl(CH 2 ) 4 Br 2f 51 8 1b n-BuLi TMEDA — Cl(CH 2 ) 3 I 2d 51 9 1b n-BuLi TMEDA — Cl(CH 2 ) 4 I 2f 85 10 1b n-BuLi TMEDA — MeI 1d 91 11 1b n-BuLi TMEDA CuCl Cl(CH 2 ) 3 I 2d 95(91) 12 1b n-BuLi TMEDA CuBr Cl(CH 2 ) 3 I 2d 94 13 1b n-BuLi TMEDA CuBr.Me 2 S Cl(CH 2 ) 3 I 2d 94 14 1b n-BuLi TMEDA CuI Cl(CH 2 ) 3 I 2d 98 15 1b n-BuLi TMEDA CuBr.Me 2 S Cl(CH 2 ) 4 I 2f 90(86) 16 1b n-BuLi TMEDA CuBr Cl(CH 2 ) 2 I 2b 57 17 1b n-BuLi TMEDA CuBr.Me 2 S Cl(CH 2 ) 2 I 2b 57 a Yield refers to HPLC assay yield, obtained by comparison with an isolated pure standard. Yield in parentheses refers to isolated yield, either by silica gel chromatograph or crystallisation.
Example 3
4-Carboxy-3-(2-methoxypyrimidin-5-yl)butanoic acid
[0067] 2-Methoxypyrimidine-5-carbaldehyde (see J. Heterocycl. Chem. (1991) 28, 1281) (9.00 kg) was reacted with ethylacetoacetate (17.8 kg) in the presence of piperidine (555 g) in propan-2-ol (90 L) at 50° C. for several hours, followed by a hydrolysis with aqueous sodium hydroxide (24.2 kg of 46% NaOH in 30 L of water) at 0° C. Phase separation of the resulting mixture, acidification of the aqueous layer with concentrated hydrochloric acid (23.2 kg) to pH 2-3 and crystallization afforded the title compound (12.7 kg; 85% yield).
[0068] 1 H NMR (250 MHz, methanol-d 4 ) δ 8.52 (s, 2 H), 3.98 (s, 3 H), 3.54 (tt, J=9.2, 6.1 Hz, 1H), 2.82 (dd, J=16.2, 6.1 Hz, 2 H), 2.67 (dd, J=16.2, 9.2 Hz, 2 H); 13 C NMR 63 MHz, methanol-d 4 ) δ 174.9, 165.9, 160.2, 131.4, 55.6, 40.5, 34.6.
Example 4
4-(2-Methoxypyrimidin-5-yl)glutaric anhydride
[0069]
[0070] 4-Carboxy-3-(2-methoxypyrimidin-5-yl)butanoic acid (11.5 kg) was treated with trifluoroacetic anhydride (12.1 kg) in THF (58 L) at 50-55° C. for several hours. Slow addition of heptane (195 L) followed by cooling to ambient temperature resulted in the crystallization of the title compound; 94% yield.
[0071] 1 H NMR (250 MHz, CD 2 Cl 2 ) δ 8.41 (s, 2 H), 3.99 (s, 3 H), 3.49-3.35 (m, 1 H), 3.18-3.07 (m, 2 H), 2.92-2.79 (m, 2 H); 13 C NMR (63 MHz, CD 2 Cl 2 ) δ 165.3, 164.9, 157.4, 125.6, 54.8, 36.2, 29.2.
Example 5
(3S)-4-(Methoxycarbonyl)-3-(2-methoxypyrimidin-5-yl)butanoic acid
[0072]
[0073] Toluene (180 L) was charged to a vessel containing anhydride (XII) (9.0 kg) and quinidine (13.15 kg) under a nitrogen atmosphere. The resulting slurry was cooled, with stirring, to −40° C. Methanol (13.0 kg), which had been pre-cooled to approx. 5° C., was then added over 15 minutes. The resulting reaction mixture was held at about −35° C. for 8 hours and then allowed to warm to ambient temperature overnight.
[0074] The reaction mixture was then extracted twice with water (2×60 L). The combined aqueous extracts were acidified with concentrated hydrochloric acid (4.0 kg), then seeded with the authentic product (45 g) before another portion of concentrated hydrochloric acid (4.0 kg) was added. The temperature of the resulting slurry was adjusted to 20° C., aged for 2 hours and then filtered to afford 6.54 kg of 98% e.e. pure crystalline product (63% yield).
[0075] 1 H NMR (250 MHz, methanol-d 4 ) δ 8.52 (s, 2 H), 3.98 (s, 3 H), 3.62-3.48 (m, 1 H), 3.59 (s, 3 H), 2.85 (dd, J=16.2, 11.6 Hz, 1 H), 2.82 (dd, J=16.3, 11.7 Hz, 1 H), 2.73 (dd, J=16.2, 9.0 Hz, 1 H), 2.67 (dd, J=16.2, 9.0 Hz, 1 H); 13 C NMR (63 MHz, methanol-d 4 ) δ 174.8, 173.5, 165.9, 160.2, 131.3, 55.6, 52.3, 40.4,40.4, 34.6.
[0076] Two polymorphic crystal forms of (XIa) have been identified. Form A is characterized by a melting point of 148° C. and having an XRPD pattern at ( FIG. 1 ), which has the significant peaks listed in Table 4:
TABLE 4 Angle d value Intensity 2-Theta ° Angstrom Count 9.4 9.40 686 14.2 6.23 727 14.6 6.04 633 15.1 5.88 280 18.2 4.88 193 19.5 4.55 850 19.9 4.46 249 22.2 4.00 246 23.1 3.85 2009 26.7 3.33 2221 28.4 3.14 1674 30.4 2.94 244
[0077] Form B is characterized by a melting point of 145° C. and having an XRPD pattern at ( FIG. 2 ), which has the significant peaks listed in Table 5:
TABLE 5 Angle d value Intensity 2-Theta ° Angstrom Count 12.5 7.10 435 13.0 6.81 1289 13.7 6.45 158 16.9 5.24 241 21.2 4.18 1008 22.9 3.88 1002 23.7 3.74 2306 29.4 3.03 394
Example 6
Methyl (3S)-3-(2-methoxypyrimidin-5-yl)-5-oxo-6-(triphenylphosphoranylidene)hexanoate
[0078]
[0079] A suspension of methyltriphenylphosphonium bromide (18.2 kg) in THF (82 L) was cooled to −60° C. Hexyllithium (13.8 kg) was-then added over 30 minutes, while keeping the internal temperature below −10° C. Once the addition was complete, the batch was aged at 0° C. for 90 minutes and then cooled to −80° C. and held awaiting the mixed anhydride formation.
[0080] A solution of acid-ester (XI) (4.38 kg) and trimethylacetyl chloride (2.06 kg) in THF (34 L) was cooled to −5° C. and triethylamine (1.72 kg) was added over a period of 30 minutes. After a rinse with THF (0.5 L), the resulting slurry was aged between −5 and 0° C. for 30 minutes and then added to the above ylide mixture whilst maintaining the internal temperature at approximately −70° C. The mixed anhydride vessel was rinsed with THF (8 L) and this rinse was also added to the batch.
[0081] After an age of 40 minutes the reaction mixture was transferred into an aqueous solution of potassium dihydrogenphosphate (1.20 kg KH 2 PO 4 in 64 L of water), keeping the temperature of the quenched mixture between 0 and 10° C. Isopropyl acetate (IPAc) (85 L) was added to the quenched reaction mixture and the two phases were separated. The aqueous layer was further extracted with IPAc (85 L) and the combined organic extracts were then washed twice with half-saturated brine (6.95 kg NaCl in 38 L of water, each). The resulting organic layer was concentrated under reduced pressure to a volume of 25 L. IPAc (34 L) was added and the batch was again concentrated until a final volume of 25 L was reached. Crystallization of the product had occurred during this distillation and, after cooling to 0° C., the solid was collected by filtration, washing the wet-cake with MTBE (10.5 L). Drying overnight, under vacuum, at 30° C. afforded 6.28 kg of phosphorane (XIIIb) (70% corrected yield) as cream-coloured crystals.
[0082] 1 H NMR (250 MHz, CD 2 Cl 2 ) δ 8.33 (s, 2 H), 7.52-7.28 (m, 15 H), 3.88 (s, 3 H), 3.60-3.48 (m, 2 H), 3.47 (s, 3 H), 2.70 (dd, J=15.7, 5.9 Hz, 1 H), 2.58-2.45 (m, 3 H); 13 C NMR (63 MHz, CD 2 Cl 2 ) δ 189.3 (d, J=2 Hz), 172.4, 165.0, 159.1, 133.3 (d, J=10 Hz), 132.5 (d, J=3 Hz), 130.6, 129.1 (d, J=12 Hz), 127.3 (d, J=91 Hz), 55.0, 53.2 (d, J=107 Hz), 51.8, 46.8 (d, J=16 Hz), 40.7, 34.8.
Example 7
1,1-Dimethylethyl 2-chloro-5,6,7,8-tetrahydro-9H-pyrido[2,3-b]azepine-9-carboxylate
[0083]
[0084] Tetramethylethylenediamine (5.85 kg) was dissolved in THF (54.5 L) and degassed. The bath was cooled to −20° C. and then hexyllithium (˜2.5 M, 22 L) was charged over 35 minutes maintaining the internal temperature between −10° C. and −20° C. The batch was aged for 30 minutes between −18° C. to −16° C. and then cooled further to −75° C. A solution of 1,1-dimethylethyl [6-chloro-2-pyridinyl]carbamate (5.23 kg) in THF (16 L) was added to the above solution, maintaining the temperature below −65° C. The red/brown dianion solution was aged for 1 hour at −70° C. and then a solution of 1-chloro-4-iodobutane (7.57 kg) in THF (5 L) was added, maintaining the internal temperature below −65° C. After the addition, the reaction was allowed to warm slowly to ambient temperature and then heated to reflux for 9 hours. The solution was then cooled to 60° C. and water (54.5 kg) added, maintaining the internal temperature above 40° C. The aqueous layer was cut and extracted with IPAc (54.4 L). The combined organic layers were washed with water (27 L), azeotropically distilled in vacuo to a volume of 26 L, and then solvent switched to heptane to a final volume of 26 L. The resulting slurry of crystals was cooled to 5° C., aged for 1 hour and then isolated by filtration. A wash with cold heptane (10 L) and overnight drying in vacuo at 40° C. furnished the title compound (5.05 kg) in 78% yield. Recrystallisation from ethyl acetate furnished an analytically pure sample; m.p. 166-168° C.
[0085] 1 H NMR (400 MHz, d 6 -DMSO, 343 K): δ 7.62 (d, J=7.9 Hz, 1H), 7.17 (d, J - 7.9 Hz, 1H), 3.35 (m, 2H), 2.58 (m, 2H), 1.62 (m, 2H), 1.51 (m, 2H), 1.22 (s, 9H); 13 C NMR (100 MHz, d 6 -DMSO, 343 K): δ 155.7, 153.8, 146.7, 142.8, 134.0, 123.3, 80.6, 47.1, 32.6, 29.5, 28.8, 25.7.
Example 8
tert-Butyl 2-(3-oxopropyl)-5,6,7,8-tetrahydropyrido[2,3-b]azepine-9-carboxylate
[0086]
[0087] Acrolein diethyl acetal (3.51 kg) was added over 30 minutes to 0.41 M 9-BBN in THF (57.4 L) which had been pre-cooled to 0° C. The resulting reaction mixture was warmed to room temperature and then aged for 5 hours to give the hydroborated acrolein acetal.
[0088] A suspension of 1,1-dimethylethyl 2-chloro-5,6,7,8-tetrahydro-9H-pyrido[2,3-b]azepine-9-carboxylate (3.32 kg), potassium carbonate (3.25 kg), palladium acetate (132 g) and 1,1′-bis(diphenylphosphanyl)ferrocene (dppf) ((326 g) in THF (16.5 L) was degassed and put under an atmosphere of nitrogen. The THF solution of the hydroborated acrolein acetal was then added. The reaction mixture was degassed, purged with nitrogen and then heated at reflux for 26 hours. The reaction mixture was then cooled to 20° C., water (66 L) was added and the mixture was stirred for 30 minutes. The two layers were allowed to settle and the lower aqueous phase was discarded. IPAc (10 L) was then added and, after stirring for 5 minutes and allowing the mixture to settle, the lower aqueous phase was again discarded. The resulting organic layer was concentrated by distillation under reduced pressure to minimum volume (55 L of distillate removed) and a second portion of IPAc (33 L) was then charged. The two layers were again separated, the aqueous phase was discarded and the remaining organic layer was concentrated to minimum volume (10 L) under reduced pressure. IPAc (23 L) was added and the mixture held overnight at ambient temperature. The solution was cooled to 0° C. and treated with pre-cooled (0° C.) 2M hydrochloric acid (23.0 L), while keeping the temperature below 10° C. The resulting two phase mixture was stirred at 0° C. for 4 hours.
[0089] The mixture was allowed to settle and the phases separated. The aqueous phase was filtered, cooled to 0-5° C. and IPAc (16.5 L) added. The mixture was then basified (to pH 8) by addition of 10% aqueous potassium carbonate (5.5 kg dissolved in 49.5 L of water). The mixture was agitated for 5 minutes, allowed to settle and the phases separated. The aqueous phase was extracted with IPAc (2×16.5 L) and the combined IPAc extracts were washed with water (8.25 L). The IPAc solution was concentrated by distillation under reduced pressure to low volume (ca. 10 L). Isopropanol (33 L) was added and the solution again distilled to low volume under reduced pressure. Additional isopropanol (33 L) was added and the solution concentrated to about 15 L by distillation under reduced pressure. The isopropanol solution was then assayed for the desired aldehyde (yield: 3.075 kg; 86%).
Example 9
tert-Butyl 2-[(7S)-8-methoxycarbonyl-7-(2-methoxypyrimidin-5-yl)-5-oxo-3-octenyl]-5,6,7,8-tetrahydropyrido[2,3-b]azepine-9-carboxylate
[0090]
[0091] A solution of the priopionaldehyde of Example 8 (3.02 kg) in isopropanol (11.98 kg total mass) was charged to a vessel containing methyl (3S)-3-(2-methoxypyrimidin-5-yl)-5-oxo-6-(triphenylphosphoranylidene)hexanoate (Example 6; 4.84 kg). The resulting slurry was degassed, put under an atmosphere of nitrogen and then heated to reflux. The resulting clear solution was aged for 12 hours. The reaction mixture was allowed to cool to room temperature overnight and directly used in Example 10 without isolation of the intermediate enone.
[0092] 1 H NMR (250 MHz, CD 2 Cl 2 ) δ 8.37 (s, 2 H), 7.46 (d, J=7.6 Hz, 1 H), 6.94 (d, J=7.6 Hz, 1 H), 6.86 (dt, J=15.9, 6.7 Hz, 1 H), 6.06 (dt, J=15.9, 1.5 Hz, 1 H), 3.94 (s, 3 H), 3.7-3.2 (br, 2H), 3.69-3.55 (m, 1 H), 3.57 (s, 3 H), 3.02-2.81 (m, 4 H), 2.78-2.53 (m, 6 H), 1.88-1.75 (m, 2 H), 1.72-1.55 (m, 2 H), 1.38 (s, 9H); 13 C NMR (63 MHz, CD 2 Cl 2 ) δ 197.5, 171.9, 165.1, 158.9, 157.7, 155.5, 154.1, 147.5, 139.3, 132.5, 130.8, 130.0, 121.6, 80.0, 55.1, 52.0, 47.2, 45.3, 40.1, 36.2, 33.5, 32.6, 32.3, 29.9, 28.4, 26.4.
Example 10
tert-Butyl 2-[(7S)-8-methoxycarbonyl-7-(2-methoxypyrimidin-5-yl)-5-oxooctyl]-5,6,7,8-tetrahydropyrido[2,3-b]azepine-9-carboxylate
[0093]
[0094] The solution of the enone intermediate of Example 9 in isopropanol was charged to a hydrogenation vessel under an atmosphere of nitrogen. A slurry of wet (58 wt % water) palladium on carbon catalyst (1.27 kg) in isopropanol (10 L) was added, washing with further isopropanol (15 L). After degassing the resulting reaction mixture was hydrogenated at 2.8 bar for 2 hours. The catalyst was filtered and washed with isopropanol (4×15 L). The combined filtrates (88.0 kg) were concentrated under reduced pressure to a total volume of ca. 20 L and the solution was directly used in Example 11 without isolation of the product. 1 H NMR (250 MHz, CD 2 Cl 2 ) δ 8.37 (s, 2 H), 7.43 (d, J 7.6 Hz, 1 H), 6.92 (d, J=7.6 Hz, 1 H), 3.93 (s, 3 H), 3.9-3.0 (br, 2H), 3.66-3.52 (m, 1H), 3.57 (s, 3 H), 2.90-2.62 (m, 7 H), 2.55 (dd, J=15.9, 8.7 Hz, 1 H), 2.45-2.28 (m, 2 H), 1.86-1.75 (m, 2 H), 1.70-1.49 (m, 6 H), 1.37 (s, 9H); 13 C NMR (63 MHz, CD 2 Cl 2 ) δ 208.2, 171.9, 165.1, 159.3, 158.9, 155.3, 154.1, 139.1, 132.0, 130.0, 121.5, 79.9, 55.1, 52.0, 47.9, 47.1, 43.3, 40.0, 37.6, 33.5, 32.0, 29.9, 29.5, 28.5, 26.5, 23.5.
Example 11
tert-Butyl 2-[7S)-8-carboxy-7-(2-methoxypyrimidin-5-yl)-5-oxooctyl]-5,6,7,8-tetrahydropyrido[2,3-b]azepine-9-carboxylate
[0095]
[0096] The solution of the BOC-protected methyl ester in isopropanol (ca. 20 L) from Example 10 (4.50 kg) was cooled to 0° C. 2M Sodium hydroxide (5.6 L) was added and the resulting reaction mixture aged at 0° C. for 2 hours. The resulting thin slurry was diluted with water (43 L) and warmed to 20° C. The resulting aqueous solution was washed once with MTBE (43 L) and twice with IPAc (2×43 L). The aqueous layer was treated with 2M hydrochloric acid (0.56 L,) and IPAc (43 L) was then added. The resulting biphasic solution was stirred and acidified with a second portion of 2M hydrochloric acid (5.04 L,). The two layers were separated and the aqueous phase (pH 3.8) was extracted with IPAc (43 L) and the combined organic extracts washed with water (21 L). The resulting solution was treated with Ecosorb™ C-941 (0.43 kg) and stirred for 1 hour at room temperature. The mixture was filtered washing the filterbed with IPAc (2×12 L). The filtrate was concentrated under reduced pressure to a total volume of ca. 20 L and the combined washes were then added along with a further portion of IPAc (16 L). The slurry was concentrated to a total volume of ca. 20 L and heptane (10 L) was added over a period of 30 minutes, at room temperature. The resulting slurry was aged, and then cooled to 0° C. The solids were then collected by filtration, washing with 2:1 IPAc:heptane (4.5 L). The off-white solid was dried under vacuum, with a slight nitrogen purge, overnight at 45° C. to afford the BOC-protected intermediate (3.45 kg; 71% overall yield from the phosphorane intermediate).
[0097] 1 H NMR (250 MHz, CD 2 Cl 2 ) δ 9.8-8.9 (br, 1 H), 8.43 (s, 2 H), 7.49 (d, J=7.6 Hz, 1 H), 6.97 (d, J=7.6 Hz, 1 H), 4.2-2.5 (br, 2H), 3.93 (s, 3 H), 3.64 (app quintet, J=7.2 Hz, 1H), 2.94 (dd, J=17.4, 6.6 Hz, 1 H), 2.78 (dd, J=17.2, 9.8 Hz, 1 H), 2.71-2.61 (m, 5 H), 2.56 (dd, J=15.7, 7.6 Hz, 1 H), 2.45-2.29 (m, 2 H), 1.87-1.44 (m, 8 H), 1.35 (s, 9H); 13 C NMR (63 MHz, CD 2 Cl 2 ) δ 208.3, 173.8, 164.9, 159.2, 158.8, 154.8, 153.9, 140.0, 132.6, 130.7, 122.0, 80.3, 55.2, 47.9, 47.1, 42.8, 40.6, 36.7, 33.4, 32.2, 29.8, 29.6, 28.3, 26.3, 23.4.
Example 12
(3S)-3-(2-Methoxypyrimidin-5-yl)-5-oxo-9-(6,7,8,9-tetrahydro-5H-pyrido[2,3-b]azepin-2-yl)nonanoic acid
[0098]
[0099] The BOC-protected product of Example 11 (15 g) was dissolved in dichloromethane (75 ml) and the solution cooled to 5° C. Trifluoroacetic acid (48.7 g) was added dropwise maintaining the internal temperature at <10° C. The reaction mixture was then heated to 30° C. and aged for ca. 2 hours. The reaction mixture was then cooled to 0° C. and a 2M solution of sodium hydroxide was added dropwise maintaining the temperature at or below ambient. The resulting solution was allowed to settle for ca. 1 hour and the layers separated. The aqueous layer was treated with Ecosorb™ C-941 (0.75 g) at ambient temperature for 1 hour. The resulting mixture was filtered through a bed of Hyflo™. The filter-bed was washed with water (10 ml). The combined filtrates were acidified to pH 6.0 by adding concentrated hydrochloric acid (ca. 8 ml) whilst maintaining the temperature at or below ambient temperature. The aqueous solution was extracted with dichloromethane (2×150 ml) and the organics washed with water (50 ml). The solution was solvent switched to isopropanol (65 ml) at atmospheric pressure and the solution warmed to 40° C., seeded with 0.6% w/w seed, and maintained at 40° C. for 12 hours. Heating was then removed and the slurry allowed to cool to 20° C. Isolation by filtration and washing with isopropanol (3×15 ml) afforded the title compound (9.0g, 74% yield).
[0100] 1 H NMR (400 MH, DMSO-d 6 ) δ 8.34 (s, 2 H), 7.07 (d, J=7.4 Hz, 1 H), 6.31 (d, J=7.4 Hz, 1 H), 3.79 (s, 3 H), 3.41-3.32 (m, 1H), 3.01-2.96 (m, 2 H), 2.79 (dd, J=17.1, 6.4 Hz, 1 H), 2.74 (dd, J=17.1, 7.8 Hz, 1 H), 2.58-2.20 (m, 8 H), 1.65-1.52 (m, 4 H), 1.48-1.32 (m, 4H); 13 C NMR (101 MHz, DMSO-d 6 ) δ 209.3, 173.1, 165.0, 162.0, 159.3, 157.7, 139.5, 131.2, 121.7, 113.8, 55.1, 47.9, 45.6, 43.1, 40.6, 37.3, 33.6, 32.6, 30.9, 29.2, 27.1, 23.9.
Example 13
Preparation of TRIS Salt of Compound of Formula (A) Where n=3
[0101]
[0102] A slurry of the zwitterion of the compound of formula (A) where n=3 (3.62 kg) and tris(hydroxymethyl)aminomethane (1.01 kg) in 2-propanol (35.7 L) and water (1.46 L) was heated to reflux to effect dissolution. The resulting solution was then cooled to 50° C. and seeded with authentic TRIS salt of the compound of formula (A) where n=3 (3.0 g). The batch was aged for 1 h at 50° C. and then cooled to 20° C. over a period of 2 h. The resulting slurry was diluted with 2-propanol (25 L) and then concentrated under a partial vacuum at 35° C., to a volume of 35 L. This procedure was repeated until the water content had reached <1.0% according to a Karl Fisher titration. Upon completion, the slurry was cooled to 20° C. and the solids filtered. The wet cake was washed with 2-propanol (1×20 L; 1×15 L) and dried overnight at 40° C. under vacuum to afford 4.40 kg of the TRIS salt (95% yield, 100 wt % pure) as a white solid. | The present invention relates to the synthesis of intermediates for the preparation of compounds of formula (A): wherein n is 2 or 3 and various salt forms of these compounds. The compounds of formula (A) are useful as ανβ3 receptor antagonists. | 2 |
FIELD OF THE INVENTION
The present invention relates to methods of traffic smoothing for frames of different video sources in Broadband Integrated Services Digital Networks.
BACKGROUND OF THE INVENTION
A recurring problem in traffic studies of Broadband Integrated Services Digital Networks (B-ISDN) is the finding of methods by which traffic can be smoothed so that the network does not have to concern itself with extreme variations in bit-rates. Heretofore, this problem was addressed by means of flow control (using a leaky bucket and its variants) and congestion control (e.g. distributed source control, stop and go queuing, feedback control methods and dynamic window methods).
The present invention addresses a problem similar in nature to flow control but which is very different in terms of its objectives and scope.
SUMMARY OF THE INVENTION
In order to better understand the present invention, consider a statistical multiplexer at a network ingress which is receiving traffic from various video sources. Assume that there are K types of video calls. Type k calls arrive according to a Poisson process at a rate λ k and their call durations have a general distribution with mean 1/μ k . Each call, while in progress, generates a frame every τ ms (τis 33 in most applications). The number of Mbits in a frame is modelled by using the video sources studied by Verbiest and Pinnoo in an article "A Variable Rate Video CODEC for Asynchronous Transfer Mode Networks", in IEEE Journal on Selected Areas in Communications, 7(5), PP 761-770, Jun. 1989. Assume that the output channel rate of the multiplexer is C (e.g., C=150 Mbps) and that the input channel rate for call type k is R k (e.g., R k =150 Mbps). When a source of type k transmits, it transmits a full frame as a burst at rate R k , without any gaps. Thus if a particular frame has X Mbits, the source of type k transmits for X×10 3 /R k ms and then remains silent for τ-X×10 3 /R k ms. Assume that the stationary distribution of X k (the frame size) for type k calls is given by G k (x), whose mean is g k (in Mbits). This implies that the mean bit-rate of a type k call is g k ×10 3 /τMbps. The multiplexer adopts the following admission control strategy. When a new video call arrives, the mean bit-rate of all currently active calls is added with the new call. The new call is admitted if this sum is less than or equal to σ times C (the output channel capacity of the multiplexer), otherwise it is not admitted. Now assume that marks are placed on the time axis at 0, τ, 2τ, . . . ms and with each source j is an offset O j (O<O j <τ). This means that the frames corresponding to source j begin to arrive at the multiplexer at times O j , τ+O j , 2τ+O j , . . . Let k j denote the type of call for source j. If the ith frame from source j is of size X kj (i) (in Mbits), then the ith frame from source j is received at the multiplexer over the interval [(i-1)τ+O j , (i-1)τ+O j +X k j (i)×10 3 /R k j ]. If no control is exercised on the video sources, then O j is assumed to be uniformly distributed between O and τ. If this happens, then it is possible that the start times of the frames belonging to the currently active sources are temporally very close to one another, which may result in high input rate for some time (and consequently, lead to lost packets) and poor performance. To alleviate this situation, a mechanism is needed which prevents the frames from different sources from being transmitted at or about the same time (i.e., prevent the frames from bunching). That is, the start time of the frames from different sources should be evenly spread out over the interval of τ ms. If this could be achieved, it should be possible to achieve less packet loss and better performance. Assume that this control is effected by the network by picking any value of O j it chooses. This choice is exercised only once per call, at the time of call admission. Once this number is determined for a particular call, it cannot be changed at a later time for the entire call duration (otherwise it may lead to synchronization problems at the destination). The problem is to find optimal methods of determining the value O j for a newly arrived call, given that the offsets of the currently active calls are known. The present invention provides solutions to the problem.
A principal object of the present invention is therefore, the provision of a method of temporal placement control of video frames in a B-ISDN network.
An object of the present invention is the provision of a midpoint method of temporal placement control of video frames.
A further object of the present invention is the provision of a smaller interval method of temporal placement control of video frames.
Another object of the present invention is the provision of an optimization method of temporal placement control of video frames.
A still further object of the present invention is the provision of a method of temporal placement control of video frames for reducing the loss rate of the high priority cells.
A still another object of the present invention is the provision of a method of interval placement control of video frames for minimizing the smoothness index of the traffic.
Further and still other objects of the present invention will become more clearly apparent when the following description is read in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graphical presentation of the midpoint method of practicing the present invention;
FIG. 2 is a graphical representation of the smallest interval method of practicing the present invention;
FIG. 3 is a graphical representation of high priority cell loss rate when practicing the present invention in the case of homogeneous video sources;
FIG. 4 is a graphical representation of high priority cell loss rate when practicing the present
invention in the case of heterogeneous video sources and three type 1 sources;
FIG. 5 is a graphical representation of high priority cell loss rate when practicing the present invention in the case of heterogeneous video sources and five type 1 sources;
FIG. 6 is a graphical representation of low priority cell loss rate when practicing the present invention in the case of heterogeneous video sources and three type 1 sources; and
FIG. 7 is a graphical representation of the complementary distribution of queue length when practicing the present invention in the case of heterogeneous video sources.
DETAILED DESCRIPTION
A first preferred method of practicing the present invention is referred to as the midpoint method. In accordance with the midpoint method, a circle is drawn having a circumference equal to the value τ (inter-frame interval). The offsets O j for the jth active call is drawn on the circumference of the circle. The 12 O'clock position is used for an offset of zero and the offsets are measured in the clockwise direction from the 12 O'clock position. Thus, any interval of the type [(i-1)τ, iτ] along the time axis is represented by the circle, with the 12 O'clock point representing the point iτ for i=1, 2, . . . For example, if there are n-1 active calls, the circumference of the circle is divided into n-1 intervals. If O 1 ≦O 2 ≦. . . ≦O n-1 , then the intervals are (O j , O j+1 ) for j=1, . . . , n13 2 and the last interval is from O n-1 to O 1 in the clockwise direction. The largest interval is selected and the midpoint of the selected interval is chosen as the offset for the newly arrived call. The concept underlying the midpoint method is that as calls depart, they do so in a random manner. The randomness in departures could result in the remaining calls being bunched together. However, the midpoint method alleviates the bunching effect by choosing an offset which fills empty areas.
A second preferred method of practicing the present invention is referred to as the smallest interval method. In this method, a circle is drawn having a circumference τ as before. For each source, an interval is defined over which the source is expected to transmit. If there are n active sources and k j denotes the type of source j, then this interval for source j is defined as [O j , E j ], where E j ={O j +g k j ×10 3 /R k j }, where R k j is the access line speed. Here, the angle brackets ({ }) refer to modulo- τ arithmetic, so that all numbers remain between O and τ. These n intervals are drawn on the circle and shaded as shown, for example, in FIG. 2. The shaded regions are areas with higher probability during which the currently active sources are transmitting. Therefore, the newly arrived source is made to transmit during the unshaded areas. The method requires defining an interval of length g k n ×10 3 /R k n for the nth call and then trying to locate the nth call in the smallest unshaded interval at least as large as the interval of the nth call. The locating is done so that O n =E j for some j(j=1, . . ., n-1). The result is that the shaded regions from two sources will be located end-to-end on the circle. Note that as calls depart, unshaded gaps on the circle will be created. It is possible that at some time, all of the unshaded intervals may be too small to locate the newly arrived call. In such event, the previously described midpoint method is used.
A third preferred method of practicing the present invention, based on an optimization problem, will now be described. Assume that n-1 calls are currently in progress whose call types (k j ) access line speeds (R k j ) and offsets (O j ) are known (for j=1, . . . , n-1). Assume further that call n is of type k n and has an offset O n , which is to be determined. From the knowledge of the parameters, it is possible to determine the expected bit-rate at time t, for O<t<τ. The expected bit rate is P n (t,O 1 , . . . , O n ). To clarify the meaning of P n (.) further, the value of ∫ 2 o P n (t,.)dt is the expected number of Mbits transmitted in the interval (O, x). The present optimization method attempts to choose a value of O n in such a manner that the function P n (.) has the greatest smoothness property. That is, O n is chosen to minimize ##EQU1##
Minimizing this function is likely to reduce the extreme variation in bit-rates. The following is a description of how this is accomplished. There are two parts in this description. First, a method of solving the problems is discussed. Second, a method of speeding up the convergence of the computations is shown.
Let G k j (x) denote the distribution function of the number of Mbits generated in a frame by source j and let G k j (x) denote its complementary function (i.e., G k j (x)=1-G k j (X)). Consider a source j for 1≦j≦n. First, assume that the offset O j is zero. The expected number of Mbits that arrive during (t,t+dt) from source j can be obtained by the following argument. Assume that the number of Mbits generated by this source in a particular frame is x. If x>R k j t, the number of Mbits that arrive in (t,t+dt)is R k j dt. If x≦R k j t, the number of Mbits that arrive in (t,t+dt)is zero. Therefore, the expected bit-rate at time t for source j is given by
h.sub.j (t)=R.sub.k.sub.j G.sub.k.sub.j (R.sub.k.sub.j, t).
Note that h j (t) is only defined for O≦t<τ. Define the periodic version of h j (t) by h j (t),i.e.,
h.sub.j (t+kτ)=h.sub.j (t),
for k=0, 1, . . . If the offset O j is not zero, the expected bit-rate at time t is given by
ƒ.sub.j (t,O.sub.j)=h.sub.j (t-O.sub.j).
From the definition of P n (t, O 1 , O 2 , . . . , O n ), the result is ##EQU2##
Next, it is necessary to find the optimal O n that minimizes the variance of P n (t, O 1 ,O 2 , . . . , O n ), i.e., minimizes Eq.(1). But ##EQU3## dt is the expected number of Mbits transmitted in (0, τ)] and equals ##EQU4## So the problem is equivalent to ##EQU5##
To perform the minimization in Eq.(3), first assume that the number of Mbits generated by a video source of type k in a frame can be represented by a truncated and shifted second-degree Erlang random variable X k . This is a rich two parameter family of distributions (the parameters are α k and S k ) which should meet most modeling needs. The density function of this random variable is ##EQU6## where B is a suitable normalization constant which makes the density integrate to one. Since τR k (the number of Mbits that can be transmitted in time τ) is much greater than the expected value of X k , the normalization constant B is actually very close to one in Eq.(4). The numerical results below were obtained using values of K=1, 2. for source type 1, α 1 =9.411 (1/Mbits) and S 1 =3.467 (Mbits) were chosen. With these choices, the mean and standard deviation of X 1 turn out to be 0.559 Mbits and 0.15 Mbits. This is a good approximation because Verbiest and Pinnoo supra report a mean and standard deviation of 0.56 and 0.143 Mbits respectively. It is further assumed that the type 2 sources are a scaled version of type 1 sources by a factor of 0.5, then α 2 =α 1 /0.5 and S 2 =0.5S 1 . Note that this scaling preserves all other characteristics (such as autocorrelations) of the sources of type 1.
The complementary distribution of X k (k=1, . . . , K) is ##EQU7## The Fourier coefficients of h k (t) are now given by ##EQU8## Note that a different assumption on G k (x) in Eq. (5) would cause a different result for c m (k). In all other respects, the methodology remains the same. Let {φ m } denote the Fourier coefficients of P n (t,O 1 , . . . , O n ). Then, from Eq. (2), ##EQU9## Using Parseval's theorem, the result is ##EQU10## To carry out the minimization Eq. (3), allow L possible choices of O n on a grid, so that O n =τ(l-1)/L for l=1, . . . , L. Then choose that value of l which minimizes Eq. (6).
Now the second part will be addressed, i.e., the speed of convergence of the computations. Since c m (k) is of the order m -1 , Eq. (6) has the same rate of convergence as the series Σm -2 . While this may be satisfactory in some applications, it is possible to speed up this rate of convergence further as described below. Define ##EQU11## Note that P n (t, O 1 , . . . , O n ) has n discontinuities at t=O 1 , . . . , O n , while P * n (t, O 1 , . . . , O n )
is continuous. Let {d m } denote the Fourier coefficients of ##EQU12## Then ##EQU13## Let {φ * m } denote the Fourier coefficients of P * n (t, O 1 , . . . , O n ). From Eq. (7),
|φ.sub.m |.sup.2 =|φ.sup.*.sub.m -d.sub.m |.sup.2 =|φ.sup.*.sub.m |.sup.2 +|d.sub.m |.sup.2 =2Re(φ.sub.md.sub.m), (9)
where d m is the complex conjugate of d m . Substitute Eq. (9) in Eq. (6) to get ##EQU14## The second term on the right hand side of Eq. (10) can be simplified as follows: ##EQU15##
Let B 2 (x)=x 2 -X+6 -1 denote the Bernoulli polynomial of second degree and let B 2 (x) be the periodic version of B 2 (x), i.e., B 2 (x+mτ)=B 2 (x) for m=0,1, . . . and O≦×<τ. From the well known identities ##EQU16## Eq. (10) becomes ##EQU17##
Since the derivative of P * n (t, O 1 , . . . , O n ) with respect to t has bounded variation, φ * m is of order m -2 . Hence, Eq. (11) has the same convergence rate as the series Σm -3 which is much better than that of Eq. (6). It is possible to speed up the convergence rate even more by adding a quadratic (or higher order) term to Eq. (7), which guarantees the existence of the second (or higher order) derivative of P n (t, O 1 , . . . , O n ) with respect to t. However, this is possible at the cost of considerable extra effort. Moreover, very satisfactory results were obtained with the method presented above. This completes the description of the speed of convergence of the computations.
Having described the theoretical basis for the three preferred methods of practicing the invention, the effects of applying these methods by simulation will now be described. A fluid-flow model as described in the article by D.S. Lee, et al entitled, "TES Modeling for Analysis of a Video Multiplexer, in Performance Evaluation, Vol 16,. PP 21-34, 1992, is used in order to keep the run time for the simulations within reasonable limits. The number of Mbits in a frame (X k ) is modelled by using the sum of two autoregressive processes and a Markov chain. This model matches the bit-rate histogram and the autocorrelation function for video sources studied by Verbiest and Pinnoo supra. The mean bit-rate of these sources is 16.8 Mbps (which corresponds to 0.56 Mbits per frame). If K=2, then two types of sources are considered. One type of source which is high bit-rate and the other type of source whose bit-rate is scaled by a factor of 0.5 (i.e., half the bit-rate, but otherwise preserving all other characteristics of the sources). The sources arrive according to a Poisson process and may or may not be admitted to the multiplexer according to the admission control strategy described above. Thus, the number of active sources in the simulation changes with time. The call holding time is assumed to be distributed uniformly between 5400 and 9000 frames. It is assumed that a layered coding scheme has been employed and therefore, the primary interest is in the loss rate of the high priority cells. The buffer threshold to discard low priority cells is 50 (in cells) and the total buffer size of the multiplexer is 300 cells. In order to faithfully compare the three methods, four systems (three control policies and the system without control) are simulated subject to the same arrival processes and holding times of video sources. Specifically one sequence of call arrivals and holding times is generated and fed to all four systems. This means that all four systems receive the same number of Mbits per frame from all accepted calls. In all the results, C=150 Mbps, R k =150 Mbps for k=1, 2, σ=0.95 and L=33.
In the first set of comparisons (see FIG. 3), it was assumed that K=1, i.e., the sources are homogeneous. The sources arrive according to a Poisson process of rate 0.03 (1/sec). The loss rate of the high priority cells is computed conditioned on the fact that n sources are active. This conditional loss probability is plotted against n in FIG. 3. FIG. 3 shows that both the Fourier analysis method and the midpoint method outperform the smallest interval method. Further, all three are much better than having no control at all. It is not difficult to understand the qualitative aspect of this result. The smallest interval method places the shaded arcs end-to-end on the circle. This means that severe bunching of the offsets is avoided, i.e., the offsets are not too close to each other. However, if there are only two or three sources which have just started transmission, then their shaded regions will lie close to one another in one part of the circle. This is to be contrasted with the midpoint method, in which if two or three sources have just started transmission, their offsets will be very far apart from each other. This explains why the latter method is better than no control and why the midpoint method is so much better than the smallest interval method. The Fourier analysis method in this case performs about the same as the midpoint method. The reason why the two graphs do not coincide is that the criterion of optimality (greatest smoothness in expected bit-rate) is different from the criterion of loss rate (which is what is shown in FIG. 3). Moreover, the fact that the Fourier analysis method chooses a point on a discrete grid makes it non-optimal.
For the case when K=2, which is referred to as the heterogeneous case, the results are shown in FIGS. 4 and 5. The sources of both types arrive according to Poisson processes of rate 0.015 (1/sec). Again, the results are obtained by a single simulation run in which the loss rate of high priority cells of both types of calls conditioned on n 1 type 1 calls and n 2 type 2 calls being active. Then, FIG. 4 is plotted with n 1 =3 with n 2 as the x-axis and FIG. 5 is the corresponding graph with n 1 =5. In both of these graphs, it is obvious that having any control method is far better than having no control. But this time, note that the Fourier analysis method far outperforms the other two heuristic methods. This is intuitive, since the two heuristics were not designed specifically for heterogeneous traffic. Imagine that n 1 =n 2 =1. The midpoint method would try to place one offset at 0 and the other at τ/2 without taking into consideration the fact that the two sources are very different in size. The Fourier analysis method, being analytical, takes into account these factors automatically. It places the offset of the type 1 source at 0 and that of the type 2 source at about 2τ/3, since a type 1 source has twice the bit-rate of a type 2 source. Also observe that when n 2 becomes large, the two heuristics perform about equally well. This is also to be expected. When the circle is more filled with shaded regions, two things happen. Either the shortest interval method reverts to the midpoint method or the shaded arcs lie reasonably close to one another with a small amount of gap. In either case, its behavior is not expected to be too different from that of the midpoint method. The low priority cell loss rate is shown in FIG. 6 for n 1 =3. The complementary distribution of queue length (unconditional) during the entire simulation is shown in FIG. 7. Again the Fourier analysis method provides the best performance for the low priority cell loss rate and the queue length distribution.
In addition to the loss probability, another measure was used to compare the three methods. This measure is the smoothness index (η), which is the square root of the quantity in Eq. (1). The square root of the quantity in Eq. (1) is used because it has the more natural units of Mbits. The computation of the smoothness index was done by two simulation runs, one for the homogeneous case and the other for the heterogeneous case. For the homogeneous and the heterogeneous cases, the (unconditional) value of the smoothness index is shown in Table 1 for the problem in which no control is exercised as well as the three control methods. As expected, the smoothness index is lowest for the Fourier analysis method, followed very closely by the midpoint method. The difference between these two and the smallest interval method as well as the no control case is more. Even by this criterion, the Fourier analysis method and midpoint methods give much better results. Note that the difference between the Fourier analysis method and the midpoint method is quite small. This is to be contrasted with the conditional loss probabilities reported for the heterogeneous case, in which the difference between these two methods was much higher. The reason this difference occurs is because of the bursty traffic. It is possible to have a difference in measures such as loss probabilities while more robust measures like mean and variance of queue length show very little difference. The smoothness measure is (in some sense) measuring the variation in the input rate. While this measure correctly preserves the relative ranking of the different control methods, it does not give the complete picture about loss probabilities.
TABLE 1______________________________________Smoothness index (in the unit of Mbuts) for thehomogeneous case and the heterogeneous case. no smallest Fourier control interval midpoint analysis______________________________________homogeneous 26.2 22.3 21.4 21.5heterogeneous 23.5 20.3 19.9 19.5______________________________________
In summary, three methods for temporal placement control of video frames have been described. The results show that any reasonable form of control is much better than having no control. Of the three methods, the midpoint method is very simple and performs generally as well as the Fourier analysis method for homogeneous sources. However, for heterogeneous sources, the Fourier analysis method provides the best results.
While there has been described and illustrated several methods of temporal placement control of video frames on B-ISDN networks, it will be apparent to those skilled in the art that variations and modifications are possible without deviating from the broad principle and spirit of the present invention which shall be limited solely by the scope of the claims appended hereto. | Methods of traffic smoothing for frames of different video sources where each video source transmits frames at fixed intervals and the network is free to decide the relative temporal spacing of video frames from different sources provide significant performance advantages. The time at which a given source begins to transmit its first frame is under the control of the network; however, thereafter, all frames from the source are transmitted at fixed intervals. Two heuristic and one optimization method control the temporal placement of the video frames from different sources in order to reduce the loss rate of the high priority cells and to minimize the smoothness index of the traffic. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to a circuit arrangement for controlling the operating functions, for example, of a broadcast receiver, in which an up/down counter is associated with each operating function, of which the particular count corresponds to a certain setting of the operating function and which comprises an up-counting input and a down-counting input and, in dependence upon function control signals at these inputs, counts pulses supplied by a clock-pulse generator.
In modern broadcast receivers, such as radio broadcast receivers or television broadcast receivers, operating functions, such as volume, brilliance, colour saturation and the like, can be controlled by means of so-called touch keys. For adjusting volume for example, two touch keys are present, one for "louder" and one for "softer". An up/down counter is associated with this "volume" operating function, its particular count corresponding to a certain volume setting. One such counter is also associated with each of the other operating functions. If, in the case of the "volume" operating function for example, the touch key for "louder" is operated, a binary control signal is delivered to the up-counting input of this counter, causing the counter to count clock pulses delivered to it from a clock-pulse generator in the up direction for as long as the touch key is touched. The resulting increase in the count leads to an increase in volume. Conversely, if the touch key for "softer" is touched, a binary control signal is delivered to the down-counting input of the counter, causing the counter to count the clock pulses in the down direction which leads to a reduction in the count and, hence, to a reduction in volume. If neither of the two touch keys is touched, the count remains unchanged so that there is also no change in volume. As can be seen, at least two inputs are required on the up/down counter for controlling the three functions of up-counting, down-counting and standstill.
In order to simplify the structure, it is desirable to accommodate the entire control circuit as far as possible in a single integrated circuit. A major problem in the construction of complicated integrated circuits such as these is that only a limited number of connecting pins is available on the circuit housing. For each up/down counter associated with an operating function, it is necessary to provide one up-counting input and one down-counting input solely for controlling the counting mode of the counter. In view of the relatively large number of operating functions required for a broadcast receiver, this would lead to a large number of connecting pins on the housing of the integrated circuit which would involve considerable costs. In view of the intended application, however, costs such as these are unacceptable.
In addition to or as an alternative to the possibility of controlling the operating functions through touch keys, the operating functions may also be remote-controlled. In this case, the remote-control generator transmits signals which are decoded in the remote-control receiver in the broadcast receiver and produce the same effect as depression of the corresponding touch keys for the required operating function. Accordingly, the above-mentioned problem concerning the number of connecting pins also exists in cases where the operating functions are remote-controlled.
The object of the present invention is to construct a circuit arrangement of the type referred to above in such a way that it may be produced in the form of an integrated circuit at reasonable cost.
SUMMARY OF THE INVENTION
According to the invention, this object is achieved by virtue of the fact that two threshold-value circuits with different threshold values are provided for each operating function, of which the inputs are interconnected whilst their outputs are connected to the up-counting input and to the down-counting input, respectively, of the associated up/down counter and which, in dependence upon the value of a voltage delivered to their inputs, furnish a function control signal having one or the other binary signal value, and by virtue of the fact that the interconnected inputs of the threshold-value circuits are connected to switch means which permit one of several voltage values to be applied to the inputs in accordance with a required setting of the operating function.
In the circuit arrangement according to the invention, only one input is provided for each operating function, to which one of several voltage values may be applied by the switch means. In dependence upon the size of the voltage value, the threshold-value circuits furnish signals having one or the other binary signal value which subsequently pass to the control inputs of the up/down counter and control the counter in such a way as to produce the effect on the count which corresponds to the voltage value applied. Accordingly, the counter may be controlled through a single input in such a way that it counts up, counts down or stands still. Accordingly, by virtue of the construction of the circuit arrangement according to the invention in the form of an integrated circuit, only one connecting pin is required for each operating function. The effect of this saving is of course more favourable, the larger the number of operating functions to be controlled.
Preferably, the switch means comprise two resistors connected in series between the terminals of a feed voltage source, of which the connecting point may be connected by switches either to one or to the other of the feed voltage terminals or to neither, and the connecting point of the resistors is connected to the interconnected inputs of the threshold value circuits. Three different voltage values may be applied by these switch means to the interconnected inputs of the threshold-value circuits which, by delivering corresponding function control signals having one or the other signal values, subsequently produce the required setting of the operating function by initiating the corresponding counting mode of the up/down counter associated with them.
According to the invention, the resistors advantageously consist of MOS field-effect transistors, in each of which the drain electrode is connected to the gate electrode, and said MOS field-effect transistors, together with the threshold-value circuits which also consist of MOS field-effect transistors and the associated up/down counters, are integrated in a single semiconductor circuit.
In one advantageous embodiment of the invention, the threshold value of the first threshold-value circuit is fixed in such a way that the function control signal which it furnishes has a high signal value when the voltage delivered to its input has a low value, and a low signal value when the voltage delivered to its input has a medium or high value, whilst the threshold value of the second threshold-value circuit is fixed in such a way that the function control signal which it furnishes has a low signal value when the voltage delivered to its input has a low or medium value and a high signal value when the voltage delivered to its input has a high value. By virtue of this embodiment of the circuit arrangement according to the invention, it is possible to distinguish three voltages lying in different ranges from one another and to deliver to the up/down counter function control signals which exactly characterise these voltage values so that the required setting of the operating function is obtained.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be explained by way of example with reference to the accompanying drawings, wherein:
FIG. 1 is a block circuit diagram of a circuit arrangement according to the invention capable of distinguishing between three different voltage values.
FIG. 2 is a circuit diagram of one possible embodiment of the circuit arrangement according to the invention without the up/down counter.
FIG. 3 is a diagram showing the output signals of the threshold-value circuits in dependence upon the voltage applied at the input.
DETAILED DESCRIPTION OF THE INVENTION
The circuit arrangement shown in FIG. 1 comprises a switching device 1, two threshold-value circuits 2, 3 with different threshold values and an up/down counter 4 which is fed with clock pulses from a clock-pulse generator 4a.
By means of the switching device 1, three different voltage values can be produced in one input conductor 5. As can be seen from FIG. 1, the input conductor may be directly applied by means of the switches 6a and 6b on the one hand to the positive terminal 7 of the feed voltage source and, on the other hand, to ground 8. In the inoperative position of the switches 6a and 6b shown in FIG. 1, the input conductor 5 carries a voltage of medium value arising out of the voltage divider consisting of the two resistors R1 and R2 which are connected in series between the terminal 7 and earth 8. The input conductor 5 is connected to the connecting point of the resistors R1 and R2.
The input conductor 5 is also directly connected to the inputs 9 and 10 of the threshold value circuits 2, 3. The output 11 of the threshold-value circuit 2 is connected to the up-counting input 12 of the up/down counter 4, whilst the output 13 of the threshold-value circuit 3 is connected to the down-counting input 14 of the up/down counter 4. As will be explained in more detail, the up/down counter 4 counts the clock pulses delivered to it by the clock-pulse generator 4a in the up or down direction or stands still in dependence upon function control signals at its inputs 12 and 14.
FIG. 3 shows how the threshold-value circuits 2 and 3 behave. The curve 15 represents the waveform of the output voltage V2 of the threshold-value circuit 2 in dependence upon the voltage present at its input 9, whilst the curve 16 represents the waveform of the output voltage V3 of the threshold value circuit 3 in dependence upon the voltage present at its input 10. As can be seen from curve 15, the output voltage V2 of the threshold-value circuit 2 has a high signal value as long as the voltage at the input 9 has a low value lying in the range A. For any higher value of the voltage at the input 9, the output voltage V2 of the threshold value circuit 2 has a low signal value. This applies to all voltage values in the range B and in the range C.
By contrast, the output voltage V3 of the threshold value circuit 3 only has a high signal value when the value of the voltage at its input 10 is also high, i.e. has a value lying in the range C. For values of the voltage at the input 10 in the ranges A and B, the output voltage V3 of the threshold-value circuit 3 has a low signal value.
As already mentioned, three different voltage values may be produced in the input conductor 5 and, hence, at the inputs 9 and 10 of the threshold-value circuits 2 and 3 by means of the switching device 1. The low voltage value V 1A , which is formed when the input conductor 5 is directly applied to ground through the switch 6b, is therefore the ground value belonging to the range A. The high voltage V 1C is produced in the input conductor 5 by virtue of the fact that the input conductor 5 is directly connected to the positive terminal 7 of the feed voltage source through the switch 6a. From this it follows that the feed voltage selected has to be so high that it has a value V 1C lying in the range C of FIG. 3. The voltage divider formed by the resistors R1 and R2 has to be dimensioned in such a way that the voltage occurring in the input conductor 5 in the inoperative position of the switches 6a and 6b has a value V 1B in the range B.
Accordingly, the three voltage values which can be produced in the input conductor 5 by means of the switching device 1 are converted by the threshold-value circuits 2 and 3 into binary signal values which are unequivocally associated with the particular input voltage value V 1A , V 1B , V 1C . The association is shown in the following Table:
______________________________________V.sub.1 V.sub.2 V.sub.3______________________________________V.sub.1A 1 0V.sub.1B 0 0V.sub.1C 0 1______________________________________
The binary signal values provide for defined control of the up/down counter 4, i.e. up-counting, down-counting or standstill.
The up/down counter 4 may be constructed for example in the same way as one of the binary counters present in the integrated circuit TMS 3712 manufactured by TEXAS INSTRUMENTS INCORPORATED. This binary counter only counts the clock pulses delivered to it in the up direction when the signal present at its up-counting input has a high signal value, and only counts these pulses in the down direction when the signal present at its down-counting input has a high signal value, retaining its count when neither of its input signals has a high signal value.
Taking the above-described behaviour of the threshold-value circuits into account, it can be seen that the counter counts in the up direction when the input voltage V1 has the ground value V 1A , the output voltage V2 of the threshold-value circuit having a high value and the output voltage V3 of the threshold-value circuit 3 a low value. If the input voltage V1 has the high value V 1C , the values of the output voltages V1 and V2 are reversed, so that the counter counts down. When the input voltage V1 has the value V 1B lying in the range B, as fixed by the voltage divider resistors R1 and R2, the counter does not change its count. By suitably evaluating and converting the count of the counter, it is possible to obtain the required control of the operating function. For example, volume will increase with up-counting of the counter, decrease with down-counting of the counter and remain unchanged when the counter is stationary.
FIG. 2, in the form of a block circuit diagram, shows how the switching device 1 and the threshold-value circuits 2 and 3 can be formed using only MOS field-effect transistors. In this circuit, the resistor R1 of the switching device 1 is formed by the transistor T1 and the resistor R2 by the transistor T2. As in the case of the switching device 1 shown in FIG. 1, the input conductor 5 may be connected through switches 6a and 6b to the positive terminal of the feed voltage source or to ground. In the circuit shown in FIG. 2, the threshold-value circuit 2 is formed by the transistors T3 and T4 and the threshold-value circuit 3 by the transistors T5 to T12.
The circuit described thus far behaves as follows: when the input conductor 5 is applied to ground 8, ground potential is applied to the gate electrode of the transistor T4, so that this transistor is blocked. Accordingly, no current can flow through the transistor T3 acting as a resistor, so that a high voltage value occurs at the output 11.
At the same time, the voltage value in the input conductor 5 is applied to the gate electrode of the transistor T5 so that this transistor is also blocked.
This transistor T5 is only conductive when the input voltage of high value V 1C lying in the range C is applied to its gate electrode by the input conductor 5. Accordingly, the transistor T5 only conducts at a higher input voltage value than the transistor T4. This higher threshold value of the threshold-value circuit formed by the transistors T5 and T6 arises out of the fact that the source electrode 17 of the transistor T5 is not connected to ground 8 directly, but instead through the drain-source path of the transistor T6 acting as a resistor. Accordingly, the transistor T5 can only conduct when the input voltage is higher than its own threshold voltage plus the threshold voltage of the transistor T6.
In FIG. 3, the curve 18 represents the waveform of the voltage at the source electrode of the transistor T5 if the voltage at its gate electrode were to be continuously increased from 0 to a value in the range C. As curve 18 shows, the voltage range in which the output voltage at the output 11 and at the source electrode of the transistor T5 has a low value, is very narrow. However, this is unfavourable for the reliable and clear differentiation of the required input voltage ranges A, B and C. For this reason, the source voltage of the transistor T5 is not directly used as the output voltage of the threshold-value circuit 3, but instead is first shaped in further stages containing the transistors T7 to T12 in such a way that it finally assumes the waveform represented by curve 16 in FIG. 3 at the output 13. Accordingly, the sole function of these transistors T7 to T12 is to make the transition of the output voltage V3 from the low value to the high value steeper.
The circuit arrangement shown in FIG. 2 is formed exclusively by MOS field-effect transistors. It may readily be produced in the form of an integrated circuit together with the associated up/down counter and other such circuit arrangements with the counters for other operating functions and a clock-pulse generator common to all the counters. By means of the circuit arrangement shown in FIG. 2, it is possible to produce at the outputs 11 and 13 signals of which the respective binary values are strictly associated with one of three input voltage values applied to the input conductor 5. Accordingly, it is possible to control an up/down counter, which for the purposes of exact control has to receive function control signals at two inputs, by applying one of three voltage values to one conductor. As already mentioned, the up/down counter of each operating function may therefore be controlled through a single connecting pin of the integrated circuit which corresponds to the input conductor 5 in FIG. 2. | A circuit arrangement for controlling the operating functions in a device such as a broadcast receiver, including an up/down counter associated with each operating function wherein a particular count corresponds to a certain setting of the operating function. Switch means coupled by a single conductor to the common inputs of two threshold-value circuits provide one of several voltages thereto which cause one or the other or neither of the threshold-value circuits to output a control signal to the up/down center, which in turn counts up, down, or remains at the same count. | 7 |
A portion of the disclosure of this patent document contains material subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyright rights whatsoever.
FIELD OF INVENTION
The present invention relates generally to a data processing system and method and more specifically to remote transaction cache associated with a security token.
BACKGROUND
Security tokens are tamper resistant hardware devices used to securely store digital credentials, cryptographic keys and other proprietary information. The tokens are packaged in a convenient and easily transportable medium and generally communicate with a host client using standardized IEEE serial communications protocols. Examples of security tokens include smart cards, integrated circuit cards, subscriber identification modules (SIM), wireless identification modules (WIM), USB token dongles, identification tokens, secure application modules (SAM), secure multi-media tokens (SMMC) and like devices.
The single input/output nature of a serial connection is known to cause local device contentions when multiple requests to access the security token are received by the local client. In a multi-user networking environment, serial device contentions can impair network performance as each requesting remote service must wait in line for its request to be processed by a particular security token. The device contentions can be minimized to some extent by assigning priorities to the access requests. However, prioritization does not provide significant performance improvements in operating environments where a multitude of identically prioritized requests occur within a small time frame such as at the start or end of a work day where large numbers of entities are logging into or out of a network.
A second problem arises when the information contained in the security token is shared among multiple services, Information requested by one application may be altered, moved or deleted by another application resulting in application errors, system crashes and lost data. One solution known in the art is to exclusively lock the security token to a particular application until all transactions between the exclusive application and security token have been completed. This solution has limited usefulness though since exclusively locking the security token for prolonged periods may exacerbate the network performance issues described above.
Other solutions include the use of secure shared memory arrangements and caching techniques. Memory sharing is useful if the information to be shared does not require extensive security protocols to be implemented. While secure memory sharing mechanisms do exist, the increasing complexity of maintaining the integrity of the shared memory tends to be system resource intensive and inadvertent “security holes” are always a concern. Caching of information is another common technique which provides reasonable performance improvements. An example of a data object caching technique is disclosed in U.S. Pat. No. 6,304,879 to Sobeski, et al. This patent describes a reasonable caching technique suitable for data objects but is not well suited for implementation with a security token as there are no intrinsic security measures incorporated into the disclosed invention.
Thus, it would be highly advantageous to provide a reasonably secure caching mechanism suitable for implementation with a security token which addresses the limitations described in the relevant art above.
SUMMARY
This invention addresses the limitations described above. The caching mechanism comprises a security token interface applications programming interface (API) which is mapped to a cache API and may be installed in a local client, one or more servers or co-located in both the client and server(s).
The cache API receives requests for information from the security token interface API which includes a cross reference containing a specific unique identifier associated with the security token and an encoded semantic. The unique identifier is usually a serial number masked into the security token by the token manufacturer. Information is stored in the memory cache by associating the unique security token identifier with the semantic forming a unique cache identifier. It is also envisioned that semantics related to set of security tokens may be cached as well. For example, a semantic may be defined to determine which security tokens contain a digital certificate for updating purposes.
A separate unique cache identifier is required for each instance of information stored in the memory cache to differentiate data obtained from a single security token. In the preferred embodiment of the invention, handles are used in lieu of the actual serials numbers and/or semantics to simplify the various combinations of unique identifiers and semantics. Handles as defined herein include a pseudonym or token that a program can use to identify and access an object.
The cache API locates the particular security token record in the memory cache by using a handle related to the security token's unique identifier, a semantic or both to arrive at the unique cache identifier. If no occurrence of the requested information is included in the cache, the request is redirected to the token interface API for processing and retrieval of the information from a security token.
If the requested information is not present in the security token, a pseudo-entry is generated by the security token interface API and transferred to the cache API for storage in the memory cache. The pseudo-entry appears to the cache API as regular data entry and is used to prevent future requests for the same missing information being routed to the security token.
Once information is retrieved from the security token, the security token interface API transfers the information to the cache API for storage in the memory cache where it is available for future retrieval. The type of information to be cached is categorized as non-proprietary, proprietary and administrative. In the preferred embodiment of the invention, the memory cache is divided into three distinct components including a first component generally containing non-proprietary, a second component containing proprietary information, and a third component containing administrative information necessary to manage and utilize the information stored in the other portions of the memory cache. Dividing the memory cache into three separate components provides greater flexibility for future enhancements to the memory cache by simply adding additional cache components.
The types of information stored in the memory cache include digital certificates, public keys, password information, properties and configurations related to these datum, token management information, security state information and listings of applets installed inside the security token(s). It should be apparent to one skilled in the art that any information retrievable from a security token may be stored in the memory cache.
An additional feature of this invention includes a residence time limitation for which in formation remains in the memory cache. After a preset period without repeated access, all or the proprietary portion of the memory cache is flushed. To maintain synchronicity with the information retrieved from the security token, a counter mechanism is included to ensure that the calling application receives the latest version of information contained in the security token.
BRIEF DESCRIPTION OF DRAWINGS
The features and advantages of the invention will become apparent from the following detailed description when considered in conjunction with the accompanying drawings. Where possible, the same reference numerals and characters are used to denote like features, elements, components or portions of the invention. It is intended that changes and modifications can be made to the described embodiment without departing from the true scope and spirit of the subject invention as defined in the claims.
FIG. 1 —is a generalized block diagram illustrating the placement of the invention in various computer systems.
FIG. 1 A—is a generalized block diagram illustrating the major components included in the invention.
FIG. 2 —is a detailed block diagram illustrating the routing and data content of a request for information.
FIG. 2 A—is a detailed block diagram illustrating the initial processing of the request for information by a cache API and associated memory cache components.
FIG. 2 B—is a detailed block diagram illustrating the retrieval of the requested information from the memory cache.
FIG. 2 C—is a detailed block diagram illustrating the attempted retrieval of the requested information which is not available from an associated security token.
FIG. 2 D—is a detailed block diagram illustrating the return of a not available message from the memory cache.
FIG. 3 —is a detailed block diagram illustrating a request to retrieve information from the memory cache which has not yet been retrieved from the associated security token.
FIG. 3 A—is a detailed block diagram illustrating a newly retrieved item being stored in the memory cache and generation of associated cross references
FIG. 4 —is a flowchart illustrating the major steps involved in implementing the preferred embodiment of the invention.
DETAILED DESCRIPTION
This present invention provides a system and method for caching of information retrieved from a security token to minimize local device contentions, improve network performance and maintain consistency of information stored in an associated security token.
Referring to FIG. 1 , a security token 5 is shown operatively connected to a local client 10 . The local client 10 may be in processing communications over a network 25 with one or more servers 20 , 20 A. The local client includes one or more applications 30 requiring access to information originally stored in the security token 5 . The application 30 is associated with a token API 35 . The token API 35 is a middleware applications programming interface which communicates with the security token 5 and a local cache API 40 . Requests received from the application 30 usually include a unique identifier associated with a particular security token and a semantic which are converted by the token API 35 into a unique reference identifier for storage in the memory cache 45 .
The invention may be installed on one or more local clients 10 , 10 A, one or more servers 20 , 20 A or both clients and servers 10 , 10 A, 20 , 20 A. Each instance of the invention operates independently of each other and may contain the same, overlapping or completely different information. The contents of each cache 45 , 45 A, 45 B, 45 C is dependent on information requests promulgated by each application 30 , 30 A, 30 B, 30 C to each token API 35 , 35 A, 35 B, 35 C and cached by each cache API 40 , 40 A, 40 B, 40 C.
For purposes of this invention, if remote caches are implemented rather than local caches, each local client provides the necessary hardware and software interfaces for the security token 5 , 5 A to communicate with each server 20 , 20 A but otherwise does not enter into the system.
FIG. 1A depicts the details of the invention. The application 30 is associated with a token API 35 . The token API 35 is a middleware applications programming interface which communicates with the security token 5 and a cache API 40 . A counter applet is installed in each security token which increments each time information is written to the security token. The incremented value # 65 A is compared 70 to a reference value # 65 B initially retrieved by the token API 35 . If the incremented value # 65 A does not match the reference value # 65 B, the contents of the memory cache 45 are refreshed before information is released to the requesting application 30 . In an alternative embodiment of the invention, a most recent process identifier (PID) is stored inside the security token which is compared against the PID initially retrieved by the token API to determine if a change has been made to the contents of the security token. Alternative methods such as maintaining and comparing time stamps will work as well.
The cache API 40 controls the memory cache 45 . The memory cache 45 is divided into at least three components. The first component G 50 of the memory cache 45 retrievably stores generally uncontrolled information for example, public keys, digital certificates and other non-proprietary information. The second component P 55 of the memory cache 45 retrievably stores proprietary information for example, passwords and related information.
The third component A 60 retrievably stores administrative information used by the cache API 40 to retrieve information stored in the either the general or proprietary cache components 50 , 55 . The third component A 60 of the memory cache 45 may exist as part of the cache or as a separate lookup table and includes unique reference numbers, cross reference information, and time stamps associated with information stored in the memory cache 45 .
FIG. 2 depicts the routing and processing of an incoming request 205 . The application 30 generates or otherwise routes a request for information 205 to the token API 35 . The request 205 includes numeric information concerning the unique token identifier CID[#] and/or a numeric semantic request SEM[#].
The token API 35 includes logical instructions to first determine if the requested information 205 is available from the cache API 40 and secondly if the information stored in the cache is current 70 before attempting to retrieve the information from the associated security token referenced by CID[#].
Referring to FIG. 2A , the cache API 40 converts the original request 205 into a unique reference identifier REQ[ 8021 ] 210 which is then routed to the cache API 40 for processing. The cache API 40 performs a lookup function 230 of unique references REQ# 215 contained in the administrative component 60 of the cache using the reference identifier 210 . To better illustrate the lookup function, an example unique reference identifier REQ[ 8021 ] 210 is sent to the administrative component A 60 to determine if the requested information 210 has already been retrieved.
In this example, a match is found 230 indicating that the requested information 210 is already present in the memory cache 45 . The unique cache identifiers C# 245 are used to both uniquely identify the requested information and also determine which cache component contains the information. In this example, cache identifiers beginning with the number 2 denotes proprietary information which is stored in the second cache component P 55 . Cache identifiers beginning with a 1 are stored in the first cache component G 50 under cache identifier C# 235 .
A new time stamp 232 is applied to the identified information 230 . The time stamps 225 are used to define the residence time for information stored in the memory cache 45 and are adjustable to suit different operating conditions. If after a predetermined period has expired without repeat access to a particular piece of stored information, the unused information is flushed from the cache.
FIG. 2B continues with the example described above, in which the unique cache identifier 202 264 points 234 to the second cache component P 55 which allows retrieval 269 of the information PW 2 268 associated with unique cache identifier 202 266 . The retrieved information 255 is then returned 275 to the calling application 30 via the token API 35 .
Referring to FIG. 2C , a problem could arise where a request for non-existent information causes repeat attempts to access the security token, defeating the purpose of the cache. To prevent this situation, after the first occurrence of the unavailable information, the cache API 40 generates a pseudo entry which is stored in the appropriate cache component 50 , 55 by the cache API 40 . Upon receipt of an otherwise valid request REQ[ 8017 ] 260 , the cache API 40 performs a lookup 257 which points 270 to a pseudo entry 271 contained 272 in the first cache component G 50 and updates the time stamp 265 associated with this entry.
FIG. 2D continues with the example described in above, in which a ‘not available’ NA 273 message is retrieved 275 by the cache API 40 and forwarded INFO[NA] 280 to the requesting application.
Referring to FIG. 3 , this last example depicts the case where a request for information has not previously been processed. An incoming request 305 REQ[ 8055 ] is processed by the cache API 40 and no match is found 310 . A not found message NF 315 is generated by the cache API and sent 320 to the token API 35 which signals the token API 35 to retrieve the information from the security token originally identified in the received request.
In FIG. 3A , the information is retrieved by the token API 35 and sent 327 to the cache API 40 for storage. A new entry 347 is added to the administrative cache component 330 , a new cache ID 203 349 and a new time stamp 345 are assigned to the entry. The new information PW 3 353 is stored 340 in the proprietary cache component according to the newly generated cache identifier 203 351 .
In FIG. 4 , the steps to implement the preferred embodiment of the invention are depicted. The process is initiated 400 by a request for information being received 405 by the token API. The token API then determines if the information contained in the memory cache is current 410 . If the information of the cache is current 410 the request is routed directly to the cache API for processing 420 . If the information is not current 410 , the cache is first refreshed 415 then referred to the cache API 420 for processing.
The cache API determines if the requested information is available from the cache 425 . If the information is not available from the cache 425 the cache API notifies the token API to retrieve the information from the associated security token 430 . If the information is not available from the security token 440 , the token API generates a pseudo cache entry 445 which is stored in the memory cache by the cache API, a not available “A” message is returned to the requester 460 , a new time stamp entry is created 465 by the cache API, followed by processing termination 470 .
If the information is available from the security token 450 , the information is retrieved, a copy stored in the memory cache 450 , the information returned to the requestor 455 , a new time stamp entry is created 465 for the new entry by the cache API, followed by processing termination 470 .
If the information is directly available from the cache 425 , the cache API retrieves the information from the cache 435 , the information returned to the requestor 455 , the time stamp entry is updated 465 by the cache API, followed by processing termination 470 .
The foregoing described embodiments of the invention are provided as illustrations and descriptions. They are not intended to limit the invention to precise form described. In particular, it is contemplated that functional implementation of the invention described herein may be implemented equivalently in hardware, software, firmware, and/or other available functional components or building blocks. No specific limitation is intended to a particular security token operating environment. Other variations and embodiments are possible in light of above teachings, and it is not intended that this Detailed Description limit the scope of invention, but rather by the claims following herein. | This invention provides a system and method for implementing a middleware caching arrangement to minimize device contention, network performance and synchronization issues associated with enterprise security token usage. The invention comprises a token API mapped to a cache API. Logic associated with the token API preferentially retrieves information from a memory cache managed by the cache API. Mechanisms are included to periodically purge the memory cache of unused information. | 6 |
[0001] The present application claims priority to Provisional Application No. 60/912,399, filed Apr. 17, 2007 and is herein incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The present disclosure relates generally to programmable devices, and more particularly to a programmable interconnect matrix.
BACKGROUND
[0003] Field-programmable gate arrays (FPGAs) and Programmable Logic Devices (PLDs) have been used in data communication and telecommunication systems. Conventional PLDs and FPGAs consist of an array of programmable elements, with the elements programmed to implement a fixed function or equation. Some currently-available Complex PLD (CPLD) products comprise arrays of logic cells. Conventional PLD devices have several drawbacks, such as limited speed and limited data processing capabilities.
[0004] In developing complex integrated circuits, there is often a need for additional peripheral units, such as operational and instrument amplifiers, filters, timers, digital logic circuits, analog to digital and digital to analog converters, etc. As a general rule, implementation of these extra peripherals create additional difficulties: extra space for new components, additional attention during production of a printed circuit board, and increased power consumption. All of these factors can significantly affect the price and development cycle of the project.
[0005] The introduction of the Programmable System on Chip (PSoC) features digital and analog programmable blocks, which allow the implementation of a large number of peripherals. A programmable interconnect allows analog and digital blocks to be combined to form a wide variety of functional modules. The digital blocks consist of smaller programmable blocks and are configured to provide different digital functions. The analog blocks are used for development of analog elements, such as analog filters, comparators, inverting amplifiers, as well as analog to digital and digital to analog converters. Current PSoC architectures provide only a coarse grained programmability where only a few fixed functions are available with only a small number of connection options.
SUMMARY
[0006] A programmable interconnect matrix includes horizontal channels that programmably couple different groups of one or more digital blocks together. The interconnect matrix can include segmentation elements that programmably interconnect different horizontal channels together. The segmentation elements can include horizontal segmentation switches that programmably couple together the horizontal channels for different groups of digital blocks in a same row. Vertical segmentation switches can programmably couple together the horizontal channels for different groups of digital blocks in different rows.
[0007] Vertical channels can programmably connect the horizontal channels in different rows. The horizontal channels provide more connectivity between the digital blocks located in the same rows than connectivity provided by the vertical channels connecting the digital blocks in different rows. Two digital blocks in a same digital block pair can be tightly coupled together to common routes in a same associated horizontal channel and different digital block pairs can be less tightly coupled together through the segmentation elements.
[0008] Programmable switches are configured to connect different selectable signals from the digital bocks to their associated horizontal channels. Programmable tri-state buffers in the segmentation elements can be configured to selectively couple together and drive signals between different horizontal channels.
[0009] A Random Access Memory (RAM) can be configured to programmably control how the different digital blocks are coupled together through the interconnection matrix. Undedicated Inputs and Outputs (I/Os) can be programmably coupled to different selectable signals in different selectable digital blocks through different selectable routes in the interconnection matrix. The undedicated Inputs and Outputs refer to the connections on the Integrated Circuit (IC) to external signals.
[0010] A micro-controller system is programmably coupled to the different digital blocks through the interconnect matrix and is programmably coupled to the different programmable Inputs/Outputs (I/Os) through the interconnect matrix. The micro-controller system can include a micro-controller, an interrupt controller, and Direct Memory Access (DMA) controller. Interrupt requests can be programmably coupled between the interrupt controller and different selectable digital blocks or different selectable I/Os through the interconnect matrix. DMA requests can also be programmably coupled between the DMA controller and different selectable digital blocks or different selectable I/Os through the interconnect matrix. In one embodiment, the micro-controller, digital blocks, I/Os, and interconnect are all located in a same integrated circuit.
[0011] In one embodiment, the digital blocks comprise a first group of uncommitted logic elements that are programmable into different logic functions and also include a second group of structural logic elements that together form a programmable arithmetic sequencer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a schematic block diagram illustrating an example PSoC architecture that includes a Universal Digital Block (UDB) array.
[0013] FIG. 2 is a schematic block showing an interconnect matrix in the UDB array.
[0014] FIG. 3 is a schematic block diagram showing how a pair of UDBs are tightly coupled to a horizontal routing channel.
[0015] FIG. 4 is a schematic block diagram showing programmable switches that connect the UDBs in FIG. 3 to the horizontal routing channel.
[0016] FIG. 5 is a schematic block diagram showing segmentation elements in the interconnect matrix.
[0017] FIG. 6 is a schematic block diagram showing different programmable switches in the segmentation elements of FIG. 5 in more detail.
[0018] FIG. 7 is a schematic block diagram that shows how the interconnect matrix of FIG. 2 can connect different interconnect paths to a micro-controller system.
[0019] FIG. 8 is a schematic diagram that shows one of the UDBs in more detail.
[0020] FIG. 9 is a schematic diagram that shows a datapath in the UDB of FIG. 8 in more detail.
INTRODUCTION
[0021] A new programmable routing scheme provides improved connectivity both between Universal Digital Blocks (UDBs) and between the UDBs and other micro-controller elements, peripherals and external Inputs and Outputs (I/Os) in the same Integrated Circuit (IC). The routing scheme increases the number of functions and the overall routing efficiency for programmable architectures. The UDBs can be grouped in pairs and share associated horizontal routing channels. Bidirectional horizontal and vertical segmentation elements extend routing both horizontally and vertically between different UDB pairs and to the other peripherals and I/O.
DETAILED DESCRIPTION
[0022] FIG. 1 is a high level view of a Universal Digital Block (UDB) array 110 contained within a Programmable System on a Chip (PSoC) Integrated Circuit (IC) 100 . The UDB array 110 includes a programmable interconnect matrix 130 that connects together the different UDBs 120 . The individual UDBs 120 each include a collection of uncommitted logic in the form of Programmable Logic Devices (PLDs) and structural dedicated logic elements that form a datapath 210 shown in more detail in FIGS. 8 and 9 .
UDB Array
[0023] The UDB array 110 is arranged into UDB pairs 122 that each include two UDBs 120 that can be tightly coupled to a shared horizontal routing channel 132 . The UDB pairs 122 can also be programmably connected to the horizontal routing channels 132 of other UDB pairs 122 either in the same horizontal row or in different rows through vertical routing channels 134 . The horizontal and vertical routing channels and other switching elements are all collectively referred to as the interconnect matrix 130 .
[0024] A Digital System Interconnect (DSI) routing interface 112 connects a micro-controller system 170 and other fixed function peripherals 105 to the UDB array 110 . The micro-controller system 170 includes a micro-controller 102 , an interrupt controller 106 , and a Direct Memory Access (DMA) controller 108 . The other peripherals 105 can be any digital or analog functional element in PSoC 100 . The DSI 112 is an extension of the interconnect matrix 130 at the top and bottom of the UDB array 110 .
[0025] FIG. 2 shows the interconnect matrix 130 in more detail and includes horizontal routing channels 132 that programmably connect with one or more associated Universal Digital Blocks (UDB) 120 . In this example, pairs 122 of UDBs 120 are tightly coupled together through their associated horizontal routing channel 132 . However, more than two UDBs 120 can be tightly coupled together through the same horizontal routing channel 132 .
[0026] The interconnect matrix 130 also includes Horizontal/Vertical (H/V) segmentation elements 125 that programmably interconnect the different horizontal routing channels 132 together. The segmentation elements 125 couple together the horizontal routing channels 132 for the different digital block pairs 122 in the same rows. The segmentation elements 125 also programmably couple together the horizontal routing channels 132 for digital block pairs 122 in different rows through vertical routing channels 134 .
[0027] FIG. 3 shows one of the UDB pairs 122 in more detail. The UDBs 120 A and 120 B each contain several different functional blocks that in one embodiment include two Programmable Logic Devices (PLDs) 200 , a data path 210 , status and control 204 , and clock and reset control 202 . The operations of these different functional elements are described in more detail below in FIGS. 8 and 9 .
[0028] The two UDBs 120 A and 120 B in UDB pair 122 are tightly coupled together to common routes in the same associated horizontal routing channel 132 . Tight coupling refers to the UDB I/O signals 127 in the upper UDB 120 A and the corresponding signals 128 in the lower UDB 120 B all being directly connected to the same associated horizontal routing channel 132 . This tight coupling provides high performance signaling between the two UDBs 120 A and 120 B. For example, relatively short connections 127 and 128 can be programmably established between the upper UDB 120 A and the lower UDB 120 B.
[0029] In one embodiment, the horizontal routing channels 132 can also have a larger number of routes and connections to the UDBs 120 A and 120 B than the vertical routing channels 134 shown in FIG. 2 . This allows the horizontal routing channels 132 to provide more interconnectivity both between the UDBs 120 A and 120 B in UDB pair 122 and also provides more interconnectivity between different UDB pairs 122 in the same rows of interconnect matrix 130 .
[0030] Thus, the interconnect matrix 130 in FIGS. 1 and 2 more effectively uses chip space by providing more traces and connectivity for the shorter/higher performance horizontal routing channels 132 than the relatively longer/lower performance vertical routing channels 134 .
[0031] FIG. 4 shows switching elements 145 that connect the different I/O signals 127 and 128 for the UDBs 120 A and 120 B in FIG. 3 to the horizontal routing channel 132 . In this example, an output 127 A from the upper UDB 120 A in the UDB pair 122 drives an input 128 A in the lower UDB 120 B. A buffer 138 is connected to the UDB output 127 A and a buffer 140 is connected to the UDB input 128 A. The output 127 A and input 128 A are connected to vertical wires 146 and 148 , respectively, that intersect the horizontal routing channel wire 132 A with a regular pattern.
[0032] At the switch points, RAM bits operate RAM cells 136 and 138 which in turn control Complementary Metal Oxide Semi-conductor (CMOS) transmission gate switches 142 and 144 , respectively. The switches 142 and 144 when activated connect the UDB output 127 A and the UDB input 128 A to horizontal routing channel wire 132 A.
[0033] The RAM cells 136 and 137 are programmably selectable by the micro-controller 102 ( FIG. 1 ) by writing values into a configuration RAM 410 ( FIG. 7 ). This allows the micro-controller 102 to selectively activate or deactivate any of the gate switches 142 and 144 and connect any I/O 127 or 128 from either of the two universal digital blocks 120 A and 120 B to different wires in the horizontal channel 132 .
[0034] FIG. 5 shows the interconnect matrix 130 previously shown in FIGS. 1 and 2 in further detail. The segmentation elements 125 can include different combinations of horizontal segmentation switches 152 and vertical segmentation switches 154 . The horizontal segmentation switches 152 programmably couple together adjacent horizontal routing channels 132 located in the same row. The vertical segmentation switches 152 programmably couple together horizontal routing channels 132 located vertically in adjacent rows via vertical routing channels 134 .
[0035] In addition to the segmentation elements 125 , the interconnect matrix 130 includes the switching elements 145 previously shown in FIG. 4 that programmably connect the upper and lower UDBs 120 A and 120 B with their associated horizontal routing channels 132 .
[0036] Referring to FIGS. 5 and 6 , the segmentation elements 125 comprise arrays of horizontal segmentation switches 152 that are coupled in-between different horizontal routing channels 132 and vertical segmentation switches 154 coupled in-between the vertical routing channels 134 . Each segmentation switch 152 and 154 is controlled by two bits 162 A and 162 B from the configuration RAM 410 ( FIG. 7 ). The two bits 162 A and 162 B together control a tri-state buffer 164 .
[0037] When bit 162 A is set, the buffer 164 A drives one of the horizontal or vertical channel lines 166 from left to right. When bit 162 B is set, the buffer 164 B drives the same horizontal or vertical channel line 166 from right to left. If neither bit 162 A or bit 162 B is set, the buffers 164 A and 164 B drive line 166 to a high impedance state.
Configuration and Programmability
[0038] Any combination of the switching elements 145 , horizontal segmentation switches 152 , and vertical segmentation switches 154 can be programmably configured to connect together almost any combination of external I/O pins 104 ( FIG. 1 ), UDBs 120 , and micro-controller system elements 170 , fixed peripherals 105 , and UDBs 120 ( FIG. 1 ).
[0039] FIG. 7 shows different examples of how different types of interconnect paths can be programmed through the interconnect matrix 130 . A Random Access Memory (RAM) or a set of configuration registers 410 are directly readable and writeable by the micro-controller 102 . The configuration registers 410 are shown as a stand-alone RAM in FIG. 7 for illustrative purposes. However, it should be understood that certain configuration registers 410 can be located within the individual UDBs 120 while other configuration registers can be stand-alone registers that are accessed by multiple different functional elements.
[0040] A first set of bits in RAM section 412 are associated with the RAM cells 136 and 137 shown in FIG. 4 that control connections between the inputs and output of UDB and their associated horizontal routing channels 132 . A second set of bits in RAM section 414 control how the horizontal segmentation switches 152 in FIGS. 5 and 6 connect the horizontal routing channels 132 in the same rows together and other bits in RAM section 414 control how the vertical segmentation switches 154 connect together the horizontal routing channels 132 in different rows.
[0041] Pursuant to the micro-controller 102 programming RAM 410 , the interconnect matrix 130 is configured with a first interconnect path 176 that connects a UDB 120 C to the interrupt controller 106 . The UDB 120 C can then send interrupt requests to the DMA controller 108 over interconnect path 176 . A second interconnect path 178 is established between a peripheral (not shown) in the PSoC chip 100 ( FIG. 1 ) and the DMA controller 108 . The peripheral sends DMA requests to the DMA controller 108 over the interconnect path 178 established over the interconnect matrix 130 .
[0042] A third interconnect path 180 is also configured by the micro-controller 102 by loading bits into RAM sections 412 and 414 . The DMA controller 108 uses the interconnect path 180 to send a DMA terminate signal to UDB 120 D. A fourth interconnect path 182 is programmably configured between one of the PSoC I/O pins 104 and a fixed digital peripheral, such as the micro-controller 102 . The interconnect path 182 is used to send I/O signals between the micro-controller 102 and the I/O pin 104 .
[0043] Interconnect paths 176 - 182 are of course just a few examples of the many different interconnect configurations that can be simultaneously provided by the interconnect matrix 130 . This example also shows how different I/O pins 104 , UDBs 120 , and other peripherals can be connected to the same interrupt line on the interrupt controller 106 or connected to the same DMA line on the DMA controller 108 .
[0044] Typically, interrupt requests received by an interrupt controller and DMA requests received by a DMA controller can only be connected to one dedicated pin. The interconnect matrix 130 allows any variety of different selectable functional elements or I/O pins to be connected to the same input or output for the interrupt controller 106 or DMA controller 108 according to the programming of RAM 410 by micro-controller 102 .
[0045] The programmability of the interconnect matrix 130 also allows any number, or all, of the I/O pins 104 to be undedicated and completely programmable to connect to any functional element in PSoC 100 . For example, the pin 104 can operate as an input pin for any selectable functional element in FIG. 7 . In another interconnect matrix configuration, the same pin 104 can operate as an output pin when connected to a first peripheral and operate as an output pin when connected to a different peripheral.
Universal Digital Block
[0046] FIG. 8 is a top-level block diagram for one of the UDBs 120 . The major blocks include a pair of Programmable Logic Devices (PLDs) 200 . The PLDs 200 take inputs from the routing channel 130 and form registered or combinational sum-of-products logic to implement state machines, control for datapath operations, conditioning inputs and driving outputs.
[0047] The PLD blocks 200 implement state machines, perform input or output data conditioning, and create look-up tables. The PLDs 200 can also be configured to perform arithmetic functions, sequence datapath 210 , and generate status. PLDs are generally known to those skilled in the art and are therefore not described in further detail.
[0048] The datapath block 210 contains highly structured dedicated logic that implements a dynamically programmable ALU, comparators, and condition generation. A status and control block 204 allows micro-controller firmware to interact and synchronize with the UDB 120 by writing to control inputs and reading status outputs.
[0049] A clock and reset control block 202 provides global clock selection, enabling, and reset selection. The clock and reset block 202 selects a clock for each of the PLD blocks 200 , the datapath block 210 , and status and control block 204 from available global system clocks or a bus clock. The clock and reset block 202 also supplies dynamic and firmware resets to the UDBs 120 .
[0050] Routing channel 130 connects to UDB I/O through a programmable switch matrix and provides connections between the different UDBs in FIG. 7 . A system bus interface 140 maps all registers and RAMs in the UDBs 120 into a system address space and are accessible by the micro-controller 102 .
[0051] The PLDs 200 and the datapath 210 have chaining signals 212 and 214 , respectively, that enable neighboring UDBs 120 to be linked to create higher precision functions. The PLD carry chain signals 212 are routed from the previous adjacent UDB 120 in the chain, and routed through each macrocell in both of the PLDs 200 . The carry out is then routed to the next UDB 120 in the chain. A similar connectivity is provided by the datapath chain 214 between datapath blocks 210 in adjacent UDBs 120 .
[0052] Referring to FIG. 9 , each UDB 120 comprises a combination of user defined control bits that are loaded by the micro-controller 102 into control registers 250 . The control registers 250 can be part of the control blocks 202 and 204 described above in FIG. 8 . The control registers 250 feed uncommitted programmable logic 200 . The same control blocks 202 and 204 described above in FIG. 8 also include associated status registers 256 that allow the micro-controller 102 to selectably read different internal states for structural arithmetic elements 254 within the datapath 210 .
[0053] The datapath 210 comprises highly structured logic elements 254 that include a dynamically programmable ALU 304 , conditional comparators 310 , accumulators 302 , and data buffers 300 . The ALU 304 is configured to perform instructions on accumulators 302 , and to update the sequence controlled by a sequence memory. The conditional comparators 310 can operate in parallel with the ALU 304 . The datapath 210 is further optimized to implement typical embedded functions, such as timers, counters, etc.
[0054] The combination of uncommitted PLDs 200 with a dedicated datapath module 210 allow the UDBs 120 to provide embedded digital functions with more efficient higher speed processing. The dedicated structural arithmetic elements 254 more efficiently implement arithmetic sequencer operations, as well as other datapath functions. Since the datapath 210 is structural, fewer gates are needed to implement the structural elements 254 and fewer interconnections are needed to connect the structural elements 254 together into an arithmetic sequencer. Implementing the same datapath 210 with PLDs could require additional combinational logic and additional interconnections.
[0055] The structured logic in the datapath 210 is also highly programmable to provide a wide variety of different dynamically selectable arithmetic functions. Thus, the datapath 210 not only conserves space on the integrated circuit 100 ( FIG. 1 ) but also is more accessible and programmable than other structured arithmetic sequencers.
[0056] The functional configurability of the datapath 210 is provided through the control registers 250 and allow the micro-controller 102 to arbitrarily write into a system state and selectively control different arithmetic functions. The status registers 256 allow the micro-controller 102 to also identify different states associated with different configured arithmetic operations.
[0057] The flexible connectivity scheme provided by the routing channel 130 selectively interconnects the different functional element 250 , 200 , 254 , and 256 together as well as programmably connecting these functional element to other UDBs, I/O connections, and peripherals. Thus, the combination of uncommitted logic 200 , structural logic 254 , and programmable routing channel 130 provides more functionality, flexibility, and more efficiently uses less integrated circuit space.
[0058] The interconnect matrix 130 also requires little or no dedicated UDB block routing. All data, state, control, signaling, etc, can be routed through the interconnect matrix 130 in the UDB array 110 . The array routing is efficient because there is little or no difference between a local UDB net and a net that spans the UDB array. Horizontal and vertical segmentation allow the array to be partitioned for increased efficiency and random access to the RAM 410 allow high speed configuration or on the fly reconfigurability.
[0059] The system described above can use dedicated processor systems, micro controllers, programmable logic devices, or microprocessors that perform some or all of the operations. Some of the operations described above can be implemented in software and other operations can be implemented in hardware.
[0060] For the sake of convenience, the operations are described as various interconnected functional blocks or distinct software modules. This is not necessary, however, and there can be cases where these functional blocks or modules are equivalently aggregated into a single logic device, program or operation with unclear boundaries. In any event, the functional blocks and software modules or features of the flexible interface can be implemented by themselves, or in combination with other operations in either hardware or software.
[0061] Having described and illustrated the principles of the invention in a preferred embodiment thereof, it should be apparent that the invention can be modified in arrangement and detail without departing from such principles. Claim is made to all modifications and variation coming within the spirit and scope of the following claims. | A programmable routing scheme provides improved connectivity both between Universal Digital Blocks (UDBs) and between the UDBs and other micro-controller elements, peripherals and external Inputs and Outputs (I/Os) in the same Integrated Circuit (IC). The routing scheme increases the number of functions, flexibility, and the overall routing efficiency for programmable architectures. The UDBs can be grouped in pairs and share associated horizontal routing channels. Bidirectional horizontal and vertical segmentation elements extend routing both horizontally and vertically between different UDB pairs and to the other peripherals and I/O. | 7 |
CROSS REFERENCE TO RELATED PATENT APPLICATIONS
The instant patent application is a Continuation of U.S. patent application Ser. No. 11/245,493, filed on Oct. 7, 2005, which is now U.S. Pat. No. 7,717,926, which claims priority to each of U.S. Provisional Patent Application Ser. No.: 60/617,104, filed on Oct. 8, 2004, and U.S. Provisional Patent Application Ser. No.: 60/617,016, filed on Oct. 8, 2004, which are both herein incorporated by reference in their entirety.
TECHNICAL FIELD
The technical field relates to surgical clip appliers and more particularly to an endoscopic surgical clip applier having a mechanism for stabilizing the jaw structure during the insertion of a surgical clip.
DESCRIPTION OF THE RELATED ART
Endoscopic staplers and clip appliers are known in the art and are used for a number of distinct and useful surgical procedures. In the case of a laparoscopic surgical procedure, access to the interior of an abdomen is achieved through narrow tubes or cannulas inserted through a small entrance incision in the skin. Minimally invasive procedures performed elsewhere in the body are often generally referred to as endoscopic procedures. Typically, a tube or cannula device is extended into the patient's body through the entrance incision to provide an access port. The port allows the surgeon to insert a number of different surgical instruments therethrough using a trocar and for performing surgical procedures far removed from the incision.
During a majority of these procedures, the surgeon must often terminate the flow of blood or another fluid through one or more vessels. The surgeon will often apply a surgical clip to a blood vessel or another duct to prevent the flow of body fluids therethrough during the procedure. An endoscopic clip applier is known in the art for applying a single clip during an entry to the body cavity. Such single clip appliers are typically fabricated from a biocompatible material and are usually compressed over a vessel. Once applied to the vessel, the compressed clip terminates the flow of fluid therethrough.
One significant design goal is that the surgical clip be loaded between the jaws without any compression of the clip from the loading procedure. Such bending or torque of the clip during loading is disfavored and care is exercised to prevent any damage to the jaws and/or the clip or compression to the clip by a force during loading. This compression could slightly alter the alignment of the clip between the jaws, or damage the clip causing the surgeon to remove the clip from between the jaws for discarding the clip. Additionally such preloading compression may slight compress parts of the clip and change the geometry of the clip. This will cause the surgeon to remove the compressed clip from between the jaws for discarding the clip. Accordingly, there is a need for an apparatus that eliminates one or more of the aforementioned drawbacks and deficiencies of the art.
SUMMARY
According to a first aspect of the present disclosure, there is provided an apparatus for application of surgical clips to body tissue. The apparatus has a handle portion with a body extending distally from the handle portion defining a longitudinal axis and a plurality of surgical clips disposed within the body. The apparatus also has a jaw assembly mounted adjacent a distal end portion of the body with the jaw assembly including first and second jaw portions movable between a spaced-apart and an approximated position. The apparatus further has a wedge plate longitudinally movable between the first and the second jaw portions, and a clip pusher configured to individually distally advance a surgical clip to the jaw assembly while the jaw portions are in the spaced apart position with an actuator. The actuator is at least partially disposed within the body and longitudinally movable in response to actuation of the handle portion and has a cam link. The apparatus also has a jaw closure member positioned adjacent the first and second jaw portions to move the jaw portions to the approximated position. The cam link longitudinally moves wedge plate between the first and the second jaw portions.
According to another aspect of the present disclosure, the apparatus has the wedge plate biasing the first and the second jaw portions when said wedge plate is longitudinally moved between the first and the second jaw portions and the wedge plate maintains the first and the second jaw portions in a fixed predetermined relationship during loading of the clip. The fixed predetermined relationship prevents flexing of the first and the second jaw members during clip loading.
According to another aspect of the present disclosure, the apparatus has the wedge plate with a rounded distal tip.
According to another aspect of the present disclosure, the apparatus has the wedge plate with a first proximal window. The first proximal window is adapted to be engaged by a member disposed in the body with the member being configured to hold the wedge plate in a distal most position. The distal most position being between the first and the second jaw members.
According to another aspect of the present disclosure, the apparatus has the wedge plate with a second proximal window. The second proximal window is adapted to be engaged by the member and the second proximal window is configured to hold the wedge plate in a proximal most position retracted from the first and the second jaw members. The proximal most position of the wedge plate is configured to allow the first and the second jaw members to be moved to the approximated position to compress the clip.
According to another aspect of the present disclosure, the apparatus has the first proximal window connected to the second proximal window by a longitudinal slot.
According to another aspect of the present disclosure, the apparatus has the member movable from the second proximal window to first proximal window by moving the wedge plate distally.
According to still another aspect of the present disclosure, the apparatus has the cam link engageable with a cam slot in the wedge plate. The cam slot has a driving edge.
According to another aspect of the present disclosure, the member is a flexible leg.
According to another aspect of the present disclosure, the apparatus has the cam slot with a proximal side and a distal side. At the distal side, the cam link traverses past the driving edge at a demarcation line. At the demarcation line, the cam link terminates distal movement of the wedge plate.
According to another aspect of the present disclosure, the apparatus has the wedge plate further comprising a biasing device. At the demarcation line, the disengagement between the cam link and the driving edge permits the biasing device to retract the wedge plate.
According to another aspect of the present disclosure, the cam link disengages the wedge plate at the demarcation line, and the disengagement of the cam link permits retraction of the rounded distal end from between the first and the second jaw members.
According to another aspect of the present disclosure, there is provided an apparatus for application of surgical clips to body tissue. The apparatus has a handle portion and a body extending distally from the handle portion and defining a longitudinal axis with a plurality of surgical clips disposed within the body and a jaw assembly mounted adjacent a distal end portion of the body. The jaw assembly has first and second jaw portions movable between a spaced-apart and an approximated position. The apparatus also has a clip pusher configured to individually distally advance a surgical clip to the jaw assembly while the jaw portions are in the spaced apart position and an actuator at least partially disposed within the body and longitudinally movable in response to actuation of the handle portion. The actuator is biased to longitudinally move proximally. The apparatus also has a jaw closure member positioned adjacent the first and second jaw portions to move the jaw portions to the approximated position and a rack having a plurality of ratchet teeth being connected to the actuator with a pawl biased to the handle portion. The pawl has at least one tooth configured to engage the ratchet teeth. As the actuator is moved longitudinally, the plurality of ratchet teeth are passed over the pawl and the pawl is configured to prevent inadvertent return of the actuator before full actuation of the apparatus.
According to another aspect of the present disclosure, the pawl is biased by a spring and the spring is connected to the handle portion to bias the pawl into engagement with the rack.
According to another aspect of the present disclosure, the apparatus has the pawl is pivotally mounted in the handle portion.
According to another aspect of the present disclosure, when actuation of the handle portion is terminated in mid stroke, the ratchet teeth restrain the pawl against proximal motion, and any inadvertent partial actuation of the jaw assembly is prevented.
According to another aspect of the present disclosure, the apparatus has the first jaw and second portions moved to the approximated position and the ratchet teeth are advanced a predetermined distance past the pawl to permit retraction of the actuator.
According to another aspect of the present disclosure, there is provided an apparatus for application of surgical clips to body tissue. The apparatus has a handle assembly with a handle and a trigger movable relative to the handle, and a body extending distally from the handle portion and defining a longitudinal axis. The apparatus also has a plurality of surgical clips disposed within the body and a jaw assembly mounted adjacent a distal end portion of the body with the jaw assembly including first and second jaw portions movable between a spaced-apart and an approximated position. The apparatus further has a clip pusher configured to individually distally advance a surgical clip to the jaw assembly while the jaw portions are in the spaced-apart position and an actuator at least partially disposed within the body and longitudinally movable in response to actuation of the handle portion. The apparatus also has a link connected at a first end to the actuator and connected at a second end to the trigger with a jaw closure member positioned adjacent the first and second jaw portions to move the jaw portions to the approximated position.
According to another aspect of the present disclosure, the link is connected to a rack having a plurality of ratchet teeth and the ratchet teeth are connected to a pawl and are configured to prevent inadvertent return of the actuator before full actuation of the apparatus.
According to another aspect of the present disclosure, the apparatus has the pawl biased to the handle. As the trigger is actuated the link is advanced distally and the link advances the rack distally. The pawl ratchet teeth slide along the pawl.
According to another aspect of the present disclosure, the apparatus has the pawl is pivotally connected to the handle.
BRIEF DESCRIPTION OF THE DRAWINGS
A particular embodiment of a surgical clip applier is disclosed herein with reference to the drawings wherein;
FIG. 1 is a perspective view of a surgical clip applier;
FIG. 2 is another perspective view of the surgical clip applier of FIG. 1 ;
FIG. 3 is an enlarged perspective view of the jaw structure of the surgical clip applier;
FIG. 4 is a top view of the surgical clip applier;
FIG. 5 is a side view of the surgical clip applier;
FIG. 6 is a side view, with half of the body removed, of the handle assembly of the surgical clip applier;
FIG. 7 is an exploded perspective view of the handle of the clip applier, with shaft assembly;
FIG. 8 is a perspective view of a pawl;
FIG. 9 is a perspective view of a yoke;
FIG. 10 is an exploded perspective view of the shaft assembly of the surgical clip applier;
FIG. 10A is a perspective view of a feed bar;
FIG. 10B is a perspective view of a follower and surgical clips;
FIGS. 10C and 10D are opposite perspective views of a trip block;
FIG. 10E is a perspective view of a spindle;
FIG. 10G is an enlarged area of detail of FIG. 10E ;
FIG. 10F is an enlarged area of detail of FIG. 10E ;
FIG. 11 is a perspective view of the distal end of the spindle and a driver;
FIG. 12 is a perspective view of a trip lever mechanism on the spindle;
FIG. 13 is a perspective view of a wedge plate and biasing spring;
FIGS. 14 and 15 are opposite perspective views of a filler component;
FIG. 16 is a perspective view of the rotation knob and shaft assembly;
FIG. 17 is a perspective view of the overpressure assembly;
FIG. 18 is a perspective view of the spindle and jaw assembly;
FIG. 19 is an enlarged area of detail of the spindle and jaw assembly of FIG. 18 ;
FIG. 20 is an enlarged area of detail of the spindle and trip lever of FIG. 18 ;
FIG. 21 is an enlarged view of the distal end of the surgical clip applier with outer tube removed;
FIG. 22 is a perspective view of the surgical clip applier shaft assembly with parts removed;
FIG. 23 is an enlarged area at detail of FIG. 22 ;
FIG. 24 is an enlarged area of detail of FIG. 22 ;
FIG. 25 is an enlarged area of detail of FIG. 22 ;
FIG. 26 is a perspective view of the spindle, driver and jaw assembly;
FIG. 27 is an enlarged area of detail of FIG. 26 ;
FIG. 27A is a cross-sectional view taken along line 27 A- 27 A of FIG. 27 .
FIG. 28 is a perspective view of the cam link and wedge plate assembly;
FIG. 29 is an enlarged area of detail of FIG. 28 ;
FIG. 30 is an enlarged area of detail of FIG. 29 ;
FIG. 31 is a perspective view of the filler component and jaw assembly;
FIG. 32 is an enlarged perspective view of the jaw assembly of FIG. 31 ;
FIGS. 33 and 34 are perspective views of the distal end of the spindle including wedge plate and driver;
FIG. 35 is a side view, partially shown in section, of the surgical clip applier in a pre-fired condition;
FIG. 36 is in enlarged area of detail of FIG. 35 ;
FIG. 37 is an enlarged area of detail of FIG. 35 ;
FIG. 38 is in enlarged area of detail of FIG. 37 showing the trip lever;
FIG. 39 is an enlarged area of detail of FIG. 37 showing the follower;
FIG. 40 is an enlarged the area of detail of FIG. 37 ;
FIG. 41 is enlarged area of detail of FIG. 40 ;
FIG. 42 is a side view, shown in section, of the distal end of the surgical clip applier of FIG. 37 ;
FIG. 43 is a perspective view of the wedge plate and jaw assembly;
FIG. 44 is an enlarged area of detail of FIG. 43 showing the wedge plate and jaw members;
FIG. 45 is a top view of FIG. 43 taken along line 45 - 45 ;
FIG. 46 is an enlarged area of detail of FIG. 45 showing the jaw and the wedge plate;
FIG. 47 is an enlarged area of detail of FIG. 45 showing the wedge plate and cam link;
FIG. 48 is a side view, shown in section, of the handle housing at the beginning of an initial stroke;
FIG. 49 is an enlarged area of detail of FIG. 48 showing the rack and pawl;
FIG. 50 is an enlarged area of detail of FIG. 48 similar to FIG. 49 ;
FIG. 51 is a side view, shown in section, of the feed bar and trip lever;
FIG. 52 is a side view, shown in section, of the follower;
FIG. 53 is a side view, shown in section, of the endoscopic portion of the surgical clip applier;
FIG. 54 is an enlarged area of detail of FIG. 53 illustrating the spindle movement;
FIG. 55 is a top view of the wedge plate and filler component illustrating the movement of the cam link;
FIG. 56 is a side view, shown in section, illustrating the feed bar advancing a clip;
FIG. 57 is a top view of the wedge plate and cam link moving distally;
FIG. 58 is a side view, shown in section, showing the movement of the flexible leg cammed out of a wedge plate window;
FIG. 59 is a side view, shown in section, illustrating a clip entering the jaws;
FIG. 60 is a further top view of the cam link and wedge plate movement;
FIG. 61 is a side view, shown in section, of the flexible leg and wedge plate disengagement;
FIG. 62 is a top view of the wedge plate entering the jaw structure;
FIG. 63 is a perspective view illustrating the wedge plate camming open the jaw structure;
FIG. 64 is a top view illustrating further advancement of the cam link in the wedge plate;
FIG. 65 is a side view, shown in section, illustrating the trip lever engaged with the feed bar;
FIG. 66 is a side view, shown in section, illustrating the spindle camming the flexible leg out of engagement with the wedge plate;
FIG. 67 is a side view, shown in section, illustrating the feed bar loading a clip into the jaw structure;
FIG. 68 is a side view, shown in section, illustrating the trip lever being cammed out of engagement with the feed bar by means of a trip block;
FIG. 69 is a side view, shown in section, illustrating the retraction of the wedge plate and feed bar;
FIG. 70 is a side view, shown in section, illustrating further advancement of the spindle;
FIG. 71 is a side view, shown in section, illustrating the retraction of the wedge plate and further advancement of the spindle;
FIG. 72 is a perspective view of the wedge plate retracting from the jaw structure;
FIG. 73 is a side view, shown in section, with the spindle engaging the driver and a latch retractor engaging the spindle;
FIG. 74 is a side view of the handle housing with the trigger at full stroke;
FIG. 75 is an enlarged area of detail of FIG. 74 with the pawl clearing the ratchet rack;
FIG. 76 is a side view, shown in section, of the driver camming the jaws closed about a surgical clip;
FIGS. 77 to 79 are sequential views of the driver camming the jaws closed about a surgical clip;
FIG. 80 is a view, shown in section, of the overpressure mechanism including the impact spring;
FIG. 81 is a perspective view of a surgical clip formed on a vessel;
FIG. 82 is an enlarged area of detail of the ratchet mechanism resetting;
FIG. 83 is a side view, shown in section, illustrating the latch retractor resetting;
FIG. 84 is a side view, shown in section, illustrating the spindle retracting; and
FIGS. 85 and 86 are top views illustrating the cam link resetting within the wedge plate.
DETAILED DESCRIPTION
There is disclosed a novel endoscopic surgical clip applier having a jaw control mechanism configured to maintain jaws of the surgical clip applier in a spaced apart and stable position during insertion of a surgical clip. It should be noted that, while the disclosed jaw control mechanism is shown and described in an endoscopic surgical clip applier, the disclosed jaw control mechanism is applicable to any surgical clip applier or other instrument having a pair of compressible jaws.
Referring now to FIGS. 1-5 , surgical clip applier 10 generally includes a handle assembly 12 and an endoscopic portion including an elongated tubular member 14 extending distally from handle assembly 12 . Handle assembly 12 is formed of a plastic material while elongated tubular member 14 is formed of a biocompatible material such as stainless steel. A pair of jaws 16 are mounted on the distal end of elongated tubular member 14 and are actuated by a trigger 18 movably mounted in handle assembly 12 . Jaws 16 are also formed of a biocompatible material such as stainless steel or titanium. A knob 20 is rotatably mounted on a distal end of handle assembly 12 and affixed to elongated tubular member 14 to provide 360 degree rotation of elongated tubular member 14 and jaws 16 about its longitudinal axis. Referring for the moment to FIG. 3 , jaws 16 define a channel 22 for receipt of a surgical clip therein.
Referring now to FIGS. 6 and 7 , handle assembly 12 of clip applier 10 is shown. Handle assembly 12 includes a longitudinally movable yoke 24 connected to trigger 18 by a link 26 . Handle assembly 12 includes housing channels 28 to guide yoke wings 30 of yoke 24 within handle assembly 12 during actuation of clip applier 10 . Yoke 24 is connected to the drive mechanisms and is biased to a proximal position by a return spring 32 . Knob 20 includes a flange 34 which is rotatably mounted in a journal 36 in housing 12 .
Referring to FIGS. 6-9 , in order to prevent inadvertent return of trigger 18 and yoke 24 before full actuation of surgical instrument 10 , yoke 24 includes a rack 38 having rack teeth 40 . A pawl 42 is pivotally mounted in handle assembly 12 and includes pawl teeth 44 engageable with rack teeth 40 . Pawl 42 is biased into engagement with rack 38 by a spring 46 . Rack 38 and pawl 42 prevent release of trigger 18 before full actuation in a manner described in more detail hereinbelow.
Combinations of the various elements and mechanisms associated with clip applier 10 will now be described.
Referring to FIG. 10 , a bushing 48 , including retention pins 50 , is provided to secure the bushing 48 to the knob 20 . A drive link 52 is connected, typically with a snap type connection, to yoke 24 such that a proximal end of drive link 52 engages yoke 24 .
An over pressure mechanism including an impact spring 56 is provided about outer tube 14 , between bushing 48 and housed in a bore of knob 20 to prevent over compression of jaws 16 during actuation of the instrument in a manner described in more detail hereinbelow. Drive link 52 extends through a bore 58 in knob 20 .
A flange located at a proximal end of elongated tube member 14 abuts a proximal end of bushing 48 .
In order to actuate the various components there is provided an actuation mechanism or spindle 60 mounted for longitudinal movement through elongated tubular member 14 . Spindle 60 includes a boss 62 at its proximal end which is engageable with a recess 64 on the distal end of drive link 52 . A camming mechanism including a driver 66 and a slider joint 68 extend from a distal end of spindle 60 to cam closed jaws 16 about a surgical clip.
Clip applier 10 is configured to retain a plurality of surgical clips for application to tissue. Clip applier 10 includes an elongated channel member 70 configured to retain a plurality of surgical clips 72 and convey surgical clips 72 to jaws 16 . It should be noted that channel member 70 and jaws 16 do not move longitudinally relative to elongated tubular member 14 . A follower 74 is biased by a spring 76 to urge surgical clips 72 distally within channel member 70 . A channel cover 78 overlies channel 70 to retain and guide spring 76 and surgical clips 72 therein. A nose 80 is provided at a distal end of channel cover 78 to assist in directing surgical clips 72 into jaws 16 .
A feeder mechanism including a feed bar 82 is provided for longitudinal movement relative to channel cover 78 in order to advance individual clips 72 into jaws 16 . A trip block 84 having a guide pin 86 and a feed bar spring 88 are provided adjacent the proximal end of channel cover 78 to bias feed bar 82 in a proximal direction. Specifically, a proximal end 90 of guide pin 86 is interconnected with a hook 92 on an underside of feed bar 82 ( FIGS. 38A & B) and through slot 94 in trip block 84 . (See also FIGS. 10 A, C, & D) In order for spindle 60 to move feed bar 82 , spindle 60 is provided with a trip lever 96 and a biasing spring 98 . Trip lever 96 is engageable with a proximal end of feed bar 82 in a manner described in more detail herein below.
A notable advantage of presently disclosed clip applier 10 is that it is provided with a wedge plate 100 which is configured to advance into jaws 16 during actuation of surgical clip applier 10 and maintain jaws 16 in a spaced apart condition while receiving a surgical clip 72 . Cam slot 136 ( FIG. 13 ), described in detail hereinbelow, formed through wedge plate 100 and a filler component 102 mounted within elongated tubular member 14 , cooperate in connection with a cam link 104 , provided on spindle 60 , to move wedge plate 100 relative to filler component 102 and jaws 16 . Filler component 102 is positioned directly behind jaws 16 and does not move relative to elongated tubular member 14 .
Turning to FIG. 10A , and as noted above, feed bar 82 is provided to move surgical clips 72 into jaws 16 . Feed bar 82 is driven by trip lever 96 on spindle 60 . (See FIG. 10 .) Specifically, feed bar 82 is provided with an elongated window 106 which is configured to be engaged by trip lever 96 as spindle 60 is driven distally. To facilitate insertion of the clip into jaws 16 , feed bar 82 is provided with a pusher 108 at its distal end which is configured to advance an individual clip 72 out of the line of clips 72 and into jaws 16 . As shown in FIG. 10B , follower 74 is positioned behind the line of clips to advance clips 72 through surgical clip applier 10 .
Referring to FIG. 10C , as noted above, trip block 84 includes a slot 94 to receive hook 92 of feed bar 82 . In order to disengage trip lever 96 from window 106 and thus feed bar 82 , trip block 84 is provided with an angled surfaces 110 which is configured to engage trip lever 96 and disengage it from window 106 of feed bar 82 as best shown in FIG. 10D .
Referring now to FIGS. 10E-10G , various features of spindle 60 will now be described. A perspective view of spindle 60 , isolated from other components is shown in FIG. 10E . With specific reference to FIG. 10F , at a proximal end, spindle 60 includes a pivot point 112 for attachment of trip lever 96 at its proximal end. Additionally, a boss 114 is provided in spindle 60 for attachment of biasing spring 98 to bias trip lever 96 into engagement with window 106 of feed bar 82 . Similarly, with respect to FIG. 10G , at a distal end, spindle 60 is provided with a boss 116 for mounting cam link 104 . Spindle 60 is additionally provided with a raised feature 118 which functions to disengage filler component 102 from wedge plate 100 in a manner described in hereinbelow.
Referring to FIG. 11 , spindle 60 is provided to advance driver 66 into engagement with jaws 16 to close jaws 16 about a surgical clip after the surgical clip has been positioned within jaws 16 . A distal end 120 of slider joint 68 resides in a recess 122 in driver 66 . A proximal projection 124 of slider joint 68 rides within a longitudinal slot 126 in the distal end of spindle 60 . The length of longitudinal slot 126 allows spindle 60 to move a predetermined longitudinal distance before engaging and moving driver 66 longitudinally to close jaws 16 about a clip 72 . A latch retractor 128 is provided within a slot 130 in slider joint 68 so as to allow driver 66 to be driven distally after wedge plate 100 has been allowed to retract proximally in a manner described in more detail hereinbelow. A spindle guard 132 is provided between latch retractor 128 and the surface of spindle 60 to prevent damage to the plastic surface of spindle 60 by the surface of latch retractor 128 .
Referring now to FIG. 13 , wedge plate 100 will be described in more detail. As noted above, wedge plate 100 is provided to maintain jaws 16 in a spaced apart condition during loading of a surgical clip 72 within jaws 16 . Additionally, the presence of wedge plate 100 provides stability to jaws 16 to prevent them from flexing during loading of surgical clip 72 . As shown, wedge plate 100 includes a distal tip 134 which is configured to engage and cam jaws 16 open and maintain them in a spaced condition. Additionally, wedge plate 100 includes a cam slot 136 which is configured to cooperate with cam link 104 mounted on spindle 60 to control the motions of wedge plate 100 as discussed in more detail below. Further, distal and proximal windows 138 and 140 , respectively, are provided to engage flexible structure on the filler component 102 . A biasing spring 142 is provided on a mount 144 to bias wedge plate 100 generally proximally within elongated tubular member 14 . Finally, a stop 146 is configured to engage corresponding structure on filler component 102 .
Referring now to FIGS. 14 and 15 , various aspects of filler component 102 will now be described. Filler component 102 includes a flexible leg 152 which is configured to engage distal and proximal windows 138 and 140 in wedge plate 100 . Filler component 102 also includes an elongated cam slot 148 configured to receive part of cam link 104 . A disengaging edge 150 is provided within cam slot 148 to facilitate disengaging cam link 104 from within cam slot 136 in wedge plate 100 . Filler component 102 additionally includes a recess 154 for engagement with stop 146 on wedge plate 100 ( FIG. 13 ), to limit the proximal retraction of wedge plate 100 , as well as a longitudinal recess 156 to accommodate the length of return spring 142 of wedge plate 100 .
FIGS. 16 and 17 illustrate the position of impact spring 56 relative to rotation knob 20 . As noted above, impact spring 56 is provided as an over pressure mechanism to prevent over compression of jaws 16 during the crimping of a surgical clip 72 as described in more detail below with respect to the operation of surgical clip applier 10 . The over pressure mechanism is designed to prevent overstroke of trigger 18 applied by the surgeon and ultimately prevent damage to jaws 16 .
Referring to FIGS. 18-20 , spindle 60 and related drive components are shown with elongated tubular member 14 removed. Specifically, with regard to FIG. 19 , pusher 108 of feed bar 82 extends through a slot 158 in nose 80 to engage a surgical clip 72 . Similarly, as shown in FIG. 20 , at a proximal end of spindle 60 , trip lever 96 extends through window 106 in feed bar 82 . In this position, trip lever 96 can engage an edge of slot 106 to drive feed bar 82 distally along with spindle 60 through elongated tubular member 14 .
Referring to FIG. 21 , there is a view similar to FIG. 19 , however, nose 80 has been removed to illustrate pusher 108 engaging a surgical clip 72 located in channel 70 .
Referring now to FIG. 22 , spindle 60 and associated components are shown with feed bar 82 removed.
Referring to FIG. 23 , there are illustrated multiple clips 72 positioned within channel 70 for supply to jaws 16 at a distal end of spindle 60 . Clips 72 are arranged in longitudinal alignment within channel 70 . Retention fingers 71 are provided at a distal end of channel 70 to restrain a stack of clips 72 within channel 70 until advanced into jaws 16 by feed bar 82 .
Referring to FIG. 24 , there is illustrated an intermediate section of spindle 60 assembled with follower 74 and follower spring 76 . As noted, spring 76 biases follower 74 distally relative to spindle 60 .
With reference to FIG. 25 , there is illustrated spindle 60 assembled with trip lever 96 and biasing spring 98 , with trip lever 96 being biased into a upward most position by biasing spring 98 .
Referring to FIGS. 26 and 27 , an opposed side of spindle 60 assembled with driver 66 about jaws 16 is illustrated. As noted above, driver 66 is configured to cam jaws 16 closed about a surgical clip. Thus, jaws 16 include angled camming surfaces 160 for receipt of corresponding camming surfaces 184 ( FIG. 34 ) of driver 66 . A pocket 187 ( FIG. 31 ) in the proximal end of jaws 16 limits the retraction of driver 66 . Specifically, protrusion 186 of slider joint 68 engages pocket 187 of jaws 16 . (See FIGS. 31 & 34 ).
Referring for the moment to FIG. 27A , camming surfaces 160 on jaws 16 and corresponding camming surfaces 184 of driver 66 are smoothly rounded, curved or radiused. By forming these camming surfaces in this manner, the friction between camming surfaces 160 and 184 is greatly reduced providing an improved smooth closure of jaws 16 about clip 72 .
Referring to FIGS. 28-30 , the relative assembled positions of channel 70 , trip lock 84 , wedge plate 100 and filler component 102 will now be described. Referring initially to FIGS. 29 and 30 , filler component 102 is positioned on channel 70 . Proximal end of filler component 102 abuts a stop 162 positioned on channel 70 . The wedge plate 100 lies over filler component 102 in the manner shown. As best shown in FIG. 30 , filler component 102 includes a cam slot 148 having a disengaging edge 150 formed within cam slot 148 . Similarly, wedge plate 100 includes a cam slot 136 . As noted above, a cam link 104 is provided attached to spindle 60 (not shown) in order to drive wedge plate 100 distally. To facilitate driving wedge plate 100 , cam link 104 is provided with a cam link boss 164 which rides in cam slots 136 and 148 of wedge plate 100 and filler component 102 respectively. As cam link 104 is advanced distally relative to wedge plate 100 cam link boss 164 engages a driving edge 166 of wedge plate 100 to drive wedge plate 100 distally. In the manner described hereinafter, once cam link 104 , and in particular cam link boss 164 , engages disengaging edge 150 of filler component 102 cam link boss 164 is cammed out of engagement of driving edge 166 .
Referring to FIG. 30 , filler component 102 is provided with a flexible leg 152 which is movable between distal and proximal windows 138 , 140 , respectively, of wedge plate 100 . In order to cam flexible leg 152 out of one of the proximal or distal windows, there is provided a cam surface 168 on flexible leg 152 which cams flexible leg 152 out of the windows in response to relative movement of wedge plate 100 relative to filler component 102 .
As noted hereinabove, jaws 16 are provided to receive and crimp surgical clips 72 positioned therein. Referring to FIGS. 31 and 32 , jaws 16 generally include a pair of flexible legs 170 fixed to a base 172 . Jaw members 16 A and 16 B are located at a distal end of flexible legs 170 . A pair of locking arms 174 extend distally from base 172 and terminate in tabs 176 . Tabs 176 are configured to engage corresponding holes 177 on elongated tube 14 ( FIG. 10 ) to secure jaws 16 to elongated tube 14 . Jaws 16 include channel 22 for receipt of surgical clips 72 . As shown, filler component 102 is positioned directly behind jaws 16 and, as with jaws 16 , does not move longitudinally relative to outer tubular member 14 .
Referring for the moment to FIG. 32 , jaws 16 are configured to receive wedge plate 100 such that the distal tip 134 of wedge plate 100 is used to initially separate jaws section 16 a and 16 b and maintain them in a separated and aligned configuration during insertion of a surgical clip into jaws 16 . As noted, this prevents any torquing or flexing of jaw 16 a relative to jaw 16 b while a surgical clip 72 is being loaded therein. Each of flexible legs 170 includes a cam edge 178 (see FIGS. 44 & 63 ) to guide distal tip 134 of wedge plate 100 within jaws 16 .
Referring to FIG. 33 , wedge plate 100 is illustrated positioned on spindle 60 such that latch retractor 128 extends through a slot 182 in wedge plate 100 . As best shown in FIG. 34 , with wedge plate 100 removed, it can be seen that a distal end of driver 60 is provided with camming surfaces 184 . Camming surfaces 184 cooperate with cam surfaces 160 on jaws 16 , (see FIG. 27 ), to cam jaws 16 together in response to longitudinal movement of driver 60 relative to jaws 16 . Protrusion 186 on slider joint 68 extends through a slot 188 in wedge plate 100 to limit retraction of slider joint 68 relative to jaws 16 .
The operation of surgical clip applier 10 to crimp a surgical clip around a target tissue, such as, for example, a vessel, will now be described. With reference to FIGS. 35 and 36 , trigger 18 is in a generally uncompressed state with yoke 24 biased to a proximal-most position by return spring 32 . As best shown in FIGS. 37-42 , and with initial reference to FIG. 38 , in an unfired state, trip lever 96 carried by spindle 60 , biased upwardly by biasing spring 98 , is positioned adjacent to, and in contact with, a slot in feed bar 82 . Trip block 84 is in a distal position relative to trip lever 96 .
Referring to FIG. 39 , follower 74 is biased distally by a spring 76 such that clips 72 are biased in a distal direction.
Referring to FIG. 40 , spindle 60 and feed bar 82 are stationery with latch retractor 128 biased to an upward position.
Referring to FIG. 41 , flexible leg 152 of filler component 102 is in the distal window 138 of wedge plate 100 . Raised feature 118 on spindle 60 is proximal of flexible leg 152 .
As best shown in FIG. 42 , at the distal end of surgical clip applier 10 , when at rest in an unfired state, wedge plate 100 and feed bar 82 are in a proximal-most position relative to jaws 16 .
FIGS. 43-47 illustrate the initial at rest position of the wedge plate 100 , jaws 16 and filler component 102 .
Referring initially to FIGS. 43 and 44 , as shown, wedge plate 100 is in a proximal-most position relative to jaws 16 . As shown in FIG. 43 , flexible leg 152 is in distal window 138 of wedge plate 100 , while cam link 104 is in a proximal-most position relative to cam slot 136 in wedge plate 100 .
As best shown in FIGS. 45 and 46 , wedge plate 100 is in a proximal most position relative to jaws 16 with distal tip 134 proximal of cam edges 178 of jaws 16 .
Referring to FIG. 47 , wedge plate 100 is in a proximal-most position relative to filler component 102 , such that driving edge 166 of wedge plate 100 is proximal of disengaging edge 150 of filler component 102 .
Referring to FIG. 48 , to initiate actuation of clip applier 10 , trigger 18 is moved through an initial swing as shown by arrow A such that link 26 drives yoke 24 distally as shown by arrow B. As best shown in FIG. 49 , as yoke 24 is driven distally in the direction of arrow C, rack teeth 40 on rack 38 slide over pawl teeth 44 on pawl 42 . With reference for the moment to FIG. 50 , if the trigger 18 is released at this point, rack teeth 40 would restrain pawl teeth 44 against proximal motion, preventing release of trigger 18 and partial or inadvertent partial actuation of surgical clip applier 10 .
During the initial stroke, spindle 60 moves a predetermined distance. With regard to FIG. 51 , as spindle 60 is driven an initial distal distance, trip lever 96 engages elongated window 106 feed bar 82 and moves feed bar 82 distally a similar distance. As shown in FIGS. 42 & 51 , as feed bar 82 is driven distally and a clip 72 is driven into jaws 16 , follower 74 moves distally ( FIG. 52 ) due to the bias of spring 76 to urge the stack of surgical clips 72 distally.
Referring to FIGS. 53 and 54 , as spindle 60 and feed bar 82 move distally, spindle 60 drives cam link 104 distally an initial distance such that cam link boss 164 on cam link 104 engages wedge plate 100 . As shown, flexible leg 152 of filler component 102 is positioned in distal-most window 138 of wedge plate 100 .
As shown in FIG. 55 , as cam link 104 moves distally with spindle 60 , cam link boss 164 engages driving edge 166 on wedge plate 100 to urge wedge plate 100 distally relative to filler component 102 .
Referring to FIG. 56 , as feed bar 82 moves distally, pusher 108 at the distal end of feed bar 82 engages a clip 72 and begins to urge clip 72 into jaws 16 . Notably, at this point, spindle 60 has not yet contacted driver 66 , thereby preventing compression of jaws 16 prior to full insertion of surgical clip 72 .
Turning again to FIG. 55 , as surgical clip applier 10 is actuated through a further second predetermined distance, cam boss 164 on cam link 104 continues to drive wedge plate 100 distally and flexible leg 152 is cammed out of distal window 138 and into proximal window 140 by cam surface 168 to engage wedge plate 100 with filler component 102 . As shown in FIGS. 57 & 58 , at this point, feed bar 82 , wedge plate 100 , spindle 60 , clips 72 and follower 74 ( FIG. 52 ) are all moving in a distal-most direction.
Referring to FIG. 59 , feed bar 82 continues to urge pusher 108 at the distal end of feed bar 82 against a surgical clip 72 to urge clip 72 into channel 22 in jaws 16 . Surgical clips 72 contained in channel 70 are biased in a distal direction by follower 74 ( FIG. 52 ) and wedge plate 100 ( FIG. 54 ) continues to move distally while driver 66 remains stationery relative to elongated tubular member 14 .
Referring to FIG. 60 , as spindle 60 is moved further, cam boss 164 of cam link 104 is cammed out of engagement with driving edge 166 of wedge plate 100 by means of disengaging edge 150 formed in filler component 102 as best shown by the arrows in FIG. 60 . During this further stroke of a predetermined distance, flexible leg 152 of filler component 102 snaps into proximal window 140 of wedge plate 100 , thereby preventing retraction of wedge plate 100 from its distal-most position.
As shown in FIG. 61 , flexible leg 152 is positioned within proximal window 140 of wedge plate 100 , thereby restraining wedge plate 100 against retraction, while feed bar 82 and spindle 60 continue to move in a distal direction as shown by the arrows.
As shown in FIGS. 62-63 , distal tip 134 of wedge plate 100 urges jaw members 16 a and 16 b apart by engaging cam surfaces 178 in jaw members 16 a and 16 b . As noted above, by positioning wedge plate 100 in cam surfaces 178 of jaw members 16 a and 16 b , wedge plate 100 not only spreads the jaws 16 apart to properly receive surgical slip 72 , but additionally restrains each individual jaw member 16 a and 16 b from flexing with respect to each other, thereby preventing any torque of clip 72 as it is being inserted into jaws 16 .
Referring to FIG. 64 , as noted above, flexible leg 152 restrains wedge plate 100 from proximal retraction while cam link 104 continues to advance through slots 148 and 136 in filler component 102 ( FIG. 64 ) and wedge plate 100 .
As best shown in FIG. 65 , as spindle 60 continues to move distally through the stroke, trip lever 96 is urged distally with spindle 60 until trip lever 96 engages camming surface 110 (See FIG. 10D ) of trip block 84 . As camming surface 110 of trip block 84 is urged against trip lever 96 , trip lever 96 will be cammed out of engagement with elongated window 106 of feed bar 82 allowing feed bar 82 to return to a proximal position due to the bias of feed bar spring 88 (see FIG. 10 ).
Referring for the moment to FIG. 66 , as spindle 60 continues to move through its stroke, raised feature 118 on spindle 60 begins to cam flexible leg 152 out of proximal window 140 of wedge plate 100 , so that the wedge plate 100 will be able to retract prior to, and so that, surgical clip 72 is crimped between jaws 16 . This is best illustrated in FIG. 67 where feed bar 82 has fully inserted clip 72 within jaws 16 and wedge plate 100 has retracted to a proximal-most position.
FIG. 68 illustrates trip lever 96 being cammed out of engagement with feed bar 82 by camming surface 110 of trip block 84 and against the bias of biasing spring 98 such that feed bar 82 is disengaged from trip lever 96 and feed bar 82 can start to retract proximally. As shown, in FIG. 69 , pusher 108 of feed bar 82 is retracted to a proximal position behind the next distal most clip 72 as wedge plate 100 retracts leaving clip 72 inserted into jaws 16 .
Referring to FIG. 70 , trip lever 96 is completely cammed down by cam surface 110 on trip block 84 and spindle 60 continues to move distally through a further predetermined stroke.
Referring for the moment to FIG. 71 , as wedge plate 100 retracts proximally while spindle 60 continues to move distally, flexible leg 152 on filler component 102 snaps into distal window 138 of wedge plate 100 . As shown in FIG. 72 , wedge plate 100 is retracted to a proximal position relative to jaws 16 .
Referring to FIG. 73 , when latch retractor 128 is cammed downwardly relative to spindle 60 , spindle 60 has moved distally to a predetermined distance. The action of spindle 60 , now engaging driver 66 , pushes driver 66 distally. Driver 66 draws slider joint 68 and simultaneously slider joint 68 drags latch retractor 128 distally mechanically forcing cam surface no. of latch retractor 128 downward to underside of jaw pad 172 and engaging latch retractor 128 with slot 126 of spindle 60 .
Referring to FIGS. 74-75 , as trigger 18 is fully compressed to drive spindle 60 to a distal-most position, rack 38 clears pawl 42 so that the entire drive assembly can retract when the trigger is released. Notably, a full stroke of the spindle 60 is required to take a clip 72 from an initial position to a fully inserted position in the jaws 16 . As spindle 60 moves through its distal-most position, it moves driver 66 in the manner described hereinabove to crimp a surgical clip 72 . For example, referring to FIGS. 76-79 , driver 66 advances distally relative to camming surfaces 160 on jaws 16 a and 16 b , such that camming surfaces 184 on driver 66 cam jaws 16 a and 16 b closed thereby closing surgical clip 72 contained therebetween.
Referring for the moment to FIG. 80 , a security mechanism is provided to prevent an overstroke condition and thereby excessive compression of clip 72 from damaging tissue, jaws 16 or driver 66 . If trigger 18 is continued to be squeezed past a stroke required for a full forming of clip 72 impact spring 56 compresses within the space defined between knob 20 and bushing 48 thereby preventing any further distal movement of spindle 60 .
A fully formed clip formed about vessel V is illustrated in FIG. 81 .
Referring to FIG. 82 , as trigger 18 is released (not shown), pawl 42 rotates against the bias of pawl spring 46 such that pawl teeth 44 ride along rack teeth 40 to reset the handle assembly. As shown in FIG. 83 , when driver 66 retracts, latch retractor 128 is again biased up into its upper-most position, thereby, resetting the drive mechanism.
Referring to FIGS. 84-86 , as spindle 60 retracts, raised feature 118 of spindle 60 moves past flexible leg 152 in filler component 102 . It should be noted that wedge plate 100 does not move as it has already fully retracted. As spindle 60 retracts, it draws cam link 104 proximally within slots 136 and 148 of wedge plate 100 and filler component 102 to its initial position. As best seen in FIG. 86 , in this position, clip applier 10 is again in an initial position to be refired and thus to attach another clip to a vessel. | An apparatus for application of surgical clips to body tissue has a handle portion with a body extending distally from the handle portion defining a longitudinal axis and a plurality of surgical clips disposed within the body. The apparatus also has a jaw assembly mounted adjacent a distal end portion of the body with the jaw assembly including first and second jaw portions movable between a spaced-apart and an approximated position. The apparatus further has a wedge plate longitudinally movable between the first and the second jaw portions, and a clip pusher configured to individually distally advance a surgical clip to the jaw assembly while the jaw portions are in the spaced apart position with an actuator. The actuator is at least partially disposed within the body and longitudinally movable in response to actuation of the handle portion and has a cam link. The apparatus also has a jaw closure member positioned adjacent the first and second jaw portions to move the jaw portions to the approximated position. The cam link longitudinally moves wedge plate between the first and the second jaw portions. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for efficiently preparing a syndiotactic polymer of an unsaturated carboxylic acid ester (i.e., unsaturated carboxylate) such as (meth) acrylate having a narrow molecular weight distribution and a high molecular weight, and a block copolymer of an α-olefin such as ethylene with an unsaturated carboxylate.
2. Description of the Related Art
In the prior art, as the known technique for the preparation of polyacrylates having narrow molecular weight distributions, many processes are known which concern an anion polymerization with the use of an alkali metal and an alkaline earth metal compound. For example, when lithium is used as the initiator in liquid ammonia, one with a relatively narrower molecular weight distribution of Mw/Mn=1.5 can be obtained (W. E. Good, J. Polym. Sci., 42, 367, 1960), and when 1,1-diphenylhexyllithium is used, a polymethyl methacrylate wherein Mw/Mn=1.18 can be obtained (H. Hatada, Kobunshi Ronbunshu, 43, 857, 1986). Further, also with a Grignard reagent, a polymethyl methacrylate wherein Mw/Mn=1.2 can be obtained, but the narrowness of the molecular weight distribution and the syndiotacticity obtained are not satisfactory.
As the method of preparing a polyacrylate with an extremely narrow molecular weight distribution, there are known the method using sodium-biphenyl (A. Roig, J. Polym. Sci., B3, 171, 1965) and the method using aluminum-poephyrin (Japanese Unexamined Patent Publication (Kokai) No. 1-259008), but these involve problems such that the molecular weight of the polymer obtained is small, the polymerization rate is slow, and an expensive polar solvent must be used.
Yasuda and Nakamura et al. have reported that a syndiotactic polymethyl methacrylate having a high molecular weight with a relatively lower molecular weight distribution can be obtained by using a lanthanide divalent compound as the initiator (Chemical Society of Japan, 58th Anniversary Meeting Pre-text I, 1 II B07, 1989). The polymerization using a lanthanide divalent compound as the initiator is attracting attention because it is a living polymerization, and because a polymer with a relatively narrower molecular distribution can be obtained.
Nevertheless, the polymethyl methacrylate formed with the above-mentioned lanthanide divalent compound is not very narrow, i.e., about Mw/Mn=1.2, and the initiator efficiency remains as low as 25%. Also, the lanthanide divalent compound alone has no olefin polymerization activity, and no polymerization initiation ability for an acrylate.
The copolymer of a polymethacrylate and a polyolefin may be considered to have an excellent adhesiveness, printability, and compatibility with other polymers, but an efficient method of synthesizing same is not known. Japanese Unexamined Patent Publication (Kokai) No. 59-43003, proposed a method of copolymerizing propylene with an unsaturated carboxylate, using TiCl 4 and Al(C 2 H 5 ) 3 as the catalyst in the presence of a Lewis acid, and Japanese Unexamined Patent Publication (Kokai) No. 64-14217, proposed a copolymerization of ethylene with an unsaturated carboxylate using a zero valent nickel chelate compound and aluminoxane, but these methods involve problems such that a large amount of Lewis acid is required, or a large amount of aluminoxane of the co-catalyst is required.
SUMMARY OF THE INVENTION
Accordingly, the objects of the present invention are to eliminate the above-mentioned disadvantages of the prior art and to provide a process for efficiently preparing a polymer of an unsaturated carboxylic acid ester having a narrow molecular weight distribution and a high molecular weight.
Another object of the present invention is to provide a process for efficiently preparing a copolymer of an α-olefin (e.g., ethylene) with an unsaturated carboxylic acid ester.
Other objects and advantages of the present invention will be apparent from the following description.
In accordance with the present invention, there is provided a process for preparing a polymer of an unsaturated carboxylic acid ester, comprising the step of polymerizing the unsaturated carboxylic acid ester in the presence, of, as an initiator, at least one organometallic compound selected from the group consisting of (a) trivalent organic Sc compounds, (b) trivalent organic Y compounds, and (c) trivalent organic lanthanide (La, Ce, Pr, Nd, Pm, Sm, Eu, Ga, Tb, Dy, Ho, Er, Tm, Yb, Lu) compounds.
In accordance with the present invention, there is also provided a process for preparing a copolymer of an unsaturated carboxylic acid ester, comprising the step of copolymerizing the unsaturated carboxylic acid ester with an α-olefin in the presence of, as an initiator, at least one organometallic compound selected from the group consisting of (a) trivalent organic Sc compounds, (b) trivalent organic Y compounds, and (c) trivalent organic lanthanide (La, Ce, Pr, Nd, Pm, Sm, Eu, Ga, Tb, Dy, Ho, Er, Tm, Yb, Lu) compounds.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be better understood from the description set forth below with reference to the accompanying drawing of FIG. 1, which is an IR spectrum of the polyethylene-PMMA polymer obtained in Example 10 (Note: those obtained in Examples 11-15 also showed the same absorption).
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present inventors made a further intensive study, and found that, 1) by carrying out a polymerization of, for example, an acrylate or a methacrylate by using an organic Sc compound, or an organic lanthanide compound, or a compound obtained from an organic aluminum together therewith, a living polymerization will proceed to give, for example, a polyacrylate and a polymethacrylate with a narrower molecular distribution and higher molecular weight, with a good efficiency, and further, 2) by carrying out a living polymerization of, for example, ethylene, and reacting an unsaturated carboxylic acid at the growth end thereof, a block ethylene-unsaturated carboxylate can be obtained, to thus accomplish the present invention.
The trivalent organic Sc compound and the trivalent organic Y compound are represented by the formulae (1) and (2): ##STR1## wherein R 1 to R 10 are a hydrogen atom, a hydrocarbon group having 1 to 5 carbon atoms or a hydrocarbon group containing silicon, and R 1 to R 10 may be also bonded through a hydrocarbon group to an adjacent R group. M is Sc, Y, La, Ce, Pr, Nd, Pm, Sm, Eu, Ga, Tb, Dy, Ho, Er, Tm, Yb, Lu. X is a hydrogen atom, a hydrocarbon group having 1 to 10 carbon atoms, or a hydrocarbon group containing silicon. A is an alkylene group having 1 to 3 carbon atoms or a silyalkylene group. D is a solvent molecule, and n is 0 to 3.
Examples of such compounds may include
biscyclopentadienyllutetium hydride,
biscyclopentadienyllutetiummethyl,
biscyclopentadienyllutetiumethyl,
biscyclopentadienyllutetiumbistrimethylsilylmethyl,
bispentamethylcyclopentadienyllutetium hydride,
bispentamethylcyclopentadienyllutetiummethyl,
bispentamethylcyclopentadienyllutetiumbistrimethylsilylmethyl,
biscyclopentadienylytterbium hydride,
biscyclopentadienylytterbiummethyl,
bispentamethylcyclopentadienylytterbium hydride,
bispentamethylcyclopentadienylytterbiummethyl,
bispentamethylcyclopentadienylytterbiumbistrimethvlsily-1- methyl,
biscyclopentadienylsamarium hydride,
biscyclopentadienylsamariummethyl,
bispentamethylcyclopentadienylsamarium hydride,
bispentamethylcyclopentadienylsamariumbistrimethylsilvlmethyl,
biscyclopentadienyleuropium hydride,
biscyclopentadienyleuropiummethyl,
bispentamethylcyclopentadienyleuropium hydride,
bispentamethylcyclopentadienyleuropiummethyl,
bispentamethylcyclopentadienylcerium hydride,
bispentamethylcyclopentadienylytriummethyl,
bispentamethylcyclopentadienylscandium hydride,
bispentamethylcyclopentadienylscandiummethyl,
bisindenyllutetiummethyl,
ethylenebisindenyllutetiummethyl,
ethylenebiscyclopentadienyllutetiummethyl and etherates,
tetrahydrofuranates of these compounds, etc., but are not limited thereto.
These compounds can be synthesized by known methods (Tobin J. Marks, J. Am. Chem. Soc., 107, 8091, 1985.; William J. Evans, J. Am. Chem. Soc., 105, 1401, 1983.; P. L. Watson, A. C. S. Symp., 495, 1983.; Tobin J. Marks, WO 8605788), but are not limited to the synthetic methods.
The organic aluminum compounds usable in the present invention are represented by the formula (3):
AlR.sub.n X.sub.3 -n
wherein R is an aliphatic hydrocarbon group, X is a halogen element, n is an integer of 1 to 3.
Examples of the unsaturated carboxylic acid esters usable in the present invention are acrylates and methacrylates having by the formulae (4) and (5): ##STR2## wherein R is a monovalent group selected from among aliphatic hydrocarbon groups, aromatic hydrocarbon groups, and hydrocarbon groups containing functional groups such as halogen, amine, ether.
Specifical examples thereof are methyl acrylate, ethyl acrylate, n-propyl acrylate, isopropyl acrylate, n-butyl acrylate, isobutyl acrylate, sec-butyl acrylate, t-butyl acrylate, isoamyl acrylate, lauryl acrylate, benzyl acrylate, phenyl acrylate, vinyl acrylate, methyl methacrylate, ethyl methacrylate, n-propyl methacrylate, isopropyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, sec-butyl methacrylate, t-butyl methacrylate, isoamy methacrylate, n-hexyl methacrylate, cyclohexyl methacrylate, lauryl methacrylate, allyl methacrylate, vinyl methacrylate, benzyl methacrylate, phenyl methacrylate, naphthyl methacrylate, 2-methoxyethyl methacrylate, diethylene glycol monomethyl ether methacrylate, 2-dimethylaminoethyl methacrylate, but these are not limitative of the present invention.
Polymerization may be carried out in an inert gas by using the organic Sc trivalene compound and the organic Y trivalent compound and the trivalent organic lanthanide compound as the initiator, and charging a predetermined amount of an acrylate or a methacrylate which is the monomer in the presence of a solvent. For the copolymerization, an α-olefin such as ethylene or propylene, which is the first monomer, is introduced under an atmospheric pressure to carry out an α-olefin polymerization, and then an unsaturated carboxylate is added to the system to carry out a copolymerization, to thereby obtain a block copolymer.
There are no specific limitations to a ratio of the unsaturated carboxylic acid ester to the α-olefin, but the preferable ratio is 0.0001:1 to 1:1, more preferably 0.001:1 to 1:1.
As the inert gas, nitrogen, helium, and argon, etc., may be employed, but preferably argon is used.
The solvent usable in the polymerization includes halogenated hydrocarbons such as methylene chloride, chloroform, carbon tetrachloride, hydrocarbons such as benzene, toluene, xylene, tetrahydrofuran, and ether, and all thereof are preferably dehydrated and degassed before use. Polymerization is also possible in the absence of a solvent.
The unsaturated carboxylate usable in the polymerization is thoroughly dried with calcium hydride, molecular sieved, and distilled under an inert gas immediately before the polymerization.
The polymerization temperature may be varied over a wide range from the solidifying point to the boiling point of the solvent, but more preferably is not higher than room temperature. A specific feature of the preparation process of the present invention is that a polyacrylate and polymethacrylate with a narrow molecular weight distribution can be prepared over a wide temperature range from the solidifying point of the solvent to room temperature.
The preparation process of the present invention enables a polyacrylate and a polymethacrylate, and a block copolymer thereof with ethylene, to be easily synthesized.
In the present process, corresponding halides of the organic Sc trivalent compound and the organic Y trivalent compound and the organic lanthanide compound (e.g., biscyclopentadienylluthethium chloride, bispentamethylcyclopentadienylytterbium bromide) can be allowed to react with an alkyl alkali compound in an equal amount or less, to also give a polymerization catalysts.
Further, as a major specific feature of the present invention, once the initiator concentration and the monomer concentration are determined, the molecular weight of the polymer can be controlled over a wide range of 1,000 to 1,000,000 by controlling the reaction temperature and the polymerization time.
According to the process of the present invention, it is possible to prepare, for example, syndiotactic polymethacrylates and polyacrylates with a narrow molecular weight distribution and high molecular weight. The polymer is ideal as the standard substance for gel permeation chromatography. Also, by formulating the above-mentioned copolymer in thermoplastic resins such as polyolefins, the various properties of the resin such as coatability and adhesiveness can be improved due to the increase in the compatibility of the resins.
EXAMPLES
The present invention will now be further illustrated by, but is by no means limited to, the following Examples.
In the Examples and Comparative Examples, the molecular weight of the polymer formed was determined by GPC, and the molecular weight distribution estimated by Mw/Mn. The regularity of the polymer was calculated by 1 H-NMR.
EXAMPLE 1
Into a 50 ml flask thoroughly replaced with dry argon were charged 1 ml of a toluene solution of bispentamethylcyclopentadienylyttriummethyl monoetherate (0.02 M) synthesized by a known method (P. L. Watson, A. C. S. Symp., 495, 1983) and 20 ml of dry toluene, and the mixture was adjusted to a polymerization temperature of 0° C. while stirring with a magnetic stirrer. Then, to the mixture was added 1 ml of methyl methacrylate dried with calcium hydride and molecular sieves by a syringe, and after the reaction, the reaction mixture was poured into a large amount of methanol to precipitate the polymer, which was washed and weighed after drying, followed by a GPC measurement.
EXAMPLE 2
Example 1 was repeated except that the polymerization temperature was made -40° C.
EXAMPLE 3
Example 1 was repeated except that bispentamethylcyclopentadienylsamarium hydride was employed as the initiator.
EXAMPLE 4
Example 1 was repeated except that bispentamethylcyclopentadienylsamarium hydride was temperature made -40° C.
EXAMPLE 5
Example 1 was repeated except that bispentamethylcyclopentadienylsamarium hydride was employed as the initiator, and the polymerization temperature made -78° C.
EXAMPLE 6
Example 1 was repeated except that bispentamethylcyclopentadienylsamariumbistrimethylsilylmethyl was employed as the initiator.
EXAMPLE 7
Example 1 was repeated except that bispentamethylcyclopentadienylsamariumbistrimethylsilylmethyl was used as the initiator, and the polymerization temperature made -40° C.
COMPARATIVE EXAMPLE 1
Example 1 was repeated except that 1,1-diphenylhexyllithium was employed as the initiator.
EXAMPLE 8
Example 1 was repeated except that bispentamethylcyclopentadienylytterbiummethyltrimethylaluminum was employed as the initiator.
EXAMPLE 9
Example 1 was repeated except that bispentamethylcyclopentadienylsamarium hydride was employed as the initiator, and methyl acrylate as the monomer.
TABLE 1__________________________________________________________________________Polymerization of methyl methacrylate and methyl acrylate with variousinitiators Molecular Molecular weight Syndio- Polymerization Polymerization weight distribution tacticity YieldNo. Initiator time (h) temp. (°C.) Mn/10.sup.3 Mw/Mn rr % (%)__________________________________________________________________________Example 1 Cp*.sub.2 YbMe (OEt).sub.2 1 0 85 1.06 84.8 59Example 2 Cp*.sub.2 YbMe (OEt).sub.2 15 -14 89 1.06 88.6 98Example 3 (Cp*.sub.2 SmH).sub.2 1 0 194 1.04 82.4 98Example 4 (Cp*.sub.2 SmH).sub.2 15 -40 137 1.06 88.3 98Example 5 (Cp*.sub.2 SmH).sub.2 7.5 -78 82 1.06 93.0 98Example 6 Cp*.sub.2 SmCH (SiMe.sub.3).sub.2 1 0 733 1.18 83.8 98Example 7 Cp*.sub.2 SmCH (SiMe.sub.3).sub.2 15 -40 1117 1.26 88.3 98Example 8 Cp*.sub.2 Yb (μ-Me).sub.2 AlMe.sub.2 1 0 130 1.05 84.3 34Example 9 (Cp*.sub.2 SmH).sub.2 1 0 25 1.10 81.0 98Comparative CH.sub.3 (CH.sub.2).sub.4 C(C.sub.6 H.sub.5).sub.2 Li 3 -78 10 1.18 83.8 100Example 1__________________________________________________________________________
Examples of block copolymers are shown in the following.
The molecular weights of the copolymers formed below were determined by GPC and the molecular weight distributions estimated by Mw/Mn. The quantitative ratio of ethylene and carboxylate in the copolymer was calculated from 1 H-NMR and 13 C-NMR.
EXAMPLE 10
Into a 50 ml flask thoroughly replaced with dry argon were charged 1 ml of a toluene solution of bispentamethylcyclopentadienylyttrbiummethyl monoetherate (0.02 M) synthesized by a known method (P. L. Watson, A. C. S. Symp., 495, 1983) and 20 ml of dry toluene, and after replacement of the argon gas with ethylene by cooling under a reduced pressure, the mixture was adjusted to a polymerization temperature of 30° C. while stirring with a magnetic stirrer. After the ethylene polymerization was carried out for 5 minutes, the unreacted ethylene gas was again replaced with argon gas by cooling under a reduced pressure. The polyethylene formed at this time was sampled in an amount of 5 ml by a syringe. To the remainder of the reaction mixture was added 1 ml of methyl methacrylate dried with aclacium hydride and molecular sieves by a syringe, and after the reaction, the reaction mixture was poured into a large amount of methanol to precipitate the polymer. The polymer obtained was heated under reflux in chloroform, and the insolubles in chloroform were filtered, dried and weighed, followed by GPC and NMR measurements.
EXAMPLE 11
Example 10 was repeated except for changing the polyethylene polymerization time to 10 minutes.
EXAMPLE 12
Example 10 was repeated except for changing the polymethylene polymerization time to 15 minutes.
EXAMPLE 13
Example 10 was repeated except for using bispentamethylcyclopentadienylsamarium hydride as the initiator, and changing the polyethylene polymerization time to 1 minute.
EXAMPLE 14
Example 10 was repeated except for using bispentamethylcyclopentadienylsamarium hydride as the initiator and changing the polyethylene polymerization time to 3 minutes.
COMPARATIVE EXAMPLE 2
Copolymerization was carried out in the same manner as in Example 10 except for using bispentamethylytterbiumbistetrahydrofuranate (divalent) as the initiator, but no copolymer was obtained.
EXAMPLE 15
Example 10 was repeated except for using bispentamethylcyclopentadienylytterbiummethyltrimethylaluminum as the initiator.
EXAMPLE 16
Example 10 was repeated except for using bispentamethylcyclopentadienylsamarium hydride as the initiator and methyl acrylate as the monomer.
The IR spectrum of the polyethylene-PMMA copolymer obtained in Example 10 is shown in FIG. 1.
TABLE 2__________________________________________________________________________Preparation of polyethylene-PMMA copolymer with organic lanthanidetrivalent compound ##STR3## Polyethylene Polyethylene Ethylene:Example polymerization Copolymer block PMMA block MMA inNo. Initiator time (min.) yield (mg) Mw n Mw m Mw/Mn polymer__________________________________________________________________________10 Cp*.sub.2 YbMe(OEt).sub.2 5 120 5800 207 13800 138 1.85 1.5:111 Cp*.sub.2 YbMe(OEt).sub.2 10 150 8500 303 2400 24 2.21 11.5:112 Cp*.sub.2 YbMe(OEt).sub.2 15 150 73000 2600 5200 52 2.92 49.0:113 [Cp*.sub.2 SmH].sub.2 1 80 33000 1178 7500 75 2.03 15.7:114 [Cp*.sub.2 SmH].sub.2 2 100 48300 1725 1725 17 2.27 100.0:115 Cp*.sub.2 YbMe/AlMe.sub.3 10 70 54400 2000 2000 20 1.86 100.0:1 .sup. 16*.sup.2[Cp*.sub.2 SmH].sub.2 5 57 5800 207 1380 16 2.05 13.0:1__________________________________________________________________________ *.sup.1 Cp* = pentamethylcyclopenntadienil *.sup.2 In Example 16, methyl acrylate was employed in place of methyl methacrylate | A process for preparing a narrow molecular weight distribution syndiotactic block copolymer of an unsaturated carboxylic acid ester (e.g., acrylate of methacrylate) with an α-olefin (e.g., ethylene) by using, as an initiator, at least one organometallic compound of the group consisting of (a) trivalent organic Y compounds, and (b) trivalent organic lanthanide (La, Ce, Pr, Nd, Pm, Sm, Eu, Ga, Tb, Dy, Ho, Er, Tm, Yb, Lu) compounds, or a combination thereof with an organoaluminum compound. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an integrated circuit capable of synchronizing multiple outputs, and more particularly, to a source driver of a display device capable of synchronizing multiple outputs.
[0003] 2. Description of the Prior Art
[0004] [Liquid crystal display (LCD) devices are used in various devices such as personal computers or television screens due to their advantages of thinness, light weight, and low power consumption. Color liquid crystal display devices with an active matrix system in particular, which are advantageous for controlling image quality with high definition, have become dominant.
[0005] FIG. 1 shows a diagram of a prior art liquid crystal display device 10 including an LCD panel 12 , a controller 14 , a plurality of gate drivers 16 , and a plurality of source drivers 20 - 2 n. Though the details of the LCD panel 12 are not illustrated, the LCD panel 12 is constituted from a structure including a semiconductor substrate with transparent pixel electrodes and thin film transistors (TFTs) disposed thereon, an opposing substrate with one transparent electrode formed on an entire surface thereof, and a liquid crystal sealed between these two opposing substrates. Then, by controlling the TFTs, a predetermined voltage is applied to each pixel electrode, and the transmissivity or reflectivity of the liquid crystal is changed by a potential difference between each pixel electrode and the electrode on the opposing substrate. A scanning signal in a pulse form is sequentially transmitted to a scan line on the LCD panel 12 from a corresponding gate driver 16 . TFTs connected to the gate line to which a pulse is applied are all turned on. At this point, gray-scale voltages are supplied to the data lines of the LCD panel 12 from the respective source drivers 20 - 2 n and applied to pixel electrodes through the turned-on TFTs. Then, when the TFTs connected to the gate line to which no pulse is applied any longer are turned off, potential differences between the pixel electrodes and the opposing substrate electrode are held for a period until subsequent gray-scale voltages are applied to the pixel electrodes. Then, by sequential pulse application, predetermined gray-scale voltages are applied to all pixel electrodes. By performing gray-scale voltage rewriting in each frame period, an image can be displayed.
[0006] FIG. 2 shows a diagram of the source driver 20 of the liquid crystal display device 10 constituting an interface circuit for chip-to-chip data transfer. Since the source drivers 21 - 2 n have the same structure as the source driver 20 shown in FIG. 2 , corresponding illustrations and descriptions will be omitted. The source driver 20 includes an RSDS (reduced swing differential signaling) receiver 30 , a shift register 40 , a data capturing circuit 50 , a latch 60 , a level shifter 70 , a digital-to-analog conversion circuit (which will be hereinafter referred to as a D/A converter) 80 , and an output buffer 90 . Based on the input signal INV 1 , the RSDS receiver 30 generates the output signal OUT 1 and a data signals DATA to the shift register 40 and the data capturing circuit 50 , respectively. The latch 60 holds the data signals captured by the data capturing circuit 50 at the timing of the front edges of the latch signals STB, and then collective supplies the latched data signals to the level shifter 70 during each horizontal period. The level shifter 70 increases the voltage levels of the data signals DATA from the latch 60 , and then outputs the data signals to the D/A converter 80 . The D/A converter 80 supplies gray scale voltages corresponding to the logic values of the data signals to the output buffer 90 , which then outputs the gray-scale voltages at the timing of the rear edges of the latch signals STB. For the liquid crystal display device 10 to function efficiently, the output signals supplied by the RSDS receivers (referred to as 30 - 3 n in FIG. 3 ) of the source drivers 21 - 2 n have to be synchronized.
[0007] Since the input signals are generated by the controller 14 , different input signals encounter different resistance according the distances between the controller 14 and corresponding RSDS receivers. FIG. 3 is a diagram showing an equivalent circuit of the RSDS receiver 30 - 3 n of the source drivers 20 - 2 n. In FIG. 3 , VDD and VSS are power sources supplying power to the RSDS receivers 30 - 3 n via a power line PL and a ground line GL, respectively. 11 - 1 n are analog current sources. RD 1 -RDn are parasitic resistors of the power line PL, and RS 1 -RSn are parasitic resistors of the ground line GL. VD 1 -VDn and VS 1 -VSn represent the bias voltages of the RSDS receivers 30 - 3 n, respectively. Usually the RSDS receivers 30 - 3 n are disposed in a way such that the parasitic resistors RD 1 -RDn and RS 1 -RSn have the same resistance. The voltage difference established across each parasitic resistor when the liquid crystal display device 10 is operating is represented by A. The bias voltages VD 1 -VDn can be respectively represented by VDD-Δ, VDD- 2 *Δ, . . . , VDD-n*Δ, and the bias voltages VS 1 -VSn can be respectively represented by VSS+Δ, VSS+2*Δ, . . . , VSS+n*Δ. Since each RSDS receiver has different bias voltages, the output signals OUT 1 -OUTn cannot be outputted simultaneously. Therefore, the performance of the prior art liquid crystal display device 10 cannot be optimized.
SUMMARY OF THE INVENTION
[0008] The present invention provides an integrated circuit capable of synchronizing multiple outputs comprising a first power source, a second power source, a first and second units for providing a plurality of output voltages at corresponding output ends, a first charging switch, a second charging switch, a first discharging switch, and a second discharging switch. The first charging switch includes a first end coupled to the first power source, a second end coupled to a first end of the first inversion unit, and a control end coupled to a second end of the second inversion unit. The second charging switch includes a first end coupled to the first power source, a second end coupled to a first end of the second inversion unit, and a control end coupled to a second end of the first inversion unit. The first discharging switch includes a first end coupled to the second power source, a second end coupled to the second end of the first inversion unit, and a control end coupled to the first end of the second inversion unit. The second discharging switch includes a first end coupled to the second power source, a second end coupled to the second end of the second inversion unit, and a control end coupled to the first end of the first inversion unit.
[0009] The present invention also provides a circuit for synchronizing outputs of a first and a second output buffers, each of which has a first and second end for receiving bias voltages, the circuit comprising a first switch having a first end coupled to receive a first voltage, a second end coupled to the first end of the first output buffer, and a control end coupled to the second end of the second output buffer; a second switch having a first end coupled to receive the first voltage, a second end coupled to the first end of the second output buffer, and a control end coupled to the second end of the first output buffer; a third switch having a first end coupled to receive a second voltage, a second end coupled to the second end of the first output buffer, and a control end coupled to the first end of the second output buffer; and a fourth switch having a first end coupled to receive the second voltage, a second end coupled to the second end of the second output buffer, and a control end coupled to the first end of the first output buffer.
[0010] The present invention also provides a circuit for synchronizing outputs of a first, second and third output buffers, each of which has a first and second end for receiving bias voltages, the circuit comprising a first switch having a first end coupled to receive a first voltage, a second end coupled to the first end of the first output buffer, and a control end coupled to the second end of the second output buffer; a second switch having a first end coupled to receive the first voltage, a second end coupled to the first end of the second output buffer, and a control end coupled to the second end of the first output buffer; a third switch having a first end coupled to receive a second voltage, a second end coupled to the second end of the first output buffer, and a control end coupled to the first end of the second output buffer; a fourth switch having a first end coupled to receive the second voltage, a second end coupled to the second end of the second output buffer, and a control end coupled to the first end of the first output buffer; a fifth switch having a first end coupled to receive the first voltage, a second end coupled to the first end of the third output buffer, and a control end coupled to the second end of the third output buffer; and a sixth switch having a first end coupled to receive the second voltage, a second end coupled to the second end of the third output buffer, and a control end coupled to the first end of the third output buffer.
[0011] These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 shows a diagram of a prior art liquid crystal display device.
[0013] FIG. 2 shows a diagram of a source driver in the liquid crystal display device in FIG. 1 .
[0014] FIG. 3 is a diagram showing an equivalent circuit of the RSDS receivers of the liquid crystal display device in FIG. 1 .
[0015] FIG. 4 is a diagram showing an RSDS receiver circuit according to a first embodiment of the present invention.
[0016] FIG. 5 is a diagram showing an RSDS receiver circuit according to a second embodiment of the present invention.
[0017] FIG. 6 is a diagram showing a CMOS inverter used for the RSDS receiver circuits in FIGS. 4 and 5 .
[0018] FIG. 7 is a diagram showing a CMOS inverter used for the RSDS receiver circuits in FIGS. 4 and 5 .
DETAILED DESCRIPTION
[0019] The present invention provides RSDS receiver circuits capable of synchronizing a plurality of outputs. FIG. 4 is a diagram showing an RSDS receiver circuit 40 according to a first embodiment of the present invention. The first embodiment of the present invention can provide odd output signals simultaneously. For ease of explanation, the RSDS receiver circuit 40 in FIG. 4 only provides three output signals OUT 1 -OUT 3 . The RSDS receiver circuit 40 includes power sources VDD and VSS, a power line PL, a ground line GL, inversion units U 1 -U 3 (output buffers), P-type metal-oxide semiconductor (PMOS) transistors MP 1 -MP 3 , N-type metal-oxide semiconductor (NMOS) transistors MN 1 -MN 3 , and analog current sources 11 - 13 . The power sources VDD and VSS provide bias voltages to the inversion units U 1 -U 3 via the power line PL and the ground line GL, respectively. RD 1 -RD 3 are parasitic resistors of the power line PL, and RS 1 -RS 3 are parasitic resistors of the ground line GL. Each of the analog current sources I 1 -I 3 is coupled between the power line PL and the ground line GL.
[0020] The PMOS transistors MP 1 -MP 3 provide current paths for charging the inversion units U 1 -U 3 , and the NMOS transistors MN 1 -MN 3 provide current paths for discharging the inversion units U 1 -U 3 . Each of the PMOS transistors MP 1 -MP 3 includes a source coupled to the power line PL and a drain coupled to a first bias end of a corresponding inversion unit. Each of the NMOS transistors MN 1 -MN 3 includes a source coupled to the ground line GL and a drain coupled to a second bias end of a corresponding inversion unit. The gates of the PMOS transistors MP 1 -MP 3 are coupled to the drains of the NMOS transistors MN 3 -MN 1 , respectively. The gates of the NMOS transistors MN 1 -MN 3 are coupled to the drains of the PMOS transistors MP 3 -MP 1 , respectively.
[0021] Usually the inversion units U 1 -U 3 are disposed in a way such that the parasitic resistors RD 1 -RD 3 and RS 1 -RS 3 have the same resistance. The voltage difference established across each parasitic resistor when the RSDS receiver circuit 40 is operating is represented by Δ. The source voltages Vs(MP 1 )-Vs(MP 3 ) of the PMOS transistors MP 1 -MP 3 and the source voltages Vs(MN 1 )-Vs(MN 3 ) of the NMOS transistors MN 1 -MN 3 can be represented by the following formulae:
Vs ( MP 1)= VDD−Δ;
Vs ( MP 2)= VDD− 2*Δ;
Vs ( MP 3)= VDD− 3*Δ;
Vs ( MN 1)= VSS+Δ;
Vs ( MN 2)= VSS+ 2*Δ;
Vs ( MN 3)= VSS+ 3*Δ;
[0022] When the PMOS transistors MP 1 -MP 3 and the NMOS transistors MN 1 -MN 3 are turned on, the drain-to-source voltages of the transistors are very small and can thus be regarded as zero. Therefore, the drain voltages Vd(MP 1 )-Vd(MP 3 ) of the PMOS transistors MP 1 -MP 3 and the drain voltages Vd(MN 1 )-Vd(MN 3 ) of the NMOS transistors MN 1 -MN 3 can be represented by the following formulae:
Vd ( MP 1)≅ Vs ( MP 1);
Vd ( MP 2)≅ Vs ( MP 2);
Vd ( MP 3)≅ Vs ( MP 3);
Vd ( MN 1)≅ Vs ( MN 1);
Vd ( MN 2)≅ Vs ( MN 2);
Vd ( MN 3)≅ Vs ( MN 3);
[0023] Since the gates of the PMOS transistors MP 1 -MP 3 are coupled to the drains of the NMOS transistors MN 3 -MN 1 , respectively, the absolute values of the gate-to-source voltages Vgs(MP 1 )-Vgs(MP 3 ) of the PMOS transistors MP 1 -MP 3 can be represented by the following formulae:
|Vgs ( MP 1)|=| Vs ( MN 3)− Vs ( MP 1)| ≅VDD−VSS− 4*Δ;
| Vgs ( MP 2)|=| Vs ( MN 2)− Vs ( MP 2)| ≅VDD−VSS− 4*Δ;
| Vgs ( MP 3)|= |Vs ( MN 1)− Vs ( MP 3)|≅ VDD−VSS− 4*Δ;
[0024] Since the gates of the NMOS transistors MN 1 -MN 3 are coupled to the drains of the PMOS transistors MP 3 -MP 1 , respectively, the gate-to-source voltages Vgs(MN 1 )-Vgs(MN 3 ) of the NMOS transistors MN 1 -MN 3 can be represented by the following formulae:
Vgs ( MN 1)= Vs ( MP 3)− Vs ( MN 1)≅ VDD−VSS− 4*Δ;
Vgs ( MN 2)= Vs ( MP 2)− Vs ( MN 2)≅ VDD−VSS− 4*Δ;
Vgs ( MN 3)= Vs ( MP 1)− Vs ( MN 3)≅ VDD−VSS− 4*Δ;
[0025] Since the absolute values of the gate-to-drain voltages of all transistors in the RSDS receiver circuit 40 are the same, the transistors can be turned on simultaneously. Therefore, the transistors provide the same driving ability for the inversion units U 1 -U 3 . By adjusting the sizes (W/L ratios), the NMOS and PMOS transistors can provide signals having the same rise and fall time, thereby synchronizing the output voltages OUT 1 -OUT 3 for subsequent signal sampling.
[0026] FIG. 5 is a diagram showing an RSDS receiver circuit 50 according to a second embodiment of the present invention. The second embodiment of the present invention can provide even output voltages simultaneously. For ease of explanation, the RSDS receiver circuit 50 in FIG. 5 only provides four output voltages OUT 1 -OUT 4 . The RSDS receiver circuit 50 includes power sources VDD and VSS, a power line PL, a ground line GL, inversion units U 1 -U 4 , PMOS transistors MP 1 -MP 4 , NMOS transistors MN 1 -MN 4 , and analog current sources I 1 -I 4 . The power sources VDD and VSS provide bias voltages to the inversion units U 1 -U 4 via the power line PL and the ground line GL, respectively. RD 1 -RD 4 are parasitic resistors of the power line PL, and RS 1 -RS 4 are parasitic resistors of the ground line GL. Each of the analog current sources I 1 -I 4 is coupled between the power line PL and the ground line GL.
[0027] The PMOS transistors MP 1 -MP 4 provide current paths for charging the inversion units U 1 -U 4 , and the NMOS transistors MN 1 -MN 4 provide current paths for discharging the inversion units U 1 -U 4 . Each of the PMOS transistors MP 1 -MP 4 includes a source coupled to the power line PL and a drain coupled to a first bias end of a corresponding inversion unit. Each of the NMOS transistors MN 1 -MN 4 includes a source coupled to the ground line GL and a drain coupled to a second bias end of a corresponding inversion unit. The gates of the PMOS transistors MP 1 -MP 4 are coupled to the drains of the NMOS transistors MN 4 -MN 1 , respectively. The gates of the NMOS transistors MN 1 -MN 4 are coupled to the drains of the PMOS transistors MP 4 -MP 1 , respectively.
[0028] Usually the inversion units U 1 -U 4 are disposed in a way such that the parasitic resistors RD 1 -RD 4 and RS 1 -RS 4 have the same resistance. The voltage difference establish across each parasitic resistor when the RSDS receiver circuit 50 is operating is represented by Δ. The source voltages Vs(MP 1 )-Vs(MP 4 ) of the PMOS transistors MP 1 -MP 4 and the source voltages Vs(MN 1 )-Vs(MN 4 ) of the NMOS transistors MN 1 -MN 4 can be represented by the following formulae:
Vs ( MP 1)= VDD−Δ;
Vs ( MP 2)= VDD− 2*Δ;
Vs ( MP 3)= VDD− 3*Δ;
Vs ( MP 4)= VDD− 4*Δ;
Vs ( MN 1)= VSS+Δ;
Vs ( MN 2)= VSS+ 2*Δ;
Vs ( MN 3)= VSS+ 3*Δ;
Vs ( MN 4)= VSS+ 4*Δ;
[0029] When the PMOS transistors MP 1 -MP 4 and the NMOS transistors MN 1 -MN 4 are turned on, the drain-to-source voltages of the transistors are very small and can thus be regarded as zero. Therefore, the drain voltages Vd(MP 1 )-Vd(MP 4 ) of the PMOS transistors MP 1 -MP 4 and the drain voltages Vd(MN 1 )-Vd(MN 4 ) of the NMOS transistors MN 1 -MN 4 can be represented by the following formulae:
Vd ( MP 1)≅ Vs ( MP 1);
Vd ( MP 2)≅ Vs ( MP 2);
Vd ( MP 3)≅ Vs ( MP 3);
Vd ( MP 4)≅ Vs ( MP 4);
Vd ( MN 1)≅ Vs ( MN 1);
Vd ( MN 2)≅ Vs ( MN 2);
Vd ( MN 3)≅ Vs ( MN 3);
Vd ( MN 4)≅ Vs ( MN 4);
[0030] Since the gates of the PMOS transistors MP 1 -MP 4 are coupled to the drains of the NMOS transistors MN 4 -MN 1 , respectively, the absolute values of the gate-to-source voltages Vgs(MP 1 )-Vgs(MP 4 ) of the PMOS transistors MP 1 -MP 4 can be represented by the following formulae:
| Vgs ( MP 1)|=| Vs ( MN 4)− Vs ( MP 1)|≅ VDD−VSS− 5*Δ;
| Vgs ( MP 2)|=| Vs ( MN 3)− Vs ( MP 2)|≅ VDD−VSS− 5*Δ;
| Vgs ( MP 3)|= |Vs ( MN 2)− Vs ( MP 3)| ≅VDD−VSS− 5*Δ;
| Vgs ( MP 4)|= |Vs ( MN 1)− Vs ( MP 4)| ≅VDD−VSS− 5*Δ;
[0031] Since the gates of the NMOS transistors MN 1 -MN 4 are coupled to the drains of the PMOS transistors MP 4 -MP 1 , respectively, the gate-to-source voltages Vgs(MN 1 )-Vgs(MN 4 ) of the NMOS transistors MN 1 -MN 4 can be represented by the following formulae:
Vgs ( MN 1)= Vs ( MP 4)− Vs ( MN 1)≅ VDD−VSS− 5*Δ;
Vgs ( MN 2)= Vs ( MP 3)− Vs ( MN 2)≅ VDD−VSS− 5*Δ;
Vgs ( MN 3)= Vs ( MP 2)− Vs ( MN 3) ≅VDD−VSS− 5*Δ;
Vgs ( MN 4)= Vs ( MP 1)− Vs ( MN 4) ≅VDD−VSS− 5*Δ;
[0032] Since the absolute values of the gate-to-source voltages of all transistors in the RSDS receiver circuit 50 are the same, the transistors can be turned on simultaneously. Therefore, the transistors provide the same driving ability for the inversion units U 1 -U 4 . By adjusting the sizes (W/L ratios), the NMOS and PMOS transistors can provide signals having the same rise and fall time, thereby synchronizing the output voltages OUT 1 -OUT 4 for subsequent signal sampling.
[0033] The inversion units used in the RSDS receiver circuits 40 and 50 can include complimentary metal-oxide semiconductor (CMOS) inverters. FIG. 6 is a diagram showing a CMOS inverter 60 used for the inversion units of the RSDS receiver circuits 40 and 50 . The CMOS inverter 60 includes a PMOS transistor MP and an NMOS transistor MN. The gate and the drain of the PMOS transistor MP are coupled to the gate and the drain of the NMOS transistor MN, respectively. When an input signal INV received at the gates of the transistors has a high level (logic 1), the NMOS transistor MN is turned on, and the PMOS transistor MP is turned off, thereby generating an output signal OUT having a low level (logic 0). When the input signal INV has a low level, the NMOS transistor MN is turned off, and the PMOS transistor MP is turned on, thereby generating an output signal OUT having a high level.
[0034] FIG. 7 is a diagram showing another CMOS inverter 70 used for the inversion units of the RSDS receiver circuits 40 and 50 . The CMOS inverter 70 includes PMOS transistors MP 1 -MP 2 and NMOS transistors MN 1 -MN 2 . The gates of the PMOS transistors MP 1 and MP 2 are respectively coupled to INVp and INVN, and the gates of the NMOS transistors MN 1 and MN 2 are respectively coupled to INVN and INVp. The source of the NMOS transistor MN 1 , the drain of the NMOS transistor MN 2 , the drain of the PMOS transistor MP 1 , and the source of the PMOS transistor MP 2 are coupled together. Input signals INVn and INVP are supplied to the gates of the transistors, and a corresponding output signal OUT is generated based on the levels of the input signals INVn and INVP. The inverters shown in FIGS. 6 and 7 are only two embodiments of the inversion units. Other types of inverters can also be adopted for the RSDS receivers of the present invention.
[0035] In the RSDS receivers of the present inventions, a plurality of PMOS transistors are provided for charging the inversion units, and a plurality of NMOS transistors are provided for discharging the inversion units. The gates of the transistors are coupled, as illustrated in FIGS. 4 and 5 , so as to compensate different voltage drops caused by the parasitic resistors of the power lines. By adjusting the W/L ratio, the NMOS and PMOS transistors can generate signals having the same rise and fall time, thereby synchronizing multiple output signals for subsequent signal sampling.
[0036] Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims. | A source driver of an LCD includes a first and second power sources, a first and second inversion units, a first and second charging switches, and a first and second discharging switches. The first charging switch is coupled to the first power source, a first end of the first inversion unit, and a second end of the second inversion unit. The second charging switch is coupled to the first power source, a first end of the second inversion unit, and a second end of the first inversion unit. The first discharging switch is coupled to the second power source, the second end of the first inversion unit, and the first end of the second inversion unit. The second discharging switch is coupled to the second power source, the second end of the second inversion unit, and the first end of the first inversion unit. | 6 |
BACKGROUND OF THE INVENTION
This invention relates generally to a combination microwave oven and exhaust vent or ventilator appliance, and more particularly to an air flow system for the combination.
Combination microwave oven and conventional range systems are well known in the art. Many manufacturers of major appliances market such systems. One popular system is comprised of a unitary structure having a traditional electric range mounted in a lower portion and a microwave oven mounted in an upper portion. Another popular combination is that of a traditional gas or electric range adapted to accommodate a microwave generating system in the same oven cavity. More recently, a number of major appliance manufacturers have marketed a microwave oven adaptable for installation above and separate from a traditional range. These microwave ovens utilize the space formerly allocated to the range hood ventilation system, and have been modified or adapted to accommodate the functions formerly provided by the exhaust vents.
Because these combination microwave oven and exhaust vents or ventilators are designed to accomplish the purposes originally accomplished by two appliances, compromises have been made. Significant compromises have also been required in light of the limited space generally available above a range, cooktop or grille, such cooking surfaces normally being approximately 30" wide. For example, most ceilings are only 8' high with the kitchen in many homes designed to place cabinets above the lower cooking surface. Traditional vent hoods or ventilators have been designed to adapt to or coordinate with these kitchen cabinets, placing the hood far enough away from the cooking surface to allow easy access to the heating elements and the controls, yet close enough to remove the hot, frequently greasy, air rising from the lower cooking surface.
As a result of these space limitations in particular, the prior art attempts to provide for an overhead mounting of a microwave oven, or the combination of a microwave oven with a ventilator, have heretofore required compromises in the microwave oven, the ventilating system, or both. Some such compromises have resulted in smaller-than-usual microwave oven cooking cavities to allocate greater space to the ventilator portion of the system. One example will be noted in U.S. Pat. No. 4,254,450 to White et al, issued Mar. 3, 1981. Other systems have attempted to retain most of the advantages and size of a typical countertop microwave oven by reducing the air handling capability of the ventilating portion of the combination appliances.
A major design consideration for such combination appliances, particularly in view of the space limitations, is the maintenance of the separate air circulation systems that microwave ovens and ventilation hoods normally require or exhibit. Specifically, the microwave oven portion of such a system requires a quantity of air to cool the high voltage compartment. It also requires, in the case of an air driven microwave stirrer or antenna distribution system, a source of air movement to rotate the energy distribution system. Lastly, it has generally been found to be preferable in the operation of a microwave oven to circulate air past the door to remove any steam condensed thereon. This improves the visibility in the oven cavity. All of the above-mentioned requirements for air are for relatively dry, cool and clean air.
Cool, uncontaminated air is generally not what rises from the surface of a conventional range, cooktop or grille when in operation. The process of cooking, by its very nature, vaporizes quantities of water and grease, creating much of the air which a ventilation hood removes due to the heat expansion of the air. Water, for example, expands approximately 1800 times when it becomes steam. It is primarily this hot, grease-laden air that rises from the cooking surface and is exhausted by a ventilator. Hence, the operation of the ventilator portion of a combination system in removing the hot, grease-laden air rising from the cooking surface is not necessarily compatible with the microwave oven portion. The problems are compounded by the fact that the exhaust vent itself requires a certain amount of cool, dry and clean air to ensure its long life and serviceability.
SUMMARY OF THE INVENTION
The instant invention, then, is to an overall air flow system for a microwave oven and exhaust vent combination appliance for installation above a traditional range, cooktop or grille taking into consideration the air needs of the microwave oven, the air needs of the ventilator and the need to remove hot, moist and sometimes grease-laden air generated by cooking on the lower cooking surface. The air flow system is a substantial improvement over the prior art in that it accommodates the appliance's need for air, in both the microwave oven and the ventilator, while removing the undesirable and volatile by-products generated by a cooking surface therebeneath. Further, it accomplishes its goals in the space available and in a manner which allows easy cleanability and serviceability of all components and assemblies.
According to the invention, there is provided an air flow system for a combination microwave oven and ventilator appliance for installation above a conventional range, cooktop or grill which exhausts hot, grease-laden air much the same as a traditional ventilator while simultaneously providing an ambient environment substantially free of contaminates from which air can be drawn into the microwave oven.
The primary object of the invention is to provide, in a combination appliance, an air flow system which enables the functioning of the microwave oven and ventilator portions to the same capability sought in independent installations, providing both with the quality and quantity of air most desired for maximum performance.
Another object of the invention is to provide an air circulation system for such a combination appliance that maximizes the amount of air that may be exhausted from a range, cooktop or grille surface.
Another object of the invention is to minimize the movement of hot air rising from the surface of the lower cooking surface past the front of the microwave oven portion of the dual appliance.
A further object is to provide an air flow system for a combination microwave oven and exhaust vent that is readily cleaned and serviced.
Another object is to provide an air flow system for such a combination appliance that effectively increases the efficiency and useful life of the components of the appliance.
A further object is to provide the microwave oven portion of the combination appliance with a working or operating environment similar to that normally associated with a living area, that is, free of contaminated air from the underlying cooking surface, notwithstanding the close relationship thereto.
Another object is to provide a combination microwave oven and exhaust vent appliance wherein the exhaust vent portion of the appliance is adaptable to vertical or horizontal air exhaustion to accommodate alternative installations without loss of air exhaust capacity.
The objects of the invention are basically achieved by the provision of an overhead ventilator or ventilator assembly which incorporates a central support shelf or oven receiving compartment in conjunction with means for receiving contaminated air from an underlying range top, cooking surface, or the like for movement of the air to a point of discharge without affecting the operating environment of the oven itself. The ventilator assembly includes an enlarged air receiving cavity underlying the microwave oven which, through appropriately mounted filters, directly receives the air rising from the range. This air is channeled vertically to each side of the oven into a pair of laterally spaced overlying chambers which in turn communicate with a central blower chamber within which an exhaust blower is mounted for an inward drawing of the air followed by an exhausting thereof through appropriate duct work to a remote point. The contaminated air moves along paths which ensure a proper discharge of the contaminated air while providing an ambient atmosphere of clean dry air for operation of the microwave oven to the optimum, notwithstanding the combining of the microwave oven and ventilator into a single appliance and the positioning of the microwave oven in a position directly over a range top or the like.
Other objects and advantages of this invention will become apparent from the following description, the accompanying drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustrative, exploded perspective view of the combination microwave oven and ventilator appliance of the present invention.
FIG. 2 is a perspective view of the assembled appliance shown in FIG. 1 with portions broken away showing a portion of the air flow.
FIG. 3 is a perspective view of the appliance shown in FIG. 2 with the microwave oven removed and portions broken away showing another portion of the air flow.
FIG. 4 is a front view of the appliance shown in FIG. 3 attached to a soffit.
FIG. 5 is a side view of the appliance shown in FIG. 4 with portions removed and broken away to show more of the air flow.
FIG. 6 is a front view of a portion of the appliance shown in FIG. 4 with greater detailing of the related air movement.
FIG. 7 is a side view of the structure shown in FIG. 6 with portions removed.
FIG. 8 is a front perspective view of a portion of the appliance shown in FIG. 3 and FIG. 4.
FIG. 9 is a bottom or lower perspective view of the same portion of the appliance shown in FIG. 8.
FIG. 10 is a view showing how a portion of the assembly shown in FIG. 3 and FIG. 6 may be rotated to adapt to different installational requirements.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now more particularly to the drawings, wherein like numerals refer to like parts, FIG. 1 illustrates, in an exploded perspective, a combination microwave oven and ventilator appliance 10. Appliance 10 is broadly made up of a microwave oven 12 and a combination exhaust vent and microwave oven support shelf assembly 14. When installed, microwave oven 12 is slid into position in a central compartment assembly 14 and secured by suitable screws 16 through holes 18. Microwave oven 12 is supplied with current through an electrical plug 20 engaged in outlet 22 which is, in turn, connected to an external source of, for example, 120 volt, 20 ampere, alternating current. Microwave oven 12 may use any microwave circuitry and related components as well known in the art.
Installation of microwave oven 12 into assembly 14 is completed by attachment of a louvered facing panel 24. Panel 24 may contain controls 26 for operation of the range hood assembly 14. In such case, controls 26 may be suitably electrically connected for operating of the hood exhaust, in any manner well known in the art, through engagement of electrical plug 28 to outlet or socket 30. Panel 24 may be connected to assembly 14 in any number of ways well known in the art.
Microwave oven 12 is equipped with a light bulb 32 for illumination of the cooking cavity of microwave oven 12. Access to the bulb 32 may be reached through disassembly of microwave oven 12 and assembly 14 opposite to the manner in which they are assembled or through an appropriate access panel in the ventilator assembly.
Prior to the assembling of appliance 10, assembly 14 may be suitably attached to wall 36 in any appropriate manner. In FIGS. 1 and 5, assembly 14 is attached directly to wall studs 38 by channels 40. Channels 40 are first positioned on wall 36 by screws 42 engaged therethrough and into studs 38. Next, channel-mating hangers or hanger portions 44 on assembly 14 are positioned on channels 40 and removably attached to channels 40 by screws 46 for support of the assembly.
Also shown in FIG. 5 as well as FIG. 4, is an alternative installation of assembly 14 wherein the assembly 14 is attached to soffit 48. In the soffit mounting arrangement, vertical threaded rod members 50 hold assembly 14 to soffit 48 by engagement through the overhead soffit joints 52 with tee nuts 54 threaded on the upper ends of the rod members. The upper portion of assembly 14 may be suitably strengthened by the use of horizontal support members 56 to withstand the weight of assembly 14 and avoid tearing out the sheet metal in the area of vertical members 50. It is understood that there are many other ways in which appliance 10 may be attached to and supported on wall 36 or soffit 48, and the manner of attachment shown is merely illustrative.
Structural, the assembly 14 includes an enlarged, normally rectangular, housing 58 which is adapted to receive and mount the oven 12 in spaced overlying relation to a range surface or cooking grille (not shown).
The housing 58 includes a bottom panel or shelf 60 which directly receives and supports the oven, a rear panel 62 incorporating the hangers 44, opposed side panels 64, and a top panel 66.
The forward edge of the bottom panel 60 is rigidified by a full length rail 68 which receives the oven mounting screws 16. This rail 68 depends below the bottom panel or shelf 60, as do the lower edges of the rear and side panels 62 and 64, to define a shelf underlying cavity 70. An appropriate rear rail may also be provided.
A pair of conventional grease filters 72 are mounted, utilizing appropriate filter-edge receiving support and/or crossbars 74, in parallel spaced underlying relation to the support shelf 60 in order to define an air flow passage or chamber within the cavity 70 immediately above the filters.
A vertical air passing channel 76 is provided along the inner face of each of the side panels 64 and provides direct communication between the shelf underlying cavity 70, at the corresponding end thereof, and the interior of a secondary housing 78 mounted on the top panel 66. As will be appreciated from FIG. 3 in particular, the channels 76 open respectively through the bottom and top panels 60 and 66. The channels 76 are of a generally rectangular configuration with planar inner faces 80 which define side walls of a central compartment within the housing 58 wherein the oven 12 is positioned. The outer wall of each of the channels 76 will normally be defined by the adjacent housing side panel 64.
As will be appreciated from the drawings, the depth of the secondary housing 78 is substantially less than that of the housing 58 and extends transversely across the top panel 66 offset rearwardly from the front of the housing 58.
Noting FIGS. 3 and 5 in particular, it will be appreciated that the side channels 76 incline slightly rearward from the lower cavity communicating end thereof to the upper end thereof in communication with the interior of the secondary housing 78. In this manner, the channels 76 communicate centrally both with the underlying cavity 70 and the rearwardly offset secondary housing 78. Incidentally, in order to ensure a positive movement of air from the underlying cavity 70, and ensure an effective exhausting of hot, grease-laden air rising from an underlying range top, the channels 76 are preferably of a depth substantially equal to that of the shelf underlying cavity into which, through the filters 72, the air is initially drawn.
The secondary housing 78, also preferably of a rectangular configuration, includes a pair of opposed end chambers 81, each provided with an access panel 82 through the front wall of the secondary housing 78. The end chambers 80 have the upper ends of the vertical channels 76 directly communicating therewith. The blower 84 for the assembly 14 is mounted within a central chamber 86 defined between the two end chambers 80 of the secondary housing 78 by a pair of spaced side walls 88. The blower 84 comprises a pair of laterally spaced blower scrolls 90 bolted, as at 92, to the opposite end plates 94 of the outer casing 96 of a motor 98. The blower wheel 100 within each scroll 90 mounts on and is directly driven by the motor shaft 102.
The blower 84 is mounted within the secondary housing 78 by the chamber defining side walls 88. The side walls 88 are directly screwed, bolted, or otherwise affixed to the opposed outer faces of the blower scrolls 90, note, as an example, screws 104. These side walls 88, in turn, incorporate outwardly turned edge flanges 106 along two edges thereof which are screwed or bolted, as at 108, to the top panel 66 of the housing 58, this panel defining the bottom of the secondary housing 78. Noting FIG. 10 in particular, it will be appreciated that the secondary housing 78 is square in cross-section with the wall mounted blower assembly 84 being readily oriented to direct the scroll outlets 110 not only vertically, as indicated in FIGS. 1-7, but also horizontally should a particular installation require such an arrangement. FIG. 10 schematically illustrates the manner in which the blower assembly is rotated 180° about a vertical axis and 90° about a horizontal axis to position the outlets for horizontal discharge.
Access to the blower chamber 86 for servicing, removal, or reorientation of the blower 84, is achieved through an enlarged opening 112 defined through the top panel 66 immediately underlying the blower assembly 84. This opening 112 is of a size to allow passage of the blower assembly 84, including the side walls 88, vertically therethrough. The outwardly turned edge flanges 106 along the side wall edges constituting the bottom edges, this depending on the particular orientation of the blower assembly 84, will engage against the undersurface of the top panel 66 to the opposed sides of the opening. The blower assembly 84 is fixed in position by means of the previously referred to fasteners 108 engaging upward through the bottom edge flanges 106 and into or through appropriate fastener receiving apertures 114 through the aligned edge portions of the top panel 66. As will be best appreciated from FIGS. 8 and 9, in order to accommodate the outwardly turned edge flanges 106 which lie along the vertical edges of the side walls, the assembly accommodating opening 112 will be provided with corner slots 116, particularly along the forward edge thereof. It is believed the significance of the slots will be appreciated when considering FIGS. 3 and 10 in particular which best show the outward turning of the flanges 106 along both the bottom edge and forward edge of each side wall 88 in both contemplated positions of the blower assembly 84. The third and fourth edges of each of the side walls 88, for purposes of rigidity, may be inwardly turned. This will have no effect on the introduction or removal of the blower assembly through the access opening 112.
As will be readily appreciated from the drawings, the blower induced air flow is drawn inward through the blower 84 and subsequently discharged through the outlets 110 which exhaust through an appropriate damper assembly 118 which in turn discharges through conventional external duct work to the exterior.
In order to provide for the desired air flow through the blower or blower assembly 84, it will be appreciated that the blower-mounting side walls 88 are provided with central openings therein aligning with the side intakes of the blower wheels 100.
A cooling flow of air through the motor casing 96 is also desired. As such, the inner face 119 of each blower scroll 90 is provided with an enlarged shaft surrounding opening which provides for a direct communication with the openings 120 in the motor casing end plate 94. Appropriate openings or vents 122 about the body of the casing 96 will provide for introduction of the cooling air. Appropriate sealing means, such as gaskets 124, will be provided between each blower scroll and the corresponding end plate of the motor casing 96 as a means to ensure proper cooling air flow through the motor casing without leakage, and also to reduce vibration and noise by preventing direct metal-to-metal contact therebetween.
Motor cooling air is introduced to the blower compartment 86 through the access opening 112 in the underlying top panel 66 of the main housing 58. A removable shallow tray 126 is mounted to the undersurface of the top panel 66 to underlie the air passing opening 112 and extend forwardly therefrom beyond the front wall of the secondary housing 78 and in underlying relation to a series of upwardly opening air-passing louvers 128. Additional air accommodating openings 130 may be provided in the front upturned flange of the air passage forming tray 126. With the louvers, in particular, so positioned, it will be appreciated that the motor-cooling air will be drawn from a zone of uncontaminated cool air above the oven and quite remote from both the oven compartment and the air flow from the range top itself.
The tray 126 will normally be removably retained, along the vertically projecting rear flange thereof, by a slot 132 within the flange which engages over a projecting tab 134 along the corresponding rear edge of the panel opening 112. The front of the tray is affixed to the overlying panel 66 by a screw 136 engaged between the overlying top panel 66 and a laterally directed lip 138 on the vertical front flange of the tray 126. Appropriate sealing strips or gaskets 140 may be provided as needed between the tray and the overlying top panel 66. The removal nature of the air passage forming tray 126 is desirable in order to allow access to the blower for servicing, repositioning, and the like.
The manner in which assembly 84 is accessed for rotation to the alternative exhaust position or accessed for the purposes of repair or servicing is best shown in FIGS. 7, 8 and 9 in combination with FIGS. 1 and 3. Access to assembly 84 is gained by disassembly of appliance 10 including removal of panel 24 and microwave oven 12. After removal of microwave oven 12, channel 126 is dropped down as shown in FIG. 8 by removal of screw 136. Dropping down channel 126 exposes screws 108, shown in FIG. 7, which hold assembly 84 in place. Removal of screws 108 from holes 114 allows assembly 84 to drop down through opening 112 for easy rotation to a horizontal exhaust position or for servicing or repair. Note in FIG. 8 that channel 126, when attached to assembly 14 by screw 136, is further held in place by sliding tab 134 into slot 132. Channel 126 is firmly contacted to assembly 14 by the gaskets 140. This provides a good seal against air leakage from the oven compartment into the blower chamber.
By making assembly 84 directly rotatable to adapt to different installations without modification, appliance 10 exhibits the same exhaust ventilation capacity regardless of the manner of installation. This is a distinct advantage in that the same appliance will exhibit the same ventilation capacity in either a vertical or a horizontal exhaust installation. In other words, the capacity will be a function only of the static pressure exhibited by the external ductwork, not the orientation of assembly 84 in appliance 10. This adds flexibility to appliance 10 by allowing its manner of installation to be changed without a corresponding changing of the ventilation capacity. The cubic feet of air moved through the appliance 10 does not change unless the external ductwork changes.
FIGS. 3, 4 and 5 show the air movement along an air flow path through assembly which particularly relates to ventilation of a range top or the like. Hot, grease-laden air rising from an underlying range surface or cooking grille (not shown) is drawn through filters 72 into the overlying cavity 70 which actually constitutes the air intake. FIG. 5 is a side view of that shown in FIG. 4 with side panel 64 removed. The air subsequently moves through channels 76 and into blower scrolls 90 through openings in side walls 88 by motor 98. From blower scrolls 90, the air is exhausted from appliance 10 through damper assembly 118 and appropriate external ductwork not shown but well known in the art.
Cooling air movement through motor 98 and into blower scrolls 90 is shown in detail in FIG. 6 and FIG. 7 in combination with FIG. 3. The air moving along a separate air path is drawn into assembly 14 through intake louvers 128 and openings 130. The air enters tray or channel 126 and is ducted to the general area of motor 98. The air is drawn through openings 122 in outer case 96 and past windings 142 of motor 98 by the negative pressure created in blower scrolls 90 by blower wheels 100. From the motor, the air is drawn into blower scrolls 90 through openings 120 in motor end plates 94 and exhausted into damper 118 for discharge in the manner already described.
By drawing in air at a relatively high level above the lower cooking surface, motor 98 is cooled with relatively cooler, dryer and cleaner air. As a result, motor windings 142 are kept cooler and cleaner, and motor 98 operates correspondingly more efficiently. Furthermore, the introduction of cool clean air tends to maintain the blower assembly relatively uncontaminated from water, cooking fumes, odors and cooking grease.
The air flow through appliance 10 is completed by the separate microwave oven air flow system or air path shown in FIG. 2. Air is drawn in at a relatively high level intake through panel 24 remote from the hot air receiving cavity 70 and into the oven blower scroll 144. From there the air is directed through the high voltage component compartment (not shown) and through the cooling fins of the magnetron (not shown) in any number of ways well known in the art. A portion of the air may be directed through the oven cavity and past an air driven microwave stirrer or antenna (not shown) and exhausted from the oven in any manner well-known in the art. One such representative microwave oven air flow system is shown and described in U.S. Pat. No. 4,284,868 which is hereby incorporated by reference.
As already shown and described, appliance 10 is readily adaptable to a vertical or a horizontal exhaust installation. In addition, the entire system is readily cleanable and serviceable. Furthermore, by its very design, the frequency and the nature of any needs to clean or service the appliance 10 are greatly reduced. The three air flow systems that together make up the air flow system for appliance 10 are such that appliance 10 remains relatively clean. Hot, grease-laden air is drawn into appliance 10 through grease filters 72, and moved along a flow path segregated from sensitive components or the microwave oven compartment. The volatile cooking by-products, not caught by the grease filters 72, are swept up into channels 76 by the negative pressure created by blower wheels 100. The centrifuge action of wheels 100, in forcing the air against the outer walls of the scrolls, tends to cool and pressurize the air and liquefy the water and grease vapor, not caught by filters 60, within the blower housing.
As a result of the distinct air flow systems, the microwave oven 10 is provided with the coolest possible, the dryest possible and cleanest possible air for its sensitive air needs. Furthermore, the exhaust motor 98 is similarly provided with cool, dry and clean air to maximize its efficiency and simultaneously minimize the amount of grease build up in the motor windings.
In a complimentary fashion the structure of the system is designed to minimize grease build-up which occurs. This may best be appreciated in FIGS. 1, 2, 3 and 4. Noting FIG. 1, the oven bulb 32, may be reached through one of the access panels 82 into an overlying chamber provided with a similar access panel 146 in the bottom wall thereof. The same access panels 82 allow easy access to the area of blower scrolls 90 for cleaning purposes. Furthermore, removal of grease filters 72 allows access to channels 76 for cleaning purposes. Hence, the entire appliance 10 is readily accessible in the event of accumulation of a buildup of grease rising off the lower range, cooktop or grille surface.
Although the air flow system for appliance 10 has been described with respect to specific details of certain preferred embodiments, it is not intended or required that such details limit the scope of the invention otherwise set forth in the following claims. It will be apparent that various modifications and changes may be made by those skilled in the art without the parting from the spirit of the invention as expressed in the accompanying claims. Hence, all matters shown and described are intended to be interpreted as illustrative and not in a limiting sense. | A system of combining a microwave oven and ventilator over a range top or the like wherein the ventilator comprises an assembly including a central oven receiving compartment and air handling components providing for an exhausting of the range top atmosphere and a maintenance of the oven in a relatively contamination free environment. The ventilator includes a downwardly directed filter-mounting cavity underlying the oven. A pair of vertically extending air directing channels are provided to each side of the oven receiving compartment and extend vertically from communication with the underlying cavity to a pair of chambers located above the oven compartment and in direct communication with an exhaust blower positioned centrally therebetween. The exhaust blower is communicated with the ambient atmosphere above the oven compartment for introduction of cooling uncontaminated air. The microwave oven itself incorporates a separate air flow system wherein air is drawn in from the front face of the assembly at a point remote from the point of introduction of the range air into the ventilator. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to atherectomy catheters, and more specifically to atherectomy catheters having a composite tissue cutter formed with a cutter and a sensor mount.
2. Previous Art
Atherosclerosis is a condition characterized by the deposit of fatty deposits (atheromas) which adhere to the internal lining of human blood vessels. Atherosclerosis manifests itself in a variety of ways. Angina, hypertension, myocardial infarction, and strokes may result from untreated atherosclerosis.
Regions of a blood vessel blocked by atheroma, plaque, or other material are called stenotic regions. The blocking material is known as stenotic material or plaque. Stenotic material is often relatively soft and tractable. However, stenotic material can also be calcified and hard. Plaque may be harder than ordinary tissue and may firmly adhere to the walls of blood vessels and other biological conduits.
Atherectomy catheters are used to remove stenotic material from the inside of blood vessels. A typical atherectomy catheter has a distal end which inserts into a biological conduit to remove plaque. A housing with a nose cone attaches to the distal end. A cutter is enclosed in the housing. A cutter torque cable extends within the catheter and attaches to the cutter. The cutter cuts stenotic material from the inside of a blood vessel in response to movement of the cutter torque cable when the catheter is appropriately positioned.
During an atherectomy procedure, an atherectomy catheter is inserted into the femoral artery of a patient by a physician. The physician manipulates the catheter and positions the housing of the catheter adjacent a stenotic region having stenotic material within the blood vessel. The cutter is manipulated for the removal of stenotic material. The removed stenotic material is captured by the nosecone of the catheter.
Atherectomy catheters having tissue cutters have enjoyed substantial success and acceptance in the medical community. Atherectomy catheters have been most effective when used for the removal of relatively soft (e.g. non-calcified) stenotic material. The removal of hard material such as calcified plaque, however, has been more problematic. When the cutter of an atherectomy catheter encounters calcified plaque, for example, the cutting edge of the cutter becomes dull. Hardened plaque is difficult to remove with a dull cutter.
Cutters fabricated from harder materials have been developed to minimize dulling. The harder materials enable cutters to cut hardened calcified plaque without dulling or deforming. Examples of such cutters are disclosed in U.S. Pat. No. 5,507,760, issue Date, Apr. 16, 1996 to Wynne et al., entitled "Cutter Device", the disclosure of which is incorporated herein by reference.
The state of the art has advanced. The use of cutters having ultrasonic imaging sensors is now known. An example of a cutter having an ultrasonic imaging transducer is described in U.S. Pat. No. 5,000,185, Issued Mar. 3, 1991 Yock. Ultrasonic imaging sensors perform various useful functions such as safely guiding an atherectomy device through a vascular system, for example. Ultrasonic imaging sensors inspect the stenotic material to be cut and have proven to be useful when employed with devices such as atherectomy catheters.
Proper attachment of a sensor to the cutter of an atherectomy device should align the sensor with respect to the cutter and protect the sensor from damage. Attachment of the sensor is effectively accomplished by machining a portion of the cutter and attaching the sensor to the machined portion of the cutter. In this way, a firm base for attachment of the sensor is established. Machining is difficult, however, for a variety of reasons. The hardness of the atherectomy cutters in combination with the very small size of atherectomy cutters makes machining of the cutters difficult. Adapting a hard cutter to house a sensor is expensive and impractical when accomplished by common machining methods.
It is desirable to provide a device having a cutter which is capable of cutting calcified deposits without dulling. It is also desirable to provide a device which is adapted to hold a sensor which can guide the device through the vasculature of a patient.
SUMMARY OF THE INVENTION
The following objects of the invention are presented to describe the present invention by way of example only and should not be read in any way which limits the scope of the appended claims.
It is an object of this invention to provide a device having a cutter which is hard enough to cut calcified tissue.
It is an object of this invention to provide a device which is capable of aligning a cutter with a sensor to improve atherectomy procedures.
It is an object of this invention to provide a device which has a machinable portion to house a sensor and a hardened portion for cutting hardened tissue.
In accordance with the above objects and those that will be mentioned and will become apparent below, the present invention is an atherectomy device for cutting material from the inside of a biological conduit, comprising:
a catheter having a housing and a rotatable cutter torque cable, the catheter being insertable into the biological conduit, the cutter torque cable extending through the catheter to the housing;
a sensor mount having a proximal end and a distal end, the proximal end of the sensor mount being attached to the cutter torque cable and being adaptable for holding a sensor, the distal end of the sensor mount including a tapered portion, the sensor mount rotates with the cutter torque cable; and
a cutter having a proximal end, a distal end, a faded portion, and a cutting edge, the cutting edge being formed on the distal end of the cutter, the tapered portion of the sensor mount being bonded to the faded portion of the cutter, the cutter being attached to the sensor mount to rotate with the cutter torque cable,
whereby when the catheter is inserted into a biological conduit, the cutter and the sensor mount move within the housing in response to movement of the cutter torque cable to cut material from inside of the biological conduit.
In a preferred embodiment, the distal end of the sensor mount includes a tapered portion, the cutter includes a faded portion. The tapered portion of the sensor mount bonds with the faded portion of the cutter. The tapered portion of the sensor mount has external splines and an annular recess. The faded portion of the cutter has internal splines. The proximal end of the cutter has an annular lock. The annular lock and the internal splines of the cutter mechanically interlock with the annular recess and the external splines of the sensor mount respectively.
In a preferred embodiment, the proximal end of the sensor mount defines an interior which is connectable to the cutter torque cable. The proximal end of the sensor mount includes an attachment hole which enables the sensor mount to be connectable with the cutter torque cable.
In a preferred embodiment, the sensor mount is fabricated from machinable grade stainless steel and the cutter is fabricated from tungsten carbide. The cutter includes a coating to increase the hardness of the cutting edge. In a variation of this preferred embodiment, the coating is fabricated from titanium nitride.
In a preferred embodiment the cutter defines an interior having an internal ridge. The sensor mount inserts through the distal end of the cutter. The proximal end of the sensor mount contacts the interior of the cutter at the proximal end of the cutter. The distal end of the sensor mount contacts the internal ridge. Accordingly, the interior, the proximal end and the internal ridge of the cutter cooperate to hold the sensor mount and the cutter together.
In a preferred embodiment, the sensor mount includes a trough. The trough being configured having a geometry adaptable for holding a sensor. In a variation of this embodiment, the sensor mount includes an interior, the trough extends into the interior of the sensor mount. In a variation of this embodiment, the sensor mount includes a periphery. The periphery being adaptable for bonding to a sensor.
In a preferred embodiment, the cutter includes an interior and an internal seat formed with the interior. The sensor mount includes an exterior and a cap. The cap of the sensor mount contacts the proximal end of the cutter. The exterior of the sensor mount bonds to the interior of the cutter and the distal end of the sensor mount contacts the internal seat of the cutter.
In a preferred embodiment, the cutter includes an annular face, a cylindrical extension, and an externally defined annular ring. The sensor mount includes an internal annular groove. The cylindrical extension extends perpendicularly from the annular face of the cutter, the annular ring encircles a portion of the cylindrical extension, the annular ring snaps into the internal annular groove in the sensor mount to mechanically interconnect the sensor mount and the cutter.
It is an advantage of this invention to provide a cutter which includes a cutting surface hard enough to cut calcified tissue.
It is an advantage of this invention to provide a cutter which is capable of housing an imaging sensor to improve atherectomy procedures.
It is an advantage of this invention to provide a cutter which is machinable to appropriately house an sensor to improve atherectomy procedures.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further understanding of the objects and advantages of the present invention, reference is made to the following detailed description, in conjunction with the accompanying drawing, in which like parts are given like reference numerals and wherein:
FIG. 1 is a perspective view of an atherectomy catheter and a composite cutter in accordance with the present invention.
FIG. 2 is a perspective view of a cutter torque cable and the composite cutter of FIG. 1 in accordance with the present invention.
FIG. 3 is a cross-sectional view of an embodiment of the composite cutter of FIG. 2 as seen along the line 3--3.
FIG. 4 is an exploded view of a variation of the embodiment of the composite cutter of FIG. 3.
FIG. 5 is an exploded view of a variation of the embodiment of the composite cutter of FIG. 3.
FIG. 6 is a perspective view of an embodiment of the composite cutter of FIG. 2.
FIG. 7 is an exploded view of the composite cutter of FIG. 6.
FIG. 8 is a cross-sectional view of an embodiment of the composite cutter of FIG. 6 as seen along the line 8--8.
FIG. 9 is an exploded perspective view of an embodiment of the sensor mount of the composite cutter of FIG. 6.
FIG. 10 is an exploded perspective view of another embodiment of the sensor mount of the composite cutter of FIG. 6.
FIG. 11 is a perspective view of an embodiment of the composite cutter of FIG. 2.
FIG. 12 is an exploded view of the composite cutter of FIG. 11.
FIG. 13 is a cross-sectional view of an embodiment of the composite cutter of FIG. 11 as seen along the line 13--13.
FIG. 14 is an exploded perspective view of an embodiment of the sensor mount of the composite cutter of FIG. 11.
FIG. 15 is an exploded perspective view of another embodiment of the sensor mount of the composite cutter of FIG. 11.
FIG. 16 is an exploded perspective view of an embodiment of the composite cutter of FIG. 2.
FIG. 17 is an exploded side view of the composite cutter of FIG. 16.
DETAILED DESCRIPTION OF THE INVENTION
With particular reference to FIG. 1, an atherectomy catheter 102 having a cutter housing 104, a window 106, a composite cutter 100, a nose cone 110, a cutter torque cable 126 and a guide wire 108 is shown. The cutter housing 104 encloses the composite cutter 100. The window 106 of the cutter housing 104 aligns with the composite cutter 100. The nose cone 110 attaches to the cutter housing 104. The guide wire 108 extends through the atherectomy catheter and beyond the nosecone 110.
During an atherectomy, for example, the atherectomy catheter 102 is inserted into the vascular system of a patient. The window 106 invaginates material from the interior wall of a blood vessel. The composite cutter 100 reciprocates within the housing and severs the invaginated material. The severed material is stored in the nosecone 110. An example of an operable atherectomy catheter and the use thereof is disclosed by Gifford III et al. in U.S. Pat. No. 5,471,125, entitled "Atherectomy Catheter and Method of Forming the Same", the disclosure of which is incorporated herein by reference. The operation of a sensor with an atherectomy cutter is disclosed in U.S. Pat. No. 5,427,107, issued Jun. 27, 1995 to Milo et al., entitled "Optical Encoder for Catheter Device", which is commonly assigned and incorporated herein by reference.
With particular reference to FIG. 2, there is shown the cutter torque cable 126, the composite cutter 100 and the guide wire 108. The guide wire 108 extends axially through the composite cutter 100 and the cutter torque cable 126. The composite cutter 100 includes a sensor mount 130 and a cutter 140. The cutter 140 has a cutting edge 112. The composite cutter 100 aligns coaxially with and attaches to the cutter torque cable 126.
The cutting edge 112 has an arcuate shape. The cutting edge 112 is sharp, being between 5-10 microns thick. The cutting edge 112 has a hardness relatively greater than the hardness of the sensor mount 130. A cutting edge 112 having a Rockwell "A" hardness of 90, or harder is preferred because such an edge is hard enough to cut calcified plaque from a biological conduit. In an embodiment of the present invention, the sensor mount 130 is fabricated from a machinable grade of stainless steel and the cutting edge 112 is fabricated from tungsten carbide.
The cutting edge 112 can be of various shapes and configurations. For example, the cutting edge 112 can be configured having cutting surfaces of types described in co-pending in U.S. Pat. No. 5,507,760, Issue Date, Apr. 16, 1996 to Wynne et al., entitled "Cutter Device"which is commonly assigned and incorporated herein by reference.
The composite cutter 100 is generally cylindrical in shape. The composite cutter 100 includes a middle portion 105 which is relatively narrower than the remainder of the composite cutter 100.
When the atherectomy 102 (see FIG. 1) inserts into a biological conduit (e.g. a blood vessel) and window 106 aligns adjacent to stenotic material, an operator manipulates the cutter torque cable 126 to reciprocate the composite cutter 100. A motor drive unit (not shown) rotates the cutter torque cable 126. The composite cutter 100 and cutter torque cable 126 are designed to rotate within the range of 1500-2500 revolutions per minute (RPM). When the cutter torque cable 126 rotates and advances, the composite cutter 100 rotates and advances to cut tissue which extends into the cutter housing 104 via the window 106. An example of a cutter torque cable 126 is described in copending U.S. patent application Ser. No. 08/606,678, filed Feb. 26, 1996 entitled "Flexible Composite Drive Shaft for Transmitting Torque" by Milo, et al., Attorney Docket No. DEVI1434CON, which is a file wrapper continuation of U.S. patent application Ser. No. 08/165,058, filed Dec. 9, 1993, entitled "Composite Drive Shaft" by Milo, et al. which is commonly assigned and incorporated herein by reference.
With particular reference to FIG. 3, there is shown an embodiment of the composite cutter 100 of FIG. 2. The sensor mount 130 has a proximal end 132, a distal end 134, an interior 142 and a tapered portion 135. The cutter 140 has a proximal end 139, a distal end 138 having a cutting edge 112, an interior surface 162, and a faded portion 137.
The proximal end 132 of the sensor mount 130 is attachable to a cutter torque cable (see FIG. 2). The tapered portion 135 of the sensor mount 130 connects with the faded portion 137 of the cutter 140. Tapered, for the purposes of the present invention, means a male connector having an end with a narrow diameter which slopes to a relatively wider diameter, the tapered slope being constant. Faded, for the purposes of the present invention means a female connector having an open mouth with an end having a wide diameter which slopes to a relatively narrower inner diameter, the faded slope being constant.
The tapered portion 135 of the sensor mount 130 mechanically interlocks (i.e. forms a mechanical force-fit) with the faded portion 137 of the cutter 140. The cutter 140 and the sensor mount 130 interconnect in coaxial alignment. The interconnection between the sensor mount 130 and cutter 140 is reinforced by any of a number of interconnection techniques (processes) such as brazing, welding, soldering or adhesive bonding. The interconnection between the sensor mount 130 and the cutter 140 protects, aligns and holds the sensor 164 relative to the cutter 140 during operation of the composite cutter.
With particular reference to FIG. 4, there is shown an exploded side view of the composite cutter 100 depicted in FIG. 3. The sensor mount 130 and the cutter 140 join together in the direction of the arrow 113. The proximal end 132 of the sensor mount 130 has an attachment hole 156. The attachment hole 156 facilitates the selected process which interconnects the sensor mount 130 and the cutter torque cable 126 e.g. soldering, brazing, or welding. The sensor 164 is positioned within the interior 142 of the sensor mount 130. The sensor 164 attaches to the interior 142 by adhesive bonding for example. An opening 154 is defined on the surface 152 of the middle portion 105 of the composite cutter 100. The opening 154 is circular in shape. The sensor 164 is circular in shape and fits within the opening 154. The opening 154 is defined on the sensor mount 130 and permits sensory communication between the sensor 164 and the environment which surrounds the composite cutter 100.
With particular reference to FIG. 5, a variation of the embodiment of the composite cutter 100 illustrated in FIG. 4 is shown. The tapered portion 135 of the sensor mount 130 is formed with at least one external spline 117. The faded portion 137 of the cutter 140 is formed with at least one internal spline 115. The internal spline 115 and the external spline 117 mechanically interlock.
When internal spline 115 and the external spline 117 mechanically interlock, the cutter 140 and the sensor mount 130 align coaxially. The sensor mount 130 includes an annular recess 119 which circumscribes the external spline 117. The proximal end 139 of the cutter 140 includes an annular lock 121. The annular lock 121 snaps into the annular recess 119.
With particular reference to FIG. 6, an embodiment of the composite cutter 100 is shown. A portion of the proximal end 139 of the cutter 140 and the sensor mount 130 are cut away to show an opening 160 which is defined by the proximal end 139. The opening 160 is adaptable for receiving, and bonding to, the cutter torque cable 126 (see FIG. 2).
The cutter 140 is machined to form an opening 154 having a periphery 137. The opening 154 permits communication between the sensor 164 (see FIG. 9 and FIG. 10) and the environment surrounding the cutter 140. When the sensor 164 attaches with the sensor mount 130, the sensor mount 130 and the cutter 140 cooperate to protect the sensor 164 from damage, hold the sensor 164, and align the sensor 164 relative to the cutting edge 112 of the cutter 140.
With particular reference to FIG. 7, there is shown an exploded view of the composite cutter 100 of FIG. 6. An arrow 109 indicates that the sensor mount 130 inserts into the cutter 140 via the distal end 138 where the cutting edge 112 is situated.
The proximal end 139 of the cutter 140 has a rounded edge 158. The rounded edge 158 permits the cutter 140 to slide against biological tissue which may enter the cutter housing 104 during use of the atherectomy catheter 102 (see FIG. 1).
With particular reference to FIG. 8, there is shown a cross-section of the composite cutter 100 of FIG. 6. The cutter 140 includes a proximal end 139, an interior surface 162, a distal end 138 and a ridge 172. The sensor mount 130 includes a proximal end 132, a distal end 134, and an interior 142. The sensor mount 130 attaches coaxially within the cutter 130. The interior 142 of the sensor mount 130 is cylindrical shaped, being configured for circumscribing the cutter torque cable 126 and being adaptable for attachment to the cutter torque cable 126.
The ridge 172 is formed on the interior surface 162 of the cutter 140 near the distal end 138 of the cutter 140. The ridge 172 contacts the distal end 134 of the sensor mount 130. The proximal end 139 of the cutter 140 contacts the proximal end 132 of the sensor mount 130. The ridge 172 and the proximal end 139 of the cutter 140 cooperate with the distal end 134 and the proximal end 132 of the sensor mount 130 respectively to hold the cutter 140 and the sensor mount 130 together. The outer surface 152 of the sensor mount 130 bonds to the interior surface 162 of the cutter 140.
With reference to both FIG. 9 and FIG. 10, variations of the sensor mount 130 are shown having a sensor 164. Each sensor mount 130 has a support 136. Each support 136 is machined into the exterior surface of the sensor mount 130. The sensor 164 is attachable with each support 136 by an adhesive bond. The support 136 is appropriately configured, having a rectangular shape, to coincide with the shape of sensor 164. The sensor 164 and the sensor mount 130 are sealed in a cover (not shown) such as a plastic wrap to protect the sensor 164 during use.
The sensor 164 communicates with an operator electronically via a wire 170 (partially shown) included with the sensor 164. The wire 170 extends from the sensor 164, through the opening 160 (see FIG. 6) and along the atherectomy catheter 102 (see FIG. 1) to appropriate signal processing equipment.
With particular reference to FIG. 9, an embodiment of sensor mount 130 is shown where the support 136 is a trough which cuts through the surface 152 into the interior 142 of the sensor mount 130. The sensor includes a periphery 184 and sides 182. Edges 168 of the support 136 hold the sensor 164 and bond to the sensor 164 at appropriate regions such as the side 182 and periphery 184 of the sensor 164. The proximal end 132 of the sensor housing 130 is rounded to conform in shape to the inner surface 162 of the cutter 140 (see FIG. 8).
With particular reference to FIG. 10, there is shown a variation of an embodiment of sensor mount 130 of FIG. 9 where the support 136 is a trough formed on the surface 152 of sensor mount 130. The support 136 includes a flat portion 186. The sensor 164 bonds with the flat portion 186 of the support 136.
With particular reference to FIG. 11 an embodiment of the composite cutter 100 of FIG. 2 is shown. The sensor mount 130 attaches within the cutter 140. A portion of the sensor mount 130 and the proximal end 139 of the cutter 140 are cut away to show the hole 160. The hole 160 is formed through the proximal end 139 of the cutter for circumscribing the cutter torque cable 126 when the cutter 140 bonds with the cutter torque cable 126. The cutter 140 defines a hole 154 having a periphery 137.
With particular reference to FIG. 12, there is shown an exploded side view of the composite cutter 100 of FIG. 11. An arrow 111 indicates that the sensor mount 130 inserts into the cutter 140 via proximal end 139 of the cutter 140. A portion of the surface 152 of the sensor mount 130 is machined to form the support 136. The opening 154 is defined in the cutter 140. When the sensor mount 130 attaches to the interior surface 162 of the cutter 140, the opening 154 permits communication between the sensor 164 (shown in FIG. 14 and FIG. 15) and the environment which surrounds the composite cutter 100.
With particular reference to FIG. 13, there is shown a cross-section of an embodiment of the composite cutter 100 of FIG. 11. The cutter 140 has a proximal end 139, an interior surface 162 having a seat 178, and a distal end 138. The sensor mount 130 includes a surface 152 and a cap 175 formed with a rounded edge 174 and an annular shoulder 176. The cap 175 is affixed at the proximal end 132 of the sensor mount 130. The surface 152 of the sensor mount bonds with the interior surface 162 of the cutter 140. The cap 175 of the sensor mount 130 contacts the proximal end 139 of the cutter 140. The distal end 138 of the sensor mount 130 contacts the seat 178. The seat 178 has an arcuate geometry which meets securely with the distal end 138. The interior surface 162, the proximal end 130, and the seat 178 of the cutter 140 cooperate to hold the sensor mount 130.
With reference to both FIG. 14 and FIG. 15, sensor mount 130 is shown having a sensor 164 positioned adjacent the support 136. The support 136 is adaptable to conform with the shape of the sensor 164 (i.e. includes a geometry capable of holding the sensor 164). Both the support 136 and the sensor 164 are rectangular shaped and are adhesively bonded together. The sensor 164 communicates with an operator electronically via a wire 170 included with sensor 164. The wire 170 extends from sensor 164, along a conduit 180 formed through cap 175 and out through the atherectomy catheter 102 to electrically communicate with a sensor system (not shown).
With particular reference to FIG. 14, the sensor mount 130 of FIG. 13 is shown. The support 136 is a trough formed in the surface 152 of sensor mount 130. The sensor 164 bonds to the flat portion 186 of the support 136.
With particular reference to FIG. 15, a variation of the embodiment of sensor mount 130 of FIG. 14 is shown. The support 136 is a trough which cuts into the interior 142 of sensor mount 130. The edges 168 hold the sensor 164 in place and provide a bonding surface. More particularly, the edges 168 bond to appropriate regions of the sensor 164 such as the side 182 and periphery 184.
With particular reference to FIG. 16, an embodiment of the composite cutter 100 of FIG. 1 is shown. The cutter 140 includes an annular face 188, a cylindrical extension 190, an annular ring 192 and a guide 196. The cylindrical extension 190 extends perpendicularly from the annular face 188 of the cutter 140. The annular ring 192 circumscribes the cylindrical extension 190. The cylindrical extension 190 is adaptable to circumscribe and bond with the cutter torque cable 126.
The sensor mount 130 includes an internal annular groove 194. The annular ring 192 of the cylindrical extension 190 snaps into the internal annular groove 194 in the sensor mount 130 to mechanically interconnect the sensor mount 130 and the cutter 140.
The sensor mount 130 is fabricated from a plastic and attaches to the cutter torque cable 126 via heat bonding. In a preferred embodiment, the sensor mount is fabricated from a material selected from the following group: poly-carbonate and poly-propylene.
The cylindrical extension 190 extends perpendicularly from annular face 188 of the cutter 140. The cylindrical extension 190 attaches with the sensor mount 130 and includes a hollow interior for receiving and bonding with the cutter torque cable 126.
The cylindrical extension 190 includes a guide 196. The guide 196 includes a triangular cross-section which extends between the annular face 188 and the cylindrical extension 190. The guide 196 contacts with the edge 198 of the opening 154 and aligns the sensor mount 130 into a desired position with the cutter 140. During operation, the guide 196 contacts the sensor mount 130 so that the sensor mount 130 and the cutter 140 rotate together. The guide 196 may include a reflective coating to reflect ultrasonic energy radiated by the sensor 164.
The sensor 164 is shown between the cutter 140 and the sensor mount 130. Communication between the sensor 164 and the environment surrounding the composite cutter is established via the opening 154. Electronic communication is established between the sensor 164 and a sensor system via the wire 170 (shown in part) which passes through the sensor mount 130, the opening 160 and through the atherectomy catheter 102 (see FIG. 1).
The cutter 140 has an edge 199 and the sensor mount 130 has an edge 198. When the cutter 140 and the sensor mount 130 attach, the edges 198 and the edge 199 conform to the shape of the sensor 164. The edge 198 and the edge 199 are configured to hold the sensor 164. The sensor 164 adhesively bonds to the edge 198 and to the edge 199. An arrow 115 indicates the direction in which the sensor mount 130 mates with the cutter 140.
Numerous methods of bonding the sensor mount 130 to the cutter 140 exist. In one variation of an embodiment of the present invention, the sensor mount 130 attaches to the cutter 140 via injection molding. In another variation, the sensor mount 130 bonds to the support 136 adhesively.
Numerous methods of bonding the composite cutter 100 to the cutter torque cable 126 exist. Each method of bonding depends on the geometry and the material to be bonded. For example, a bonding method may first be chosen for the cutter 140 and the sensor mount 130 which is based on the material composition of the parts to be joined. The sensor mount 130 and the cutter 140 are then configured having an appropriate geometry, suitable for the chosen bonding method in accordance with industry standards and practical cost constraints. With any geometry, however, precise alignment between the sensor mount 130 and the cutter 140 is desirable.
The sensor mount 130 is fabricated from a machinable or conformable material which is adaptable to provide an appropriate support 136 for a sensor, or a sensor system for example. The cutter 140 is fabricated from a material of an appropriate hardness to resist deformation such as dulling. Materials such as diamond, cubic boron nitride and other materials could be used to form portions of the cutter such as the cutting edge 112. An appropriate coating can be applied to the composite cutter 100, or portions thereof, for increased bio-compatibility or wear resistance, for example. In a preferred embodiment, the cutter 140 has a coating of titanium nitride.
With particular reference to FIG. 17, an exploded view of the composite cutter 100 of FIG. 16 is shown. An arrow 113 indicates the direction in which the sensor mount 130 connects with the cutter 140 via proximal end 139. A portion of the surface 152 of the sensor mount 130 is machined to form the support 136 which includes the opening 154.
Examples of the sensor 164 and the atherectomy catheter 102 are described in U.S. Pat. No. 5,429,136, Issue date Jul. 4, 1995, entitled "Imaging Atherectomy Apparatus" by Milo et al which is assigned to the assignee of the present invention and which is incorporated herein by reference.
Although the sensor 164 is shown having a rectangular shape, a variety of shapes can be accommodated by the present inventive concept. For example, the support 136 can be adapted to coincide with the shape of a square, or circular shaped sensor. The support can be formed within the cutter 140, on the sensor mount 130, or any other suitable alternative which holds the sensor 164 and permits communication between the sensor 164 and the environment.
A sensor capable of generating and communicating a description of the interior of a blood vessel is employed by the present invention. The sensor 164 is an ultrasonic transducer which is capable of determining the density of surrounding tissues during operation of the present invention. The sensor 164 communicates with an operator by the wire 170 which may be wrapped about the surface 152 of the sensor mount and securely held by, for example, a plastic wrap, or an adhesive. The wire 170 extends through the atherectomy catheter 102 to establish electronic communication with an operator.
The foregoing detailed description has described the composite cutter 100 in terms of various embodiments. It is to be understood that the above description is illustrative only, and does limit the scope of disclosed invention. Particularly, the specific details of the cutting edge can differ from those illustrated and described so long as the cutting is enabled. It will be appreciated that the shape and situs of the support 136 which holds the sensor 164 can differ from that disclosed so long as the sensor communicates with the environment surrounding the composite cutter 100. The shape of the composite cutter 100 can vary. Although specific details of the present invention are disclosed as above, the scope of the present inventive concept is to be limited only by the claims set forth below. | An athetectomy catheter is disclosed having a composite cutter which is capable of cutting material, including hardened plaque, from a biological conduit. The composite cutter has a cutter and a sensor mount. The cutter has a proximal end and a distal end with a cutting edge. The proximal end of the cutter bonds with the sensor mount. The sensor mount is adaptable for holding a sensor and attaching to a cutter torque cable of an atherectomy catheter. Typically, the atherectomy catheter has a cutter housing with a window. The composite cutter is positioned in the cutter housing and moves in response to movement of the cutter torque cable to cut material from the biological conduit via the window. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application No. 60/789,170, filed Apr. 4, 2006, the entire disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates generally to a process for preparing a polyethylene terephthalate for use in food-grade and other containers. More particularly, the invention is directed to a process for treating recycled polyethylene terephthalate and combining the recycled polyethylene terephthalate with virgin polyethylene terephthalate.
BACKGROUND OF THE INVENTION
[0003] Polyethylene terephthalate resin (PET) is widely used in the production of containers for carbonated soft drink (CSD), food-grade containers, and other packages. Post-consumer PET is widely processed into useful products. The recycling process commences with the collection of PET containers, such as carbonated soft drink bottles, which are then sorted, washed, and separated to yield a clean, mostly pure source of material known as recycled polyethylene terephthalate (RPET). RPET is most typically in “granular” or “flake” form, and is either melt-processed by an end user, or is further converted by pelletizing and solid-stating.
[0004] Production of PET packaging, and in particular CSD bottles, typically requires PET having an intrinsic viscosity (IV) within a certain range of values. The IV of CSD bottle-grade PET must be in the certain range of values or the physical properties of the bottles will suffer. Typically, bottle-grade PET resin immediately following an initial esterification of polycondensation monomers, the resin also known as early-stage PET, has an IV substantially lower than desired. Conventional monomers include ethylene glycol (EG) and purified terepthalic acid (PTA). One or more polycondensation reactions are generally required to increase the IV of the early-stage PET to near-acceptable levels.
[0005] In order to achieve the desired IV for PET containers, it is known in the art to solid-state the resin. Solid-stating is a process by which PET resin, in an amorphous precursor pellet form (the solid state, as opposed to the melted state), is subjected to a suitably high temperature, generally a temperature just below a melting temperature of the PET resin, in the absence of oxygen. Since PET is a poly-condensation polymer, the solid-stating will, over time, build the mean molecular weight of the resin though transesterification, and result in an increase in the measured IV.
[0006] Typically, the amorphous precursor includes either or both virgin polyethylene terephthalate (VPET) and RPET pellets, prepared by esterification and subsequent polycondensation reaction processes known in the art. However, these known processes are time-consuming and expensive.
[0007] It is desirable to prepare a PET composition including RPET treated in a manner that accelerates PET polycondensation and solid-stating, the PET composition suitable for use in the preparation of PET articles.
SUMMARY OF THE INVENTION
[0008] In concordance with the instant disclosure, a process for treating RPET for accelerated PET processing, and a process for preparing a PET composition suitable for use in the preparation of PET articles, has surprisingly been discovered.
[0009] In one embodiment, a process for preparing a PET composition includes the steps of: providing an early stage VPET and an RPET; comminuting the RPET; and blending the RPET and the early stage VPET to form the VPET/RPET blend. The RPET is introduced prior to a polycondensation reaction.
[0010] In a further embodiment, a process for preparing a PET composition includes the steps of: comminuting a quantity of RPET flakes to form RPET particles having an average particle size between about 0.01 mm and about 2.5 mm in diameter; adding the comminuted RPET to an early stage VPET before a polycondensation reaction process, wherein contaminants are caused to diffuse out of the comminuted RPET; and solid-stating the VPET/RPET blend. The PET composition is thereby formed.
[0011] In another embodiment, a process for preparing a PET composition includes the steps of: providing an early stage VPET having an intrinsic viscosity between about 0.01 and about 0.03; providing an RPET having an intrinsic viscosity between about 0.8 and about 0.95; comminuting the RPET to form RPET particles having an average particle size between about 0.01 mm and about 2.5 mm in diameter; decontaminating the RPET particles; melting the decontaminated RPET particles; blending the RPET melt and the early stage VPET to form the VPET/RPET blend, wherein the intrinsic viscosity of the VPET/RPET blend is greater than the intrinsic viscosity of the VPET melt; conducting at least one polycondensation reaction adapted to increase the intrinsic viscosity of the VPET/RPET blend; and solid-stating the VPET/RPET blend to form the PET composition having an intrinsic viscosity between about 0.72 dg/L and about 0.84 dg/L.
[0012] The processes of the present disclosure are particularly useful for treating RPET for subsequent use in the preparation of food-grade and other containers.
DETAILED DESCRIPTION
[0013] The term “RPET flakes” as it is used herein means, generally, the commercially available recycled polyethylene terephthalate materials produced by conventional PET recycling methods. It should be understood that RPET flakes are usually supplied in flake form, but may additionally be in the form of chunks, spheres, pellets, and the like. As nonlimiting examples, RPET flakes are generally made available in bulk in a substantially uniform particle size from about ¼ inch to about ½ inch, although other sizes may also be suitable. RPET flakes may also be provided in bulk not having a substantially uniform particle size. Suitable recycled polyethylene terephthalate materials may include conventional recycled PET homopolymers and modified-PET copolymers as are known in the art.
[0014] As a nonlimiting example, a single ⅜ inch RPET flake typically exhibits a surface to volume ratio of about 177. Contaminants which have penetrated the RPET flake matrix diffuse out at the surface of the RPET flake. Contaminants which have diffused far into the RPET flake matrix generally cannot diffuse out of the flake between the time the RPET flake is produced in the conventional recycling process and the time the RPET flake is utilized in a melt processing operation for producing a new PET article.
[0015] According to the present invention, RPET flakes are comminuted by any conventional means to prepare a quantity of finely divided RPET particles having an average mean particle size from about 0.0005 inch (about 0.01 mm) to about 0.1 inch (about 2.5 mm) in diameter. In particular embodiments, the particle size ranges from about 0.005 inch to about 0.05 inch. One of ordinary skill should understand that the comminuting results in a substantial reduction in the size of the individual RPET flakes, and thereby a substantial increase in total surface area of the RPET, enabling contaminants to be driven out in a rapid and efficient manner. For example, a particle of RPET having a radius of about 0.058 inch (about 1.5 mm) and a concentration of benzene of about 25,000 ppm typically requires over 96 hours of diffusion time at 70° C. for the level of benzene to fall to a concentration of about 0.25 ppm. By way of contrast, it has been discovered that a particle of RPET having a radius of about 0.00876 inch (about 0.2 mm) requires less than about 3 hours to reach the same 0.25 ppm concentration level, all other parameters being substantially equal.
[0016] Thus, RPET flakes may be decontaminated by the process of the present disclosure. It should be understood that the decontamination process includes the step of particle size reduction, without the need for elaborate or exotic means such as twin-screw compounding, vacuum extraction, or lengthy residence times such as are taught in the prior art.
[0017] In one embodiment of the present disclosure, following comminution of the RPET flakes, the resultant RPET particles are treated to decontaminate the RPET. The treatment causes contaminants to diffuse out at the surfaces of the RPET particles. The treatment may further cause an increase in the intrinsic viscosity of the RPET particles to a level greater than 0.8 dg/L. The increase in the intrinsic viscosity is accomplished merely by air drying the RPET particles, for example, by passing a stream of a gas, preferably air, over and through the particles at an elevated temperature.
[0018] The time required to achieve the substantial elimination of contaminants from the RPET particles is much less than the time that otherwise would be required to achieve the same elimination of contaminants from an equal mass of RPET flakes, utilizing the same conditions. A skilled artisan should appreciate that suitable conditions for decontamination of the RPET may be selected as desired. It should be further appreciated that the RPET may be decontaminated to a point where it is substantially free of contaminants, or to a point where a level of contamination remaining in the RPET is at an acceptable level.
[0019] In another embodiment, the comminuted RPET is simply allowed to reside in bulk at an elevated temperature until the contaminants have diffused out of the particles. The RPET particles may be further heated in a conventional manner which will accelerate the diffusion of the contaminants out from the particles. Also, the RPET particles may be placed in a heated liquid solution that can leach the contaminants out from the particles. These, as well as other conventional methods may be used to drive the contaminants out from the RPET particles. However, in each case, the time required will be substantially less than would otherwise be required to effect the same level of decontamination upon an equal mass of RPET flakes.
[0020] In a further embodiment, the comminuted RPET is introduced as finely divided particles into an early stage VPET as described herein. At the temperature associated with an early stage VPET, the diffusion of the contaminants from the RPET particles is accelerated, and the finely divided RPET particles melt readily to provide a substantially homogenous VPET/RPET blend. The contaminants therefore leach out of the particles and are removed from the VPET/RPET blend via conventional processes associated with polycondensation reactors known in the art.
[0021] In an alternative embodiment, the RPET is first decontaminated and then introduced into a VPET manufacturing process to form an VPET/RPET blend. The VPET/RPET blend may act, with or without further processing, as an amorphous precursor to solid-stating. According to one embodiment of the present invention, the treated RPET is added to the early stage VPET at a point following the initial VPET esterification and before any VPET polycondensation reaction, wherein the VPET polycondensation reaction is adapted to increase the IV of the VPET.
[0022] In a further embodiment, the treated RPET is added to the early stage VPET at a point following the initial VPET esterification and before a solid-stating operation.
[0023] One of ordinary skill in the art should understand that, during the initial stages of conventional VPET esterification, the intrinsic viscosity of the early stage VPET is very low; typically between about 0.01 and 0.03 dg/L. Having such a low intrinsic viscosity, it should further be understood that early stage VPET is in a liquid or melt form at conventional operating temperatures. The early stage VPET is generally processed through at least one additional polycondensation reaction designed to increase IV and remove water, excess reactants, and other contaminants. By the time the conventional VPET exits the final polycondensation reactor stage, it typically exhibits a maximum intrinsic viscosity of about 0.6 dg/L. The treated RPET may be introduced into the VPET melt by conventional means. For example, the treated RPET particles may be melted in an extruder, and introduced directly into the VPET melt.
[0024] As nonlimiting examples, the introduction of RPET having an intrinsic viscosity greater than about 0.8 dg/L into the conventional VPET manufacturing process provides at least two advantages. Firstly, the conventional VPET producer reduces the cost of product by the introduction of less expensive RPET into the final PET product. Secondly, since transesterification occurs rapidly in the melt, the intrinsic viscosity of the VPET rises significantly prior to the final polycondensation reactor stage.
[0025] The aforementioned advantages provide a manufacturer of PET compositions with a number of desirable options. As a result of the process of the present invention, the manufacturer may opt to produce a solid-stating amorphous precursor having a desirably high intrinsic viscosity. Alternatively, the manufacturer may opt to lower a temperature of one or more polycondensation reactor stages adapted to increase the intrinsic viscosity of the early stage VPET, and still produce a solid-state precursor having the desirable intrinsic viscosity. Further, the manufacture may opt to increase a throughput of the system while maintaining the same precursor intrinsic viscosity.
[0026] In a further illustrative embodiment, the VPET/RPET blend is solid-stated to form the final PET composition. Solid-stating is a process whereby the intrinsic viscosity of the PET composition is raised by transesterification. Intrinsic viscosity is an important physical characteristic which in large part determines the ultimate strength of the final PET article, for example, a bottle or food-grade container produced from the PET. A bottle or container produced from PET, having a low intrinsic viscosity, will not perform as well as a bottle or container made from a high intrinsic viscosity PET. A typically desired IV range for bottle-grade PET is from about 0.72 to about 0.84 dg/L.
[0027] PET, unlike most other polymers, has the ability to be “put back together” in the solid-stating process, which raises the intrinsic viscosity up to an acceptable level. Solid-stating occurs at high temperatures, often just below the melting point of the polymer. The solid-stating process typically employs a dry gas stream flowing through the bed of polymer particles. The gas stream often is an inert gas, such as nitrogen. In some embodiments, the solid-stating process is carried out under a vacuum. Solid-stating depends on diffusion mechanics to remove by-products of the transesterification process, and thermal dynamics to raise the temperature of the PET.
[0028] The processes for treating RPET for accelerated PET processing, as described hereinabove, are generally disclosed in terms of their broadest application to the practice of the present invention. Occasionally, the process conditions as described may not be precisely applicable to each VPET/RPET combination included within the disclosed scope. Those instances where this occurs, however, will be readily recognized by those ordinarily skilled in the art. In all such cases, the process may be successfully performed by conventional modifications to the disclosed method.
[0029] The present invention is more easily comprehended by reference to specific embodiments recited hereinabove which are representative of the invention. It must be understood, however, that the specific embodiments are provided only for the purpose of illustration, and that the invention may be practiced otherwise than as specifically illustrated without departing from its spirit and scope. | A process for preparing a PET composition is provided. The process includes the steps of: providing an early stage VPET and an RPET; comminuting the RPET; and blending the RPET and the early stage VPET to form a VPET/RPET blend, wherein the blending occurs prior to a polycondensation reaction. A process is also described that includes the step of: adding the comminuted RPET to the early stage VPET before a polycondensation reaction process, wherein contaminants are caused to diffuse out of the comminuted RPET. In a further process, the comminuted RPET is decontaminated in a step separate from the blending to form the VPET/RPET blend. | 2 |
TECHNICAL FIELD
[0001] This disclosure relates to combustion cycles for recirculating noble gas combustion power cycles and to systems including engines operating with the disclosed combustion cycles.
BACKGROUND
[0002] Power conversion cycles turning fuel into heat and heat into power are limited by basic thermodynamic considerations that have an effect on the efficiency of these conversion cycles. For example, gas turbines approach efficiencies of 35%, large bore internal combustion engines reach efficiencies of 50%, fuel cells reach efficiencies of 55%, and combined power plants, for example a combination of a Brayton cycle and a Rankine bottoming cycle that benefits from the waste heat of a gas turbine, approach efficiencies of 60%.
[0003] The efficiency of the gas power cycles used in for example turbines and engines is limited by the specific heat ratio of the working fluid. For economic and practical reasons, combustion cycles generally use ambient air to provide both the oxidizer and working fluid. Power cycles have been developed that uses a monoatomic gas in place of air as the working fluid. The power cycles can have a greater thermal efficiency than similar cycles using air because the specific heat ratio of air, 1.4, is less than the specific heat ratios of monoatomic gases, for example the specific heat ratio of Argon is 1.66. Based on the specific heat ratios, the use of a monoatomic gas may increase cycle efficiency by a factor of 1.3-1.4 compared to similar cycles using air. Further, engines running on cycles with a monoatomic gas working fluid may reuse exhausted working fluid by recirculating it back to the inlet of the engine.
[0004] Using hydrogen to generate power is being explored in applications including gas turbines, internal combustion engines, and fuel cells. Hydrogen combustion in gas turbines produces nitric oxide emissions, and is limited in efficiency and temperature by the material strength of the turbines to that of current power plants. Fuel cells have the disadvantage of being very expensive. Internal combustion engines running cycles including recirculating monoatomic gas working fluids have been made to utilize hydrogen, hydrocarbons, or oxigenates as a fuel and oxygen as an oxidizer. In the case of hydrogen as a fuel and oxygen as an oxidizer the resulting byproduct is water. This water may be removed easily from the recirculating working fluid. These recirculating monoatomic gas cycles have previously not been seriously considered because burning in air is inexpensive and convenient.
[0005] Methods of storing energy prior to using the energy is a growing field, particularly relating to efficiently utilizing the stored energy. Methods for electrical energy storage are various and include batteries, pumped hydro, flywheels, hydrogen energy storage, and compressed air energy storage. One area of energy storage that is being developed is load-leveling' energy storage that can shift power over hours or days. Technologies for load leveling energy storage include batteries, hydrogen energy storage, and compressed air energy storage. Batteries have high round-trip efficiencies but are cost-prohibitive for load-leveling energy storage. Compressed air energy storage has poor efficiency and poor energy density.
[0006] It is therefore desirable to provide technology for using stored energy that is inexpensive, has high energy density, is efficient, and is environmentally friendly. It is further desirable to provide methods to efficiently utilize carbonaceous fuels and produce pure carbon dioxide which may be utilized or sequestered. As such, it is desirable to provide technology for a high-efficiency combustion power cycle that is well adapted to carbon capture with low energy cost.
SUMMARY
[0007] The present technology provides embodiments of recirculating noble gas combustion power cycles and systems including engines utilizing these power cycles. Embodiments of the cycles may include a combination of a high intake/exhaust pressure, very late or early intake valve closure, late exhaust valve opening, intake preheating using exhaust gases, sensible heat recovery, direct injection of fuel and/or oxidizer, a condenser to remove combustion products and dissolved trace contaminant gases, and a carbon dioxide separation unit if carbonaceous fuels are to be used. An engine operating on these principles could provide motive force for electrical production, for example at power plants, or for transit, for example for ship engines. An engine operating with the cycles disclosed herein has high thermal efficiency and low cost. For example an argon power cycle using natural gas fuel and cryogenic oxygen air separation could reach 60% overall efficiency.
[0008] The cycles disclosed herein can be incorporated into new engine designs. Further, existing engines may be reconfigured to operate with the technology disclosed herein. In embodiments, engines operating with the disclosed recirculating noble gas combustion power cycles include features which allow the engine to also run open-looped using ambient air and direct-injected fuel (e.g. natural gas) as an alternative to the closed loop monoatomic gas recirculating, pure hydrogen and pure oxygen burning operation mode.
[0009] Embodiments of the recirculating noble gas combustion power cycles disclosed may include high-quality exhaust heat that energy is extracted from. For example, high-quality exhaust heat is supplied to a steam reforming process, or to a Rankine-type or similar “bottoming” cycle. In embodiments, the quality of the exhaust heat can be increased by preheating of the intake fluid by heat exchange, through use of a heat exchanger, with exhaust fluid.
[0010] Embodiments of the technology may include various injection methods including direct injection of both fuel and oxygen, e.g. for energy storage application, or oxygen or fuel alone, e.g. for applications where fuel and/or oxygen are not stored at high pressure.
[0011] Embodiments of the technology may include various valve timing schemes. The valve timing schemes may reduce the effective volume ratio of compression stroke, and the peak pressure and temperature can be limited. Due to the high specific heat ratio of the argon working fluid, embodiments may include very late intake valve closure in the valve timing scheme. This large ratio of expansion stroke to compression stroke affords higher thermal efficiencies and limits peak pressure and temperature within the engine.
[0012] Late intake valve closure may result in power loss which in embodiment may be offset by increasing the cycle pressure, i.e. ‘boosting’, to increase the charge density and regain this power loss. The increased cycle pressure is above the ambient pressure. Boosting also assists in reducing recirculating water content. Boosting the cycle working pressure by large amounts, for example 3-4 bar, has the additional effect of reducing the absolute humidity of the condenser exit stream. This reduces or eliminates the need for additional exhaust drying to prevent substantial efficiency penalty from the recirculating water and its effect on working fluid specific heat ratio. Further, high cycle working pressure allows for membrane or adsorbent separation with low parasitic energy cost for power cycles using carbonaceous fuels and having carbon dioxide as a combustion byproduct.
[0013] Applications for embodiments of the technology include enhanced hydrogen energy storage systems for load-leveling applications in the electrical grid. Embodiments of the disclosed cycle technology are a lower cost and more efficient means of converting stored hydrogen and oxygen back into electricity. Hydrogen energy storage systems including the technology disclosed herein have a higher energy density than compressed air energy storage, and much lower per kWh capital costs than batteries. In addition, because recirculating noble gas combustion power cycles utilize internal combustion engines, the technology has good grid electrical characteristics, including good load-following and frequency regulation. Further, in embodiments, hydrogen energy storage systems including recirculating noble gas combustion power cycles could be configured to generate electricity conventionally with carbonaceous fuels, for example, methane burning in air, when grid conditions did not make storage economically viable.
[0014] Further applications for embodiments of the noble gas combustion power cycles include medium-scale utility power generation units using hydrogen as a fuel, or alternatively direct use of carbonaceous fuels. The hydrogen fuel may be generated from steam reforming methane or coal gasification in a pre-combustion carbon capture context. High-efficiency plants of this type have excellent load-response characteristics compared to existing combined cycle plant technology, making them integrate better with increasing portfolios of variable generation. Further applications for embodiments of the technology include electrical production collocated with, and using, hydrogen byproduct from methane steam reforming employed to produce CO2 for enhanced oil recovery operations or carbon capture and sequestration schemes. Direct use of carbonaceous fuels in the power cycle, including both gaseous (e.g. natural gas) and liquid (e.g. methanol, dimethyl ether), coupled with appropriate carbon capture technology (e.g. membrane separation, pressure swing adsorption), allows for high-efficiency utilization of these fuels while producing pure CO2 for enhanced oil recovery or other carbon sequestration schemes.
[0015] Other aspects and advantages of the present technology can be seen on review of the drawings, the detailed description and the claims, which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1A shows a simplified block of an embodiment of recirculating engine.
[0017] FIG. 1B shows a simplified block of an embodiment of recirculating engine including intake preheating and boosting.
[0018] FIG. 1C shows a simplified block of an embodiment of recirculating engine including intake preheating.
[0019] FIG. 1D shows a simplified block of an embodiment of recirculating engine including a CO 2 separation membrane.
[0020] FIG. 2A , FIG. 2B , FIG. 2C , FIG. 2D , FIG. 2E , FIG. 2F , FIG. 2G , FIG. 2H , FIG. 2I , FIG. 2J , FIG. 2K , FIG. 2L , and FIG. 2M illustrate various aspects of a power cycle including very late intake valve closure with a high quality of exhaust heat.
[0021] FIG. 3A , FIG. 3B , FIG. 3C , FIG. 3D , FIG. 3E , FIG. 3F , FIG. 3G , FIG. 3H , FIG. 3I , FIG. 3J , FIG. 3K , FIG. 3L , and FIG. 3M illustrate various aspects of a power cycle including very early intake valve closure with a high quality of exhaust heat.
[0022] FIG. 4 shows a schematic of an argon power cycle in a hydrogen energy storage system.
DETAILED DESCRIPTION
[0023] The following description will typically be with reference to specific structural embodiments and methods. It is to be understood that there is no intention to be limited to the specifically disclosed embodiments and methods but that other features, elements, methods and embodiments may be used for implementations of this disclosure. Preferred embodiments are described to illustrate the technology disclosed, not to limit its scope, which is defined by the claims. Those of ordinary skill in the art will recognize a variety of equivalent variations on the description that follows. Unless otherwise stated, in this application specified relationships, such as parallel to, aligned with, or in the same plane as, mean that the specified relationships are within limitations of manufacturing processes and within manufacturing variations. When components are described as being coupled, connected, being in contact or contacting one another, they need not be physically directly touching one another unless specifically described as such. Like elements in various embodiments are commonly referred to with like reference numerals. A detailed description of embodiments of the present technology is provided with reference to the Figures.
[0024] FIG. 1A is an illustration of a system including a recirculating power cycle. The system includes a piston engine 102 in a substantially closed loop. Also within the closed loop are a sensible heat recovery element 104 , and a condenser 106 . Flowing around the closed loop is a working fluid. In the example recirculating power cycle systems shown, the working fluid comprises Argon. However, in embodiments the working fluid comprises one or more monoatomic gas including Helium, Neon, Krypton, and Xenon. Monoatomic gases only store energy on a translation mode of motion, and therefore thermodynamically they are identical. However, monoatomic gases do have different heat transfer characteristics, and therefore in embodiments the monoatomic gases for the working fluid may be selected based on a desired heat transfer characteristic of the working fluid. From a cost and practicality standpoint, Argon is preferable for many applications as it is abundant in the atmosphere, and may be isolated during a process of separating oxygen, to use in combustion in the engine, from ambient air.
[0025] Small portions of the monoatomic gas of the working fluid may leave the closed-loop system through various processes or leaks in the system. Therefore the system includes a low volume working fluid input port 108 . The input port 108 may be positioned anywhere in the closed loop. In embodiments, the working fluid may continually be introduced through the input port into the closed loop at a rate corresponding to the rate of working fluid lost from the closed loop. In embodiments, the working fluid may be intermediately introduced through the input port into the closed loop at predetermined time increments or based on sensed concentration of working fluid in the closed loop.
[0026] In embodiments, the piston engine 102 is configured to run on hydrogen as a fuel and oxygen as an oxidizer. In the embodiment shown in FIG. 1 , oxygen is introduced to the closed loop at an oxygen premixing port 110 located near the intake valve 112 of the piston engine 102 . Further, in the embodiment shown in FIG. 1 , hydrogen is directly injected into the cylinder 114 of the piston engine 102 through a direct injection nozzle 116 . The Oxygen and Hydrogen are stored separately in high or low pressure storage units (not shown). As will be discussed below, the hydrogen may be injected during the end of the compression stroke of the piston 118 within the cylinder 114 and the pressure and temperature of the working fluid will reach an ideal injection temperature which will cause spontaneous auto-ignition of the hydrogen and oxygen to occur as the hydrogen is injected.
[0027] In embodiments, the piston engine 102 includes a crank case purge (not shown). In these embodiments, the crankcase is sealed and ventilated with the Argon working fluid. The crank case purge is configured to allow any argon and combustion gases that escape through the piston ring pack to be re-introduced into the intake, which reduce losses.
[0028] In embodiments, as an alternative to premixing of oxygen, the oxygen may be directly injected, into the cylinder 114 of the piston engine 102 through one or more direct injection nozzles 116 . Advantages of direct Oxygen injection include a smaller volumetric flow rate needed for a stoichiometric reaction, and therefore less compression work. Further oxygen has a higher density and therefore direct injection provides greater jet momentum.
[0029] In embodiments, to ensure combustion of the desired amount of fuel and oxidizer an excess of one may be provided. In embodiments, excess oxygen may be introduced into the closed loop which will ensure complete combustion of the hydrogen and the oxygen will recirculate to be burned during subsequent cycles. However, it is advantageous not to provide too much excess of either fuel or oxidizer as this will dilute the concentration of working fluid which will lower the specific heat of the fluid within the system which has adverse effects on the thermal efficiency of the system.
[0030] After combustion, the exhaust gases leave the piston engine 102 through the exhaust valve 120 and passes through the sensible heat recovery element 104 . Heat is extract from the exhaust gas in the sensible heat recovery element 104 which may be used as a heat supply for a steam reforming process of converting natural gas into hydrogen, or for other purposes such as a bottoming cycle. For example, the sensible heat recovery element 104 may include an air to liquid heat exchange that can be used to preheat a natural gas stream or to generate the steam necessary for the reforming process. The hydrogen created during the reforming process may be stored and later used as the fuel injected into the piston engine. The exhaust stream will run at temperatures that strongly depend on the valve timing and level of dilution of the working fluid, as will be discussed later in this application.
[0031] In the embodiment illustrated in FIG. 1 , the exhaust is cooled down to saturation temperatures at the given pressure as it exits the sensible heat recovery element 104 and enters the condenser 106 . The condenser 106 is configured to remove byproducts of combustion and dissolved trace contaminant gases, for example CO 2 and NOx, from the exhaust of the piston engine 102 . In the embodiments including a monoatomic gas working fluid, hydrogen fuel, and oxygen oxidizer, the byproducts of combustion include water which condensates within the condenser 106 . Water and other contaminants, including trace contaminant gases and heavy particles precipitated in the water, leave the closed loop through an exit port 122 of the condenser 106 . The fluid leaving the condenser toward the intake valve 112 of the piston engine 102 is mainly composed of the working fluid, in the example Argon, though small amounts of water and minor traces of gases may also remain.
[0032] FIG. 1B is an illustration of a system including a recirculating power cycle similar to the system of FIG. 1A and including additional features. Similar to FIG. 1A , the system illustrated in FIG. 1B includes a substantially closed loop including a piston engine 102 with an intake valve 112 , an exhaust valve 120 , a cylinder 114 , and a direct injection nozzle 116 . In the embodiment shown in FIG. 1B , both hydrogen and oxygen may be directly injected into the cylinder 114 through one or more direct injections nozzles 116 . The loop also includes a condenser 106 and a low volume working fluid input port 108 , as discussed above.
[0033] The closed loop further includes a trace gas removal element 124 , located after the condenser 106 in the closed loop. Trace gases may build up during operation, and may be attributed to impurities in reactant streams and combustion of lubricating oils. However, in embodiments, non-combustible lubricating oils, for example, silicone oils, are used to prevent buildup of CO2 in hydrogen based cycles. The trace gas removal element 124 is configured to remove trace gases in the fluid leaving the condenser 106 . The trace gas removal element 124 may include processes including catalysts, urea treatment, adsorbents, and absorbents.
[0034] To remove contaminants not removed by the condenser 106 or trace gas removal element 124 , the closed loop further includes a low value purge valve 126 . The low value purge valve 126 may be configured to continuously allow removal of fluid from within the closed-loop. For example, the low value purge valve 126 may be configured to allow gases to leave the system at a rate of up 1% of the total volume of gas in the closed loop per cycle of the piston engine 102 . As discussed above, the working fluid that leaves the closed loop system, such as through the low value purge valve 126 , may be replaced through the low volume working fluid input port 108 .
[0035] In the systems described herein, the term “closed-loop”, also referred to as “substantially closed-loop”, is used to describe a system in which exhaust gases expelled from an engine are not exhausted into the ambient. In a “closed-loop” system the exhaust gases are processed to separate working fluid of the system from combustion byproducts and contaminants. The working fluid is then recirculated into the engine intake. As previously disclosed, in a closed loop system a portion of the working fluid may be lost from the system due to leaks and as part of the combustion byproduct and contaminant removal processes. Despite these losses a system is still considered to be “substantially closed-loop” because the exhaust gases are no expelled into the ambient and a substantially portion, >90%, of exhausted working fluid is returned to the intake of the engine in subsequent cycles.
[0036] In the systems illustrated in FIGS. 1A and 1B , the piston engine may maintain, or increase, pressure within the closed loop. Increasing pressure within the closed loop is referred to as “boosting”. The embodiment illustrated in FIG. 1B includes a compressor 128 in the closed loop, between the low value purge valve 126 and the low volume working fluid input port 108 , which is configured to boost the pressure in the closed loop. The boost created by the compressor, or the piston engine, may make up for pressure losses caused by recirculation through the closed-loop of ducts. Further, the boost of a compressor may make up for pressure losses in embodiments wherein the piston engine is a two-stroke cycle engine as opposed to a four-stroke cycle engine.
[0037] After the intake gas passes through the compressor 128 the intake gas passes through a heat exchanger 130 to be warmed by the exhaust gas from the piston engine 102 . The heat exchanger 130 includes a first chamber fluidly coupling the exhaust valve 120 of the piston engine 102 to the condenser 106 , and a second chamber fluidly coupling the intake gas from the condenser 106 and compressor 128 to the intake valve 112 of the piston engine 102 . The heat exchanger is configured to preheat working fluid entering the piston engine with heat extracted from working fluid exiting the piston engine. In embodiments, the heat exchanger may be of the flat plate, shell or tube type. Additionally, the heat exchanger may comprise an adiabatic wheel, or include direct contact in the case of heat recovery to a liquid. Rapid auto ignition of the injected reactants is important to limit premixing and reduce rapid pressure rise from premixed combustion, and thus the ideal injection temperature is likely to be higher than that afforded by the ideal compression volume ratio. Preheating the intake gases using the exhaust gases affords decoupling these cycle parameters, and also accomplishes some of the exhaust cooling required before the condenser step. Though auto ignition is desired, it is important to have control over when the auto ignition occurs and how the auto ignition influences the combustion event. The level of premixing before auto ignition temperatures are reached is an important parameter to adjust combustion phasing. A large amount of premixed mixture before ignition may shift backwards the combustion phasing which will lower the thermodynamic efficiency and potentially cause the breakdown of the piston engine due to extreme pressure rise rates. By adjusting the intake temperature, another control parameter is added for auto ignition to be advanced/delayed. Varying the intake temperature influences the amount of premixed mixture that the auto ignition event will include and consequently the pressure rise rate. In addition, intake preheating increases the exhaust temperature, ‘quality’, which is advantageous if the exhaust is to be utilized, for example combined with steam reforming facilities or used in a bottoming cycle.
[0038] FIG. 1C is an illustration of a system including a recirculating power cycle similar to the system of FIG. 1B . Similar to FIG. 1B , the system illustrated in FIG. 1C includes a substantially closed loop including a piston engine 102 with an intake valve 112 , an exhaust valve 120 , a cylinder 114 , and a direct injection nozzle 116 . In the embodiment shown in FIG. 1C , oxygen may be premixed through oxygen premixing port 110 . The closed-loop also includes a condenser 106 , a sensible heat recovery element 104 , a low volume working fluid input port 108 , a trace gas removal element 124 , a low volume purge valve 126 , and a heat exchanger 130 , as discussed above.
[0039] FIG. 1D is an illustration of a system including a recirculating power cycle, similar to discussed above, using direct use of carbonaceous fuels and post-combustion separation technology. Similar to FIG. 1A , the system illustrated in FIG. 1D includes a substantially closed loop including a piston engine 102 with an intake valve 112 , an exhaust valve 120 , a cylinder 114 , and a direct injection nozzle 116 . In the embodiment shown in FIG. 1D , oxygen may be premixed by through oxygen premixing port 110 . The closed-loop also includes a condenser 106 , and a low volume working fluid input port 108 , as discussed above.
[0040] In system in FIG. 1D , a carbonaceous fuel is directly injected into the cylinder 114 through the direct injection nozzle 116 . Combustion of the carbonaceous fuel, along with oxygen premixed with the working fluid at oxygen premixing port 110 , occurs in the piston engine 102 and the resulting combustion byproducts include water and carbon dioxide, CO 2 . The water is removed from the exhaust gases in the condenser 106 , as is discussed above in other embodiments.
[0041] The system in FIG. 1D further includes a CO 2 separation membrane unit 132 configured to remove the CO 2 resulting from the combustion of the carbonaceous fuel. Fluids leaving the condenser 106 enter the CO 2 separation membrane unit 132 and the CO 2 is separated from the fluid and enters a compressor 128 . The working fluid continues from the CO 2 separation membrane unit 132 back toward the intake valve 112 of the piston engine 102 , similar to the systems shown in FIG. 1A . In embodiments, CO 2 separation technologies may be utilized, including a combination of one or more of membrane separation, cryogenic separation, amine absorption, and pressure swing adsorption.
[0042] The CO 2 leaves the compressor and enters a cryogenic separation device 134 . The Argon produced in the cryogenic separation device enters the closed-loop system as is shown. The CO 2 leaves the cryogenic separation device and may be used in applications such as enhanced oil recovery.
[0043] The power cycles disclosed above may include various ratios of fuel, oxidizer, and workings fluid. Example 1: (0.5-2 part) O2 to 1 part H2 to (2-20 parts) Ar. Example 2: (2-8 parts) O2 to 1 part CH4 to (8-80 parts) Ar. Example 3: (3-12 parts) O2 to 1 part CH3OCH3 to (12-120 parts) Ar. Example 4: (1.5-6 parts) O2 to 1 part CH3OH to (8-80 parts) Ar. Further, systems as disclosed may include features allowing for dual use as a closed-loop recirculating power cycle system and an open-loop ambient air breathing power cycle system. This system is advantageous when hydrogen, oxygen or a monoatomic gas working fluid are not readily available.
[0044] FIGS. 1A, 1B, 1C and 1D , illustrate example combinations of features in recirculating power cycles, however other combinations of the components illustrated and discussed herein are envisioned within the scope of the technology disclosed herein. Further, while a piston engine with a single cylinder and single piston has been shown, the technology may be used with multiple cylinder and piston engines. Further, each piston may include one or more intake and exhaust valves.
[0045] The recirculating power cycles of the piston engines disclosed herein include valve timing schemes which are designed for the closed loop recirculating nature of the systems and high overall efficiency in mind. A key aspect of the valve time scheme is the intake valve closure. The intake valve closure determines the pressure ratio and thus the highest temperature of the working fluid. Intake valve closure time can be used to reduce the compression ratio of the compression stroke, while the expansion stroke ratio remains fixed, which helps control the load and the ignition timing.
[0046] In embodiments of the recirculating power cycles the intake valve closure is configured to reduce a compression ratio between 4:1 and 25:1; and reduce the amount of charge in the cylinder. To reduce the charge in the cylinder the intake valve is closed very early or very late relative to the intake valve closing times in an Otto cycle.
[0047] FIGS. 2A-M illustrate various aspects of a power cycle including very late intake valve closure with a high quality of exhaust heat. FIG. 2A illustrates the beginning of an intake stroke of a power cycle including very late intake valve closure. In FIG. 2A the piston 118 is at top dead center and both the intake and exhaust valves 112 and 120 are closed. FIG. 2B illustrates an intermediate position in the intake stroke where the piston 118 is located between end positions and the piston 118 is traveling toward bottom dead center and the intake valve 112 is open. FIG. 2C illustrates the end of the intake stroke with the piston 118 at bottom dead center and the intake valve 112 is open and the exhaust valve 120 is closed. FIG. 2D illustrates an intermediate position in the compression stroke where the piston 118 is located between bottom dead center and top dead center and the intake valve 112 remains open. The intake valve 112 remaining open during the beginning of the compression strokes cause gases inside of the cylinder 114 to be expelled through the open intake valve. FIG. 2E illustrates another stage in the compression stroke, after the stage illustrated in FIG. 2D , wherein the piston 118 is located between bottom dead center and top dead center. The piston 118 is travelling toward top dead center and the intake valve 112 is now closed. The closure of the intake valve 112 during the compression stroke occurs for example between 0 and 120 degrees past bottom dead center. This late closure of the intake valve and is referred to as very late intake valve closure. The very late intake valve closure results in reduced effective volume ratio of the compression stroke and a large ratio of expansion stroke to compression stroke. The very late intake valve closure occurs prior to a fuel injection angle where fuel is injected into the cylinder and auto ignition occurs. Reason being, if auto ignition occurs while the intake valve is open damage to the valve train may occur.
[0048] FIG. 2F illustrates the end of the compression stroke with the piston 118 located at top dead center. In the embodiment illustrated, at this point the fuel 202 is directly injected into the cylinder 117 and combustion occurs initiating the power stroke, as illustrated in FIG. 2F . In embodiments, fuel is injected during the compression stroke, for example up to 20-40 degrees before top dead center. The timing of the fuel injection helps control combustion phasing and control power level. The expanding gases caused by combustion push the piston toward bottom dead center as shown in FIG. 2H . At the end of the power stroke the piston is located at bottom dead center as shown in FIG. 2I . Once at bottom dead center the exhaust valve 120 may be opened as shown in FIG. 2I . With the exhaust valve 120 open the piston travels toward top dead center during the exhaust stroke forcing gases to exit the cylinder 114 through the open exhaust valve 120 as shown in FIG. 2J . The exhaust stroke ends with the piston 118 located at top dead center and the exhaust valve 120 closed as shown in FIG. 2J . After the exhaust stroke is complete the intake stroke begins and the cycle as shown in FIGS. 2A-2K repeats.
[0049] In embodiments the exhaust valve opening and closing timing may be different than shown in FIGS. 2A-2K . For example, power cycles may include late exhaust valve opening wherein the exhaust valve does not open until the initiation of the exhaust stroke which is much later than in an Otto cycle wherein the exhaust valve opens during the power stroke. In embodiments the exhaust valve opens for example between −10 degrees and 20 degrees after bottom dead center of the beginning of the exhaust stroke.
[0050] FIG. 2L illustrates an embodiment valve timings and relative opening distance of the intake and exhaust valve in a power cycle including later intake valve closure. FIG. 2M illustrates an embodiment the pressure and volume of the in a piston engine with a power cycle including late intake valve closure.
[0051] FIGS. 3A-M illustrate various aspects of a power cycle including very early intake valve closure with a high quality of exhaust heat. FIG. 3A illustrates the beginning of an intake stroke of a power cycle including very late intake valve closure. In FIG. 3A the piston 118 is at top dead center and both the intake and exhaust valves 112 and 120 are closed. FIG. 3B illustrate an intermediate position in the intake stroke where the piston 118 is located between end positions and the piston 118 is traveling toward bottom dead center and the intake valve 112 is open. FIG. 3C illustrates a second intermediate position in the intake stroke, after the position illustrated in FIG. 3B . In FIG, 3 C the piston is still traveling toward bottom dead center and the intake valve 112 is now closed. FIG. 3D illustrates a position at the end of the intake stroke and beginning of the compression stroke wherein the piston 118 is at bottom dead center and the intake valve 112 and the exhaust valve 120 are closed. The intake valve 112 closing before the end of the intake stroke cause less than the full volume of the stroke to pulled in through the intake valve during the intake stroke. The closure of the intake valve 112 during the intake stroke occurs between 120 and 0 degrees before bottom dead center. This early closure of the intake valve and is referred to as very early intake valve closure. The very early intake valve closure results in reduced effective volume ratio of the compression stroke and a large ratio of expansion stroke to compression stroke.
[0052] FIG. 3E illustrates a stage in the compression stroke, wherein the piston 118 is located between bottom dead center and top dead center, and the piston 118 is travelling toward top dead center.
[0053] FIG. 3F illustrates the end of the compression stroke with the piston 118 located at top dead center. At this point the fuel 202 is directly injected into the cylinder 117 and combustion occurs initiating the power stroke, as illustrated in FIG. 3F . The expanding gases caused by combustion push the piston toward bottom dead center as shown in FIG. 3H . At the end of the power stroke the piston is located at bottom dead center as shown in FIG. 3I . Once at bottom dead center the exhaust valve 120 may be opened as shown in FIG. 3I . With the exhaust valve 120 open the piston travels toward top dead center during the exhaust stroke forcing gases to exit the cylinder 114 through the open exhaust valve 120 as shown in FIG. 3J . The exhaust stroke ends with the piston 118 located at top dead center and the exhaust valve 120 closed as shown in FIG. 3J . In embodiments the exhaust valve opening and closing timing may be different than shown in FIGS. 3A-3K . For example, power cycles may include late exhaust valve opening as discussed above, such that exhaust valve closure may overlap with inlet valve opening. After the exhaust stroke is complete the intake stroke begins and the cycle as shown in FIGS. 3A-3K repeats.
[0054] FIG. 3L illustrates an embodiment valve times and relative opening distance of the intake and exhaust valve in a power cycle including early intake valve closure. FIG. 3M illustrates an embodiment the pressure and volume of the in a piston engine with a power cycle including early intake valve closure.
[0055] FIG. 4 shows a schematic of an argon power cycle in a hydrogen energy storage system. As shown, various energy sources including wind farms, solar farms, and gas/oil/coal power plants provide energy to the AC electric grid. The consumer demand is addressed with the energy in the grid and excess energy may go to an electrolyzer to create hydrogen and oxygen which may be stored. When consumer demand on the grid exceeds the output of the primary energy sources the stored hydrogen and oxygen may be used in the Argon Powers cycle, which utilizes the technology disclosed herein, to efficiently convert the stored hydrogen and oxygen into energy usable by the consumers.
[0056] While the present technology is disclosed by reference to the preferred embodiments and examples detailed above, it is to be understood that these examples are intended in an illustrative rather than in a limiting sense. It is contemplated that modifications and combinations will readily occur to those skilled in the art, which modifications and combinations will be within the spirit of the technology and the scope of the following claims. What is claimed is: | The present technology provides embodiments of recirculating noble gas combustion power cycles and systems including engines utilizing these power cycles. Embodiments of the cycles may include a combination of a high intake/exhaust pressure, very late or early intake valve closure, late exhaust valve opening, intake preheating using exhaust gases, sensible heat recovery, direct injection of fuel and/or oxidizer, and a condenser to remove combustion products and dissolved trace contaminant gases. An engine operating on these principles could provide motive force for electrical production, for example at power plants, or for transit, for example for ship engines. An engine operating with the cycles disclosed herein has high thermal efficiency and low cost. For example an argon power cycle using natural gas feedstock and cryogenic oxygen air separation could exceed 60% overall efficiency. | 5 |
BACKGROUND OF THE INVENTION
[0001] The invention relates to a payment-triggered audiovisual reproduction system.
[0002] These audiovisual reproduction systems are generally found in cafes or pubs. This type of system is composed of a sound reproduction machine usually called a jukebox linked to a monitor which displays video images or video clips. To do this, the jukebox is equipped with a compact video disk player and a compact video disk library and includes selection buttons which locate the titles of pieces of music that are available. Payment of a proper fee followed by one or more selections authorizes activation of the system with automatic loading in the player of the disk on which the selected piece is found. Subsequently, the desired audiovisual reproduction is played.
[0003] These systems, although allowing reliable and good quality reproduction, nevertheless have major defects. A first defect relates to the space necessary for storing the library; this consequently entails that the system will have large dimensions. Another defect of these systems relates to the mostly mechanical components using sophisticated techniques, which in turn, have high fault rates. Moreover, it is unusual for all the songs on a disk to be regularly heard, but unwanted songs cannot be eliminated from the disk, and the disk occupies physical space. Another problem is caused by the companies that manage and distribute these systems, placing in the circuit a limited number of identical disks and imposing a certain rotation on their customers. As a result, customers must wait when a disk is not available.
SUMMARY OF THE INVENTION
[0004] The object of the invention is to eliminate the various defects of the prior art systems. The invention proposes an intelligent digital audiovisual system which is practical to implement, compact, reliable, and enables storage at the title level as well as easy deletion or insertion of titles not listened to or wanted, respectively, while maintaining a large song library and outputting a high level of reproduction quality.
[0005] To do this, the audiovisual reproduction system according to the invention is developed around a microprocessor device linked to a payment device. The system includes a memory for storing in digital form the audio and visual information to be used. The microprocessor device is also linked via interfaces to a display and audio reproduction structure allowing formation of a multimedia environment. The ensemble is managed by a multitask operating system including a library of tools and services integrated in the memory.
[0006] Thus, all the audiovisual information to be used is digitized and stored in the memory and can be re-read with high fidelity, allowing the audiovisual reproduction system according to the invention to output high-quality songs and graphics.
[0007] A new title can be easily introduced into the memory, and a little heard or undesirable title can be easily deleted from the memory. With musical selections, corresponding album covers can likewise be stored in digitized form. The memory stores a minimum of 350 to 400 titles and can be expanded without any difficulty. The simplicity of operation and absence of mechanical components in the system for reproduction of audiovisual information greatly reduce the number of failures, which results in lower cost maintenance. Moreover, the multitask operating system, which includes a library containing a set of tools and services, makes it possible to greatly facilitate operation due to its integration in the memory and the resulting high flexibility. In particular, with the multitask operating system, it is possible to create a multimedia environment by simply and simultaneously managing audio reproduction, video or graphics display and video animation. In addition, since the audiovisual information is digitized and stored in the memory, it uses much less space than for a traditional audiovisual reproduction system, and consequently, the dimensions of the system according to the invention are reduced. Consequently, the dimensions of the housing in which the system is located are greatly reduced, and the cost of the ensemble is likewise greatly reduced. The external appearance of the housing of course can be easily adapted to the nature of the establishment.
[0008] Advantageously, the audiovisual reproduction system is moreover linked via an interface to a telecommunications modem, the system then being connected to an audiovisual data distribution system by the telecommunications modem and telecommunications lines, this telecommunications function is likewise managed by the multitask operating system included in the library of tools and services integrated in the memory.
[0009] Connection to the audiovisual data distribution network, of a proprietary type, then authorizes the return and quasi-immediate insertion of the desired titles in the memory of this system. The telecommunications lines are preferably high speed telecommunication lines. The multitask operating system, while allowing the formation of a multimedia environment, at the same time allows use of the telecommunications services included in the library of tools and services.
[0010] Notably the system can easily be provided with a timer for automatic and periodic activation after a predetermined period of nonuse. This timing function is written into the memory and managed by the multitask operating system. These automatic and periodic activations for partial or complete audiovisual reproductions make it possible to draw customer attention and consequently increase revenues.
[0011] Characteristically, the memory stores a catalog of titles relating to available audiovisual data with the corresponding fees. The selection of a title automatically triggers internal processing which totals the sums relative to a chosen title. Thus, the system provides an accurate calculation and verification of fees.
[0012] Likewise, each choice of a title is counted for display of use statistics, the display being triggered by activating a predetermined function. According to this characteristic, the system manager or owner is allowed to display, after activating the predetermined function, the statistical total of the various uses. This information guides him in the choice of titles to be retained or discarded. The receipts relative to the fees paid which are thus counted exactly are recovered by the system manager or owner by a key.
[0013] The audiovisual reproduction system preferably uses the aforementioned listed components, although certainly additional components could be used, and the invention is not meant to be limited.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The following description with reference to the attached drawings, given using a non-limiting example, will explain how the invention can be accomplished.
[0015] FIG. 1 is a schematic illustration of the audiovisual reproduction jukebox system according to the invention;
[0016] FIG. 2 is a block diagram of the jukebox system; and
[0017] FIG. 3 is a flowchart showing the specific service modules of a task managed by the multitask operating system, the ensemble of modules being included in a library stored in the memory.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0018] The hardware components according to the present invention will first be described with reference to FIGS. 1 and 2 .
[0019] The microprocessor device 22 to be used is a high performance PC-compatible system, such as an Intel 80486 DX/2 system which has memory and the following characteristics.
compatibility with the local Vesa bus, processor cache memory: 256 kB, RAM of 32 MB, high performance parallel and serial ports, SVGA microprocessor graphics adapter, type SCSI/2 bus type controller, self-powered static RAM.
[0027] The display consists essentially of:
a 14 inch (35.56 cm) flat screen video monitor without interleaving of the SVGA type, with high resolution and low radiation, which is used for video reproduction (for example, the covers of the albums of the musical selection), graphics or video clips, a 14 inch (35.56 cm) touch screen “Intelli Touch” from Elo Touch Systems Inc. which includes a glass coated board using “advanced surface wave technology” and an AT type bus controller. This touch screen allows display of various selection data used by the customers and command and management control information used by the system manager or owner. It is likewise used for maintenance purposes in combination with an external keyboard that can be connected to the system which has a keyboard connector for this purpose, controlled by a key lock.
[0030] Likewise comprising part of the memory, storage modules 240 , 246 using hard disks of the high speed and high capacity SCSI type are connected to the memory in the microprocessor device. These modules allow storage of audiovisual data.
[0031] A high speed 28.8 k/bps telecommunications modem adapter 26 is integrated to enable the connection to the audiovisual data distribution network 28 ( FIG. 1 ).
[0032] To reproduce the audio data of the musical selections, the system includes integrated amplified loudspeakers 30 and is equipped with commercial electronic cards of the music synthesizer type which are provided to support a large number of input sources while providing an output with CD (compact disk) type quality, in particular.
a microprocessor multimedia audio adapter of the “Sound Blaster” type SBP32AWE from Creative Labs Inc.
[0034] A thermally controlled 240 watt ventilated power supply 32 provides power to the system. This power supply is protected against surges and harmonics.
[0035] The audiovisual reproduction system and especially the microprocessor device are configurable equally by remote control 14 , for which the following are used:
an infrared remote control 14 from Mind Path Technologies Inc., an emitter which has fifteen control keys for the microprocessor system and eight control keys for the projection device. an infrared receiver 14 b with serial adapter from Mind Path Technologies Inc.
[0038] A fee payment device 34 from National Rejectors Inc. is likewise integrated into the system. It is also possible to use any other device which allows receipt of any type of payment by coins, bills, tokens, magnetic chip cards or a combination of means of payment.
[0039] To house the system a chassis or frame of steel with external customizable fittings is also provided.
[0040] A wireless microphone 38 is incorporated into the system allowing transformation of the latter into a powerful public address system or possibly a karaoke machine. A wireless loudspeaker system can also be used by the system. Finally, remote control allows, for example from behind the bar, access to and control of various commands such as:
microphone start/stop command, loudspeaker muting command, audio volume control command, command to cancel the musical selection being played.
[0045] The choice of software developed or used to operate the audiovisual reproduction system has been oriented to be user-friendly. From this perspective all the characteristics of the system can be controlled via the easy-to-use graphics touch screen in cooperation with an auxiliary voice synthesis system.
[0046] To do this, on the touch screen used for control and assistance, at least four control panels can be selected. The first title selection panel helps customers find and select a desired title. A second management control panel controls volume, bass, treble or panoramic control on the video monitor. A third panel scans the title database, for private use, to allow the system manager or owner to examine the database containing the available titles via the audiovisual data distribution network to control and retrieve the titles. A fourth statistics panel, for private use, provides statistical estimations and calculations relative to the titles.
[0047] Customer selections of musical pieces are greatly simplified by the graphics interface which has facilities such as browsing the available titles according to various selection criteria, for example title, composer, category, etc. Moreover, when a musical piece is chosen, the album cover to which it belongs can be displayed at the same time as certain statistical data such as the composer of the piece, its length, album label, etc.
[0048] For this purpose, the system operating software has been developed around a library of tools and services largely oriented to the audiovisual domain in a multimedia environment. This library advantageously includes a multitask operating system which efficiently enables simultaneous execution of multiple fragments of code. The operating software thus allows concurrent execution, in an orderly manner and avoiding any conflict, of operations performed on the display, audio reproduction structure as well as management of the telecommunications lines via the distribution network. In addition, the software has high flexibility since it allows the owner of the establishment to use options not available before, such as:
automatic withdrawal to an auxiliary source, for example, a FM tuner, during inactivity of the main function, remote control of the audio volume, cancelling or skipping a musical piece, superposition of a microphone on the existing sound for public address or to convert the system into a karaoke machine, amplifier control with respect to output power, right or left channel balance, control of base or treble frequencies, automatic activation of audiovisual reproduction at controllable intervals when the system is inactive.
[0055] Advantageously, the audiovisual data distribution network is an integral part of the system environment according to the invention and it allows the manager or owner of the system to exploit new and powerful possibilities and services such as:
remote technical assistance: either for problems of minor malfunctions by assisting the system manager or owner, or for more major problems by assisting the technicians in locating the fault and the defective component, management of security: each system is connected to a local controller system according to a preestablished time pattern for acquisition of an approval signal in the form of a registration number which authorizes its operation. In addition, if cheating is detected or the system can no longer communicate via the network, the system automatically stops working, acquisition of musical pieces with the album covers: the system manager or owner can select and acquire musical pieces by browsing the selection database. Transfer of a musical piece with its album cover and integration into the list of available titles are done within a very short time, upgrading of the system: corrective maintenance of major or minor problems relative to the system operating software, improvements or upgrades are enabled via the telecommunications lines through the distribution network. Only a few minutes are necessary to transfer these modifications to any network system, collection of statistics: all statistics and data internal to a system are rapidly available to be compiled via the distribution network, the statistics allowing specific and efficient analysis of the entire market situation, billing: the distribution network automatically calls the system which has registered the amounts collected by the system following payment by the user, calculates the composer royalties which the system manager or owner must pay to the distribution network company, and produces the appropriate accounts, marketing and promotion: at the request of a title supplier for promotional purposes high fidelity digital reproduction of a title is available to the system manager or owner during subsequent hours via the distribution network. Digitization of the musical selections which are made available via the distribution network is done using various commercially available software tools, which provide standard formatted data files.
[0063] The digitized audiovisual data are stored in a format which uses standard compression. The system decompresses the musical selections stored in the storage means at the instant at which they are reproduced; this allows a considerable reduction in the memory space necessary to store them, while optimizing the delays during transfer via the telecommunications lines.
[0064] Each selection is available according to two digitized formats: with a hi-fi quality or CD quality. This authorizes an advantageous balance between the necessary memory space and the required reproduction quality which depends on the effective noise level in the establishment and the quality requirement.
[0065] With reference to FIG. 3 , it is noted that while all the modules described separately seem to be used sequentially, in reality the specific tasks of the modules are executed simultaneously in an environment using the multitask operating system. Consequently the flowchart of FIG. 3 indicates the specific operations which the module must perform and not a branch toward this module which would invalidate all the operations performed by the other modules.
[0066] The first module, labeled SSM, is the system startup module. This module does only one thing, and consequently, it is loaded automatically when the system is powered up. If the system is started with a correct registration number, it then directly enters the “in service” mode of the module labeled RRM.
[0067] The REG module is the registration mode module which, when it is activated for the first time or when approval for a new registration is necessary, indicates its software serial number and requests that the user enters his coordinates, such as the name of the establishment, address and telephone number. When the system is not registered, it operates only for registration, providing the manager with the appropriate information necessary to activate it. Once the user has finished entering the necessary information, the system proceeds to register itself for a predetermined registration period and then activates itself completely. Before the registration period expires, the system attempts to establish a telecommunications link to a server 28 via the distribution network 29 . If a connection is established, it renews its registration with its software serial number and provides to the server the additional user information furnished by the customer. When the registration period expires before the system is able to establish a link and renew its registration, it is invalidated after a configurable grace period has expired and sends the message “out of service”. When the manager inserts his key, he is guided for system registration. It is possible to register the system by telephone when a telecommunications line problem or telephone line fault occurs. When a system is registered and activated by the telecommunications network or via a telephone call to the distribution network headquarters, it becomes completely operational in two modes, “user” and “manager” (for system maintenance) for another registration period.
[0068] The RMM module enters the “in service” mode when its registration number has been validated. In this mode, the system is ready to handle any request which can be triggered by various predefined events such as:
customers touching the screen: when a customer or user touches the screen, the system transfers control of the foreground session to the CBSM module 19 of the customer browsing and selection mode, telecommunications network server call requests: when the system detects a loop on the phone line, it emits an asynchronous background procedure: the telecommunications services mode of the TSM module 17 , requests concerning the key switch: when the manager turns the key switch, the system hands over control of its foreground session to the management mode MMM module 12 , reception of a remote control signal: when a command is received, it is processed in a background session by the system command SCM module 15 while the foreground session remains available for other interventions, appearance of end of timing, showing inactivity of the system: when one of the various timers is activated, control is temporarily handed over to the inactivity routines IRM module for processing.
[0074] The system remains in the “in service” mode until one of the above described events takes place.
[0075] The IRM module 11 is the inactivity routines module. It contains the routines that perform predetermined functions which it can call on when the system is inactive and when a predefined but adjustable time interval has expired. The aforementioned list of functions that the system can handle is of course not limited, and new functions which would be desirable to add to the overall system of the distribution network could be added very easily at any time and as soon as they are created using the remote control services for software upgrading. Such functions can be offered and added for example when requirements have been confirmed regarding management of the ensemble of systems or simply for a given system. Some of these proposed functions with the system are described below:
display of an album cover to announce its presence or its future integration into the system: the system displays a full screen of announcements showing the album covers for a desired interval. Different panoramic effects can be used, zoom forward and back, for example, on the covers of each album to draw the attention of the customers, broadcast of parts of musical pieces present in the system: the manager in this case can control and sample the pieces broadcast during a specific interval and can have these pieces correspond to the album covers on the screen, reproduction of complete selections for internal promotional proposes: the manager can impose a period of defined inactivity after which a randomly selected musical selection is reproduced. At the end of this period, a musical selection is thus taken randomly in the system, then played in its entirety without payment of fees, audio reproductions for external promotional purposes: this option works in the same way as the preceding one, except that it authorizes the system to accept playing of the promotional musical selections for which third parties have paid and which are distributed freely over the telecommunications network, promotional spoken announcements of new musical selections: according to this option, it is possible to verbally promote newly added selections or to add them in the near future to the system via loudspeakers integrated into the system, withdrawal to an auxiliary source: at his discretion the manager can request that the system, when inactive, withdraw to an auxiliary source. For example, when this option is activated and when a FM tuner is connected to the system inputs and the system is inactive, the system directs its auxiliary source input to its main output after the delay determined by the inactivity has expired.
[0082] The SCM module 15 is the system commands module. This module allows functions that control the system to accept a required input by an infrared remote control device 14 . These functions are handled instantaneously without the process being stopped. A large number of these functions are possible, only some are listed below, in a non-limiting manner:
audio volume control of the played selections, audio volume control from the auxiliary played source, microphone start/stop command, microphone audio volume control, balance control, left channel, right channel, control of base frequency level, control of treble frequency level, command to cancel or skip a musical selection, panoramic effects command, zoom forward, zoom back, triggering of zeroing of the software program.
[0093] The MMM module 12 is the management mode module. This module is triggered when the key switch is turned by the manager. The display of an ordinary screen is replaced by a display specific to system management. With this new display, the manager can control all the settings that are possible with remote control. He can likewise take control of additional low level commands allowing for an example definition of commands to be validated or invalidated on the remote control. He is also able to define a maximum of high and low levels for each system output source, these limits defining the range available on the remote control. Using this screen, the manager can access the mode of new selection acquisition by touching a button located on the touch screen. When the manager has succeeded in defining these commands as well as the system configuration, it is then enough to remove the key, and the system returns automatically to the “in service” mode.
[0094] The NSAM module is the new selections acquisition mode module. When this mode is activated, a new control screen appears. This mode is designed to assist the manager regarding the location for fast and efficient acquisition of titles of musical selections. To do this, the screen offers different options such as:
search by title, search by artist, search by category (pop, rock country, etc.), alphabetic sorting, sorting by issue date.
[0100] The manager can browse the ensemble of available titles and select them by simply touching their designation on the screen to load them. Once the selections have been made and the manager has exited the module, the system automatically sends the list of selections to the telecommunications services mode module for processing, and then returns with foreground control to the management mode.
[0101] The CBSM module 19 is the customer browsing and selection mode module. Access to this module is triggered from the “in service” mode by touching the screen. When the customer touches the screen, the screen display disappears to make room for a menu provided for convenient browsing assisted by digitized voice messages to guide the user in his choice of musical selections.
[0102] The TSM module is the telecommunications services mode module. The TSM module allows management of all management services available on the distribution network. All the tasks specific to telecommunications are managed like the background tasks of the system. These tasks always use only the processing time remaining once the system has completed all its foreground tasks. Thus, when the system is busy with one of its higher priority tasks, the TSM module automatically will try to reduce the limits on system resources and recover all the microprocessor processing time left available. Some of these tasks managed by this module are listed below:
transfer of audio or video data, automated accounting of the fees for musical selections, accounting of musical selection use, collection of statistics, system diagnostics, system security (integrity), monitoring of the selection inventory, configuration verification, upgrading of software.
[0112] The SSC module is the system security control module. Each system is linked to a local system controller according to a preestablished time pattern for acquisition of an approval signal in the form of the registration number, authorizing it to operate. In addition, if cheating has been detected or the system cannot communicate via the network, the system automatically stops working.
[0113] The audio visual reproduction system according to the invention has a large number of advantages over systems of the prior art. This powerful system, which uses a computer, can store and reproduce any musical selection while maintaining its original quality. It allows simple and efficient replacement of all mechanical and sophisticated electronic devices of the prior art, which were sources of failures, such as the disk changing arm, lasers, etc., thus greatly reducing maintenance costs. It is simple and compact. The managers or owners of this system can efficiently monitor the titles of the musical selections since they uniquely command the desired titles, thus bypassing a distribution company which ordinarily only acquires a small number of unique titles, then imposes a rotation on their customers. With the present invention, it is possible to acquire only specific titles and at reduced prices, as well as entire CD albums if desired. Consequently, management costs can be significantly reduced. With the integrated interactive video module, this system can also be used for promotional purposes, market research or even as a karaoke machine. Finally, use of a multitask operating system enables simultaneous management providing a major advantage over prior art devices. | Payment-based audiovisual playback system characterized by comprising a microprocessor device associated with a payment device primarily including means for storing, inter alia, in digital format the visual and sound information to be used. The system is associated through interfaces with display means and sound playback means for providing a multimedia environment. The system is controlled by a multitask operating system including a tool and service library integrated into the storage means. The system, which is also associated through an interface with a telecommunications modem, is optionally connected to an audiovisual data distribution network by a telecommunications modem and telecommunications links, said telecommunications function also being controlled by said multitask operating system. | 6 |
BACKGROUND
The present disclosure generally relates to vehicles and, more particularly, relates to a step for a vehicle to improve accessibility to, and usefulness of, the roof area and a roof rack cargo storage system.
Users of vehicles, including in particular sport utility and crossover type vehicles, often desire access to the roof of the vehicle and/or upper portions of their vehicle for a variety of reasons such as cleaning the full vehicle exterior (including the windshield, moon roof, and entire vehicle roof), as well as using the roof rack and/or top of vehicle storage area. While some individuals may use of the side vehicle running board and/or rear bumper for these purposes, it is not be possible to use the side running boards to access some of the areas of the roof of the vehicle since they do not provide users enough increased reach to gain access to the primary storage area of the roof of the vehicle. It is generally known to use a step or wheel ladder or other similar device to gain access to the upper portion of the vehicle. However, such solutions are limited and can be quite inconvenient and cumbersome—particularly when the devices or tools must be brought along and stowed in the vehicle when access to the roof is desired at another location. Obviously, such devices may be forgotten or lost. When ladders or other such devices are not available, it is generally known that the user may also attempt to access the roof/upper portions of the vehicle by standing on the tires, the vehicle interior floor and the vehicle seats (with the door open). These actions may result in awkward body positions and in an increased potential for vehicle and/or cargo damage. Despite these long known solutions and their limitations and deficiencies, the generally known solutions remain unchanged. There long remains a significant need to improve the accessibility to the roof areas of a vehicle, in particular the cargo storage area.
DRAWINGS
FIG. 1 is a perspective, graphic view of a sport utility vehicle including a deployable, wheelhouse cladding step in a closed position according to an exemplary embodiment of the present disclosure.
FIG. 2 is a perspective, graphic view of the sport utility vehicle including the deployable, wheelhouse cladding step in an open position according to the exemplary embodiment of FIG. 1 .
FIG. 3 is an alternate perspective, graphic view of the sport utility vehicle including the deployable, wheelhouse cladding step in an open position according to the exemplary embodiment of FIG. 1 .
FIG. 4 is a perspective, graphic view of a vehicle including a deployable, wheelhouse cladding step according to an alternate exemplary embodiment of FIG. 1 .
FIG. 5 is an alternate perspective, graphic view of the deployable, wheelhouse cladding step in a closed position according to the alternate exemplary embodiment of FIG. 4 .
FIG. 6 is an alternate perspective, graphic view of the deployable, wheelhouse cladding step in an open position according to the alternate exemplary embodiment of FIG. 4 .
FIG. 7 is an alternate perspective, graphic view the deployable, wheelhouse cladding step in an open position according to the exemplary embodiment of FIG. 4 .
DETAILED DESCRIPTION
Referring in general to all of the Figures and in particular to FIGS. 1 through 3 , there is disclosed a wheelhouse cladding step 20 installed on a vehicle 1 according to an exemplary embodiment of the present disclosure. The vehicle 1 shown in the present disclosure is a sport utility type vehicle. The vehicle 1 includes a rear end 2 including a liftgate 3 and a cab or occupant or passenger compartment 5 as are generally known. The vehicle 1 may further include sides 6 , wheel wells or wheelhouses 7 , and wheels 8 as are generally known. In one particular exemplary embodiment of the present disclosure, the vehicle 1 may further include a side step or running board 10 for assisting an occupant in entering and exiting the cab 5 of the vehicle 1 . In a further particular exemplary embodiment of the present disclosure, the side step 10 may include a deployable extension 11 as best shown in FIG. 2 .
The vehicle 1 further includes a roof or top 9 generally extending over the cab or occupant portion 5 of the vehicle 1 . The roof 9 of the vehicle 1 may further include a cargo or roof rack storage system 15 or similar devices and/or apparatuses. The cargo storage rack 15 may be factory installed as original equipment or it may alternatively be an aftermarket installed product. The wheelhouse cladding step 20 of the present disclosure may be used with any known type passenger, commercial or cargo wheeled vehicle 1 including wheelhouses 7 , particularly where there is a need and/or desire by a user to have convenient and improved access to the roof 9 of the vehicle 1 and support while accessing and using the roof rack storage system 15 on the roof 9 of the vehicle 1 . For purpose of illustration, the implementation of the wheelhouse cladding step 20 of the present disclosure is shown only on the driver's side 6 rear wheelhouse 7 . The wheelhouse cladding step 20 of the present disclosure may be used at any and/or each wheelhouse 7 of the vehicle 1 . The body sides 6 of the vehicle 1 may generally extend downward from the roof 9 and may include a body or side panel 12 having a class A surface having a requisite fit and finish. Each body panel 12 may further include a body finishing component, proximal the wheelhouse 7 , in the form of the wheelhouse cladding step 20 to be located in a wheelhouse cladding recess 13 in the body panel 12 . The wheelhouse cladding recess 13 of the panel 12 may be modified (as compared to the non-step wheelhouse version where only a wheelhouse trim strip is provided) to create more space to better accommodate the wheelhouse cladding step 20 and its components according to the present disclosure. In particular, in one exemplary embodiment, the additional space and functionality of the wheelhouse cladding recess 13 may include a latching mechanism 40 for selectively and securely coupling a step or step member 22 of the wheelhouse cladding step 20 to the body panel 12 or other structure of the vehicle 1 .
The step member 22 may preferably have a generally semi-circular or curvilinear shape. More particularly, the step member 22 may preferably have a shape corresponding or matching the shape of the wheelhouse cladding recess 13 located along the upper periphery of the wheelhouse 7 of the vehicle 1 . In one exemplary embodiment of the present disclosure, the shape and design appearance details of the step member 22 may preferably be selected to closely match and blend with the shapes and design appearances of the panel 12 and the side 6 of the vehicle 1 and its related other trim and components. The outer surface 21 of the step 22 may be designed to appear as a class A exterior trim/ornamental piece such that the wheelhouse cladding step 20 may be visually indistinguishable, as reasonably as possible, from the traditional wheelhouse cladding trim member not including a step. The step member 22 may further include an inner or stepping surface or member 23 preferably including a surface having a non-skid material, function (e.g., a treaded surface) to provide proper, convenient and safe usage as a step to access the roof 9 and/or cargo storage 15 of the vehicle 1 .
The step 22 of the wheelhouse cladding step 20 may be movable to and from a first closed position (as best shown in FIG. 1 ) in which the inner stepping surface 23 is located in the wheelhouse cladding recess 13 of the vehicle 1 proximal the wheelhouse 7 and wherein the outer or finish surface 21 generally covers or closes the wheelhouse cladding recess 13 to provide a generally class A finish to the panel 12 of the body side 6 of the vehicle 1 . The step 22 of the wheelhouse cladding step 20 may be movable to and from a second step or open position (as best shown in FIG. 2 ) in which the inner stepping surface 23 is not located in the wheelhouse cladding recess 13 but is aligned generally horizontally aligned with and facing away from the ground (i.e., generally upward) under the vehicle 1 and wherein the outer or finish surface 21 is generally horizontally aligned with and facing toward the ground under the vehicle 1 and no longer covers or closes the wheelhouse cladding recess 13 . In the second step position of FIGS. 2 and 3 , the step 22 is usable for supporting an individual at an elevated position from the ground and closer to the roof and/or cargo storage 15 located on the roof 9 .
Referring now in particular to FIGS. 2 and 3 , the wheelhouse cladding step 20 may include hinges 30 for coupling the step 22 to the side 6 of the vehicle 1 . A first hinge 30 may be located proximal one end of the wheelhouse cladding recess 13 and a second hinge 30 may be located proximal the other end of the wheelhouse cladding recess 13 . The first and second hinges 30 may preferably be located and/or coupled proximal the ends of the step 22 but may alternatively be coupled more distal and in other locations as may be appropriate for incorporating the wheelhouse cladding step 20 into the side 6 of the vehicle 1 . The hinges 30 may be located on the side 6 of the vehicle 1 proximal the wheelhouse 7 of the vehicle. More particularly, the hinges 30 may be located proximal the lower ends or corners of the wheelhouse cladding recess 13 which may contain passages or openings for receiving each hinge when the step 22 is in the closed position. The hinges 30 may be of any known or appropriate construction for folding down and up, as well as locking, the step 22 between the first and second positions.
Referring still to FIGS. 2 and 3 , the wheelhouse cladding step 20 may also include a latching mechanism 40 for selectively coupling or latching the step 22 to the side 6 of the vehicle 1 in the closed position. The latching mechanism 40 may preferably function to selectively latch the step 22 to the wheelhouse recess 13 of the vehicle 1 when the step 22 is in the first closed position (as shown in FIG. 1 ) and the latching mechanism 40 may preferably be operated for releasing the step 22 from the wheelhouse recess 13 to be moved to the second deployed position (as shown in FIG. 2 ).
In one particular exemplary embodiment of the present disclosure, to latch, lock, secure and/or couple the wheelhouse cladding step 22 to the panel 12 when not in use and to have a flush appearance with the body side 6 of the vehicle 1 , the wheelhouse recess panel 12 may include a male portion 41 of a retention clip latching mechanism 40 (or, alternatively, multiple male portions of multiple retention clips 40 ) and the female portion 43 (such as a sprung or biased side recess) of the retention clip latching mechanism 40 may be located at a corresponding location on the step 22 for retaining the step 22 in the closed position as shown in FIG. 1 .
The wheelhouse cladding step 20 may be designed to support a user at an elevated level to provide improved access to the roof 9 and storage rack 15 located on the top of vehicle 1 as well as to more easily clean the entirety of the roof 9 of the vehicle 1 . The wheelhouse cladding step 20 of the present disclosure transforms the exterior cladding located proximal the wheelhouse 7 from a purely cosmetic styling element of the vehicle 1 to a functional fold down step 22 . The wheelhouse cladding step 20 may be used by itself or, alternatively, in combination with the side running board or step 10 as well as in conjunction with the extension 11 of the side step 10 to provide improved access to the roof 9 , the cargo rack storage system 15 and other upper portions of the vehicle 1 .
Referring now in particular FIGS. 4-7 , there is disclosed a wheelhouse cladding step 120 installed on a vehicle 1 according to an alternate exemplary embodiment of the present disclosure. The wheelhouse cladding step 120 may be installed on any vehicle 1 and generally includes a similar design as well as features and functions as the wheelhouse cladding step 20 of FIGS. 1-3 . Accordingly, the present description is limited to the comparative differences embodied in the wheelhouse cladding step 120 of FIGS. 4-7 . The wheelhouse cladding step 120 includes a unique hinge 130 including a damper, dashpot or spring mechanism 160 for use in providing at least a balancing force during movement of the wheelhouse cladding step 120 . The wheelhouse cladding step 120 may include a step member 122 that may include a step member 122 the may preferably have a generally semi-circular or curvilinear shape. More particularly, the step member 122 may also preferably have a shape corresponding or matching the shape of the wheelhouse cladding recess 13 located along the upper periphery of the wheelhouse 7 of the vehicle 1 . In the present exemplary embodiment of the present disclosure, the shape and design appearance details of the step member 122 may also preferably be selected to closely match and blend with the shapes and design appearances of the panel 12 of the side 6 of the vehicle 1 and its related other trim and components. The step member 122 may also include an outer surface 121 designed to appear as a class A exterior trim/ornamental piece such that the wheelhouse cladding step 120 that may be as visually indistinguishable as reasonably as possible from the traditional wheelhouse cladding trim member not including a step. The step member 122 may further include an inner or stepping surface or member 123 preferably including a surface having a non-skid material, function (e.g., a treaded surface) to provide proper, convenient and safe usage as a step to access the roof 9 and/or cargo storage 15 of the vehicle 1 .
The step 122 of the wheelhouse cladding step 120 may be movable to and from the first closed position as shown in FIGS. 4 and 5 and wherein the outer or finish surface 121 generally covers or closes the wheelhouse cladding recess 13 to provide the class A finish to the panel 12 of the body side 6 of the vehicle 1 . The step 122 of the wheelhouse cladding step 20 may be movable to and from the second or open position as best shown in FIGS. 6 and 7 in which the stepping surface 123 is located generally horizontal to the vehicle 1 and is aligned with and facing away from the ground (i.e., generally upward) and wherein the outer or finish surface 121 is generally horizontally aligned with and facing toward the ground. In the second step position of FIGS. 6 and 7 , the step 122 is usable for supporting an individual at an elevated position from the ground and closer to the roof and/or cargo storage 15 located on the roof 9 .
Referring still in particular to the alternate exemplary embodiment of FIGS. 4 through 7 , the step 122 may include first and second extension members 125 that are integrated and/or made unitary with the step 122 . Each extension member 125 is located proximal a respective end of the step 122 and generally extends arcuately from the inner side 123 of the step 122 as best shown in FIGS. 6 and 7 . The extension member 125 may pass through a hole or passage in the side 6 of the vehicle 1 proximal the side of the wheelhouse 7 or may be located within the wheelhouse 7 . A distal end of the extension member 125 may include an expanded portion or end 126 for limiting movement of the step 122 at the second position as shown in FIGS. 6 and 7 and for transferring forces applied to the step member 122 to the vehicle 1 .
As noted above, the hinges 130 couple or connect the step 122 to the vehicle 1 at the wheelhouse 7 of the vehicle 1 . A first hinge mechanism 130 may be located proximal one end of the wheelhouse 7 and a second hinge mechanism 130 may be located proximal the other end of the wheelhouse 7 . The first and second hinges 130 may preferably be located and/or coupled proximal the distal ends of the extension members 125 of the step 22 but may alternatively be coupled in other locations as may be appropriate for incorporating the wheelhouse cladding step 120 into the vehicle 1 . In the alternate exemplary embodiment of FIGS. 4 through 7 , each hinge 130 of the wheelhouse cladding step 120 may preferably further include a link member 131 having a first end coupled or otherwise connected proximal the end 126 of the extension member 125 and a second end pivotably coupled to a post or coupling member 133 that may be fixed or coupled to the vehicle 1 such as to a component of the frame of the vehicle 1 . The post 133 may be coupled, integrated or made unitary into any of the frame, wheelhouse 7 or vehicle 1 in any known or appropriate design. In one alternate exemplary embodiment, the distal end of the link member 131 may preferably be pivotably coupled to the post 133 so that the post 133 may function as the pivot point the step member 122 .
As noted above, each hinge 130 may further include a spring mechanism 160 having a first or input end 163 coupled to a point between the proximal and distal ends of the link member 131 as best shown in FIGS. 5 and 7 . The spring mechanism 160 may preferably be a damped strut type device and may be, alternatively, any one of a compression, extension, or torsion spring(s) which accomplishes the objective to provide a limiting and/or biasing force against the movement of the step 122 . When the step member 122 is in the first or closed position ( FIGS. 4 and 5 ), the spring mechanism 160 provides a biasing force against the movement of the step member away from the first position which helps to maintain the step member 122 in that position, in addition to, or in place of, any step latching mechanism 40 . Similarly, when the step member 122 is in the second or open position ( FIGS. 6 and 7 ), the spring mechanism 160 provides a biasing force against the movement of the step member away from the second position which helps to maintain the step member 122 in that position while it is in use as a step. The other end of the spring mechanism 160 may be coupled, integrated or made unitary into any of the frame, wheelhouse 7 or vehicle 1 in any known or appropriate design.
The present description is intended to be illustrative and not restrictive. Many embodiments as well as many applications besides the exemplary embodiments provided will be apparent to those of ordinary skill in the relevant art upon understanding the present disclosure. The scope of the claimed invention should not be determined with limiting reference to the description but should instead be determined with reference to the appended claims along with the full scope of equivalents to which such claims are entitled. Any disclosure of an article or reference, including patent applications and publications, is incorporated by reference herein for all purposes. Any omission in the claims of any aspect of subject matter disclosed herein is not a disclaimer of such subject matter.
Any numerical values recited herein or in the figures are intended to include all values from the lower value to the upper value in increments of one unit provided that there is a separation of at least 2 units between any lower value and any higher value. As an example, if it is stated that the amount of a component or a value of a process variable such as, for example, temperature, pressure, time and the like is, for example, from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70, it is intended that values such as 15 to 85, 22 to 68, 43 to 51, 30 to 32 etc. are expressly enumerated in this specification. For values which are less than one, one unit is considered to be 0.0001, 0.001, 0.01 or 0.1 as appropriate. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner. Unless expressly stated, all ranges are intended to include both endpoints and all numbers between the endpoints. The use of “generally, “about” or “approximately”, or similar words, in connection with a range applies to both ends of the range. Thus, “about 20 to 30” is intended to cover “about 20 to about 30”, inclusive of at least the specified endpoints.
The disclosure of “a” or “one” to describe an element, ingredient, component or step is not intended to foreclose additional elements, ingredients, components or steps. Plural elements, ingredients, components or steps may be provided by a single integrated element, ingredient, component or step. Alternatively, a single integrated element, ingredient, component or step may include separate plural elements, ingredients, components or steps. | A wheelhouse cladding step assembly includes a step movable between a closed position and an open or deployed position in which the step is located proximal the wheelhouse of the vehicle and provides improved access to the roof and/or rooftop cargo storage of the vehicle. The step is designed to have a shape matching the shape of the wheelhouse of the vehicle and is preferably curved and when in the closed position shows a surface that matches the vehicle trim to hide the step. The assembly includes hinges and a latching mechanism that are also contained within the assembly so they are hidden when the step is in the closed position. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a data storage device comprising a plurality of discs connected in the form of array and its data managing method.
2. Description of the Related Art
In order to manage voluminous data in offices at high speed and a high level of reliability, data storage devices have been proposed to store data by dispersing in a plurality of disc drives in unit of, for instance, block with redundancy given to data to be stored. This technology has been disclosed in the U.S. Pat. No. 5,148,432 (Sep. 15, 1992) and "RAID Technology for Improving Failure Resistance and Reliability of Disks" in the April 1993 issue of "Interface". The RAID is an abbreviation of Redundant Arrays of Inexpensive Disks. These disks include magnetic disks that are used on hard disk drives, optical disks used on optical disk drives, floppy disks used on floppy disk drives, etc.
For instance, on a data storage device comprising four hard disk drives (HDD-1 through HDD-4), parity data for the same block data stored in the HDD-1 through the HDD-3 have been stored in the same block of the HDD-4. When the Nth block data of these HDDs are assumed to be A, B, C and D, respectively, the following relationship will hold good:
A XOR B XOR C=D (XOR denotes Exclusive OR)
Here, if the HDD-1 becomes faulty and a read error results, it is possible to restore the block data A by executing the operation of:
B XOR C XOR D
Further, when reading data, as HDDs storing corresponding block data can be simultaneously accessed, it will become possible to read data at high speed.
However, this system has such a problem that parity data must be always prepared and available in order to improve reliability and a time is needed for the process when writing data.
For instance, when writing data in Block A of the HDD-1, the following operations are needed:
(1) Read Block A (old data) of the HDD-1 for data.
(2) Read Block D (old parity) of the HDD-4 for parity.
(3) Execute the XOR operation between the read out Blocks A and D.
(4) Execute the XOR operation between new data and data obtained from the operation in (3) and prepare new parity data.
(5) Write new data into Block A of the HDD-1 for data.
(6) Write the new parity data prepared in (4) into Block D of the HDD-4.
As described above, read/write from/to the HDDs and the XOR operation are required twice, respectively and a considerable time is needed.
On a data storage device that manages files in unit of block according to the RAID system as described above, two times of file reading, XOR operation and file writing processes, respectively were required whenever file data were updated, and a considerable time was needed.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a data storage device capable of promoting speed of parity data generating process in file data writing and achieving data restoration process at a high speed when errors are produced in file data reading.
Another object of the present invention is to provide a file managing method for the data storage device.
According to the present invention, there is provided a data storage device comprising a plurality of data disks for storing data in units of data blocks, a parity disk for storing parity data used for restoring data to the data disks, first managing means for managing data blocks on the respective data disks with respect to whether each data block is used for data storage, second managing means for managing the data blocks on the respective data disks with respect to whether data of each data block is used for computing parity, detecting means, responsive to the first and second managing means, for detecting each data block which is not used for data storage and is used for computing parity, and purge processing means for updating the parity data based on data in the data blocks detected by the detecting means and the parity data stored to the parity disk corresponding to the detected data blocks.
Further, according to the present invention, there is provided a data storage device comprising a plurality of first storage media for storing file data in units of data blocks; a second storage medium for storing in parity blocks parity data corresponding to data stored in corresponding blocks in the respective first storage media; first flag storage means for storing first flag data showing whether each data block is used as a file data area; second flag storage means for storing second flag data showing whether each data block is used for computing parity; detecting means, responsive to the first and second flag storage means, for detecting each data block not used as a file data area and used for computing parity; purge processing means for updating the contents of the parity blocks based on data in the data blocks detected by the detecting means and the parity data in the parity blocks corresponding to the detected data block, and for toggling the second flag data for the detected data block; and parity data generating means for judging whether a selected one of the data blocks is not used for computing parity based on the second flag data when data is newly written in the selected data block, for updating the contents of the parity block corresponding to the selected block based on parity data of the parity block corresponding to the selected data block and data to be newly written to the selected data block, and for toggling the second flag data for the selected data block.
Furthermore, according to the present invention, there is provided a data managing method for a data storage device including a plurality of first storage media for storing file data in units of data blocks and second storage medium for storing in parity blocks parity data corresponding to data stored in corresponding blocks in the respective first storage media, comprising the steps of storing first flag data showing whether each data block is used as file data area; storing second flag data showing whether each data block is used for computing parity; detecting each data block not used as a file data area and used for computing parity; updating the contents of the parity blocks based on data in the detected data blocks and the parity data in the parity blocks corresponding to the detected data block, and toggling the second flag data for the detected data block; judging whether a selected one of the data blocks is not used for computing parity based on the second flag data when data is newly written in the selected data block; updating the contents of the parity block corresponding to the selected data block based on parity data of the parity block corresponding to the selected data block and data to be newly written to the selected data block; and toggling the second flag data for the selected data block.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 is a system configuration diagram of a disk array device in one embodiment of a data storage device of the present invention;
FIG. 2A is a diagram showing the construction of a file management table used for the disk array device shown in FIG. 1;
FIG. 2B is a diagram showing the construction of an array block management table used for the disk array device shown in FIG. 1;
FIG. 3 is a flowchart showing the whole process steps of the disk array device shown in FIG. 1;
FIG. 4 is a flowchart showing the file preparation processing steps;
FIG. 5 is a flowchart showing the file read-out processing steps;
FIG. 6 is a flowchart showing the file write processing steps;
FIG. 7 is a flowchart showing the array block adding processing steps;
FIG. 8 is a flowchart showing the array block write processing steps;
FIG. 9 is a flowchart showing the file delete processing steps;
FIG. 10 is a flowchart showing the whole purge processing steps;
FIG. 11 is a flowchart showing the partial purge processing steps; and
FIG. 12 is a flowchart showing the block data restoration processing steps.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Hereinafter, a preferred embodiment of the present invention will be described with reference to the drawings.
FIG. 1 is a system configuration diagram of the disk array device in one embodiment relative to the data storage device of the present invention. In FIG. 1, the reference number 11 denotes a CPU that controls the entire data storage device. The CPU 11 reads out a program stored in the HDD-0 (12) and controls all the parts of the device according to the contents of this program. The reference number 14 denotes an array HDD controller. The array HDD controller 14 controls 4 units of HDD-1 through HDD-4 (18 1 -18 4 ). The HDD-1 through HDD-4 (18 1 -18 4 ) store and reproduce file data with parity data added. 3 units of the HDD-1 through HDD-3 (18 1 -18 4 ) out of 4 units of the HDD are used for data while the HDD-4 (18 4 ) is used for parity. Data obtained from the XOR operation of block data of the same block number in 3 units of the HDD-1 through HDD-3 (18 1 -18 3 ) have been stored in the block having the same block number of the HDD-4 (18 4 ) for parity.
Size of the HDD block of this data storage device is 1,024 bytes and the data storage device has a storage capacity of 1,000 blocks per unit. Total physical number of blocks of 4 units of the HDD-1 to HDD-4 (18 1 -18 4 ) is 4,000 blocks. However, as one unit of the HDD is for parity, the total number of blocks for storing file data are actually 3,000 blocks. Reference number 15 denotes a communication controller, which receives commands sent through a LAN 16 and transmits the processed result to other terminal equipment through the LAN 16. All parts excepting the HDD-1 to HDD-4 are connected each other through a system bus 17.
FIGS. 2A and 2B are the diagrams showing the constructions of the management tables for managing the data storage device of the present invention.
As the management tables, a file management table 21 (FIG. 22A) and an array block management table 22 (FIG. 2B) are used. These management tables 21 and 22 have been stored in the HDD-0 (12).
As shown in FIG. 2A, the file management table 21 comprises File No. ("1" to "100") 21a, Existence Flag ("1" denotes existence, "0" denotes non-existence) 21b, Using Blocks for File Data 21c, and Block No. in Array HDD storing file data (called Array Block No.) 21d, and is in construction capable of managing max. 100 files.
The Array Block Number 21d uses values from "1" to "3000". "1" to "1000" correspond to Block Nos. "1" to "1000" of the HDD-1 (181), "1001" to "2000" correspond to Block Nos. "1" to "1000" of the HDD-2 (18 2 ), and "2001" to "3000" correspond to Block Nos. "1" to "1000" of the HDD-3 (18 3 ).
As shown in FIG. 2B, the array block management table 22 comprises Array Block No. ("1" to "3000") 22a, Use Flag 22b to show whether the array blocks are used as the file data areas, and Clear Flag 22c to show whether data in the array blocks are all "0".
When the value is "1", the use flag 22b shows that the array block is in use. When the value is "1", the clear flag 22c shows that data are all "0" (cleared).
In the example shown in FIG. 2A, when the File No. 21a is "1", the number of using blocks for file data is "3", the array block numbers storing data are "1", "2" and "3". The Array Block Nos. "1", "2" and "3" correspond to Block Nos. "1", "2" and "3" of the HDD-1 (18 1 ). Further, as these array blocks are used as the file data areas, the use flags 22b for these blocks have been set at "1". In addition, the clear flags 22c for these array blocks have been set at "0" and it is seen that all data are not "0". Further, the use flag 22b for Array Block No. 6 has been set at "0" and this array block is not used as the file data area. The clear flag 22c has been set at "1" and it is seen that data in this array block are all "0".
Next, the operation in this embodiment will now be described.
FIG. 3 is a flowchart showing the processing steps of the entire data storage device of the present invention.
First, the CPU 11 reads data out of the file management table 21 and the array block management table 22 stored in the HDD-0 (12) and set them on the memory 13 (Step 301).
Thereafter, the CPU 11 checks whether a command has been received from a terminal equipment connected to the LAN 16 through the communication controller 15 (Step 302).
When a command has been received, the CPU 11 executes the file creating process (Step 303), the file reading process (Step 304), the file writing process (Step 305), the file deleting process (Step 306) and full purging process (Step 307), respectively according to the received command, and returns to Step 302 to check whether a command has been received again. If the command receiving was completed, the CPU 11 writes data of the management tables 21 and 22 on the memory 13 into the HDD-0 (12) (Step 308) and terminates the process.
In Step 302, if no command was received, the CPU 11 executes the partial purging process (Step 309) and returns to Step 302 to check again if there is any command received.
FIG. 4 is a flowchart showing the steps of the file creating processing step 303.
In the file creating process, the CPU 11 first refers to the existence flag 21b for each line of the file management table 21 (Step 401). In succession, the CPU 11 checks if the existence flag "0" is found (Step 402). If the existence flag "0" couldn t be found, the file management table 21 was full and the CPU 11 sends an error status to the requesting terminal equipment (Step 403). When the existence flag "0" has been found, the CPU 11 sets the existence flag 21b for the line where "0" has been found at "1" (Step 404), sends the status showing the proper completion of the processes and File No. of the line for which the existence flag has been set from "0" to "1" to the requesting terminal equipment (Step 405), and returns to Step 302.
For instance, when the file creating process was executed in the state of the file management table 21 shown in FIG. 2A, File No. "3" is selected, its existence flag 21b is set at "1" and File No. "3" is sent to the requesting terminal equipment.
FIG. 5 is a flowchart showing the steps of the file reading processing step 304.
In the file reading process, the CPU 11 first obtains a parameter from a terminal equipment through the communication controller 15 (Step 501). The parameter comprises File No., Read Offset Block No. and Number of Read-out Blocks. This parameter indicates the read-out of block data in numbers expressed by the number of read-out blocks from a block at the position expressed by the Read Offset Block Number of a file specified by File No. Data are read in unit of block between a terminal equipment and this data storage device and the process in unit of byte in a block is executed at the terminal equipment side.
Next, to check whether there is a file specified by the parameter, the CPU 11 refers to the existence flag 21b for a file number line in the file management table 21 (Step 502). The existence flag 21b being "1" indicates that there exists the file specified by the parameter and therefore, the CPU 11 proceeds to the next step. The existence flag being "0" indicates that the file specified by the parameter does not exist and therefore, the CPU 11 sends an error status to a requesting terminal equipment through the communication controller 15 (Step 503) and returns to Step 302.
Then, in order to check whether the read requested block specified by the parameter is within a file size, the CPU 11 compares "Read Offset Block No.+No. of Read Blocks" with "No. of File Blocks" (Step 504). When "No. of File Blocks" is larger than or equal to "Read Offset Block No.+No. of Read Blocks", the request is within the file size and therefore, the CPU 11 proceeds to the next step 505. In another case, as the request is over the file size, the CPU 11 sends an error status to the requesting terminal equipment through the communication controller 15 (Step 503) and returns to Step 302.
When "No. of File Blocks" is larger than or equal to "Read Offset Block NO."+No. of Read Blocks", as the request is within the file size, the array block number corresponding to an area specified by the parameter is obtained from the array block numbers of the file number line of the file management table 21 (Step 505).
For instance, in case of a parameter comprising File No."1", Read Offset Block No."1" and No. of Read Blocks "2", the corresponding Array Block Nos. are "2" and "3" when the file management table 21 is referred to.
Further, in case of a parameter comprising File No. "2", Read Offset Block No. "1" and No. of Read Blocks "2", the read requested block is over the file size and therefore, an error will result.
Next, the CPU 11 obtains the HDD Nos. (HDD-1 to HDD-3) and Block Nos. actually storing block data from the Array Block Nos. obtained in Step 505 and then, based on these HDD Nos. and Block Nos., reads data out of the prescribed address positions of the HDDs corresponding to the HDD Nos. and stores this data in the memory 13 (Step 506). At this time if a read error results in the HDDs, the CPU 11 reads data from the parity HDD-4 (18 4 ) and other data HDDs and based on these data, restores error data. For instance, if Array Block Nos. are "2" and "3", the CPU 11 reads block data from data stored in Block Nos. "2" and "3" of the HDD-1 (18).
Thereafter, the CPU 11 sends a status indicating the proper completion and block data stored in the memory 13 to the requesting terminal equipment through the communication controller 15 (Step 507) and returns to Step 302.
FIG. 6 is a flowchart showing the steps of the file writing process step 305.
First, the CPU 11 gets a parameter from a terminal equipment through the communication controller 15 (Step 601). This parameter comprises File No., Write Offset Block No., No. of Writing Blocks and data blocks. This parameter indicates to write block data in number expressed by the number of writing blocks from the block at the position shown by the write offset block number of the file specified by a file number.
Next, the CPU 11 checks whether there exists the file specified by the parameter likewise the file reading process (Step 602).
Then, in order to check whether the write requesting block specified by the parameter is within a file size, the CPU 11 obtains the number of additional array blocks from an equation: [Write Offset Block No.+No. of Write Blocks]-[No. of File Blocks] (Step 603). Then, the CPU 11 checks whether the number of additional array blocks is larger than "0" (Step 604). If the number of additional array blocks is larger than "0", it is necessary to add a data area block and therefore, the array block adding process shown in FIG. 7 is executed (Step 605). If error returned from this array block adding process, the array block becomes short and therefore, the CPU 11 sends an error status to the requesting terminal equipment through the communication controller 15 (Step 606) and returns to Step 302. If the number of additional blocks is less than "0", as data are to be written into the existing data block, the CPU 11 skips the array block adding process step 605.
Thereafter, the CPU 11 executes the array block writing process for the array blocks in the area specified by the parameter (Step 607).
Then, the CPU 11 sends a status indicating the proper completion and block data stored in the memory 13 to the requesting terminal equipment through the communication controller 15 (Step 608) and returns to Step 302.
FIG. 7 is a flowchart showing the steps of the array block adding process step 605.
First, the CPU 11 obtains the number of lines of which use flags 22b in the array block management table 22 are "0" (non-use) and sets it as a variable of the number of non-use array blocks (Step 701). When this number of non-use array blocks is less than the number of additional array blocks obtained in Step 603 (Step 702), the array blocks are short and the CPU 11 makes the error return (Step 703). When the number of non-use array blocks is over the number of additional array blocks, the CPU 11 selects the lines in number corresponding to additional array blocks, of which use flags 22b in the array block management table 22 are "0" and sets the use flags 22b for the array block numbers at "1" (Step 704). The CPU 11 adds the array block numbers of the selected lines to the array block number 21d of the file number line specified by the file management table 21 and after adding the number of adding array blocks to the block numbers 21c (Step 705), returns properly.
For instance, in case of a parameter comprising File No. "2", Write Offset Block No. "1" and No. of Write Blocks "2", the number of additional array blocks will be (1+2)-2=1 block. Accordingly, Array Block Number "6" of the 6th line of which use flag 22b of the array block management table 22 is "0" is selected and this use flag 22b is set at
Then, the number of blocks of the line of which File No. 21a in the file management table 21 is "2" is changed from "2" to "3" and "6" is added to the array block number 21d. As a result, "4", "5" and "6" are set for the array block number 21d.
FIG. 8 is a flowchart showing the steps of the array block writing process step 607.
In this array block writing process, assuming a variable "i" as showing Data Block No. in a parameter, the writing process is executed for each block while setting the number of write blocks starting from "1" (Steps 802, 808). When the same parameter as that shown above is specified, "1" and "2" are set sequentially for "i".
Then, the following process is executed for Data Block No. "i" in the parameter:
First, the CPU 11 obtains a value of [i+Write Offset Block No. in Parameter] of Array Block No. 21d of the file number line in the file management table 21 and then, set it as a variable "AB" (Step 803). Data is written for the array block shown by this variable "AB". For instance, when a parameter is the same as above, Array Block Nos. are the second and third array block numbers of file No. "2" and therefore, "5" and "6" are set sequentially for the variable AB.
Then, the CPU 11, referring to the array block clear flag 22c (Step 804) shown by the variable "AB" in the array block management table 22, executes the following 6 steps (Step 805) if the value of the flag is "0" (uncleared).
(1) From the value shown by the variable "AB", by reading the block data of the HDD storing the corresponding data block, stores the data in the work memory area 1 (WM1) in the memory 13.
(2) From the value shown by the variable "AB", by reading the block data of the HDD storing the corresponding parity block, stores the data in the work memory area 2 (WM2).
(3) Executes the XOR operation between data in the WM1 and the WM2 and stores the result of operating in the work memory area 3 (WM3) in the memory 13.
(4) Executes the XOR operation between data in the WM3 and the "i"th block in the parameter and stores the result of operating in the work memory area 4 (WM4) in the memory 13.
(5) Writes the "i"th block data in the parameter into the data HDD block shown by the variable "AB".
(6) Writes data in the WM4 into the parity HDD-4 (18 4 ) block shown by the variable "AB".
Further, if the value of the clear flag 22c is "1" (Cleared), the CPU 11 executes the following process in 4 steps (Step 806):
(1) From a value shown by the variable "AB", reads the block data of the HDD storing the corresponding parity block and stores in the work memory area 1 (WM1) in the memory 13.
(2) Executing the XOR Operation between the data in the WM1 and the "i"th block data in the parameter, stores the result of operation in the work memory area 2 (WM2) in the memory 13.
(3) Writes data of the "i"th block in the parameter into the data HDD block shown by the variable "AB".
(4) Writes the data in WM2 into the block of the parity HDD-4 (18 4 ) shown by the variable "AE".
Thereafter, the CPU 11 sets "0" for the clear flag 22c of the array block in the array block management table 22 into which data have been written (Step 807). That is, the value "1" of the clear flag 22c is toggled to "0".
For instance, when the same parameter as above has been specified, data are written for the array block numbers "5" and "6" and the processes comprising 6 steps are executed as the clear flag 22c for Array Block No. "5" is "0" and the processes comprising 4 steps are executed as the clear flag 22c for Array Block No. "6" is "1". Thus, there is such a merit that if data in the writing block are all "0", the number of processing steps is less and the number of work memory areas to be used is also less.
FIG. 9 is a flowchart showing the steps of the file deleting process step 306.
In the file deleting process, first, the CPU 11 acquires a parameter from a terminal equipment through the communication controller 15 (Step 901). The parameter comprises File No.
Then, likewise the file reading process, the CPU 11 checks whether there is a file specified by the parameter (Step 902). When the file does not exist, the CPU 11 sends an error status to the requesting terminal equipment (Step 903) and returns to Step 302.
When there is the file, the CPU 11 obtains Array Block No. assigned for the file data from the file management table 21 and sets the corresponding use flag 22b in the array block management table 22 at "0" (non-use) (Step 904).
Then, the CPU 11 sets "0" (non-existence) for the file number line existence flag 21b in the file management table 21, "0" for the number of blocks 21c (Step 905) and lastly, sends a status showing the proper completion to the requesting terminal equipment (Step 906), and returns to Step 302.
For instance, when the deletion of File No. "1" is specified, the array blocks with Array Block Nos. "1", "2" and "3" are released and their use flags 22b become "0".
Under the state immediately after deleting files, the clear flags 22c for these array blocks are left at "0". If these array blocks are added as the file data areas and data are written thereto, the process step becomes 6 as in the conventional example, causing deterioration of performance. So, when a process to clear data in the array blocks of which use flags 22b are "0" (non-use) and the clear flags 22c are "0" (uncleared) is carried out according to circumstances (this process will be referred to as the purging process), it becomes possible to reduce the writing process requiring 6 steps to 4. FIG. 10 is a flowchart showing the steps of the full purging process step 307.
This full purging process is to purge all array blocks in the non-use and uncleared state in the system according to a request from a terminal equipment. This request is made when access to the system is less, for instance, during the nighttime or when starting up the system or immediately before stopping the system.
The CPU 11 sets the array block numbers ranging from "1" to "3000" sequentially for a variable "AB" (Step 1001) and executes the following processes for each array block.
First, the CPU 11 refers to the use-flag 22b for the array block shown by the variable "AB" from the array block management table 22 (Step 1002) and when the value of this flag is "1" (use), proceeds to the next array block.
Further, when the value of the use flag 22b is "0" (non-use), the CPU 11 refers to the clear flag 22c (Step 1003) and if the value of the clear flag 22c is "1" (cleared), proceeds to the next array block.
Then, the CPU 11 executes the following processes for the array blocks of which use flags 22b are "0" (non-use) and the clear flags 22c are "0" (uncleared) (Step 1004).
(1) From a value shown by the variable "AB", reads block data of the HDD storing the corresponding data block and stores in the work memory 1 (WM1).
(2) From a value shown by the variable "AB", reads block data of the HDD-4 (18 4 ) storing the corresponding parity block and stores in the work memory 2 (WM2).
(3) Executes the XOR operation between data in the WM1 and WM2 and stores the result of operation in the work memory 3 (WM3).
(4) Writes data in the WM3 into the parity HDD-4 block (18 4 ) shown by the variable "AB".
Then, set "1" (cleared) for the corresponding clear flag 22c of the array block management table 22 (Step 1005), that is, the value "0" of the clear flag 22c is toggled to "1", and proceeds to the next array block.
FIG. 11 is a flowchart showing the steps of the partial purging process step 309.
This partial purging process is to purge the array blocks in the non-use and uncleared state by one block at a time when there is no request from any terminal equipment.
This process is almost the same as the full purging process shown in FIG. 10 but differs in that the CPU 11 does not execute the purging process for all array blocks but selecting any one array block in non-use and uncleared state, executes the purging process for only that array block and then, returns to Step 302.
In the full and partial purging processes, all "0" data were not written for a data block of the array blocks which were set as cleared. This is because data that were assumed to be "0" in the data block have been written in the corresponding parity block. Because of this, when restoring data by reading the same block of other HDD at the time of HDD reading error, it becomes also possible to omit a process to read a block of which clear flag 22c is "1".
FIG. 12 is a flowchart showing the block data restoring process steps.
This process is carried out when the data block reading error was taken place.
First, from the array block number ("AB") of the array block to be restored, the corresponding array block number in other 2 units of the data HDD is obtained and set for "AB1" and "AB2" (Step 1201). For instance, Array Block Nos. "1001" and "2001" are obtained for Array Block No. "1".
Then, the parity block of the array block "AB" is read and stored in the work memory 1 (WM1) (Step 1202). For instance, the first block of the HDD-4 (18 4 ) is read out for Array Block No. "1".
Then, the clear flag 22c of the array block "AB1", which is another data block in the array block management table 22 is referred to (Step 1203) and when the value of this flag is "0" (uncleared), the following processes are executed (Step 1204) by the CPU 11.
(1) Reads the data block of the array block "AB1" and stores in the work memory 2 (WM2).
(2) Executes the XOR operation between data in the WM1 and WM2 and stores the result of operation in the WM1.
When the clear flag 22c is "1" (cleared), the above processes are skipped.
Then, the similar processes are carried out for the array block "AB2" (Step 1205 and 1205).
Restored data is generated in the WM1 by these processes. For instance, when an error is generated when reading data in a block with Array Block No. "1" and data in the block is to be restored in the state of the array block management table 22 as shown in FIG. 2B, the data can be restored only when reading the first block data in the HDD-4 (18 4 ) as the clear flags 22c for corresponding array blocks ("1001" and "2001" ) in other HDD-2 (18 2 ) and HDD-3 (183) are both "1". That is, it becomes also possible to execute the data restoration process at a high speed.
As described above, according to the data storage device and its file managing method of the present invention, when data in a data block which is no longer used are cleared in advance, the parity data generating process when writing data in this data block can be made only by executing the exclusive OR operation of write data and parity data and thus, the process speed can be sharply promoted.
Further, the data restoration process when an error is generated while reading data from a certain data block can be made only by executing the exclusive OR operation of the uncleared data block data and parity data, and the data restoration process can be accelerated. | A data storage device includes a plurality of data disks for storing data in units of data blocks and a parity disk for storing parity data used for restoring data to the data disks. Data blocks on the respective data disks are managed with respect to whether each data block is used for data storage and managed with respect to whether data of each data block is used for computing parity. Each data block which is not used for data storage and is used for computing parity is detected. The parity data are updated based on data in the detected data blocks and the parity data stored to the parity disk corresponding to the detected data blocks. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a process for treating a waste liquor from hydrosulfite production process. More particularly, this invention relates to a process for treating the waste liquor comprising aerating the waste liquor to remove reducing inorganic sulfur compounds from the waste liquor and then applying an activated sludge process to the waste liquor. In this invention, by "hydrosulfite" is meant a alkali metal dithionite.
2. Description of the Prior Art
The waste liquor mentioned herein, is a waste liquor resulting from removal of a final product, anhydrous hydrosulfite, and a solvent from a reaction mixture in the process of producing anhydrous hydrosulfite by using sodium formate, alkali metal compounds, and sulfur dioxide such as the processes of U.S. Pat. Nos. 2,010,615 and 3,411,875 and British Patent No. 1,148,248. The waste liquor contains sodium thiosulfate, sodium sulfite, acid sodium sulfite, other unknown reducing inorganic sulfur compounds represented by the formula
Na.sub.x S.sub.y O.sub.z
where x, y and z are positive numbers, sodium formate and the like. Thus, if this waste liquor is directly disposed of, it becomes BOD and COD sources to cause water pollution. Therefore, some treatment should be applied before disposing of the waste liquor.
In general, the activated sludge process is known as a most effective method for treating waste liquor containing hydrophilic organic compounds and is used in various fields. For example, a waste liquor containing inorganic reducing substances such as sodium thiosulfate, sodium sulfite, and acid sodium sulfite and sodium formate can be effectively treated.
However, the present inventors have found that a conventional activated sludge process is not effective for treating hydrosulfite waste liquor. This seems to be due to unknown reducing substances present in the waste liquor from hydrosulfite process in addition to the above mentioned substances.
When a conventional activated sludge process is directly applied to the hydrosulfite waste liquor, BOD can not be sufficiently removed even if the waste liquor is diluted to a great extent, and further, the activated sludge itself becomes fine particles and is carried into the effluent without forming desirable floc, and therefore, a complete waste liquor treatment is not possible.
SUMMARY OF THE INVENTION
According to the present invention, the waste liquor is aerated at 30° - 85°C in the presence of 10 - 1000 ppm. of a metal ion such as iron, manganese, cobalt, copper and nickel ions. And then an activated sludge process is applied to the resulting waste liquor.
An object of the present invention is to provide an improved activated sludge process for treating such waste liquor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a relation between the aeration treatment temperature and aeration time in the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The waste liquor to be treated by the process of the present invention is preferably diluted with water to give an iodine consumption of 1 - 15%. By "iodine consumption" is meant in this invention the following weight %: ##EQU1##
The higher the concentration of reducing substances in the waste liquor, the more the iodine consumption.
The metal ions used in the present invention are iron, manganese, cobalt, copper and nickel ions. Among them, iron and manganese ions are preferred.
These metal ions may be added in a form of metal salt such as, for example, sulfate, chloride, nitrate and the like.
Representative metal salts may be ferric sulfate, ferric chloride, ferric nitrate, manganic sulfate, manganic chloride, manganic nitrate, cobalt sulfate, cobalt chloride, cobalt nitrate, copper sulfate, copper chloride, copper nitrate, nickel sulfate, nickel chloride, nickel nitrate and the like.
The metal ions may be used either alone or in combination. Concentration of the metal employed is usually 10 - 1000 ppm., preferably 50 - 1000 ppm. When the concentration of metal ion is lower than 10 ppm., the effect of aeration is markedly low or hardly recognized.
A gas used in the aeration may be molecular oxygen or a gas containing molecular oxygen, preferably with air.
The aeration temperature may range from 30°C to 85°C, preferably with from 40°C to 70°C. Referring to FIG. 1, the abscissa is aeration temperature (°C) and the ordinate is aeration time (hr.). The curve shows a relation between the aeration temperature and the aeration time to attain a removal efficiency of iodine consumption of higher than 90% when manganese sulfate was used at a concentration of 60 ppm. and air was supplied at a superficial velocity in a column of 60 Nm 3 /m 2 H. As is clear from FIG. 1, the velocity of oxidizing the reducing inorganic sulfur compounds is decreased to a great extent at temperatures lower than 30°C and higher than 85°C. For example, at 20°C the oxidation velocity is about 1/5 of that at 40°C.
The aeration time may be appropriately selected taking various other conditions into consideration.
The aeration may be carried out by reaction apparatus of various types, preferably with a tower type reactor. The superficial velocity in a column of air is usually higher than 10 Nm 3 /m 2 H, preferably 40 - 200 Nm 3 /m 2 H.
The hydrosulfite waste liquor is aerated under the above mentioned conditions.
It is preferred to select the aeration conditions so as to attain a removal efficiency of iodine consumption of higher than 50%, and preferably above 60%. When the removal efficiency of iodine consumption is lower than 50%, the floc is broken and thereby the activated sludge procedure becomes difficult. And when the removal efficiency of iodine consumption is lower than 60%, the load on the activated sludge treatment becomes unduly large. The load of the activated sludge treatment may be represented by BOD loading which indicates how much BOD is to be charged per unit volume of the activated sludge vessel and unit time.
The waste liquor treated by aeration may be diluted with water to 5 - 10 times. Ammonium sulfate and phosphoric acid are added to the liquor the ratio of BOD : N : P being preferably 100 : 5 : 1. The resulting liquor is treated by an activated sludge process.
In general, an activated sludge treatment is effected at a BOD loading of 1.0 - 2.0 Kg/m 3 -d and MLSS of 3000 - 5000 ppm. It is usually considered that a BOD loading of lower than 1.0 Kg/m 3 -d is commercially disadvantageous.
According to the present invention, the activated sludge does not assume fine particle form and can form good floc and thereby a complete waste liquor treatment is possible. In other words, even if the BOD loading is 1.5 Kg/m 3 -d, an excellent result can be obtained and the BOD removal efficiency can be more than 95%.
In the present invention, MLSS (Mixed Liquor of Suspended Solid) means a concentration of floc in an activated sludge vessel and SVI (Sludge Volume Index) means a compaction volume per g. of activated sludge after the suspended liquor of the activated sludge has stood still for 30 minutes and the unit is cc/g.
The following examples are given for illustrating the present invention, but by no means for limiting the present invention.
EXAMPLE 1
A waste liquor from a hydrosulfite production process (sodium formate 12%, iodine consumption 20%) 100l was mixed with 100l of water. To the resulting mixture was added 50g of FeCl 3 .6H 2 O and the liquor was fed to the top of a bubble column of 100 mm in inner diameter and 3000mm high at a rate of 6l/hr. and the liquor was continuously discharged from the bottom of the column. Air was supplied from the bottom of the column through a diffuser at a rate of 40 Nm 3 /m 2 H (as a superficial velocity in the column). Aeration temperature was kept at 60°C. Iodine consumption of the liquor decreased from 10% to 0.5% and the removal efficiency of iodine consumption was 95%. Then the liquor was diluted to 20 times, and ammonium sulfate and phosphoric acid were added to the liquor. The resulting liquor was subjected to an activated sludge treatment at MLSS 3000 ppm. and BOD loading 1.5 Kg/m 3 -d. The result is shown in Table 1 below. The resulting liquor was clear and SVI was 70.
Table 1______________________________________ Before treatment by After treatment by the activated sludge the activated sludge process process______________________________________BOD 1500 ppm. 60 ppm.COD (KMnO.sub.4) 1200 100COD (K.sub.2 Cr.sub.2 O.sub.7) 2800 260Iodineconsumption 250 0______________________________________
EXAMPLE 2
A waste liquor from a hydrosulfite production process (sodium formate 12%, iodine consumption 20%) 100l was mixed with 150l of water, and 80g of MnSO 4 .H 2 O was added to the liquor. The resulting liquor was fed to a bubble column of 100 mm in inner diameter and 3000 mm high at a rate of 8l/hr. from the bottom of the column and overflowed from the top of the column. Air was supplied from the bottom of the column through a diffuser at a rate of 70Nm 3 /m 2 H (as a superficial velocity in the column tower). Aeration temperature was kept at 40°C during the operation. Iodine consumption of the overflowing liquor was 0.2%. The resulting liquor was diluted to 15 times, and ammonium sulfate and phosphoric acid were added to the liquor. The resulting liquor was subjected to an activated sludge treatment at MLSS 4000 ppm. and BOD loading 1.6Kg/m 3 -d. The result is shown in Table 2 below. The liquor thus treated was clear and SVI was 90.
Table 2______________________________________ Before treatment by After treatment by the activated sludge the activated sludge process process______________________________________BOD 1600 ppm. 40 ppm.COD (KMnO.sub.4) 1200 90COD (K.sub.2 Cr.sub.2 O.sub.7) 2700 240Iodineconsumption 130 0______________________________________
Comparison Example 1
A waste liquor from a hydrosulfite production process (sodium formate 12%, iodine consumption 20%) was diluted to 40 times, and ammonium sulfate and phosphoric acid were added to the liquor.
The resulting liquor was subjected to an activated sludge consumption at MLSS 3000 ppm. The floc was broken at BOD loading of 0.4 Kg/m 3 -d and the fine sludge was carried over with the effluent. BOD, COD and iodine consumption were as shown in Table 3 below.
Table 3______________________________________ Before treatment by After treatment by the activated sludge the activated sludge process process______________________________________BOD 1500 ppm. 610 ppm.COD (KMnO.sub.4) 1500 680COD (K.sub.2 Cr.sub.2 O.sub.7) 3000 1550Iodineconsumption 5000 1320______________________________________
Comparison Example 2
A waste liquor from a hydrosulfite production process (sodium formate 12%, iodine consumption 20%) 100l was mixed with 100l of water, and 50 g of FeCl 3 .6H 2 O) was added to the liquor. The resulting liquor was fed to the top of a bubble column of 100 mm in inner diameter and 3000 mm high at a rate of 2l/hr while air is blown to the tower from the bottom through a diffuser at a rate of 40Nm 3 m 2 H. The liquid was continuously drawn from the bottom of the tower. The inside of the tower was kept at 20°C. After the treatment, iodine consumption of the resulting liquid was 8%. Hence this liquid was not suitable for being subjected to an activated sludge process, with or without dilution.
Comparison Example 3
A waste liquor from a hydrosulfite production process (sodium formate 12%, iodine consumption 20%) 100l was mixed with 100l of water, and then 18l of the resulting mixture was fed to a bubble column of 100 mm in inner diameter and 3000 mm high without adding any catalyst while air was blown to the bubble column from the bottom of the tower through a diffuser at a rate of 40Nm 3 /m 2 H (as a linear velocity in the ampty tower). The inside of the tower was kept at 60°C. After 24 hours, iodine consumption in the liquid in the tower was 9.8% and even after 48 hours, it was the same as above. This liquid was naturally unsuitable for being subjected to an activated sludge process, with or without dilution.
EXAMPLE 3
A waste liquor from a hydrosulfite production process (sodium formate 12%, iodine consumption 20%) 100l was mixed with 100l of water, and 100 g of CuSO 4 .5H 2 O was added to the liquor. The procedure of Example 1 was repeated except the resulting liquor was fed to the bottom of the same bubble column at a rate of 8l/hr and the liquor was continuously discharged from the top of the column. Air was supplied from the bottom of the column through a diffuser at a rate of 70 Nm 3 m 2 H (as a superficial velocity in the column). The aeration temperature was kept at 40°C. Iodine consumption of the overflowing liquor was 2%. The liquor was diluted to 20 times, and ammonium sulfate and phosphoric acid were added to the liquor. The resulting liquor was subjected to an activated sludge treatment at MLSS 4000 ppm. and BOD loading 1.3 Kg/m 3 -d. The result is shown in Table 4 below. The liquor thus treated was clear and SVI was 85.
Table 4______________________________________ Before treatment by After treatment by the activated sludge the activated sludge process process______________________________________BOD 1600 ppm. 100 ppm.COD (KMnO.sub.4) 1500 150COD (K.sub.2 Cr.sub.2 O.sub.7) 3000 350Iodineconsumption 1000 0______________________________________
EXAMPLE 4
A waste liquor from a hydrosulfite production process (sodium formate 12%, iodine consumption 20%) 100l was mixed with 100l of water, and 30 g of FeCl 3 .6H 2 O and CoCl 3 30 g were added to the liquor. The resulting liquor was fed to the top of the same bubble column as in Example 1 at a rate of 15l/hr, and the liquor was continuously discharged from the bottom of the column. Air was supplied from the bottom of the column through a diffuser at a rate of 40Nm 3 /m 2 H (as a superficial velocity in the column). The aeration temperature was kept at 60°C. Iodine consumption of the discharged liquor was 0.1%. The liquor can be effectively treated by the activated sludge process as in Example 3.
EXAMPLE 5
A waste liquor from a hydrosulfite production process (sodium formate 12%, iodine consumption 20%) 100l was mixed with 100l of water, and 200 g of NiSO 4 was added to the liquor. The procedure in Example 1 was followed except the resulting liquor was fed to the bottom of the same bubble column at a rate of 5l/hr, and the liquor was continuously discharged from the top of the column. Air was supplied from the bottom of the column through a diffuser at a rate of 70Nm 3 /m 2 H (as a superficial velocity in the column). The aeration temperature was kept at 40°C. Iodine consumption of the discharged liquor was 2.3%. The liquor can be effectively treated by the activated sludge process as in Example 3. | A process for treating a waste liquor from a hydrosulfite process by an activated sludge process is improved by aerating the waste in the presence of a metal ion before the activated sludge process. | 2 |
FIELD OF THE INVENTION
This invention pertains to controlling the temperature of process tools using thermal transfer fluids, and more particularly to meeting the needs of industries which require precise but selectable control of the temperature of units having different thermal loads, such as fabrication equipment using cluster tools for making high precision semiconductors.
BACKGROUND OF THE INVENTION
Temperature control units for industries which manufacture high precision products, such as multiple semiconductor chips on wafers, must meet a number of stringent and sometimes conflicting requirements. While the manufacture of semiconductors perhaps imposes greater demands than are encountered in most other industrial fields, this industry illustrates particularly well the extent and variety of the problems which might now be encountered with modern temperature control systems. Semiconductor fabrication installations usually include many so-called cluster tools disposed throughout a high cost facility. Wafers are processed using successive steps which demand both high energy usage and close temperature control during removal or addition of thermal energy. Examples of these steps include chemical and high energy deposition and etching procedures carried out in specialized chambers. To maintain the appropriate internal environment and the particular temperature conditions needed for a given process step, separate temperature control units are usually employed to provide a chilled or heated thermal transfer fluid for circulation through the operative process parts of a tool. The temperature control unit must not only maintain the thermal transfer fluid at a prescribed setting and also bring the fluid temperature to its setpoint within specified time limits, but also operate over long periods with very limited down time, be energy efficient and demand minimal floor space.
Preferred systems for such applications have included temperature control units as described in Kenneth W. Cowans U.S. Pat. No. 6,102,113 entitled “Temperature Control of Individual Tools in a Cluster Tool System”. These temperature control units provide multichannel capability for the control of several different process temperatures by delivery of pressurized refrigerant to chill thermal transfer fluid flows, or by regulated heating of thermal transfer fluids. For refrigerating the thermal transfer fluid, pressurized liquid refrigerant in each channel is passed through an expansion valve regulating flow to an evaporator/heat exchanger. For heating the thermal transfer fluid each channel includes a separate heat source. This temperature control unit employs a single refrigeration unit and single reservoir for the thermal transfer fluid, and uses a different pump in each channel for fluid recirculation. The system has proven to be extremely reliable, requires low floor space (footprint) and provides precise temperature control of the thermal transfer fluid, in both static and dynamic modes.
With time, however, and with the evolution of new cluster tool systems and other units for semiconductor fabrication, a number of additional and particular requirements have more recently been imposed. Thus further and different needs must now be met that necessitate greater flexibility, adaptability and performance, while the goals of long life, compactness and efficient operation remain. For example, some typical modern process tools include more than one unit, such as a process chamber, with each of these having a number of different subunits, each to be brought to and maintained at preset temperature levels. In some of these tools, there may be common settings for like subunits, while other subunits there may be no commonality among the desired settings. Holding temperature at the given levels may require substantial cooling capacity, or only moderate cooling capacity, or even the addition of heat energy. Thermal exchange capacity, usually expressed here in terms of kilowatts, is necessarily a function of both temperature and flow rate.
Overall, the requirements at a semiconductor fabricating facility may differ such that the specified temperature levels can vary from very cold (e.g. down to −40° C.), to within a moderate temperature range (e.g. 0° C. to 40° C.), or to a higher temperature (e.g. up to about 120° C. for semiconductor fabrication houses). Moreover, the thermal demand, in KW, may also be substantially different, meaning that the capacity of a compressor or pump, for example, may have to be high for one installation but can be much lower for another. Sometimes one control unit may have sufficient thermal capacity for a number of subunits. In other user environments the temperatures to be maintained may be at more extreme temperature limits, or there may be special needs for varying temperatures within specified time periods.
For most practical applications in the semiconductor fabrication industry, temperature is controlled by circulating a thermal transfer fluid through a cluster tool subunit and back to the temperature control unit, with the user specifying the temperature and flow rate needed. The thermal transfer fluid is typically an equal mixture of ethylene glycol and water, or a proprietary fluid, such as that sold under the trademark “Galden”. These both accommodate very wide differentials between freezing and boiling levels, and have viscosity characteristics which tolerate pumping force differences within the operating temperature limits.
To meet these varied requirements with a compact, low footprint unit is not enough, since it is also desirable to maintain the subunit temperatures while using minimal amounts of energy without losing the flexibility needed to meet temperature level and flow rate requirements for a substantial number of subunits. Cooling solely by air is seldom a viable option. The cheapest available temperature control medium is facilities (utilities) water, for example, which suffices for cooling down to a limited intermediate temperature range somewhat above that of the water itself. For greater chilling capacity, a pressurized refrigerant can be used, while for heating an external thermal energy source, such as an electrical heater, can be employed. Providing appropriate thermal energy solutions for a variety of coexisting needs and at the same time using a compact, high reliability and low energy demand configuration, however, presents problems that have not heretofore been satisfactorily resolved.
SUMMARY OF THE INVENTION
In a temperature control unit in accordance with the invention, separate modules of like or related form factors are received in a control chassis, there being at least two broadly distinguishable module types each having at least two different temperature control capabilities, and each with energy savings potential. The modules each have their own pump and reservoir for thermal transfer fluid, an energy efficient unit providing a cooling medium, a heat exchanger or exchangers for transfer of thermal energy between the cooling medium and the transfer fluid, and at least one element for heating the thermal transfer fluid. These modules themselves can be modified while remaining consistent with the defined form factor by the use of differently powered compressors, different capacity pumps, differently sized reservoirs, or more than one heat exchanger. Flow rates as well as thermal load capacities can be adapted or revised to service individual or multiple subunits.
This versatile module-based approach offers a variable array of functionalities to confront the individual needs of multiple operative subunits. Self contained refrigeration loops with thermal transfer fluid reservoirs and pumps enable extraction of heat from a substantial but accommodatable fluid volume in order to cool a process tool. Since the modules can be used in different combinations and internally varied as well, they can be both individually tailored and flexibly responsive to multiple needs on an overall basis. The heat removal rate requirements, which are changeable, of a variety of process tools, can thus be confronted by appropriate module sets, each adapted to meet the temperature level and flow rate needs of individual subunits in the process tools. The basic module types, used in combination, enable control from cooling at low temperatures to heating at relatively high temperatures.
In one type of module, for example, a refrigeration unit is arranged such that compressor energy in a refrigeration loop including an evaporator/heat exchanger can either cool or heat the thermal transfer fluid. This module type cools by expanding pressurized refrigerant in the refrigeration loop or heats using pressurized hot gas from the compressor in a hot gas bypass loop. Heating may additionally be supplied or augmented using the separate heating source in a thermal transfer fluid loop. Thus temperatures can be maintained at different individual prescribed levels with superior energy efficiency in each instance. A second control module type uses a liquid/liquid heat exchanger which receives facilities water as well as thermal transfer fluid, and varies the facilities water flow for mid-range cooling of the process tool unit or subunit. The facilities water flow rate is regulated by a temperature responsive flow control valve combination receiving a control signal from the system. The separate heating source in this unit corrects the thermal transfer fluid temperature rapidly, or independently heats the fluid to a selected higher level.
The entire system is advantageously processor controlled, and includes sensors for detecting the actual thermal transfer fluid temperatures in the different channels that are individually controlled by the modules. A touch screen display enables an operator to enter prescribed operating temperatures and changes, and to review operating values, including fluid flow rates. The physical system configuration is such that a chassis can receive one or more temperature control modules that are integrally sized relative to the standard form factor, such that they removably fit into matingly configured supports or receptacles in the chassis. The modules can be arranged in vertical and/or horizontal arrays, and include front end panels which provide access for adjustments, fluid filling, and draining. Backend panels provide supply and return ports for conduction of thermal transfer fluid through the process tools, and may include couplings for utilities water and electrical power. They also typically include manifolds for coupling thermal transfer fluid lines in common to more than one subunit to be held at the same temperature.
Where a larger compressor or reservoir is to be utilized, this can be accomplished with a module that is a multiple of the standard form factor in width while still being compatible with the control chassis. Where refrigeration capacity needs are less, the refrigeration loop may be simplified as by elimination of features such as a subcooler. If no utilities water is available for cooling, the condenser in the cooling loop may be of an air cooled type. Air conditioning type compressors are typically used, at considerable savings in system cost.
In a specific example of a versatile cooling and heating module, the pressurized refrigerant from the compressor is, for lower temperature chilling applications, liquefied in the condenser and provided through a solenoid controllable expansion valve and a subcooler to an evaporator/heat exchanger, from which expanded refrigerant is returned to the compressor input via the subcooler. The same unit can also be used to heat, moreover, by using a bypass loop from the compressor that is opened when the refrigerant loop conduit is closed at the solenoid expansion valve. Under this condition hot gas refrigerant is directed via a hot gas bypass valve into the evaporator/heat exchanger, heating the thermal transfer fluid to the range of as much as 120° C. This bypass loop from the compressor output proceeds through the hot gas bypass valve which opens in response to low pressures at the input to the compressor such as occur automatically when the solenoid expansion valve is shut off. The hot gas bypass loop also safeguards the compressor by returning refrigerant flow to the compressor input when greater input pressure is needed. Advantageously, the hot refrigerant gas is also directed through the reservoir for thermal transfer fluid to increase the temperature of the body of thermal transfer fluid. If desired, the thermal transfer fluid temperature can be increased further or brought more quickly to temperature by activating the electrical heater in the thermal transfer fluid line. This module also may use other expedients, such as employing a desuperheater valve responsive to compressor input temperature to divert a part of the liquid refrigerant from the condenser output to the return input at the subcooler, thus lowering the temperature of the return flow to the compressor.
Additionally, a novel differential pressure valve can be connected into a shunt tubing between the outgoing and return flows of the thermal transfer fluid loop, to prevent over-pressurization by the pump, which particularly can occur with regenerative turbine pumps. A useful indication of the flow rate of thermal transfer fluid is also obtained by a novel flowmeter in one of the lines that is responsive to pressure differentials across an internal orifice. Flow rate readings are often desired by process tool users, if obtainable without undue cost, and reliable over a substantial time period.
For efficient mid-range cooling and alternatively for heating, temperature control can be by controlling facilities water flow using the pressure of gas pressure in an enclosed volume, as determined by a control signal applied to an electrical heater. By signal-regulating the gas pressure in this way, the system opens or closes a pneumatic pressure response flow control valve that controls facilities water flow as needed for regulated cooling of the thermal transfer fluid in a heat exchanger. If the temperature is temporarily lowered too much, it can be brought back up quickly using the electrical heater in the thermal transfer fluid loop. The same heater can be used independently to heat the thermal transfer fluid to a prescribed level. The thermal capacity of this heater (in KW) can be arbitrarily selected by choice of heating elements. The pneumatic controller for the flow control valve includes a gas containing volume thermally coupled to a heater on one side and thermally insulated to a selected degree from the water reference line, to reduce the energy need when heating the bulb and limit the cool down rate when the heater is deenergized.
A novel differential pressure valve in accordance with the invention is virtually noise free and at the same time stable and reliable, and useful to prevent over-pressurization of the thermal transfer fluid loop. It incorporates a spring loaded flexible quill that supports a valve head at one end and merges at the other end into a dashpot slidable within a piston. The valve head is urged by a spring about the quill toward closure against the end face on a conduit for high pressure flow. An adjustment screw, which can be accessible from the exterior of the module, controls the axial position of the piston and therefore the valve opening pressure. The valve opens an exit path from the high pressure conduit to relieve pump pressure by diverting flow to the return line. The flexible quill and dashpot arrangement assures virtually silent operation by damping valve vibrations.
A flowmeter operable with this system comprises a differential capacitive transducer which is coupled to ports on the thermal transfer fluid line that are on the opposite sides of an orifice plate in the fluid flow path. The differential in pressure across the orifice flow path, corrected for flow and viscosity changes by an associated square root circuit, provides an accurate measure of the flow rate that is linear, precise and free from long term drift.
DESCRIPTION OF THE DRAWINGS
A better understanding of the invention may be had by reference to the following description, taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a perspective block diagram view of a multiple modular installation of temperature control units as arranged in association with a process tool system including a number of subunits which are each temperature controlled;
FIG. 2 is a simplified block diagram of a module using a refrigeration loop for both heating and cooling;
FIG. 3 is a block diagram of a temperature control module using facilities water for cooling;
FIG. 4 is a simplified sectional view of a temperature controlled pressure responsive water flow control valve in accordance with the invention;
FIG. 5 is a perspective view, partially broken away, of a temperature controlled variable pressure generator for the valve of FIG. 4;
FIG. 6 is a side sectional view of a differential pressure relief valve in accordance with the invention;
FIG. 7 is a combined side schematic and block diagram view of a flowmeter in accordance with the invention;
FIG. 8 is a perspective view of one arrangement of a practical module in accordance with FIG. 2 and employing a refrigeration loop having a 3.6 kw capacity;
FIG. 9 is a perspective view of the disposition of elements in a practical module using a facilities water cooling loop in accordance with FIG. 3;
FIG. 10 is a perspective view of the arrangement of elements in a double width module using a refrigeration loop in accordance with FIG. 2 to provide 10 hp compressor capability;
FIG. 11 is a fragmentary perspective view of a typical rear panel arrangement for modules in accordance with the invention;
FIG. 12 is a perspective view of a different example of chiller in accordance with FIG. 2, in which a double width module includes an air cooled compressor; and
FIG. 13 is a perspective view of yet another practical chiller with 5 hp compressor power but which does not employ a subcooler in the refrigeration loop.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 depicts in broad form one typical arrangement of a modular multi-function temperature control system 10 which supplies flows of thermal transfer fluid at specified temperatures and flow rates to separate subunits, or separate tools, of a process tool system 12 , depicted generically. A typical process tool 12 , such as a cluster tool for semiconductor fabrication, is chosen as the example since it represents a demanding and widespread application. However, the process tools that can be serviced by a temperature control system may vary widely in number, design and the control functions that must be performed, and this applies also within the field of chip manufacture as well. The semiconductor fabrication tool 12 that is depicted in idealized and simplified form in FIG. 1, for example, is for processing 300 mm wafers, and includes separate tools 12 A and 12 B, each having more than one subunit. The tools 12 A and 12 B are shown stacked, which is not a likely disposition in practice but is illustrative of the fact that since the temperature controls and subunits are interconnected only by supply and return lines there is no necessary geometrical relationship between them. Here the first (upper) tool 12 A has a cathode 13 , to be maintained at −20° C. to 60° C. with 1000 W of heat removal required, and a liner 14 to be held at +15 to 60° C. with a heat load requiring 800 W of heat removal. In the second tool 12 B, the subunits are a cathode 15 to be held at −20 to 60° C. with a 3000 W heat removal, a source 16 requiring 2000 W of heat removal at +40 to 80° C. and a liner/body 17 having a heat removal load of 500 W. In the first unit 12 A the pump rates (assuming the use of 50/50 ethylene glycol/water mixture) are 1.0 PGM at 80 psi for the cathode 13 and 0.075 GPM at 80 psi for the liner 14 . At the second unit 12 B the flow for the cathode 15 is 3.0 GPM at 80 psi, for the source 16 is 2.0 GPM at 80 psi and for the liner/body 17 is 0.5 GPM at 80 psi.
Two different module types, and three different configurations of modules, are mountable in a movable chassis 18 to meet these needs. For the first unit 12 A a low temperature chiller module 19 of 3.0 KW cooling power is adequate for the cathode 13 , while a mid-temperature chiller module 20 of 3.6 KW cooling power can be used for the liner 14 . These are installed, in FIG. 1, in the left upper and middle tiers of the chassis 10 . The second unit 12 B requires 10.0 KW cooling power for the cathode 15 , which is obtained from a double wide chiller module 21 , depicted in the lowest tier of the chassis 10 . Both the source 16 and the liner/body 17 are controlled by the same channel, supplied by a water-cooled heat exchanger (HEX) module 22 , installed at the right side of the upper tier.
Fluid in each recirculating thermal transfer fluid loop is supplied from a module to the associated subunit by a supply line 24 (dotted line), and the individual loop is completed by a return line 25 (dot-dash line). The modules incorporate supply and return manifolds so that more than one recirculating loop can be serviced. Only two of these lines 24 , 25 are specifically numbered inasmuch as each pair serves the same purpose for the subunit it controls. Facilities water supply and return lines, and the electrical power supply lines, are not shown in FIG. 1 but may be coupled into the back end of the chassis 16 , as will be evident below in relation to individual modules.
In the temperature control system 10 , the modules are interchangeably mounted in receptacles 28 in the mobile control chassis 18 to form an array of given total height, width and length. By way of example, one receptacle 28 is shown empty. The modular units are based on a standard form factor, in height, width and length, although width may be doubled, as seen in FIG. 1, relative to the basic form factor, where more interior volume is needed for a module. Sliders and engagement devices (not shown) within the chassis 18 are included in the sides and bottoms of the receptacles 28 for matingly receiving the modular units. Slides or roller supports for the modules may be conventional and therefore are not shown in detail.
FIG. 1 illustrates a three high configuration of the different modules 19 , 20 , 21 and 22 . The upper HEX module 22 on the right side is paired in side by side relation to the low temperature chiller 19 , while the mid-range chiller 20 is in the middle tier next to an open receptacle 28 and the lowest level tier is occupied by the double width module 21 . Each module has a face plate 29 which includes accessible fill and drain lines 30 , 31 respectively for thermal transfer fluid, and a control shaft 32 for adjusting the pressure threshold setting of an internal differential pressure valve, to be described below. The modules 19 - 22 each include conventional electrical circuit connectors (not shown in FIG. 1) for coupling into power lines and signal circuits in the chassis 18 , either by manual attachment or plug-in couplings on insertion of the module into its receptacle. Signal carrying circuits which intercouple sensors and controllable elements in the modules to an associated processor may be completed in the same manner, during or after insertion.
The signal circuits couple to a control processor 35 , for storing prescribed or setpoint commands for the different control channels, receiving various sensed actual temperature values from the modules 19 - 22 , and also supplying control signals to temperature-controlling components in the modules. A touch screen display 37 functioning with the processor 35 enables an operator to enter and adjust the setpoints and to observe actual operating temperatures and flow rates. The examples of FIG. 1 depict how different capabilities within a set of modules 19 - 22 can control subunits 13 - 17 in different parts of a cluster tool 12 , with capabilities also being available for different or added subunits. The output of one module which has adequate flow rate and heat capacity also can be manifolded to two or more subunits, as described below.
In the example of FIG. 1, a module 22 in the upper tier of the chassis 18 is coupled in common to maintain the source 16 and liner/body 17 of the lower cluster tool 12 B at 40° C.-80° C. The heat removal demand of a specific temperature in the range can be met by a single heat exchanger (HEX) module 22 using facilities water (typically about 20° C.) as the cooling medium. The cathode 15 in the same tool 12 B, which must be cooled to a lower temperature extending down to −20° C., is serviced by a single 10 KW (compressor power) refrigeration module 22 . This compressor is large enough that a larger platform, equal in extent to two of the smaller platform is required. This larger size module, 21 , is called a “double-width” module. It is shown installed in the lowest tier of the chassis 18 .
The HEX module 21 may be described as a dual mode, midrange unit for both cooling and heating. In cooling, it provides up to 40 KW, at about 20° C. over the temperature of the facilities or utilities (these words are used interchangeably herein) water used for cooling, at a flow rate of 3 gpm to 15 gpm at 100 psi. In contrast, the double width refrigerating or “chiller” module 21 provides 10-50 KW cooling capacity, dependent on compressor power (7.5 to 15 hp) and the temperature to be maintained. Thus it provides thermal capacity up to 12 KW of −40° C., or up to 50 KW at +20° C., with flows from 8 gpm to 25 gpm at 100 psi. The upper tool 12 A has a cathode 13 which is cooled in the range of −20° C. to +60° C. by a low temperature chiller module 19 providing 3000 W of heat removal capacity at −20° C. In one practical installation the actual heat removal demand is 10000 W. A liner 14 for the same tool 12 A is cooled by a mid-range temperature chiller module 20 providing a capacity of 2400 KW at +10° C. but requiring only 800 W in the given example.
The refrigeration or chiller modules 19 , 20 and 22 referenced broadly in FIG. 1 comprise, as shown schematically but in greater detail in FIG. 2, a refrigeration loop 40 which circulates an accepted environmentally compatible refrigerant that is pressurized by a compressor 42 of chosen capacity. The compressor 42 can be a production version air conditioning-type compressor that is available in quantity and at relatively low cost. Pressurized hot gas from the compressor 42 is cooled in the condenser 44 with utilities water, typically at about 20° C., provided via an input line 45 circulated through the condenser 44 , and returned via an H 2 O output line 46 . The pressurized cooled and liquefied refrigerant is regulated by a solenoid expansion valve 50 that operates with variable duty cycles in response to control inputs from the processor 35 . That is, the valve 50 is turned on for a selected fraction of each successive time interval (typically 2-5 seconds). Commercially available valves of this type recommend 6 second cycles for 10 year life expectancy, assuring long term reliability. In the refrigeration loop 40 , the regulated flow brings the thermal transfer fluid to a chosen temperature, which is to be essentially uniform throughout the system including the process tool. From the valve 50 , flow is directed to one input of a subcooler 52 , where the refrigerant is further cooled in heat exchange relation to refrigerant returning on a suction line 54 from an evaporator/heat exchanger 54 , prior to interchange of thermal energy with the thermal transfer fluid. The return flow on the suction return line 56 is input to the compressor 42 , at an increased but still acceptable temperature.
The refrigeration unit also includes a hot gas bypass loop 70 , which extends from the compressor 42 output into a point in the refrigeration loop 40 that is prior to the evaporator/heat exchanger 54 , and thereafter enters the suction line 56 . A hot gas bypass valve 72 in the loop 70 opens in response to low pressure signals from a pressure sensor 74 coupled into the suction line 56 at the compressor 42 input. The valve 72 is opened when the pressure is below a preset level, to divert a proportion of flow from the compressor 42 , as when the system does not require refrigeration and the solenoid expansion valve 50 is closed. Under these conditions, the compressor 42 output temperature for a 5 hp compressor is in the range of up to 250° F. (˜121° C.) with 3 KW output. This hot gas from the bypass loop 70 is thus effectively made useful for a heating mode at the evaporator/heat exchanger 54 . The hot gas bypass loop 70 coupled into the input to the evaporator/heat exchanger 54 is first diverted through a preheat path segment 76 in the reservoir (described below) for the thermal transfer fluid, which flow raises the temperature of the thermal transfer fluid appreciably before subsequent heat exchange. The flow then passes into the input line between the subcooler 52 and the evaporator/heat exchanger 54 , to employ that exchanger in a heating rather than a cooling mode. The hot gases also serve to drive oils contained in the refrigerant through the evaporator 54 passages, preventing oil from being trapped because of slow refrigerant flows.
For reliability and greater efficiency the refrigeration system also includes a desuperheater bypass loop 80 in which a desuperheater valve 82 couples pressurized refrigerant from the output of the condenser 44 to the return path input 86 to the subcooler 52 . The desuperheater valve 82 is responsive to levels sensed at the input to the compressor 42 by a temperature sensor 84 , and opens to divert initially pressurized liquid flow back to the input via the subcooler 52 when needed. After expanding in the subcooler 52 , the returning refrigerant both lowers the temperature of the principal refrigerant flow at the compressor 42 input and increases the compressor 42 input pressure.
Control of the temperature of thermal transfer fluid is effected in a fluid loop 90 , which includes a reservoir 92 retaining a volume of the fluid, the level being maintained above a minimum, if necessary during operation by using the fill line 30 . The level may also be diminished (or flushed completely) by use of the drain line 31 . Spring action valves (e.g. Schrader-type valves), that are accessible from the module exterior, can be employed for this purpose. In the thermal transfer fluid loop 90 fluid is drawn from the bottom region of the reservoir 92 by a pump 94 and directed through a controllable electrical heater 96 in the flow path (a heater alternatively may be external to the conduit) and which operates under control signals from the processor 35 . The fluid loop 90 proceeds through the evaporator/heat exchanger 54 for the fluid to be cooled or heated as appropriate, and the thus temperature adjusted thermal transfer fluid is then supplied to an output manifold 98 . One supply line 14 or a number of supply lines (as shown) from this output manifold 98 couple the thermal transfer fluid to the associated subunit or subunits of the process tool. After circulation through the process tool, thermal transfer fluid in one or more of the return lines 25 flows into an input or return manifold 99 and then is fed back through a flowmeter 102 to monitor actual flow rates before delivery back into the reservoir 92 , as on the display screen on FIG. 1 . The flowmeter 102 can advantageously be disposed at the return manifold 99 with greater economy of parts. The electrical heater 96 provides a fast response capability for correcting or shifting the fluid temperature level when a higher temperature is needed. A heater of 1000 W to 12,000 W power level is usually employed, depending on operational needs.
The pump 94 is, most typically, of the regenerative turbine type, and generates substantial pressure in the thermal transfer fluid. In the event that this pressure becomes excessive, an adjustable pressure valve 100 in shunt between the supply and return lines in the thermal transfer fluid loop 90 is caused to open at a selected threshold value. The valve 100 diverts high pressure in fluid on the supply side into the lower pressure return system and thus precludes generation of excessive pressure in the system. Since the requirements of the process tool are only that the output temperature of the thermal transfer fluid and its flow rate be at prescribed values, output temperature is measured by a temperature sensor 104 after the evaporator/heat exchanger 54 .
As a chiller system, a modular system 19 , 20 or 21 operates substantially conventionally with compression, condensation and heat exchange to deliver refrigeration capacity at chosen temperatures and flow rates. For models using compressors of 1.0-5.0 hp, refrigeration outputs for up to 3 KW at −40° C. and up to 15 KW at +20° C. can be supplied, at flow rates of 4 gpm to 25 gpm at 100 psi. The refrigerant flow through the subcooler 52 into the evaporator/heat exchanger 54 boils off at a rate needed to lower the temperature of the thermal transfer fluid to the level needed at the manifold 98 . Control is achieved by sensing the actual temperature of the thermal transfer fluid at a suitable location, such as just prior to the output manifold 98 , and using this signal in the processor 35 to make the necessary correction of refrigerant flow by changing the open cycle time of the solenoid expansion valve 50 . The solenoid expansion valve 50 controls temperature with stable, long life performance, but analog expansion valves can alternatively be employed, usually at some added expense.
The desuperheater valve 82 includes a thermal expansion valve that responds to undesirably high temperature levels at the compressor 42 input to open the shunt path 80 from the condenser 44 output, and to direct this flow into the suction path 56 returning to the compressor 42 , thus maintaining compressor input temperature at an adequate level.
If the process tool requires heating in a midrange, i.e., within the power capacity of the compressor 42 , then the solenoid expansion valve 50 can be shut down and compressor energy used for heating the refrigerant as hot gas, which is directed through the hot gas bypass loop 70 via the hot gas bypass valve 72 to the output flow on the refrigerant side of the subcooler 52 . Bypassing this hot gas flow through the reservoir 92 and into the input line to the evaporator/heat exchanger 54 maintains continuous flow and precludes accumulation of refrigerant oils in the passages of the evaporator/heat exchanger 54 . This alternative dual use of compressor energy contributes both to energy efficiency and unit compactness. Furthermore, the temperature of the thermal transfer fluid may cumulatively be heated to a chosen higher level by energizing the electrical heater 96 . The heater 96 alone can be used to restore the temperature of an overcooled or underheated fluid, provide rapid change of temperature increase, or establish a temperature of greater than 120° C., as required by system demands. The last alternative represents the highest temperature mode, for which a high capacity (e.g. >10 KW) electrical heater can be used.
The example of FIG. 3, to which reference is now made, provides a dual mode cooling and heating system primarily for midrange cooling operation above the temperature range of facilities water, but incorporating a heating range capability as well. In this system, the recirculating loop 90 for thermal transfer fluid is similarly arranged to that of the system of FIG. 2, and consequently the relevant components are similarly numbered. The heat exchanger 110 is a liquid/liquid heat exchanger of the counterflow type, in which thermal transfer fluid traverses one flow path in thermal exchange relation to facilities water, in an adjacent second flow path. This system functions to cool the thermal transfer fluid to a temperature of within about 20° C. of that of the facilities water. The water supply line 112 is directed into and through the counterflow heat exchanger 110 to a water return line 113 . In the water supply line 112 path, flow is controlled by a pneumatic pressure responsive valve 118 which is controlled by a temperature responsive pressure device 117 that receives control signals from the processor. The temperature responsive device 117 is also in thermal contact with a water reference line 120 which shunts the water supply and return lines 112 , 113 respectively, and the flow through which is limited by a flow restrictor 116 . This apparatus for flow control is described in greater detail in conjunction with FIGS. 4 and 5 below. Within the reservoir 92 for the thermal transfer fluid, return flow is injected via a diffuser 124 to limit the turbulence and dispersion induced by high flow rates. The diffuser 124 is a known arrangement using a 6° diverging cone to attenuate flow velocity in stable fashion.
The cooling system of FIG. 3 provides a desired thermal transfer fluid temperature by regulating the flow rate of the facilities water, the source temperature of which is effectively constant. When the temperature of the thermal transfer fluid is too high relative to a preset level, as sensed by the temperature sensor 104 responsive to the flow to the output manifold 98 , the processor of FIG. 1 generates an error control signal that is applied to the temperature responsive pressure device 117 . That pressure, within an enclosed gas volume, is communicated to the pressure responsive flow control valve 118 , to cause it to enlarge or decrease the opening, increasing or decreasing the flow of cooling utilities water thereby and consequently lowering the temperature of the thermal transfer fluid at the heat exchanger 110 . Close temperature control can be maintained because of the mass of the thermal transfer fluid, and because the electrical heater 96 in the thermal transfer fluid loop can be energized to bring the thermal transfer fluid back up to temperature rapidly in the event that it has been cooled too much. Alternatively, the electrical heater 96 may be used alone, if the temperature needs to be maintained at a high level. The Hex module offers multiple capabilities for meeting temperature control demands for one or more subunits in a process tool.
A more detailed example of the water flow control is shown in FIGS. 4 and 5, to which reference is now made. At the water reference line 120 that couples a reduced flow between water supply and return lines, a section is adjacent a spaced apart electrical heater 130 responsive to signals from the processor of FIG. 1 . The electrical heater 130 is in contact with interposed thermally conductive material 132 , such as aluminum, which also conducts heat to a control valve sensor bulb 134 that confines a pressurized gas and is disposed between the heater 130 and the reference line 120 . A pressure conduit 135 from the bulb 134 leads to a pressure chamber within the pressure responsive flow control valve 118 in the water supply line 112 . An encircling retainer 138 , such as a strap or housing holds the elements 130 , 132 and 120 in close and stable relation. A control layer of thermal insulation 140 is interposed between the bulb 134 and reference line 120 to minimize the power needed from heater 130 to heat bulb 134 to the temperature required for control. The thickness and thermal conductivity of the insulation are chosen to give a good compromise between rapid heatup of bulb 134 with limited power from heater 130 , and rapid cooldown in the absence of heater power.
The flow restricting valve 116 in the reference line 120 (not shown in FIG. 5) limits the flow that shunts between supply and the return line, because flow that is only enough to be adequate for a water temperature reference is needed. The flow control valve 118 has a valve body 142 with ports for the incoming supply and for the outgoing controlled flow. In the body 142 , a slidable valve element 143 having a seating surface 144 is biased along a chosen axis by a compression spring 145 engaged by an adjustable insert 146 in the body 142 . A shaft along the axis from the valve 143 extends from an exterior end into a chamber defined by a hollow housing 147 affixed to the valve body 142 , and engages the midregion of a flexible diaphragm 148 that spans the chamber within the housing 147 also defines the limit of a variable pressure chamber on its opposite side. Pressure variations within the chamber are determined by the temperature of the bulb 134 , the pressure being communicated through the conduit 135 , and the diaphragm 148 flexes responsively, moving the valve 143 to provide a flow gap at the valve seat 144 when the threshold force set by the spring 145 is overcome. This threshold can be adjusted by axial adjustment of the threaded insert 143 so as to set the threshold operating pressure at which the pneumatic valve 118 opens by changing the static spring force value.
Reliability is of utmost importance in these systems, which are required to operate for long intervals without variation or maintenance. The method of control provided by the example of FIGS. 4 and 5 is free of both hysteresis effects and problems with system wear. In operation standby power is fed to the electrical heater 130 to maintain the bulb 134 at a specified elevated temperature and resultant pressure. When no cooling is needed, this standby power is not sufficiently high to open the flow control valve 118 . To assure that the temperature of the sensor bulb 134 with standby power is less than that necessary to open the flow control valve, the spring 145 can also be adjusted in relation to the temperature of facilities water that is available.
In the systems of FIGS. 2 and 3, a differential pressure valve 100 is employed to prevent excessive buildup of pressure in the thermal transfer fluid that may be caused by the preferred regenerative turbine pump system. However, the differential pressure valve 100 is required to be adjustable and furthermore to be relatively free from the vibration and noise effects typically encountered with such valves. These results are achieved in a low cost and reliable fashion by the valve mechanism shown in FIG. 6, in which the elements are mounted on a Tee fitting 150 including an in-line end fitting 152 constituting an input for the high pressure supply flow line and a side arm that is coupled to the return line carrying reduced pressure return flow (after circulation through the process tool). At the opposite side from the end fitting 152 , an in-line sleeve 156 coaxial with the high pressure supply line is engaged in the Tee 150 , and supports within it a slidable piston 158 containing an interior hollow cylinder 159 . Cylinder 159 is closed at its exterior end, and has an open end facing the interior of the Tee 150 . An O-ring seal 162 between the piston exterior and sleeve 156 blocks leakage of the thermal transfer fluid during relative axial movement of the piston 150 . The head 164 of an in-line valve 163 seats in the inserted nose end of the end fitting 152 when fully engaged. Along the valve 163 , the valve head 164 is integral with a flexible elongated member or quill 165 extending from its opposite end to a dashpot piston 166 that fits and slides within the hollow cylinder 159 . A compression spring 168 seated between the interior surface of the valve head 164 and the facing end of the piston 158 biases the valve head 164 against the facing nose end of the end fitting 152 . The position of the piston 158 in the sleeve 156 is axially movable between limits, because an end cap 170 engaged to the exterior end of the sleeve 156 receives a threaded adjustment screw 172 that controls the axial position of the piston 158 and the compression of the spring 168 . The adjustment screw 172 may be of significant length, so that, as seen in FIG. 1, it can extend outside of the face plate of the module to be axially adjustable by turning the screw 172 or an attached knob.
The fit between the dashpot piston 166 and the cylinder 159 is sufficiently close (about 0.05 mm) so that any vibration along the axis of the valve is damped by resistance to fluid flow. The quill 164 is thin enough to provide sufficient flexibility between the valve 162 and cylinder 159 to allow the valve to fit perfectly against its seat on the end fitting 152 when the valve is required to seal.
The measurement of flow of thermal transfer fluid in a system associated with a process tool is highly useful, because it provides a ready indication of normal operation both in the temperature control system and in the process tool. A significant change in flow rate may also denote the presence of obstruction or malfunction in the thermal transfer fluid flow paths. Given that the thermal transfer fluid can be raised to high temperature or lowered to low temperature, and therefore is subject to a wide range of viscosity changes, high resolution readings with various mechanical-based devices, such as paddle wheel type flowmeters, have been difficult to achieve and subject to inaccuracy over time. The arrangement of FIG. 7 provides a satisfactory answer to these problems, and can be used in any of a number of locations in the thermal transfer fluid conduit system. The conduit employed here is referred to generically as a flow tube 180 and is a linear section, although the flow reading may be taken at a junction or coupling as well. Within the flow tube 180 flow is impeded by an internal orifice plate 182 having a centrally disposed orifice 184 of sufficient area to introduce a pressure differential in the flows at its opposing sides. Pressure ports 186 , 187 in the side walls of the flow tube 180 and on opposite sides of the orifice plate 182 are coupled by conduits 190 , 191 to the opposite input of a differential pressure transducer 192 of a type widely employed in automotive and other pressure sensing systems. These transducers, which are available from different sources, are most often capacitive elements disposed on deflectable ceramic bodies which deviate from a nominal position in response to the pressure differential between flows on their opposite sides. The transducers generate signals that are sensitive, precise and linear, without being subject to hysteresis or drift effects.
The signal derived from the transducer 192 is a measure of the difference in pressure on the two sides of the orifice plate 182 . However, the direct reading is not linear with flow. The pressure drop across an orifice is generally proportional to the square of the mass flowing through the orifice. In mathematical terms:
ΔP=kM 2
where;
ΔP is the pressure drop
k is a constant of proportionality
M is the flow in mass per unit time
The constant of proportionality, k, is an empirically derived constant that takes into consideration the flow velocity through the measuring orifice, density of the flow and transport properties of the fluid, mainly the fluid viscosity.
This relationship is compensated for electronically by a square root circuit 194 . Additionally, circuit 194 is responsive to the fluid temperature and compensates for the variation of the proportional constant in the pressure-drop/flow relationship due to viscosity changes in the flowing liquid.
The present approach, of segmentation of the functional and physical characteristics of modules to provide a spectrum of different capabilities for meeting the different demands of a facility using a number of process tools can better be appreciated by analysis of the basically different units of FIGS. 8-10, 12 and 13 . The modules fall into either one of two broad classes, namely refrigeration loop cooling systems (FIGS. 8, 10 , 12 and 13 ) or water loop cooling systems (FIG. 9 ). A typical rear panel is shown in FIG. 11 , demonstrating that multiple ports and gages can be accessible from this side and enable convenient coupling of thermal transfer fluid conduits from a module to different subunits or process tools.
The modules have a volumetric form factor based on a standard height, width and depth. Where larger components or subsystems are required, wider modules may be used that have the standard height and depth, and essentially double width. The system of FIG. 1 is illustrative of this approach. In practice, for example, a two-module high control chassis with may have outer dimensions of a 24″ width, 48″ height and 35″ depth for two tiers of modules with standard form factor volumes of 10″ wide, 24″ high and 35″ deep. The total assembly, including casters, drain pans and electronic controller box is about 70″ in height.
Each module is supported on interior frame elements in the control chassis and has attached upstanding face and rear panels. Thus, each module may be individually withdrawn from the receptacle in which it is seated, for parts, service, shipping to a service center, and/or insertion of a different unit. When extracted from the control chassis, each module, as seen in FIGS. 8-10, 12 and 13 is open on three sides, so that components and subunits may readily be serviced and/or replaced. There are important implications in this approach for service and maintenance operations, particularly in relation to cost and personnel. It is found that with modern equipment, operative difficulties predominantly arise in mechanical and electromechanical components, with electronic and electrical devices in contrast being far longer lasting. Consequently, with the units almost fully open for inspection and service, the mechanical and electromechanical portions can be repaired with minimal difficulty, and if changes in modules are necessary, such as the need for a larger pump, this work can also be done in the field. At the same time, the modularity allows replacements of a defective or inoperative module or major part with an entirely new module, and the original unit can be shipped back to the factory or a service center. Consequently, when this approach is followed, skilled repairmen are not often needed in the field, and field maintenance costs and training needs are greatly reduced.
FIG. 8 illustrates the physical configuration of the elements of a refrigeration loop of cooler 20 a or chiller that, in this example, can service the range from −20° C. to 120° C., and provide up to 3.6 KW of cooling at −20° C., with a flow rate from 3 gpm to 25 gpm at 100 psi. The cooling capacity in KW increases when the temperature to be maintained is higher. As seen in FIG. 8, the reservoir 82 a for thermal transfer fluid is mounted behind but adjacent the face plate, 29 a , and includes a capped fill pipe 200 for use when the system is down, and fill and drain valves 30 a , 31 a useable to add or remove thermal transfer fluid when the system is operating. The reservoir 92 a is positioned above an enclosed regenerative turbine pump 94 a of the type that contains the thermal transfer fluid within the motor enclosure, to serve as lubricant for internal hydrodynamic bearings throughout the entire operating temperature range. The motor/pump combination 94 a receives returning fluid along an axis parallel to its axis of rotation, and impels the pressurized output flow tangentially from the periphery of its turbine blades. A copending application of K. W. Cowans assigned to the assignee of the present invention, Ser. No. 09/906,624 filed Jul. 18, 2001 and entitled “Pump System Employing Liquid Filled Rotor”, describes a version of this pump which can be modified to employ double sets of turbine blades for greater flow rates if desired. In addition the motor/pump 92 a is configured for rapid disassembly and reassembly and in practice it is often convenient to attach two pumps to the motor/pump for greater flow rates. Different sizes of motor/pump combinations can also be used in the module to meet specific needs. The location of the reservoir 92 a above the pump 94 a assures sufficient pressure head at the pump at all times, so that a pressurized arrangement is not needed. Only where there are special operative demands or physical restraints, the reservoir 92 a for a module can be of smaller size and thermal transfer fluid can be fed from a common pressurized source to one or more chillers. Use of this alternative limits the versatility of the system and the ways in which modules can be employed. In the thermal transfer fluid loop, the reservoir 92 a provides a reserve fluid mass which is cooled or heated to the level that is desired for the associated process tool subunit. This feature consequently aids in temperature stabilization, since the fluid mass slows down change rates. After initial cooling to a selected level, the refrigeration loop need only counteract the heat introduced by the process tool as it is being cooled.
For purposes of increased reliability the refrigeration loop also includes a high pressure switch 202 which operates at a given threshold, shutting down the system when needed to prevent overpressurization in the refrigeration loop. In the thermal transfer fluid loop, however, overpressurization is guarded against by the differential pressure valve 100 a . A control shaft 204 for the differential pressure valve 100 a is conveniently accessible at the face plate 29 a because the valve body is coupled to a rear-to-front bypass line 206 that extends from a Tee 208 at the available output conduit from the evaporator/heat exchanger 54 a near the module rear and extends past the valve 100 a body. The refrigeration loop also includes a filter drier 210 to remove moisture accumulating in the refrigerant during cycling.
The flow meter 102 a in the example of FIG. 8 is mounted in the return manifold 99 a , adjacent the outlet end (only the ports to which the conduits and circuit are shown). The refrigeration loop includes a desuperheater valve 82 a , a hot gas bypass valve 72 a , a sight gauge 212 at the face panel, and pressure gauges 214 , 215 also accessible at the face panel (which itself is not shown). Suction and discharge gauges 217 , 218 respectively for thermal transfer fluid are in the rear panel for viewing from the process side. Connector conduits to points in the system have been omitted in this view.
In a practical implementation of a cooling system which employs only facilities water as a coolant, referring now to FIG. 9, the liquid/liquid counterflow heat exchanger 110 is mounted conveniently near the back section of the module 22 a . The supply and return manifolds 98 b , 99 b respectively for transfer fluid are adjacent, with ports (not shown in FIG. 9) facing in the direction of the process tool. The flow meter 102 b is disposed in the line from the return manifold 99 b that leads to the reservoir 92 b near the face of the module. This view more clearly shows the pressure differential valve 100 b close to the front of the module 22 a , and the thresholds adjustment shaft 204 a accessible through the face plate (not shown). Also a fan 220 at the face end is positioned in axial alignment with the motor/pump 94 b , for cooling the motor shell. The axial input to and tangential output from the motor/pump 94 b also can be more clearly seen in this view.
In the mid-region of the module 22 a , the nipples or connectors 222 and 223 for intake and outflow of facilities water (the exterior lines themselves are not shown) are on opposite sides of a pressure control device 119 a in close relation to a water reference line 120 a between the supply connector 222 and the return connector 223 . The enclosed structure including electrical heater 130 , bulb 134 and reference line 120 a of FIG. 5 is below the flow control valve 118 a in the supply line 112 . The electrical line on which a control signal is applied to the heater and the pressurized gas conduit between the bulb in the temperature responsive pressure control device 119 a and the flow control valve 118 a are not shown in this view, for simplicity and because they are straightforward implementations.
The double width module 21 a is used, as shown in FIG. 10, where a more powerful chiller is required. The elements and subsystems correspond to the system of FIG. 8, but capacity demands are substantially higher and the units therefore discernibly larger. The compressor 42 b is an upstanding 10 HP unit whose height is a considerable majority of the module 21 a height. The reservoir 92 c is again above the motor/pump 94 c but, since it has considerably greater volume, this cylindrical body is centered about a horizontal axis. The motor/pump combination 94 c is centrally disposed in front to back position as before, but a fan 226 for cooling the motor is displaced from the motor axis to one side and directs air tangentially into a shroud structure 228 which then directs cooling air axially along the motor/pump unit.
Other differences of a design nature from the smaller unit of FIG. 8 are to be noted. The electrical heater 96 c for thermal transfer fluid is similarly situated to that in FIG. 8 but of larger size and capacity. The subcooler 52 b is along a vertical axis, adjacent the compressor 42 b (facilities water conduits for which are not shown), and the other elements in the refrigeration loop are also disposed within a volume bounded by the condenser 52 b and evaporator/heat exchanger 54 b at the back plate 230 , the compressor 42 b on one side and the reservoir 96 c in the front portion. These elements include the solenoid expansion valve 50 b , hot gas bypass valve 72 b , desuperheater valve 82 b , refrigerant drier filter 210 a , and high pressure switch 202 a.
The double width chiller module 21 a of FIG. 10 incorporates a substantially larger 7.5-15 hp compressor with a 5-15 KW cooling capability down to −40° C., although again the kilowatt cooling power increases substantially if the needed temperature limit is not so low. Again the upper limit of the range is in excess of 120° C., and the flow rate at 100 psi can be in the range from 3-25 gpm with the standard pumps available.
As seen in FIG. 11, the manifolds 98 a , 99 a for the thermal transfer fluid are at or adjacent the rear panel 230 , which also includes suction and discharge gauge openings 223 , 234 visible from the process tool side of the unit. The rear panel 230 also includes an air outlet 235 open to the environment for aiding cooling. Each manifold 98 a , 99 a , as also seen in FIG. 11, includes a number of exterior ports 237 , 239 respectively for parallel connection of supply and return flows with different subunits of the process tool.
A double width configuration can also be used where the process location does not provide for or permit the use of facilities water, for condenser cooling in the refrigeration loop. In this event, referring to FIG. 12, the rear region of this double width module 21 b can mount a large air-cooled condenser 240 , and the evaporator/heat exchanger 54 c is positioned in a mid-region between the compressor 42 c and the condenser. The compressor 42 c is at one side of the module 21 b , with the desuperheater valve 82 c adjacent and the hot gas bypass valve being obscured in this view, as is the electrical heater for thermal transfer fluid. The sight gauge 212 a is visible in the front panel region, which panel, for better visualization, is not included in this view. A cooling fan and the end of the motor/pump 94 d system are also not shown in order that the condenser 240 appears more clearly. The subcooler 52 c in this arrangement is vertically disposed adjacent the compressor 42 c , while supply and return ports 242 , 243 respectively, are disposed on the process side, above the air cooled condenser 240 , instead of supply and return manifolds.
The system depicted has a cooling capacity of 2,500 watts at 40° C., using a 5 HP compressor in the double width structure. A chiller which does not require facilities water for cooling also can serve other special needs of process tools.
The chiller system 20 b of FIG. 13 is configured to be consistent with the standard form factor and use a 5 HP compressor 42 d to provide 3 kwatts of cooling at down to 20° C. This relatively lesser chilling requirement can be met without employing a subcooler in the refrigeration loop. However, the desuperheater valve 82 c and the hot gas bypass valve 72 c are used to safeguard against overheating and underpressurizing conditions.
It should also be noted that more than one evaporator/heat exchanger could be disposed in the space available within the interior of the module, side by side with the evaporator/heat exchangers that are shown. In addition, chiller units can be cascaded so that more than one compressor can be used to bring the temperature down to a minimum level.
These variants in the chiller system demonstrate that there are feasible internal changes as well as operating changes, as from cooling to heating, which make the module especially versatile.
In summary, therefore, this modular approach enhances the manner in which multiple processes can be temperature controlled with low capital expenditures. Thermal transfer fluid flows to be supplied to one subunit or different subunits, separately or in parallel, can be at chosen temperatures, given flow rates and pressures, and cooling or heating capacities can meet specific needs. At the same time, the cooling and heating requirements are met in energy efficient ways, but low demands for floor space, or restriction imposed by maintenance requirements.
Although a number of forms and modifications have been described above, it will be appreciated that the invention is not limited thereto but encompasses all variations and expedients within the terms of the appended claims. | The problem of controlling the temperature of the different units in a process tool system which have to be cooled or heated using thermal transfer fluid at selected setpoints and flow rates is resolved by a system having multiple modular units each with some operative and form factor commonality but at least dual functional capability. The modular units each have separate recirculation loops for thermal transfer fluid but cool the fluid using refrigeration cycles or facilities water supplies or heat the fluid using compressed hot gases or electrical energy. By employing operative units which can be internally varied to provide different thermal capacities within form factor constraints, the system enables concurrent temperature control needs of a number of different units to be met with an energy efficient, low footprint, highly adaptable system. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to an analyzer device for analyzing at least one gas contained in a liquid, in particular a drilling liquid, flowing in a drilling pipe in an installation for extracting fluid from a subsoil. The device comprises an analyzer for analyzing the gas and a sampling apparatus for sampling at least a fraction of the gas. The sampling apparatus has at least one porous membrane member, the member comprising a support and having a first face in contact with the liquid flowing in the drilling pipe and a second face opening into a pipe connected to the analyzer.
When drilling a well for oil or some other effluent (in particular gas, steam, water), it is known to analyze the gaseous compounds contained in the drilling muds emerging from the well. Such analysis is used to reconstruct the succession of geological formations through which the borehole is being drilled and it contributes to determining the working possibilities of the fluid deposits encountered.
Such analysis is performed continuously and comprises two main stages. The first stage consists in extracting the gas conveyed by the mud (for example hydrocarbon compounds, carbon dioxide, hydrogen sulfide). The second stage consists in qualifying and quantifying the extracted gases.
For this purpose, mechanically-stirred degassers are frequently used. However, because of their size, such degassers must be installed at a distance from the well, generally close to a vibrating screen downstream from the wellhead. Muds are conveyed from the wellhead to the degasser via a flow line that might be open to the atmosphere. Thus, a fraction of the gaseous compounds present in the mud is released into the atmosphere while the mud is traveling along the line. An analysis of the gas present in the mechanically-stirred degasser is therefore not representative of the gaseous content of the mud in the well.
To solve that problem, devices of the above-specified type have been implanted directly in the drilling pipe, upstream from the wellhead, as described in U.S. Pat. No. 5,469,917. Such devices include a capillary tubular membrane supported capillary membrane (SCMS). However, the muds flowing around the membrane are laden with pieces of rock.
In order to avoid degrading the tubular membrane under the effect of impacts against these pieces of rock, the membrane is wound on a threaded rod. The thread of the support then protects the membrane against pieces of rock of a size greater than the distance between two consecutive threads of the threaded rod.
Those devices do not give entire satisfaction. To wind the membrane around the threaded rod, and thus provide it with protection, certain stresses need to be applied to the membrane. Thus, a membrane of tubular shape must be used in order to be capable of winding between the threads of the threaded rod. Furthermore, the membrane must be relatively flexible. Consequently, only a membrane based on organic materials can be used in such a device. Unfortunately, organic membranes present abilities at withstanding high temperatures and chemical compatibilities that are not always satisfactory in certain applications.
SUMMARY OF THE INVENTION
A main object of the invention is thus to provide a device for analyzing gas contained in a liquid that contains debris of varying size, in particular a drilling fluid, the device being installed directly in a pipe of an installation for extracting fluids from the subsoil, without putting large stresses on the membrane, in particular stresses concerning the nature and the shape of the membrane.
To this end, the invention provides a device of the above-specified type, characterized in that the first face presents Vickers hardness greater than 1400 kilograms-force per square millimeter (kgf/mm 2 ), in particular Vickers hardness lying in the range 1400 kgf/mm 2 to 1900 kgf/mm 2 .
The device of the invention may comprise one or more of the following characteristics taken in isolation or in any technically feasible combination:
the porous membrane member includes a coating covering the support over the first face; the coating is based on silicon carbide; the first face is also water- and oil-repellent; the wetting angle of water on the first face is greater than 120°; the first face includes fluorine-containing polymers incorporated by grafting; the first face of the membrane member that is in contact with the liquid is substantially plane; the device further comprises a regulator for regulating the pressure in the pipe in register with the second face of the membrane member; and it includes a plurality of membrane members, and the second faces of the members open out in succession to the pipe connected to the analyzer.
The invention also provides an installation for extracting fluids from the subsoil, the installation being of the type comprising a drilling pipe connecting at least one point of the subsoil to the surface, and a delivery pipe connected to the drilling pipe at the surface. The installation is characterized in that it further comprises at least one device according to the above-described characteristics, and in that the sampling apparatus of the device is mounted on a tubular element constituted by the drilling pipe or by the delivery pipe.
The installation of the invention may comprise one or more of the following characteristics taken in isolation or in any technically feasible combination:
the first face of the membrane member in contact with the liquid is disposed substantially parallel to the long axis of the tubular element; the first face in contact with the liquid is disposed in a wall of the tubular element; the first face is disposed set back in a wall of the tubular element; the tubular element includes a branch connection and the sampling apparatus is placed in the branch connection; and the sampling apparatus of the device is placed in the drilling pipe upstream from the delivery pipe; and the installation further includes a filter downstream from the delivery pipe and it includes two devices as defined above, the respective sampling apparatus of the two devices being placed respectively upstream and downstream of the filter.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention are described below with reference to the accompanying drawings, in which:
FIG. 1 is a diagrammatic vertical section view of a drilling installation provided with an analyzer device of the invention;
FIG. 2 is a diagram showing the main elements of the analyzer device of the invention;
FIG. 3 is a diagram showing a detail of a variant of the installation shown in FIG. 1 ;
FIG. 4 is a diagrammatic vertical section view of an installation including two analyzer devices of the invention; and
FIG. 5 is a diagrammatic vertical section view showing a detail of a variant of the device shown in FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A device of the invention is used for example in an installation 11 for drilling an oil production well. As shown in FIG. 1 , the installation 11 comprises a drilling pipe 13 in a cavity pierced by a rotary drilling tool 15 , a surface installation 17 , and an analyzer device 19 of the invention mounted on the drilling pipe 13 .
The drilling pipe 13 is placed in the cavity drilled in the subsoil 21 by the rotary drilling tool 15 . At the surface, the pipe 13 has a wellhead 23 provided with a delivery pipe 25 .
The drilling tool 15 comprises a drilling head 27 , a drill string 29 , and a liquid injector head 31 .
The drilling head 27 has means 33 for drilling rock in the subsoil 21 . It is mounted at the bottom end of the drill string 29 and it is positioned in the bottom of the drilling pipe 13 .
The drill string 29 comprises a set of hollow drilling tubes. These tubes define an inside space 35 enabling a liquid to be taken from the surface 37 to the drilling head 27 . For this purpose, the liquid injector head 31 is screwed onto the top portion of the drill string 29 .
The surface installation 17 includes means 41 for supporting and rotating the drilling tool 15 , means 43 for injecting drilling liquid, and a vibrating screen 45 .
The injector means 43 are hydraulically connected to the injector head 31 to inject and drive a liquid along the inside space 35 of the drill string 29 .
The vibrating screen 45 collects the liquid laden with drilling residue that leaves the delivery pipe 25 and separates the liquid from the drilling residue.
The analyzer device 19 has a sampling head 51 for taking at least a fraction of the or each gas, and analyzer means 53 for analyzing the or each gas.
As shown in FIG. 2 , the sampling head 51 comprises a porous membrane member 55 having a plane first face 57 in contact with the liquid flowing in the pipe 13 and a second face 59 looking into a pipe 61 connected to the analyzer means 53 .
The porous membrane member 55 comprises a membrane support 63 and a coating 65 covering the support 63 beside the liquid on the first face 57 .
This first face 57 is disposed in the pipe 13 parallel to the long axis of the pipe 13 , i.e. parallel to the flow of liquid. This first face 57 is preferably disposed along a wall of the pipe 13 or else is set back a little from said wall. Thus, tools can be inserted or extracted into or from the drilling pipe 13 while minimizing any risk of damaging the membrane member 55 by mechanical contact or impact. Furthermore, having the liquid flow parallel to the first face 57 puts a limit on the abrasive forces that are applied to the coating 65 .
The membrane support 63 is made on the basis of a porous material, e.g. a ceramic. Preferably, the membrane support 63 is in the form of a disk. In the example shown in the drawings, the diameter of the support is substantially equal to 50 millimeters (mm) and its thickness is less than 10 mm.
Examples of materials suitable for use in making the membrane support 63 include sintered stainless steel, metal fibers, or alumina fibers.
The size of the pores in the membrane support 63 lies in the range 0.01 micrometers (μm) to 5 μm, depending on the intended application. Pore diameter is preferably selected to lie in the range 0.02 μm to 3 μm.
The coating 65 which constitutes the first face 57 of the membrane member 55 comprises a thin layer based on silicon carbide deposited on the support 63 . The thickness of this layer lies in the range 0.5 μm to 2 μm. This thin layer covers the surface of the support between the pores.
Thus, the membrane member 55 is permeable to all of the gas present in the mud.
Furthermore, the Vickers hardness of the first face 57 of the membrane member 55 is greater than 1400 kgf/mm 2 . In the example described in the figures, this Vickers hardness lies in the range 1400 kgf/mm 2 to 1900 kgf/mm 2 .
This thin layer thus protects the membrane member 55 against abrasion generated by pieces of rock and drilling debris.
In a variant, the coating 65 is modified by grafting fluid-containing polymer chains that are highly water- and oil-repellent. This grafting is preferably performed on the basis of a perfluoroalkylethoxysilane. This modification of the coating 65 enables the first face 57 of the membrane member 55 to be made water- and oil-repellent. Consequently, the wetting angle of water on the first face 57 of the membrane member 55 is greater than 120°, and is substantially equal to 130°.
The membrane member 55 is thus impermeable to the liquid flowing in the pipe, which contributes to limiting clogging of the pores in the support by solid residue coming from the liquid.
The pipe 61 connecting the porous membrane member 55 to the analyzer means 53 includes a gas-receiver chamber 71 , a pressure controller 73 for controlling pressure in the chamber, means 75 for conveying the extracted gas from the receiver chamber 71 to the analyzer 53 , and filter 77 for filtering the extracted gas.
The receiver chamber 71 covers the second face 59 of the membrane member, in register with the first face 57 . It comprises a bell having an inlet orifice 79 and an outlet orifice 81 connected, respectively to the conveying means 75 and to the pressure controller 73 .
The pressure controller 73 for controlling pressure in the chamber comprises elements 83 for measuring the pressure difference between the liquid in the pipe and the gas in the chamber, associated with a pressure regulator 85 mounted on the delivery pipe downstream from the chamber.
This regulator 85 is controlled in such a manner that when the device of the invention is used for analyzing the gases contained in mud, the pressure difference between the liquid flowing in the drilling pipe 13 and the gas present in the receiver chamber 71 is substantially zero. This substantially zero pressure difference prevents the liquid flowing in the drilling pipe 13 from penetrating into the membrane member 55 .
Nevertheless, if the porous membrane member 55 should become clogged, it is possible to control the pressure regulator 85 so that the pressure in the chamber 71 becomes much greater than the pressure in the drilling pipe 13 for a few seconds. The difference between these two pressures can then lie in the range 1 bar to 3 bar. It is thus possible to unclog the pores in the membrane member 55 .
The means 75 for conveying the extracted gas comprise means 87 for introducing a vector gas into the receiver chamber 71 via the inlet orifice 79 . By way of example, the vector gas is nitrogen or air.
A mass flow regulator 89 sets the rate at which the vector gas enters into the chamber 71 , and consequently the rate at which gas enters into the analyzer 53 . As a result, the rate of dilution of the extracted gas is constant over time. A volume flow meter 91 is mounted in the pipe 61 downstream from the filter means 77 in order to measure the flow of gas that results from the vector gas together with the extracted gases.
The filter 77 is disposed on the pipe downstream from the pressure regulator 85 . The filter 77 serves in particular to eliminate the water vapor present in the extracted gas. By way of example it is constituted by a desiccator based on silica gel filter cartridges, a molecular sieve, or a coalescing filter.
The analyzer 53 comprises instrumentation 93 for detecting and quantifying one or more extracted gases, together with a computer 95 for determining the gas concentration in the liquid flowing in the drilling pipe 13 .
By way of example, the instrumentation comprises infrared detector appliances for quantifying carbon dioxide, flame ionizing detector (FID) chromatographs for detecting hydrocarbons, or indeed a thermal conductivity detector (TCD), depending on the gases to be detected. It is thus possible with the device of the invention to detect and quantify a plurality of gases simultaneously.
This instrumentation 93 is placed in the explosive zone in the vicinity of the well head 23 ( FIG. 1 ) in order to avoid conveying the gases over a long distance, thereby improving measurement accuracy.
The analyzer further comprises a sensor 97 for measuring the temperature of the liquid flowing in the drilling pipe 13 .
The computer 95 has a memory 99 containing calibration charts and a processor 101 for implementing a calculation algorithm.
The calibration charts are established as a function of temperature, of flow rate, and of the characteristics of the mud. They contain data relating to the concentration of one or more gases in the mud to the concentration of the gases extracted from the mud through the membrane member, and as measured using the instrumentation.
The calculation algorithm determines the real quantities of the gases in the mud on the basis of the measurements performed by be instrumentation 93 , the temperature measured in the drilling pipe 13 by the sensor 97 , and the data contained in the memory 99 .
The concentration of gases in the mud is determined either individually or cumulatively.
The operation of the device of the invention while drilling a well is described below by way of example.
While drilling, the drilling tool 15 is rotated by the surface installation 41 . A drilling liquid is introduced into the inside space 35 of the drill string 29 by the injector means 43 . The liquid goes down to the drilling head 27 and passes into the drilling pipe 13 through the drilling head 27 . This liquid cools and lubricates the drill 33 . Thereafter the liquid collects the solid cuttings that result from the drilling, and it rises via the annular space defined between the drill string 29 and the walls of the drilling pipe 13 . This liquid flows substantially parallel to the walls.
The liquid thus flows continuously over the first face 57 of the membrane member 55 . A fraction of the gas present in the liquid is extracted through the membrane member 55 and penetrates into the extractor chamber 71 . The pressure controller 73 controlling the pressure in the chamber 71 is activated so that the pressure difference between the chamber 71 and the drilling pipe 13 is substantially zero. This prevents liquid penetrating into the membrane member 55 .
The extracted gases are then entrained by the vector gas from the extractor chamber 71 through the outlet orifice 81 , the pressure regulator 85 , and the filter 77 to the analyzer 53 . The extracted gases are then analyzed by the instrumentation 63 and the computer 95 determines the real concentration of each analyzed gas in the drilling mud as a function of time.
In the variant shown in FIG. 3 , the sampling head 51 is installed in a branch connection 111 on the drilling pipe 13 . Isolation means, such as an inlet valve 113 and an outlet valve 115 , are provided at the ends of the branch connection 111 on either side of the head 51 to isolate the branch connection and make it easy to remove the sampling head 51 . In this configuration, the risk of the membrane member 55 being damaged by mechanical contact or impact when tools are being inserted into the drilling pipe 13 or are being moved therealong is minimized.
In the variant shown in FIG. 4 , a recirculation pipe 121 is provided for conveying the liquid extracted from the vibrating screen 45 to the means 43 for injecting liquid into the inside space 35 of the drill string 29 .
Unlike the installation shown in FIG. 1 , two devices of the invention 19 and 19 A are used. The measuring head 51 of the first device 19 is disposed on the delivery pipe 25 in the upstream portion of said pipe, i.e. at the wellhead 23 . The measuring head 51 A of the second device 19 A is disposed on the injection pipe 123 between the injector means 43 and the injector head 31 . It is thus possible to quantify the difference between the gaseous content of the liquid leaving the drilling pipe 13 , and the gaseous content of the liquid reinjected after being degassed by the filtering screen 45 .
In the variant shown in FIG. 5 , unlike the device shown in FIG. 1 , the sampling head 51 has two porous membrane members 55 and 55 A. Each porous membrane member 55 , 55 A is associated with a respective receiver chamber 71 , 71 A for receiving extracted gases, and each having an inlet orifice 79 , 79 A and an outlet orifice 81 , 81 A. The inlet orifice of the first chamber is connected to the conveyor means 75 . The outlet orifice 81 of the first chamber is connected to the inlet orifice 79 A of the second chamber 71 A by the pipe 61 .
Thus, the vector gas is brought into the first chamber 71 via the inlet orifice 79 of said first chamber 71 . This gas brings the gases extracted into the first chamber 71 up to the second chamber 71 A via the outlet orifice 81 , the pipe 61 , and the inlet orifice 79 A of the second chamber 71 A. The second chamber 71 A thus receives a mixture containing the gases extracted into the first chamber 71 and the vector gas. This mixture then receives the gases extracted into the second chamber 71 A, thereby enriching it in gas coming from the drilling pipe 13 and making it easier for the analyzer 53 to detect the extracted gases.
In a variant, the support 63 of the porous membrane member has a face that presents Vickers hardness greater than 1400 kgf/mm 2 , in particular lying in the range 1400 kgf/mm 2 to 1900 kgf/mm 2 , without it being necessary to have a coating based on silicon carbide. In an example, the membrane member of this type may be made of α alumina.
In another variant, the membrane support is made on the basis of an organic material such as polytetrafluoro-ethylene, for example, and it has a coating of silicon carbide.
In another variant, a heater means is implanted on the drilling pipe upstream from the device of the invention relative to the flow direction of the drilling fluid in order to make it easier to extract dissolved or free gases. Under such circumstances, the device and the heater are disposed in a branch connection through which the mud flows freely or under assistance.
The invention as described above provides a device for analyzing accurately and continuously the gases contained in an abrasive liquid flowing along an installation for drilling into the subsoil.
Membrane members of a variety of kinds and shapes can be used with the device, depending on the characteristics of the drilling fluid and on the configuration of the well being drilled.
In particular, the device can be made from membranes that are simple in shape and easily available such as membranes in the form of plane disks.
The device is not selective and can be used to analyze individual or accumulated concentrations of a plurality of gases that are dissolved or free in the drilling liquid.
The device also presents the advantage of minimizing any risks of the device being damaged when objects are inserted into the drilling pipe and moved therealong.
The device also makes it possible to limit to a very great extent any clogging of the membranes and to limit the resulting loses of efficiency. | A device includes an analyzer ( 53 ) and a sampling apparatus ( 51 ) for taking a sample of at least one fraction of the gas that has at least one porous membrane element ( 55 ). The porous membrane element ( 55 ) has a support ( 63 ) and a first surface ( 57 ) which is in contact with liquid circulating in duct ( 13 ) and a second surface ( 59 ) which opens out into a duct ( 61 ) which is connected to the analyzer ( 53 ). The hardness of the first surface ( 57 ) is more than 1400 Vickers (kgf/mm 2 ), ranging more particularly between 1400 and 1900 Vickers (kgf/mm 2 ). The device can be used to analyze the gaseous content of oil well boring sludge. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is related, and claims priority, to U.S. Provisional Patent Application Ser. No. 61/387,863, filed Sep. 29, 2010, entitled “Minimally Obstructive Surgical Retractor and Speculum”; and U.S. Provisional Patent Application Ser. No. 61/436,119, filed Jan. 25, 2011, entitled “Minimally Obstructive Retractor;” the entire contents of both of which are incorporated herein by reference.
TECHNICAL FIELD
This invention relates generally to medical surgical instruments, particularly structurally-adjustable retractors and speculums for gynecological examinations and operations.
BACKGROUND
Devices which have been proposed for the purpose of vaginal examination and gynecological surgical procedures may not be entirely satisfactory for a variety of reasons. In many cases, they may obstruct the vision of the deep internal parts of the vaginal cavity that they are intended to expose. They may also constrain the movement of the physicians' hands and reduce the open work area for the surgeon. This often reduces the efficiency and effectiveness of vaginal examinations and surgical procedures.
Furthermore, typically the vagina walls, the perineum (which is the area of tissue between the vagina and the anus), and the anus are torn during vaginal delivery. Natural perineal tears are classified by their severity. First-degree tears involve tearing only the skin. Second-degree tears involve tearing muscle. Third-degree tears involve tearing the external anal sphincter muscle. Fourth-degree tears further involve tearing the rectal mucosa. When fourth-degree tears occur, the mother may require post-birth surgery to stitch up the torn tissue, often under general anesthetic.
Sometimes the perineum is purposely cut by a doctor performing an episiotomy, which is an incision into the perineum to enlarge the size of the vaginal opening. An episiotomy is similar to a first or second-degree natural tear.
All of the above tearing or incisions usually require post-delivery operations to stitch up the area. Stitching fourth-degree tears is particularly difficult using known specula given that fourth-degree tears typically extend from the vagina wall all the way to the rectum. Such surgery is extremely difficult due to the flaccid nature of the surrounding tissue which exists immediately after birth.
Episiotomy retractors for retracting friable postpartum vaginal tissue to facilitate repair of the episiotomy or vaginal laceration are known. The primary function of the retractor is to provide an open work area for the surgeon about the perineum and posterior vaginal wall of the patient so that the surgeon can conveniently and safely approximate and suture the tissue planes to complete repair.
The known episiotomy retractors may not be entirely satisfactory in use. Existing speculums may not permit access to the area in which the stitching is required and furthermore may tend to interfere with the surgeons ability to make the stitches in the first place.
Most importantly, conventional retractors may fail to provide sufficient open work area for the surgeon about the perineum and the posterior vaginal wall of the patient. During the delivery process the labia of the patient may become engorged with blood and thus may tends to interfere with visualization of the desired work area by the surgeon.
Furthermore, conventional retractors often include scissor arms or other elongated portions for gripping and leverage. However, these elements may increase the size and cost of the devices, and can constrain the movement of the physicians' hands and reduce the open work area for the surgeon.
SUMMARY
This application presents minimally obstructive retractors and speculums that afford an open work area of desirable size and enhanced visualization to users about the perineum and the posterior vaginal wall of the patient. The retractor may be lightweight, and configured and dimensioned to minimize slippage during use. The position of various elements of the device may be adjusted prior to, during, and after the procedure. The device may retract the engorged labia of the postpartum patient as well as the vaginal walls. The retractor may be simple and inexpensive to manufacture, use and maintain.
The device may provide several benefits, including but not limited to: permitting two-handed surgical techniques, facilitating approximation of tissue layers, retaining its angle of retraction, preventing fluids and tissues from obstructing the posterior vaginal wall and perineum, and promoting hemostasis.
The device may be used for improved visualization, access, and repair in various procedures, including, but not limited to: obstetrical/gynecological procedures: vaginal inspection; perineal inspection; vaginal wound repair; perineal wound repair; episiotomy repair; female pelvic exam; pap smear; cervical biopsy; vaginal/pelvic reconstruction; urological procedures; colorectal, general, or other surgery; the device may be turned upside-down, for example, for female urologic procedures; access to the cervix (or uterus via cervix); IUD insertion, removal, or adjustment; and dilatation & curettage (dilatation of cervix and curettage of uterus).
The minimally obstructive retractor has a proximal end and a distal end, and an exterior surface and an interior surface. In one embodiment, this retractor may comprise a central body portion, at least two wings, and at least two hinges, each configured to affix a different one of the at least two wings to the central body portion. The central body portion, the at least two wings, and the at least two hinges form a canopy.
In another embodiment, this canopy is formed such that the fluid flow through the exterior surface of the canopy, defined by the exterior surfaces of the body, wings and hinges, is substantially blocked. In an example of this embodiment, the hinges may be living hinges.
The minimally obstructive retractor may further comprise protruded portions, thinned portions, or combinations thereof. Such protruded or thinned portions may be formed on the exterior surface of the central body portion, the wing, or both the central body portion and the wing.
The minimally obstructive retractor may also comprise a ratchet mechanism. This ratchet mechanism may have one arm that is affixed to the interior surface of at least one wing.
Furthermore, in one embodiment, the retractor may further comprise a gripping proximal tip at the proximal end. Also, the retractor may further comprise a retractor limiter at the proximal end.
In some embodiments, the minimally obstructive retractor may further comprise an illumination source. This illumination source may comprise at least one light-emitting diode. In one embodiment, the illumination source may be located within the canopy. In another embodiment, the light emitting diode may be located within the canopy. Yet, in another embodiment, the illumination source is automatically turned on in conjunction with movement of the ratchet arms away from each other and/or automatically turned off in conjunction with movement of the ratchet arms towards each other.
In other embodiments, the hinge may comprise polyethylene, polypropylene, nylon, acetal plastics or a mixture thereof. The hinge may also comprise polyethylene, polypropylene, or a mixture thereof.
In an embodiment, the retractor may further comprise a lubrication source comprising a lubricant-containing reservoir integrated to the retractor and configured to provide lubricant to an outer surface of the retractor.
It is understood that other embodiments of the devices and methods will become readily apparent to those skilled in the art from the following detailed description, wherein it is shown and described only exemplary embodiments of the devices, methods and systems by way of illustration. As will be realized, the devices, systems and systems are capable of other and different embodiments and its several details are capable of modification in various other respects, all without departing from the spirit and scope of the invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
Aspects of the minimally obstructive retractor are illustrated by way of example, and not by way of limitation, in the accompanying drawings.
FIG. 1 is an isometric view of an exemplary retractor.
FIG. 2 is a side view of the exemplary retractor of FIG. 1 .
FIG. 3 is a bottom view of the exemplary retractor of FIG. 1 .
FIG. 4 is a rear view of the exemplary retractor of FIG. 1 .
FIG. 5 is an isometric view of another exemplary retractor.
FIG. 6 is a side view of the exemplary retractor of FIG. 5 .
FIG. 7 is a rear view of the exemplary retractor of FIG. 5 .
FIG. 8 is an isometric view of the exemplary retractor of FIG. 5 without a ratchet mechanism.
FIG. 9 is a retractor arm of the ratchet mechanism of the exemplary ratchet system of FIG. 5 .
FIG. 10 is another retractor arm of the ratchet mechanism of FIG. 5 .
FIG. 11 is an isometric view of separated parts of the ratchet mechanism of the exemplary retractor of FIG. 5 .
FIG. 12 is an isometric view of another exemplary retractor comprising a light source.
FIG. 13 is a close-up view of a ratchet cap, including a light source, of the exemplary retractor of FIG. 11 .
FIG. 14 is an isometric view of an alternative exemplary retractor.
FIG. 15 is an isometric view of separated parts of the exemplary retractor of FIG. 14 .
FIG. 16 is an exploded, isometric view of separated parts of the exemplary retractor of FIG. 14 .
FIG. 17 is an exploded, side view of separated parts of the exemplary retractor of FIG. 14 .
DETAILED DESCRIPTION
The detailed description set forth below in connection with the appended drawings is intended as a description of exemplary embodiments and is not intended to represent the only embodiments in which the retractors and speculums can be practiced. The term “exemplary” used throughout this description means “serving as an example, instance, or illustration,” and should not necessarily be construed as preferred or advantageous over other embodiments. The detailed description includes specific details for the purpose of providing a thorough understanding of the retractors/speculums. However, it will be apparent to those skilled in the art that the retractors/speculums and may be practiced without these specific details.
This invention relates generally to medical surgical instruments, particularly structurally-adjustable retractors and speculums for gynecological examinations and operations. These medical devices are hereafter called “minimally obstructive retractors” or “retractors.”
The minimally obstructive retractor has a proximal end and a distal end. This retractor may comprise a central body portion, at least two wings, and at least one hinge configured to affix at least one wing to the central body portion. The central body portion, the at least one wing, and the at least one hinge may form a canopy.
In some embodiments, the canopy may be formed such that the fluid flow through the exterior surface of the canopy, defined by the exterior surfaces of the body, wings and hinges, is substantially blocked. An example of this embodiment comprises a so-called “living hinge”. In this example, the retractor may be formed as one piece, by using manufacturing techniques such as molding, machining or welding. And the thinned section of the retractor, which is relatively thinner than the central body portion and the wings, forms the living hinge. Thereby, the one-piece retractor can easily flex along the line of the living hinge. A hinge of this type may be capable of many flexures over an extended period of time without the material fatiguing or breaking.
In one embodiment, the width of the living hinge is smaller than the width of the wing and/or the central body portion. In another embodiment, the living hinge width is substantially smaller than the width of the wing and/or the central body portion.
The living hinge is not the only retractor example that has a canopy wherein the fluid flow through the exterior surface of the canopy is substantially blocked. Other examples are as follows. In one example, a retractor may be formed by substantially reducing the width of the hinge and/or the width of the gap between the central body portion and the wing. In another example, the wings are formed to overlap on the exterior surface of the central body portion or the central body portion is formed to overlap on the exterior surface of the wings. Yet, in another example, the retractor may further comprise a substantially impermeable membrane that substantially covers the exterior and/or the interior surface of the canopy, or the exterior and/or the interior surface of the gap between the central body portion and the wings.
The wing has a proximal end and a distal end. The wing also has a top adjacent to the hinge and a bottom.
FIGS. 1-4 depict various views of an exemplary minimally obstructive retractor ( 100 ). The exemplary device ( 100 ) comprises wings ( 102 , 103 ). These wings may be solid. These wings may also be hollow and shell-like to provide a convex exterior and conversely, a generally concave interior to permit visual as well as manual access thereto. The wings may be of a shape, contour, thickness, angle, radius, and size to hold up the vaginal walls during various procedures.
The wings ( 102 , 103 ) may be affixed to a central body portion ( 101 ). The central body portion ( 101 ) may be convex on the exterior of the device ( 100 ) and concave on the interior. The central body portion ( 101 ) may be of a shape, contour, thickness, angle, radius, and size to hold up the vaginal walls during various procedures.
The wings ( 102 , 103 ) may be connected to the central body portion ( 101 ) by hinges ( 104 , 105 ). The hinges ( 104 , 105 ) may comprise the same or different material as the wings ( 102 , 103 ) and the central body portion ( 101 ). The hinges ( 104 , 105 ) may permit the wings ( 102 , 103 ) to flex or pivot about the central body portion ( 101 ) such that the lower longitudinal wing edges of the retractor may be pivoted open to permit visual and manual access to the interior of a body passage.
The wings ( 102 , 103 ) may also comprise protruded and/or thinned portions ( 120 , 121 ) to provide friction and prevent the device ( 100 ) from undesirable movement during use. These thinned portions are thinner than the remaining portions of the wing. The protruded and/or thinned portions ( 120 , 121 ) may protrude from the wings ( 102 , 103 ) or be etched or carved into the wings. The protruded and/or thinned portions may be anywhere on the wings. The protruded and/or thinned portions may comprise various shapes or forms such as grooves, serrations, cross-hatches, bumps, or other morphologies to provide adequate friction with the tissue, while not damaging the tissue or causing discomfort to the patient. In other embodiments, the top portion of the central body portion ( 101 ) may comprise grooves, blunted barbs, or other textures to provide friction and to resist slippage of the device within the vaginal cavity. In one exemplary embodiment, the wings comprise serrated wing edges. This serrated wing edges may be at the bottom.
The exemplary device ( 100 ) may also comprise a distal tip ( 106 ), which is the first part of the device inserted into the body. The distal tip ( 106 ) may be thick and wide enough to hold the upper portion of the vaginal walls during various procedures. The distal end of the distal tip ( 106 ) may be round and smooth to provide comfort and minimize damage to the tissue during use. The distal tip ( 106 ) may also comprise a concave portion ( 107 ) that facilitates insertion into the body and provides better contact with the tissue by conforming to the body structure. In some embodiments, the distal tip ( 106 ) may also comprise grooves, blunted barbs, or other textures to provide friction and to resist slippage of the device within the vaginal cavity.
The exemplary device ( 100 ) may also comprise a ratchet mechanism ( 108 ), as depicted in FIG. 4 . This ratchet mechanism ( 108 ) may serve to provide structural support to the wings ( 102 , 103 ) to counteract the force of the vaginal walls on the wings. This structural support may also prevent the hinges ( 104 , 105 ) from breaking due to the force of the vaginal walls on the wings ( 102 , 103 ). The ratchet mechanism ( 108 ) may also serve to hold the wings ( 102 , 103 ) in various positions with respect to each other. For example, the user may desire to have the wings ( 102 , 103 ) closer to each other during insertion and removal of the device ( 100 ). Various wing positions may also be desired for different body shapes, sizes, or morphologies.
The ratchet mechanism ( 108 ) may comprise ratchet arms ( 109 , 110 ) that are affixed to the interior surfaces of the wings ( 102 , 103 ). One ratchet arm ( 110 ) may comprise a peg ( 113 ) which may be removably interlocked in different positions to various teeth ( 114 ) on the other ratchet arm ( 109 ). In some embodiments, the ratchet arms ( 109 , 110 ) may be affixed directly to the wings ( 102 , 103 ), not shown, while in other embodiments the arms ( 109 , 110 ) may be affixed to bases ( 111 , 112 ) that are affixed to the wings ( 102 , 103 ), as shown in FIG. 4 . The bases ( 111 , 112 ) may provide additional structural support to the wings ( 102 , 103 ) and may prevent the ratchet arms ( 109 , 110 ) from breaking off of the wings ( 102 , 103 ). In some embodiments, the ratchet mechanism ( 108 ) may be configured to prevent the wings ( 102 , 103 ) from moving toward each other from the force of the vaginal walls, while in other embodiments the ratchet mechanism ( 108 ) may be configured to lock together to prevent the wings ( 102 , 103 ) from moving away from each other (due to the configuration of the hinges).
In another exemplary embodiment (not shown), the device ( 100 ) may comprise a gripping proximal tip at the proximal end. This gripping proximal tip may extend from the proximal end of the central body portion ( 101 ). This gripping proximal tip may stick out of the vagina while the rest of the device is inserted, and thus allow the user to grab the portion to facilitate removal of the device from the body.
FIG. 5 presents an isometric view of another exemplary retractor ( 100 ). In this embodiment, the retractor comprises a retractor limiter ( 201 ). The limiter ( 201 ) may be included in the same molded part as the central body portion ( 101 ). The limiter ( 201 ), shown from the side in FIG. 6 , may prevent the retractor ( 100 ) from penetrating too far into vagina, and may prevent damage to the cervix, uterus, or other parts of the female patient. The limiter ( 201 ) may also have a smooth surface free of surface protrusions or holes in order to prevent painful interaction with the clitoris.
The wings ( 102 , 103 ) of FIG. 5 also comprise lips ( 202 , 203 ) at their proximal ends. The lips ( 202 , 203 ) along with the wings ( 102 , 103 ), central body portion ( 101 ), and limiter ( 201 ) may prevent blood, tissue, or other materials from entering the area where the suturing takes place. The lips ( 202 , 203 ) may also help to prevent the retractor from penetrating too deeply into the vagina. The lips may also increase stability of the retractor, and help to secure its position with respect to the vagina.
The retractor ( 100 ) of FIG. 5 may also comprise a ratchet mechanism ( 220 ) comprising two ratchet arms ( 222 , 223 ), shown straight-on in FIG. 7 . As shown in the assembled view of FIG. 5 , the ratchet arms ( 222 , 223 ) may attach to three areas of the retractor body: at the base of each wing lips ( 202 , 203 ) and at the ratchet hub ( 221 ). As shown in FIG. 8 , the lips ( 202 , 203 ) may comprise fasteners ( 216 , 215 ), which may comprise barbed pins, that engage the fastener recesses ( 225 , 226 ) of the ratchet arms.
The ratchet arms ( 222 , 223 ) may further attach to the body of the retractor by means of central ratchet hub fastener ( 230 ) protruding from the left retractor arm ( 222 ), as shown in FIG. 9 . The ratchet hub fastener ( 230 ) may comprise barbed pins. The ratchet hub fastener pin ( 230 ) may pass through a hole ( 231 ) shown in FIG. 10 .
The ratchet hub fastener pin ( 230 ) may also fasten to a limiter recess ( 204 ) on the proximal side of the limiter ( 201 ), shown in FIG. 8 . The limiter recess ( 204 ) of FIG. 8 may be elongated along its vertical axis in order to allow the fastener pin ( 230 ) to slide up and down along the vertical axis of the limiter. This sliding may be necessary as the ratchet arms ( 222 , 223 ) move away from each other, since in this embodiment the fasteners ( 216 , 215 ) are fixed to the lips ( 202 , 203 ).
In other embodiments, the limiter recess may not be elongated, so that the fastener pin ( 230 ) would not move up or down with respect to the limiter ( 201 ). Rather, the fastener recesses ( 225 , 226 ) of the ratchet arms could be elongated so that the fasteners ( 216 , 215 ) is fixed to the lips ( 202 , 203 ) and could move along the elongated fastener recesses ( 225 , 226 ).
As shown in FIG. 5 , FIG. 6 , FIG. 7 , and FIG. 11 , the ratchet arms ( 222 , 223 ) may also comprise ratchet grasps ( 224 , 225 ). The ratchet grasps may be useful for spreading the ratchet arms away from, or closer to, each other. The ratchet grasps may also be useful for altering the position of the retractor ( 100 ), inserting the retractor, or removing the retractor. The ratchet grasps ( 224 , 225 ) may further comprise textures, or other protruded and/or thinned portions, in order to increase friction and facilitate gripping by the user.
FIGS. 9 and 10 show additional details of the ratchet mechanism ( 220 ). FIG. 9 shows the left ratchet arm ( 222 ) turned over to show its inner workings. The other ratchet arm ( 223 ), shown in FIG. 10 , comprises a ratchet release trigger ( 241 ) that comprises a ratchet release trigger handle ( 243 ) and a ratchet release tooth engager ( 242 ). The ratchet release tooth engager ( 242 ) may be configured to latch onto the ratchet teeth ( 240 ) of the ratchet arm ( 222 ) of FIG. 9 . The tooth engager ( 242 ) may release from the teeth ( 240 ) when the user presses the trigger handle ( 243 ).
In FIG. 9 , a carve-out to the right of the ratchet teeth ( 241 ) may serve as a ratchet limiter engaging slot ( 246 ) along which a ratchet limiter stop ( 245 ) of FIGS. 10 and 11 may move as the ratchet arms move relative to each other. This may prevent the distance between the bases of the of the ratchet arms ( 222 , 223 ) from exceeding three inches. In some embodiments, the distance may be more than three inches, for instance four inches. In other embodiments, it may be 2.5 inches or less.
In some embodiments, the retractor may comprise a polymer such as acrylonitrile butadiene styrene (ABS), polyurethane, acetal plastics, or another material known to those skilled in the art that provides both structural rigidity and flexibility. It may comprise flexible plastic material such as polyamide sold under the trade name “NYLON,” polytetrafluoroethylene sold under the trademark “TEFLON”. Alternatively, a polypropylene plastic or a high density polyethylene plastic may be used to manufacture the retractor. The device may be made of a transparent plastic in order to enhance the viewing area. It may also be made of metal. Mixtures or composites of these materials may also be used to manufacture the minimally obstructive retractor.
The hinge may comprise a polymer. The hinge, for example, may comprise polyethylene, polypropylene, nylon, acetal plastics or mixtures thereof. In another example, the hinge material may even be polyethylene, polypropylene or mixtures thereof.
The retractor may be sterilizable by ethylene oxide, gamma radiation or other process known to those skilled in the art. It may be disposable or reprocessable. Also, the device may be made of different sizes and/or thicknesses to accommodate different ages and sizes of patients. The device may be coated with a material to facilitate inspection and movement. For example, a lubricant can be used to coat the device to facilitate insertion and retrieval.
In one embodiment, the minimally obstructive retractor further comprises an illumination source. The illumination source may comprise more than one illumination devices.
Yet, in a further embodiment, one or all device components forming the illumination source are located within the canopy formed by the retractor. For example, the illumination source may comprise a light-emitting diode wherein the light emitting diode is located within the retractor canopy. Also, in another example, the whole illumination source is located within the retractor canopy. In such embodiments, a compact retractor with no illumination source components dangling beyond the other retractor parts may be obtained.
One exemplary embodiment of the minimally obstructive retractor ( 100 ) comprising an illumination source ( 260 ) is shown in FIG. 12 . As shown in FIG. 13 , an exemplary illumination source ( 260 ) may comprise a light ( 262 ), such as battery-powered light-emitting diode (LED), located within a light source housing ( 261 ). In the embodiment of FIGS. 12 and 13 , the light source housing ( 261 ) may be attached to a cap ( 266 ) that attaches to the limiter ( 201 ) of FIG. 12 . The cap ( 266 ) may attach to the limiter ( 201 ) by means of a fastener ( 263 ), comprising a pin ( 264 ), which connects to either a ratchet arm or the limiter ( 201 ). In some embodiments, the cap ( 266 ) does not have a fastener; rather it may attach by means of an adhesive. In some embodiments, the illumination housing ( 261 ) may be configured to swivel. In some embodiments the user may manually operate the light function externally via a mechanical switch, while in alternative embodiments, the light function may be turned on and off automatically.
FIGS. 14-17 depict various views of another exemplary retractor with alternative illumination and structural features. The device may comprise a central body portion ( 101 ), wings ( 102 , 103 ) that may be connected to the central body portion ( 101 ) via living hinges ( 104 , 105 ), and a ratchet mechanism ( 108 ). The ratchet arms ( 109 , 110 ) may be assembled together at a ratchet hub ( 221 ). For example, a ratchet hub fastener ( 230 ) on ratchet arm ( 222 ) shown in FIG. 16 may fasten to a limiter recess ( 204 ) within a limiter ( 201 ) shown in FIG. 15 .
As shown in FIG. 15 , to stabilize the sliding motion of the main body relative to the ratchet arms, the central body portion ( 101 ) may comprise two pegs ( 281 , 282 ) which are able to travel back and forth within mating grooves ( 283 , 284 , respectively) integrated within the ratchet arms ( 109 , 110 ), thereby effectively restricting rotation of the retractor ( 100 ) off axis.
As shown in FIGS. 16 and 17 , the wings ( 102 , 103 ) may flare outward along a portion of their length. In particular, distance between the opposing wings may be greater toward the end that is deeper the body cavity, and may be narrower toward the opening of the vaginal cavity. Consequently, pressure of the vaginal walls upon the length of the device's blades may tend to hold the device within the cavity, thereby preventing the device from sliding out of the vagina.
The exemplary embodiment of FIGS. 14 to 17 comprises an alternative embodiment of an illumination source ( 260 ). The illumination source ( 260 ) may comprise a plurality of light emitting components such as light emitting diodes (LEDs) ( 400 ) capable of producing sufficient visible light to view the area of interest, a power supply such as coin cell batteries ( 295 ) to drive the LED ( 400 ), power management components such as resistors, and reed sensor switch ( 294 ) to activate the LED ( 400 ). The LED ( 400 ), resistors, reed switch ( 294 ) and power supply batteries ( 295 ) may be assembled on a printed circuit board ( 299 ), also known as a PCB.
The exemplary embodiment of FIGS. 14 to 17 further comprises an illumination source that may be automatically turned on and off in conjunction with movement of the ratchet arms away from, and towards, each other, respectively.
In the exploded view of the device in FIG. 17 , the LED may be turned on and off via a reed sensor switch ( 294 ). The reed sensor switch ( 294 ) may be turned on in the presence of a magnetic field generated by a magnet ( 293 ), and may turn off in the absence of the magnetic field generated by the magnet. The reed sensor switch ( 294 ) may be sensitive to the position of the magnet ( 293 ). The magnet ( 293 ) may be positioned within a magnet receptacle ( 292 ) within the stem ( 290 ). The stem ( 290 ) may hold the magnet ( 293 ) and provide the magnet with a path to actuate the LED assembly by positioning the magnet ( 293 ) within close enough proximity to the reed sensor switch ( 294 ) to activate the switch ( 294 ).
The stem may be assembled between the limiter ( 201 ) and the ratchet arms ( 222 , 223 ). Specifically, the stem ( 290 ) may travel along a vertical path within a recess ( 204 ) of the limiter ( 201 ) as it travels along with the ratchet arms ( 222 , 223 ) when the ratchet arms are opened and closed to open and close the device wings ( 102 , 103 ). A stem pin ( 291 ) may pass through the hole ( 231 ) on ratchet arm ( 223 ) and engage with the ratchet hub fastener pin ( 230 ) of ratchet arm ( 222 ). This engagement between the stem pin ( 291 ) and the ratchet hub fastener pin ( 230 ) may cause the stem ( 290 ) to slide along the limiter recess ( 204 ) of the limiter ( 201 ).
The coin cell batteries ( 295 ) may be connected using contact wires ( 296 ) or directly assembled onto the PCB ( 299 ). Alternatively, the electronic components may be brought in contact to complete the circuit without soldering and connected by compression of the assembly packaging.
The LED assembly ( 290 ) may be placed onto a plurality of mounting posts ( 297 ) on an LED cover ( 298 ), which may comprise a translucent material, and assembled into mating features (not shown) located on the underside of the central body portion ( 101 ).
In FIG. 17 , a gasket ( 301 ), made of rubber or other materials, may be placed between the LED cover ( 298 ) and an inner surface of the central body portion ( 101 ) to prevent or minimize the ingress of fluids and dirt into the LED assembly ( 290 ). In addition, in the case of leaking power supply batteries, the gasket ( 301 ) may prevent chemicals from leaking outside the device, thereby protecting the user. The gasket ( 301 ) may be held in place by mating features in the main body surface, by adhesive, or by other means.
The LED cover ( 298 ) and LED assembly ( 298 ) may also be mated with the main body via other fastening mechanisms such as screws or epoxy.
The stem may travel in a vertical path inside a slot ( 302 ) located with the LED cover ( 298 ), thereby making the actuation mechanism hidden from to the user.
In another embodiment (not shown), the mechanism of turning the light on and off may comprise a mechanical push button switch. The switch may be placed behind the ratchet arms at a location where the arms interact with each other. When the ratchet arms are opened outward and pass over each other, the switch may be triggered, thus completing the electrical circuit and turning on the light.
In another embodiment, the mechanical push button switch may be placed between the ratchet arm surfaces where the mechanical push switch button may by pressed in the off position when the ratchet arms are closed, thus keeping the light function off. When the ratchet arms are opened outwardly, this may release the switch, thereby turning the switch to the on position, completing the electrical circuit and turning the light function on.
Alternatively, the mechanical push button switch may be accessible to the user to manually turn the light function on or off. The switch may be located on the ratchet arm hub for easy access.
In another embodiment, an optical sensor switch may be used to activate the light function. The switch may be placed in the main body or ratchet arm and between the surfaces thereby occluding the sensor of the switch from ambient light. When the ratchet arms pass over and expose the optical sensor, the switch turns the light function on.
In another embodiment, a breakoff plastic feature may be used to trigger a switch (or an incomplete circuit by a separated wire connection) to turn on the light. In the closed position, one of the ratchet arms may be connected to the switch via a plastic feature or tab. When the ratchet arms are pulled outward to open the wings, this plastic tab could break, consequently activating the switch (or completing the connection between the separated wire) to turn on the light. With this mechanism, the device light function could stay on until the batteries are drained of their power. A variation of this mechanism may use the plastic tab as a cover over the optical sensor switch. On pulling the ratchet arms outwardly, the plastic tab could break and expose the optical sensor, thereby completing the electrical circuit and turning the light on.
In other embodiments, the device may comprise a plurality of LEDs located at various portions of the interior of the device. For example, the LEDs may be located on or integrated within the interior surfaces of the central body portion ( 101 ), the distal tip ( 106 ), and/or the wings ( 102 , 103 ).
In some exemplary embodiments, the retractor may comprise a lubrication source. This lubrication source may comprise a lubricant-containing reservoir integrated with the body of the device, and a channel for delivering the biocompatible lubricant. For example, the reservoir may be located on, or integrated within, the interior surfaces of the central body portion ( 101 ), the distal tip ( 106 ), and/or the wings ( 102 , 103 ). The channels may provide lubrication to the outer surfaces of the retractor ( 100 ).
In some embodiments, a significant portion of the device ( 100 ) may be formed from a single continuous material. That is, the retractor—is formed from only one component. In these embodiments, the retractor may be manufactured by molding. For example, in an exemplary embodiment, the central body portion ( 101 ), wings ( 102 , 103 ), and distal tip ( 106 ) may be injection molded to form a single component. An exemplary material for injection molding may be polypropylene.
The device ( 100 ) may be used in various procedures, including episiotomy repair, repair of vaginal lacerations, and visualization during checkups. For example, the ratchet mechanism ( 220 ) may be adjusted to hold the wings ( 102 , 103 ) in various positions with respect to each other. For example, the user may desire to have the wings ( 102 , 103 ) closer to each other during insertion and removal of the device ( 100 ), while keeping the wings ( 102 , 103 ) farther apart from each other to maximize the viewing and working fields during procedures. Various positions may also be desired for different body shapes, sizes, or morphologies. The position of the wings may be changed during procedures using the ratchet mechanism ( 220 ).
The device may be used for improved visualization, access, and repair in various procedures, including, but not limited to: obstetrical/gynecological procedures: vaginal inspection; perineal inspection; vaginal wound repair; perineal wound repair; episiotomy repair; female pelvic exam; pap smear; cervical biopsy; vaginal/pelvic reconstruction; urological procedures; colorectal, general, or other surgery; the device may be turned upside-down, for example, for female urologic procedures; access to the cervix (or uterus via cervix); IUD insertion, removal, or adjustment; and dilatation & curettage (dilatation of cervix and curettage of uterus).
The previous description of embodiments is provided to enable any person skilled in the art to make or use the retractors and speculums. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the retractors and speculums. Thus, the retractors and speculums are not intended to be limited to the embodiments shown herein but are to be accorded the widest scope consistent with the principles and novel features disclosed herein. | This application presents minimally-obstructive and structurally-adjustable retractors which afford an open work area of desirable size and enhanced visualization for a surgeon about the perineum and the posterior vaginal wall of the patient. The retractors may be lightweight and compact, and also configured and dimensioned to minimize slippage during use. The retractors may retract the engorged labia of the postpartum patient as well as the vaginal walls. The device may also be used as a speculum. | 0 |
RELATED APPLICATIONS
This application claims priority to European Application No. 03029507.5, filed Dec. 20, 2003; European Application No. 03016224.2, filed Jul. 17, 2003; and European Application No. 03007001.5, filed Mar. 27, 2003, each of which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to a pharmaceutical composition useful for the treatment of viral infections comprising tipranavir and at least one antiviral active compound of formula (I). Furthermore the present invention relates to a use of tipranavir in combination or alternation with a compound of formula (I) in the prophylaxis or treatment of a viral infection in a patient. The present invention also relates to a use of tipranavir in combination with a compound of formula (I) for the manufacture of a medicament for the prophylaxis or treatment of a viral infection in a patient. In addition the present invention relates to a kit of parts and to a manufacture for the prophylaxis or treatment of a viral infection in a patient.
BACKGROUND OF THE INVENTION
Human immunodeficiency virus (HIV) is recognized as the causative agent in AIDS.
Current therapies for HIV infection focus on inhibiting the activity of viral enzymes which are essential to the life cycle of the virus. The agents that are presently in use fall mainly into three classes, designated Nucleoside Reverse Transcriptase Inhibitors (NRTIs), Non-nucleoside Reverse Transcriptase Inhibitors (NNRTIs), and Protease Inhibitors (PIs). Presently, combination therapies, i.e. the selection of two or more antiretroviral agents taken together to make up a “drug cocktail,” are the preferred treatment for HIV infection. Combination therapies have been shown to reduce the incidence of opportunistic infections and to increase survival time. Typically, the drug cocktail combines drugs from different classes, so as to attack the virus at several stages in the replication process. This approach has been shown to reduce the likelihood of the development of virus forms that are resistant to a given drug or class of drugs.
Treatment failure with rebound of the amount of HIV which can be measured in the blood is common for patients treated with combination antiretroviral regimens. Resistance to the drugs in the drug regimen develops as the virus replicates in the presence of these drugs. Because of structural similarities of the drugs within an antiretroviral class, cross resistance is commonly seen to the other members of that class (for example virologic failure on a regimen containing an NNRTI will lead to cross resistance to the other first generation NNRTI agents). As patients experience repeated virologic failure on antiretroviral combination therapy, their viruses develop broad multi-class antiretroviral drug resistance which limits the effectiveness of the next round of antiretroviral therapy. Many highly treatment experienced patients have been exposed to all three classes of antiretroviral drugs and cannot obtain two active drugs to form the core of a new, effective antiretroviral drug regimen.
Tipranavir is a known agent for the treatment of HIV infection.
Tipranavir, also known as U-140690 and PNU-140690, is an HIV protease inhibitor. Chemically, tipranavir is (6R)-3-((1R)-1-[3-({[5-trifluoromethyl)(2-pyridyl)]sulfonyl}amino)phenyl]propyl}-4-hydroxy-6-(2-phenylethyl)-6-propyl-5,6-dihydro-2H-pyran-2-one or ([R-(R*,R*)]-N-[3-[1-[5,6-dihydro-4-hydroxy-2-oxo-6-(2-phenylethyl)-6-prop yl-2H-pyran-3-yl]propyl]phenyl]-5-(trifluoromethyl)-2-pyridinesulfonamide) and has the following structural formula:
Tipranavir and methods for its synthesis and use in the treatment of HIV are described in WO 95/30670 and corresponding U.S. Pat. No. 5,852,195. Pharmaceutical formulations suitable for the oral administration of tipranavir are described in WO 99/06043 and WO 99/06044, and the corresponding U.S. Pat. Nos. 6,121,313 and 6,231,887.
As tipranavir is metabolized relatively rapidly by the cytochromes P450, especially the Cyp3A4 isoform, it is preferred to co-administer an inhibitor of Cyp3A4 in order to obtain therapeutically effective blood levels of tipranavir. The use of ritonavir for this purpose is described in U.S. Pat. No. 6,147,095. The use for this purpose of other inhibitors of Cyp3A4 is also possible.
Furthermore Compounds of the Formula (I)
wherein Base is selected from the group consisting of thymine, cytosine, adenine, guanine, inosine, uracil, 5-ethyluracil and 2,6-diaminopurine, or a pharmaceutically acceptable salt or prodrug thereof, are described in the WO 88/00050 and WO 91/01137 for the therapeutic and prophylactic control and treatment of AIDS, HIV infections, hepatitis B virus (HBV) infections and retrovirus infections in animals and man. These nucleoside compounds are transformed by cells or enzymes to triphosphates which inhibit the reverse transcriptase of retrovirus as well as the activity of DNA dependent polymerase of hepatitis B virus.
Combinations of tipranavir with at least one compound of the formula (I) which exhibit potent therapeutic activity against HIV and HBV would greatly aid in the development of new combination therapy against human retroviral (HRV) infections and HBV.
SUMMARY OF THE INVENTION
In one aspect, the present invention provides a novel pharmaceutical composition useful for the treatment or prophylaxis of viral infections comprising tipranavir and at least one antiviral active compound of formula (I)
wherein Base is selected from the group consisting of thymine, cytosine, adenine, guanine, inosine, uracil, 5-ethyluracil and 2,6-diaminopurine, or a pharmaceutically acceptable salt or prodrug thereof.
The pharmaceutical compositions of the present invention are useful in therapy, in particular as antivirals, especially in the treatment or prophylaxis of human retroviral (HRV) infections.
In a second aspect, there is provided a use of tipranavir in combination or alternation with at least one antiviral active compound of formula (I)
wherein Base is selected from the group consisting of thymine, cytosine, adenine, guanine, inosine, uracil, 5-ethyluracil and 2,6-diaminopurine, or a pharmaceutically acceptable salt or prodrug thereof, in the prophylaxis or treatment of a viral infection in a patient.
In a third aspect, there is provided a use of tipranavir in combination with at least one antiviral active compound of formula (I)
wherein Base is selected from the group consisting of thymine, cytosine, adenine, guanine, inosine, uracil, 5-ethyluracil and 2,6-diaminopurine, or a pharmaceutically acceptable salt or prodrug thereof, for the manufacture of a medicament for the prophylaxis or treatment of a viral infection in a patient.
In a fourth aspect of this invention, there is provided a kit of parts for the prophylaxis or treatment of a viral infection in a patient, comprising:
(a) a first containment containing a pharmaceutical composition comprising tipranavir and at least one pharmaceutically acceptable carrier, and (b) a second containment containing a pharmaceutical composition comprising an antiviral active compound of formula (I)
wherein Base is selected from the group consisting of thymine, cytosine, adenine, guanine, inosine, uracil, 5-ethyluracil and 2,6-diaminopurine, or a pharmaceutically acceptable salt or prodrug thereof, and at least one pharmaceutically acceptable carrier.
In a fifth aspect of this invention, there is provided a manufacture comprising tipranavir and at least one antiviral active compound of formula (I)
wherein Base is selected from the group consisting of thymine, cytosine, adenine, guanine, inosine, uracil, 5-ethyluracil and 2,6-diaminopurine, or a pharmaceutically acceptable salt or prodrug thereof, for use in combination or alternation in the prophylaxis or treatment of a viral infection in patient.
With the combination of tipranavir and a compound of the formula (I) according to this invention, including its use in prophylaxis and treatment, the person skilled in the art can achieve an advantageous therapeutic effect to inhibit viral replication, especially of human retrovirus (HRV) and HBV, in particular of multiresistant HIV. In most cases, the enhanced therapeutic effect is not attainable by administration of either agent alone. In a preferred but not necessary embodiment, the effect of administration of tipranavir and the compound of formula (I) in combination or alternation is synergistic. Even though a combination exhibits additive and not synergistic effects, the combination can still provide an effect that is different from the separate administration of the two agents. For example, the biodistribution, pharmacokinetics, cytotoxic effects or metabolism of one can be affected by the other.
Further aspects of the present invention become apparent to the one skilled in the art from the following detailed description and examples.
Definitions
The term “pharmaceutically acceptable salt” means a salt of the corresponding compound which is, within the scope of sound medical judgment, suitable for use in contact with the tissues of humans and lower animals without undue toxicity, irritation, allergic response, and the like, commensurate with a reasonable benefit/risk ratio, generally water or oil-soluble or dispersible, and effective for their intended use. The term includes pharmaceutically-acceptable acid addition salts and pharmaceutically-acceptable base addition salts. Lists of suitable salts are found in, e.g., S. M. Birge et al., J. Pharm. Sci., 1977, 66, pp. 1-19, which is hereby incorporated by reference in its entirety.
As used herein, the term “treatment” means the administration of the antivirally active compounds according to this invention in combination or alternation according to the present invention to alleviate or eliminate symptoms of the viral infection and/or to reduce viral load in a patient.
As used herein, the term “prevention” or “prophylaxis” means the administration of the antivirally active compounds according to this invention in combination or alternation according to the present invention post-exposure of the individual to the virus but before the appearance of symptoms of the disease, and/or prior to the detection of the virus in the blood.
As used herein, the term “human retrovirus” (HRV) includes human immunodeficiency virus type I, human immunodeficiency virus type II, or strains thereof, as well as human T cell leukemia virus 1 and 2 (HTLV-1 and HTLV-2) or strains apparent to one skilled in the art, which belong to the same or related viral families and which create similar physiological effects in humans as various human retroviruses.
DETAILED DESCRIPTION OF THE INVENTION
The virally active agents according to this invention may be in either free form or in protected form at one or more of the remaining (not previously protected) carboxyl, amino, hydroxy, or other reactive groups. The protecting groups may be any of those known in the art. Furthermore, the virally active agents according to this invention may also be used as in form of their pharmacologically acceptable salts and/or hydrates.
According to the first aspect of this invention, there is provided a novel pharmaceutical composition useful for the treatment of viral infections comprising tipranavir and at least one antiviral active compound of formula (I), or a pharmaceutically acceptable salt or prodrug thereof.
The following known compounds constitute part of the invention as preferred compounds of the formula (I) to be combined with tipranavir:
including pharmaceutically acceptable salts and prodrugs of the compounds listed above.
Preferred prodrugs of FLG are described in WO 99/09031 and WO 99/41268, which documents in their entirety are incorporated herein by reference.
The most preferred compound of the formula (I) to be combined with tipranavir according to the aspects of this invention is selected from the group consisting of:
(a) 3′-deoxy-3′-fluorothymidine, or a pharmaceutically acceptable salt or prodrug thereof, and (b) 2′,3′-dideoxy-3′-fluoroguanosine (FLG), or a pharmaceutically acceptable salt or prodrug thereof, in particular 3′-deoxy-3′-fluoro-5-O-[2-(L-valyloxy)-propionyl]guanosine, or a pharmaceutically acceptable salt thereof.
The compound of the formula (I) is very most preferably selected from the group consisting of 3′-deoxy-3′-fluorothymidine and 3′-deoxy-3′-fluoro-5-O-[2-(L-valyloxy)-propionyl]guanosine, including pharmaceutically acceptable salts thereof.
3′-deoxy-3′-fluoro-5-O-[2-(L-valyloxy)-propionyl]guanosine is a preferred prodrug of FLG and can be depicted by the following structure
The synthesis of 3′-deoxy-3′-fluoro-5-O-[2-(L-valyloxy)-propionyl]guanosine, also named as 21,3′-dideoxy-3′-fluoro-5-O-[2-(L-valyloxy)-propionyl]guanosine, is described in the WO 99/09031 and especially in example 32 therein.
Therefore, a preferred pharmaceutical composition useful for the treatment of viral infections comprises tipranavir and 3′-deoxy-3′-fluorothymidine or 3′-deoxy-3′-fluoro-5-O-[2-(L-valyloxy)-propionyl]guanosine, or a pharmaceutically acceptable salt or prodrug thereof.
Furthermore, tipranavir in combination or alternation with preferably 3′-deoxy-3′-fluorothymidine or 3′-deoxy-3′-fluoro-5-O-[2-(L-valyloxy)-propionyl]guanosine, or a pharmaceutically acceptable salt or prodrug thereof, is used in the prophylaxis or treatment of a viral infection in a patient.
Also preferred is the use of tipranavir in combination with 3′-deoxy-3′-fluorothymidine or 3′-deoxy-3′-fluoro-5-O-[2-(L-valyloxy)-propionyl]guanosine, or a pharmaceutically acceptable salt or prodrug thereof, for the manufacture of a medicament for the prophylaxis or treatment of a viral infection in a patient.
A preferred kit of parts for the prophylaxis or treatment of a viral infection in a patient, comprises:
(a) a first containment containing a pharmaceutical composition comprising tipranavir and a pharmaceutically acceptable carrier, and (b) a second containment containing a pharmaceutical composition comprising 3′-deoxy-3′-fluorothymidine or 3′-deoxy-3′-fluoro-5-O-[2-(L-valyloxy)-propionyl]guanosine, or a pharmaceutically acceptable salt or prodrug thereof, and a pharmaceutically acceptable carrier.
A preferred manufacture comprises tipranavir and 3′-deoxy-3′-fluorothymidine or 3′-deoxy-3′-fluoro-5-O-[2-(L-valyloxy)-propionyl]guanosine, or a pharmaceutically acceptable salt or prodrug thereof, for use in combination or alternation in the prophylaxis or treatment of a viral infection in a patient.
The advantageous effects of the combination of tipranavir and the compound of formula (I) are realized over a wide ratio, like for example in a ratio of between 1:250 to 250:1.
Therefore, in the compositions, combinations, kit of parts, manufacture and/or the use of the combinations according to this invention, tipranavir and the at least one compound of formula (I) are preferably present in a synergistic ratio. Usually, this ratio is between about 1:250 to about 250:1. More preferably the ratio is between about 1:50 to about 50:1. The most preferred ratio is between about 1:20 to about 20:1, which includes the ratios 1:18, 1:16, 1:14, 1:12, 1:10; 1:8; 1:6; 1:5; 1:4; 1:3; 1:2,5; 1:2; 1:1,5; 1:1,2; 1:1; 1,2:1; 1,5:1; 2:1; 2,5:1; 3:1; 4:1; 5:1; 6:1; 8:1; 10:1, 12:1, 14:1, 16:1, 18:1 and all ranges in between.
If a further therapeutic agent is added, ratios will be adjusted accordingly.
It will be appreciated that the amount of pharmaceutical composition according to the invention required for use in treatment or prophylaxis will vary not only with the particular compound selected but also with the route of administration, the nature and severity of the condition for which treatment or prophylaxis is required, the age, weight and condition of the patient, concomitant medication and will be ultimately at the discretion of the attendant physician or veterinarian. In general however the active compounds are included in the pharmaceutically acceptable carrier in an amount sufficient to deliver to a patient a therapeutically effective amount of compound to inhibit viral replication in vivo, especially HIV replication, without causing serious toxic effects in the treated patient. By “inhibitory amount” is meant an amount of active ingredient sufficient to exert an inhibitory effect as measured by, for example, an assay such as the ones described herein. A suitable dose will preferably be in the range of from about 0.05 to about 200 mg/kg of body weight per day.
The desired dose may conveniently be presented in a single dose or as divided dose administered at appropriate intervals, for example as two, three, four or more doses per day.
The pharmaceutical composition according to the present invention is conveniently administered in unit dosage form; for example containing 5 to 3000 mg, conveniently 5 to 1000 mg of active ingredient(s) per unit dosage form.
The pharmaceutical acceptable carrier(s) must be “acceptable” in the sense of being compatible with the other ingredients of the formulation and not deleterious to the recipient thereof.
Examples of pharmaceutically acceptable carriers are magnesium stearate, chalk, starch, lactose, wax, gum or gelatin. Carriers which are suited to achieve a sustained release, for example natural or synthetic polymers or liposomes, are known to the one skilled in the art. Pharmaceutically acceptable carriers also comprise liquid carriers and diluents, for example water, alcohol, glycerine or oil, which serve as a base for liquid formulations, such as solutions, suspensions or emulsions.
The compositions referred to above may conveniently be presented for use in the form of a pharmaceutical formulation and therefore pharmaceutical formulations comprising a composition as defined above together with a pharmaceutically acceptable carrier comprise a further aspect of the invention.
The individual components of such compositions may be administered either in combination, i.e. simultaneously, or in alternation, i.e. sequentially, in separate or combined pharmaceutical formulations.
When tipranavir is used in combination with a compound of the formula (I) against the same virus the dose of each compound may be either the same as or differ from that when the compound is used alone. Appropriate doses will be readily appreciated by those skilled in the art.
The compositions according to this invention preferably also comprise at least one pharmaceutically acceptable carrier.
According to the third aspect of this invention, the combination of tipranavir and at least one compound of the formula (I) is used for the manufacture of a medicament for the prophylaxis or the treatment of a viral infection in a patient.
According to one embodiment, this medicament may be a unit dosage form, which is preferably useful in combination therapy, such as capsules or tablets. The unit dosage form contains a pharmaceutical composition according to this invention, i.e. tipranavir in combination with at least one compound of the formula (I), with at least one pharmaceutically acceptable carrier.
Therefore, another object of this invention also comprises bringing tipranavir and at least a compound of the formula (I) together in conjunction or association with a pharmaceutically acceptable carrier.
According to another embodiment, this medicament is a multiple dosage form, preferably a kit of parts, which is especially useful in alternation and/or combination therapy to flexibly suit the individual therapeutic needs of the patient.
It is known, e.g. WO 00/25784, that various doses of ritonavir have substantial and significant effects on tipranavir by elevating, or enhancing, plasma concentrations of tipranavir. This pharmacokinetic drug interaction may offer the following advantages:
enhanced antiviral activity of tipranavir, reduction of the administered tipranavir dose, improved safety profile.
Therefore, according to one embodiment the combinations, compositions, kit of parts, manufactures of this invention and the uses thereof, which comprise tipranavir and at least one compound of the formula (I), or a pharmaceutically salt or prodrug thereof, further comprise ritonavir.
Following this, a preferred pharmaceutical composition useful for the treatment of viral infections comprises tipranavir in combination with ritonavir and 3′-deoxy-3′-fluorothymidine or 3′-deoxy-3′-fluoro-5-O-[2-(L-valyloxy)-propionyl]guanosine, or a pharmaceutically acceptable salt or prodrug thereof.
Furthermore, tipranavir in combination with ritonavir and in combination or alternation with preferably 3′-deoxy-3′-fluorothymidine or 3′-deoxy-3′-fluoro-5-O-[2-(L-valyloxy)-propionyl]guanosine, or a pharmaceutically acceptable salt or prodrug thereof, is used in the prophylaxis or treatment of a viral infection in a patient.
Also preferred is the use of tipranavir in combination with ritonavir and 3′-deoxy-3′-fluorothymidine or 3′-deoxy-3′-fluoro-5-O-[2-(L-valyloxy)-propionyl]guanosine, or a pharmaceutically acceptable salt or prodrug thereof, for the manufacture of a medicament for the prophylaxis or treatment of a viral infection in a patient.
A preferred kit of parts for the prophylaxis or treatment of a viral infection in a patient, comprises:
(a) a first containment containing a pharmaceutical composition comprising tipranavir and ritonavir and a pharmaceutically acceptable carrier, and (b) a second containment containing a pharmaceutical composition comprising 3′-deoxy-3′-fluorothymidine or 3′-deoxy-3′-fluoro-5-O-[2-(L-valyloxy)-propionyl]guanosine, or a pharmaceutically acceptable salt or prodrug thereof, and a pharmaceutically acceptable carrier.
Another preferred kit of parts for the prophylaxis or treatment of a viral infection in a patient, comprises:
(a) a first containment containing a pharmaceutical composition comprising tipranavir and a pharmaceutically acceptable carrier, and (b) a second containment containing a pharmaceutical composition comprising ritonavir and a pharmaceutically acceptable carrier, and (c) a third containment containing a pharmaceutical composition comprising 3′-deoxy-3′-fluorothymidine or 3′-deoxy-3′-fluoro-5-O-[2-(L-valyloxy)-propionyl]guanosine, or a pharmaceutically acceptable salt or prodrug thereof, and a pharmaceutically acceptable carrier.
A preferred manufacture comprises tipranavir, ritonavir and a compound of the formula (I) selected from the group consisting of 3′-deoxy-3′-fluorothymidine or 3′-deoxy-3′-fluoro-5-O-[2-(L-valyloxy)-propionyl]guanosine, or a pharmaceutically acceptable salt thereof, for use in combination or alternation in the prophylaxis or treatment of a viral infection in a patient.
In said combinations, compositions, kit of parts, manufactures, which comprise tipranavir, ritonavir and at least one compound of the formula (I) the ratio and the amount of tipranavir and ritonavir present in these combinations are preferably chosen to achieve therapeutically effective plasma levels of tipranavir. Upper limits, lower limits and therapeutically preferred areas of dosage regimens are known from scientific literature, e.g. WO 00/25784, and may be optimized in view of the combination with the compounds of the formula (I) according to known methods.
According to further embodiments the combinations, compositions, kit of parts, manufactures of this invention and the uses thereof comprise a combination selected from the group consisting of:
a compound of the formula (I), tipranavir and one, two or more further NRTIs; a compound of the formula (I), tipranavir, a NNRTI and optionally one, two or more further NRTIs; a compound of the formula (I), tipranavir, an entry inhibitor and optionally one, two or more further NRTIs; a compound of the formula (I), tipranavir, a NNRTI, an entry inhibitor and optionally one, two or more further NRTIs; a compound of the formula (I), tipranavir, an integrase inhibitor and optionally one, two or more further NRTIs; a compound of the formula (I), tipranavir, a NNRTI, an integrase inhibitor and optionally one, two or more further NRTIs.
In the above listed combinations, compositions, kit of parts, manufactures and uses thereof tipranavir may advantageously be combined with ritonavir as described hereinbefore.
In the foregoing and in the following, the term “further NRTI” refers to a nucleoside reverse transcriptase inhibitor, or a pharmaceutically acceptable salt or prodrug thereof, other than the selected compound of the formula (I). Examples of further NRTIs are Abacavir Sulfate (Ziagen), Didanosine (ddI, Videx), Emtricitabine (Emtriva), Lamivudine (3TC, Epivir), Stavudine (d4t, Zerit), Tenofovir disoproxil fumarate (nucleotide, bis (POC) PMPA, Viread), Zalcitabine (ddc, Hivid), Zidovudine (AZT, Retrovir), Amdoxovir (DAPD; Gilead Sciences), Elvucitabine (ACH-126443; Achillion Pharm.), GS-7340 (Gilead Sciences), INK-20 (thioether phospholipid formulation of AZT; Kucera Pharm.), MIV-310 (Medivir AB), MIV-210 (Medivir AB), Racivir (racemic FTC; Pharmasset), Reverset (RVT, D-D4FC, DPC-817; Pharmasset), SPD-754 ((−)dOTC; Shire Pharm), BCH-13520 (Shire Pharm) and BCH-10618 (Shire Pharm).
In the foregoing and in the following, the term “NNRTI” refers to a non nucleoside reverse transcriptase inhibitor, or a pharmaceutically acceptable salt or prodrug thereof. Examples of NNRTIs are Delavirdine (Rescriptor), Efavirenz (DMP-266, Sustiva), Nevirapine (BIRG-587, Viramune), (+)-Calanolide A and B (Advanced Life Sciences), Capravirine (AG1549, S-1153; Pfizer), GW-695634 (GW-8248; GSK), MIV-150 (Medivir), MV026048 (R-1495; Medivir AB/Roche), NV-05 (Idenix Pharm.), R-278474 (Johnson & Johnson), RS-1588 (Idenix Pharm.), TMC-120/125 (Johnson & Johnson), TMC-125 (R-165335; Johnson & Johnson), UC-781 (Biosyn Inc.) and YM-215389 (Yamanoushi).
In the foregoing and in the following, the term “entry inhibitor” refers to an entry inhibitor, including fusion inhibitors, inhibitors of the CD4 receptor, inhibitors of the CCR5 co-receptor and inhibitors of the CXCR4 co-receptor, or a pharmaceutically acceptable salt or prodrug thereof. Examples of entry inhibitors are AMD-070 (AMD-11070; AnorMed), BlockAide/CR (ADVENTRX Pharm.), BMS 806 (BMS-378806; BMS), Enfurvirtide (T-20, R698, Fuzeon), KRH-1636 (Kureha Pharmaceuticals), ONO-4128 (GW-873140, AK-602, E-913; ONO Pharmaceuticals), Pro-140 (Progenics Pharm), PRO-542 (Progenics Pharm.), SCH-D (SCH-417690; Schering-Plough), T-1249 (R724; Roche/Trimeris), TAK-220 (Takeda Chem. Ind.), TNX-355 (Tanox) and UK-427,857 (Pfizer).
Examples of integrase inhibitors are L-870810 (Merck & Co.), c-2507 (Merck & Co.) and S(RSC)-1838 (Shionogi/GSK).
According to still further embodiments the combinations, compositions, kit of parts, manufactures of this invention and the uses thereof comprise a combination selected from the group consisting of a compound of the formula (I), tipranavir and a further antiviral agent. In these still further embodiments tipranavir may advantageously be combined with ritonavir as described hereinbefore.
A further antiviral agent may be selected from the group of the maturation inhibitors, antisense compounds or protease inhibitors, other than tipranavir. Examples of further antivirals are PA-457 (Panacos), KPC-2 (Kucera Pharm.), HGTV-43 (Enzo Biochem), Amprenavir (VX-478, Agenerase), Atazanavir (Reyataz), Indinavir Sulfate (MK-639, Crixivan), Lexiva (fosamprenavir calcium, GW-433908 or 908, VX-175), Lopinavir+Ritonavir (ABT-378/r, Kaletra), Nelfinavir Mesylate (Viracept), Saquinavir (Invirase, Fortovase), AG-1776 (JE-2147, KNI-764; Nippon Mining Holdings), AG-1859 (Pfizer), DPC-681/684 (BMS), GS224338 ('4338; Gilead Sciences), KNI-272 (Nippon Mining Holdings), Nar-DG-35 (Narhex), P(PL)-100 (P-1946; Procyon Biopharma), P-1946 (Procyon Biopharma), R-944 (Hoffmann-LaRoche), RO-0334649 (Hoffmann-LaRoche), TMC-114 (Johnson & Johnson), VX-385 (GW-640385; GSK/Vertex), VX-478 (Vertex/GSK).
The combinations, compositions, kit of parts, manufactures of this invention and the uses thereof of the above mentioned embodiments may be combined with further active ingredients.
Examples of such further active ingredients are acyclic nucleosides such as acyclovir, ganciclovir; interferons such as alpha-, beta- and gamma-interferon; glucuronation inhibitors such as probenecid; nucleoside transport inhibitors such as dipyridamole; immunomodulators such as interleukin II (IL2) and granulocyte macrophage colony stimulating factor (GM-CSF), erythropoietin, ampligen, thymomodulin, thymopentin, foscarnet, glycosylation inhibitors such as 2-deoxy-D-glucose, castanospermine, 1-deoxynojirimycin; and inhibitors of HIV binding to CD4 receptors such as soluble CD4, CD4 fragments, CD4-hybrid molecules and inhibitors of the HIV aspartyl protease such as L-735,524.
The compounds, or their pharmaceutically acceptable derivative or salts thereof, can also be mixed with other active materials that do not impair the desired action, or with materials that supplement the desired action, such as antibiotics, antifungals, antiinflammatorics, protease inhibitors, or other nucleoside or non-nucleoside antiviral agents, as discussed in more detail above.
In general, during alternation therapy, an effective dosage of each agent is administered serially, whereas in combination therapy, an effective dosage of two or more agents are administered together. The dosages will depend on such factors as absorption, biodistribution, metabolism and excretion rates for each drug as well as other factors known to those of skill in the art. It is to be noted that dosage values will also vary with the severity of the condition to be alleviated. It is to be further understood that for any particular subject, specific dosage regimens and schedules should be adjusted over time according to the individual need and the professional judgment of the person administering or supervising the administration of the compositions. Examples of suitable dosage ranges for tipranavir, compounds of formula (I), preferably 3′-deoxy-3′-fluorothymidine, ritonavir, further NRTIs and other antivirals can be found in the scientific literature. Many examples of suitable dosage ranges for other compounds described herein are also found in the public literature or can be identified using known procedures. These dosage ranges can be modified as desired to achieve a desired result.
It has been recognized that drug-resistant variants of HIV can emerge after prolonged treatment with an antiviral agent. Drug resistance most typically occurs by mutation of a gene that encodes for an enzyme used in the viral life cycle, and most typically in the case of HIV, in either the reverse transcriptase or protease genes. It has been demonstrated that the efficacy of a drug against HIV infection can be prolonged, augmented, or restored by administering the compound in combination or alternation with a second, and perhaps third, antiviral compound that induces a different mutation(s) from that selected for by the principle drug. Alternatively, the pharmacokinetics, biodistribution, or other parameter of the drug can be altered by such combination or alternation therapy. In general, combination therapy is typically preferred over alternation therapy because it induces-multiple simultaneous stresses on the virus. In the case of administering the antiviral compounds in alternation, i.e. sequentially, the time gap between administering the first compound and the second compound is preferably not too long in order to achieve a beneficial effect. Preferably, the time gap is less than half a day, most preferably less than 6 hours.
While it is possible that, for use in therapy, a compound of the invention may be administered as the raw chemical it is preferable to present the active ingredient as a pharmaceutical formulation. The invention thus further provides a pharmaceutical formulation comprising tipranavir and a compound of the formula (I) with one or more pharmaceutically acceptable carriers and, optionally, other therapeutic and/or prophylactic ingredients.
Pharmaceutical formulations include those suitable for oral, rectal, nasal, topical (including buccal and sub lingual), transdermal, vaginal or parenteral (including intramuscular, sub-cutaneous and intravenous) administration in liquid or solid form or in a form suitable for administration by inhalation or insufflation. The formulations may, where appropriate, be conveniently presented in discrete dosage units and may be prepared by any of the methods well known in the art of pharmacy. All methods include the step of bringing into association the active compound(s) with liquid carriers or finely divided solid carriers or both and then, if necessary, shaping the product into the desired formulation.
Pharmaceutical formulation suitable for oral administration may conveniently be presented as discrete units such as capsules, including soft gelatin capsules, cachets or tablets each containing a predetermined amount of the active ingredient(s); as a powder or granules; as a solution, a suspension or as an emulsion, for example as syrups, elixirs or self-emulsifying delivery systems (SEDDS). The active ingredient(s) may also be presented as a bolus, electuary or paste. Tablets and capsules for oral administration may contain conventional excipients such as binding agents, fillers, lubricants, disintegrants, or wetting agents. The tablets may be coated according to methods well known in the art. Oral liquid preparations may be in the form of, for example, aqueous or oily suspensions, solutions, emulsions, syrups or elixirs, or may be presented as a dry product for constitution with water or other suitable vehicle before use. Such liquid preparations may contain conventional additives such as suspending agents, emulsifying agents, non-aqueous vehicles (which may include edible oils), or preservatives.
The pharmaceutical composition according to the invention may also be formulated for parenteral administration (e.g. by injection, for example bolus injection or continuous infusion) and may be presented in unit dose form in ampoules, pre-filled syringes, small volume infusion or in multi-dose containers with an added preservative. The compositions may take such forms as suspensions, solutions, or emulsions in oily or aqueous vehicles, and may contain formulatory agents such as suspending, stabilizing and/or dispersing agents. Alternatively, the active ingredient(s) may be in powder form, obtained by aseptic isolation of sterile solid or by lyophilisation from solution, for constitution with a suitable vehicle, e.g. sterile, pyrogen-free water, before use.
Pharmaceutical formulations suitable for rectal administration wherein the carrier is a solid are most preferably presented as unit dose suppositories. Suitable carriers include cocoa butter and other materials commonly used in the art, and the suppositories may be conveniently formed by admixture of the active compound(s) with the softened or melted carrier(s) followed by chilling and shaping in moulds.
When desired the above described formulations adapted to give sustained release of the active ingredient(s) may be employed.
The compositions, combinations, kit of parts, manufacture and/or the use of the combinations according to this invention are advantageous in the treatment and/or prophylaxis of viral infections in a patient, preferably human retrovirus (HRV) infections and hepatitis B, in particular HIV infections, especially multiresistant HIV infections. Therefore this invention may offer an aid especially for highly treatment experienced patients suffering from multiresistant HIV. In addition to the treatment of said diseases, the combinations, formulations and compositions according to this invention can be used prophylactically to prevent or retard the progression of clinical illness in individuals who are anti-HIV antibody or HIV-antigen positive or who have been exposed to HIV.
The compositions, combinations, kit of parts, manufacture and/or the use of the combinations according to this invention may also be beneficial in preventing perinatal transmission of human retroviral (HRV) infections, in particular HIV-1, from mother to baby. According to this method, tipranavir and a compound of the formula (I), preferably 3′-deoxy-3′-fluorothymidine, and optionally further active compounds as described hereinbefore or hereinafter are administered in combination or alternation to the mother before giving birth.
The compositions, combinations, kit of parts, manufacture and/or the use of the combinations according to this invention may also be beneficial in the treatment and/or prophylaxis of other HIV/AIDS-related conditions such as AIDS-related complex (ARC), persistent generalized lymphadenopathy (PGL), AIDS-related neurological conditions, anti-HIV antibody positive and HIV-positive conditions, Kaposi's sarcoma, thrombocytopenia purpurea and opportunistic infections.
Therefore, patients to be treated would be especially those individuals:
1) infected with one or more strains of a human retrovirus as determined by the presence of either measurable viral antibody or antigen in the serum; and/or 2) in the case of HIV, having either a asymptomatic HIV infection or a symptomatic AIDS defining infection such as i) disseminated histoplasmosis, ii) isopsoriasis, iii) bronchial and pulmonary candidiasis including pneumocystic pneumonia, iv) non-Hodgkin's lymphoma or v) Kaposi's sarcoma and being less than sixty years old; or having an absolute CD4+ lymphocyte count of less than 500/mm 3 in the peripheral blood.
The pharmaceutical combination according to this invention can be tested for additive and synergistic activity against HIV according to a number of assays known in scientific and public literature, including the one described in the WO 98/44913 and WO 00/51641, which are included herein by way of reference.
The present invention is illustrated in further detail by the following non-limiting examples of combinations according to this invention, comprising a 1 st compound, a 2 nd compound, optionally a 3 rd compound, optionally a 4 th compound and optionally a 5 th compound.
Table 1 illustrating combinations of a compound of the formula (I), tipranavir (TPV) and one, two or more further NRTIs
1 st compound
2 nd compound
3 rd compound
4 th compound
FLT
TPV
Abacavir
Sulfate
FLT
TPV
Didanosine
FLT
TPV
Emtricitabine
FLT
TPV
Lamivudine
FLT
TPV
Stavudine
FLT
TPV
Tenofovir
disoproxil
fumarate
FLT
TPV
Zalcitabine
FLT
TPV
Zidovudine
FLT
TPV
Amdoxovir
FLT
TPV
Elvucitabine
FLT
TPV
GS-7340
FLT
TPV
INK-20
FLT
TPV
MIV-210
FLT
TPV
Racivir
FLT
TPV
Reverset
FLT
TPV
SPD-754
FLT
TPV
BCH-13520
FLT
TPV
BCH-10618
FLT
TPV
Ritonavir
Abacavir
Sulfate
FLT
TPV
Ritonavir
Didanosine
FLT
TPV
Ritonavir
Emtricitabine
FLT
TPV
Ritonavir
Lamivudine
FLT
TPV
Ritonavir
Stavudine
FLT
TPV
Ritonavir
Tenofovir
disoproxil
fumarate
FLT
TPV
Ritonavir
Zalcitabine
FLT
TPV
Ritonavir
Zidovudine
FLT
TPV
Ritonavir
Amdoxovir
FLT
TPV
Ritonavir
Elvucitabine
FLT
TPV
Ritonavir
GS-7340
FLT
TPV
Ritonavir
INK-20
FLT
TPV
Ritonavir
MIV-210
FLT
TPV
Ritonavir
Racivir
FLT
TPV
Ritonavir
Reverset
FLT
TPV
Ritonavir
SPD-754
FLT
TPV
Ritonavir
BCH-13520
FLT
TPV
Ritonavir
BCH-10618
FLG
TPV
Abacavir
Sulfate
FLG
TPV
Didanosine
FLG
TPV
Emtricitabine
FLG
TPV
Lamivudine
FLG
TPV
Stavudine
FLG
TPV
Tenofovir
disoproxil
fumarate
FLG
TPV
Zalcitabine
FLG
TPV
Zidovudine
FLG
TPV
Amdoxovir
FLG
TPV
Elvucitabine
FLG
TPV
GS-7340
FLG
TPV
INK-20
FLG
TPV
MIV-310
FLG
TPV
Racivir
FLG
TPV
Reverset
FLG
TPV
SPD-754
FLG
TPV
BCH-13520
FLG
TPV
BCH-10618
FLG
TPV
Ritonavir
Abacavir
Sulfate
FLG
TPV
Ritonavir
Didanosine
FLG
TPV
Ritonavir
Emtricitabine
FLG
TPV
Ritonavir
Lamivudine
FLG
TPV
Ritonavir
Stavudine
FLG
TPV
Ritonavir
Tenofovir
disoproxil
fumarate
FLG
TPV
Ritonavir
Zalcitabine
FLG
TPV
Ritonavir
Zidovudine
FLG
TPV
Ritonavir
Amdoxovir
FLG
TPV
Ritonavir
Elvucitabine
FLG
TPV
Ritonavir
GS-7340
FLG
TPV
Ritonavir
INK-20
FLG
TPV
Ritonavir
MIV-310
FLG
TPV
Ritonavir
Racivir
FLG
TPV
Ritonavir
Reverset
FLG
TPV
Ritonavir
SPD-754
FLG
TPV
Ritonavir
BCH-13520
FLG
TPV
Ritonavir
BCH-10618
Table 2 illustrating combinations of a compound of the formula (I), tipranavir, a NNRTI and optionally one, two or more further NRTIs
1 st compound
2 nd compound
3 rd compound
4 th compound
FLT
TPV
Delavirdine
FLT
TPV
Efavirenz
FLT
TPV
Nevirapine
FLT
TPV
(+)-
Calanolide A
or B
FLT
TPV
Capravirine
FLT
TPV
GW-695634
FLT
TPV
MIV-150
FLT
TPV
MV026048
FLT
TPV
NV-05
FLT
TPV
R-278474
FLT
TPV
RS-1588
FLT
TPV
TMC-120/125
FLT
TPV
TMC-125
FLT
TPV
UC-781
FLT
TPV
YM-215389
FLT
TPV
Ritonavir
Delavirdine
FLT
TPV
Ritonavir
Efavirenz
FLT
TPV
Ritonavir
Nevirapine
FLT
TPV
Ritonavir
(+)-
Calanolide A
or B
FLT
TPV
Ritonavir
Capravirine
FLT
TPV
Ritonavir
GW-695634
FLT
TPV
Ritonavir
MIV-150
FLT
TPV
Ritonavir
MV026048
FLT
TPV
Ritonavir
NV-05
FLT
TPV
Ritonavir
R-278474
FLT
TPV
Ritonavir
RS-1588
FLT
TPV
Ritonavir
TMC-120/125
FLT
TPV
Ritonavir
TMC-125
FLT
TPV
Ritonavir
UC-781
FLT
TPV
Ritonavir
YM-215389
FLG
TPV
Delavirdine
FLG
TPV
Efavirenz
FLG
TPV
Nevirapine
FLG
TPV
(+)-
Calanolide A
or B
FLG
TPV
Capravirine
FLG
TPV
GW-695634
FLG
TPV
MIV-150
FLG
TPV
MV026048
FLG
TPV
NV-05
FLG
TPV
R-278474
FLG
TPV
RS-1588
FLG
TPV
TMC-120/125
FLG
TPV
TMC-125
FLG
TPV
UC-781
FLG
TPV
YM-215389
FLG
TPV
Ritonavir
Delavirdine
FLG
TPV
Ritonavir
Efavirenz
FLG
TPV
Ritonavir
Nevirapine
FLG
TPV
Ritonavir
(+)-
Calanolide A
or B
FLG
TPV
Ritonavir
Capravirine
FLG
TPV
Ritonavir
GW-695634
FLG
TPV
Ritonavir
MIV-150
FLG
TPV
Ritonavir
MV026048
FLG
TPV
Ritonavir
NV-05
FLG
TPV
Ritonavir
R-278474
FLG
TPV
Ritonavir
RS-1588
FLG
TPV
Ritonavir
TMC-120/125
FLG
TPV
Ritonavir
TMC-125
FLG
TPV
Ritonavir
UC-781
FLG
TPV
Ritonavir
YM-215389
Table 3 illustrating combinations of a compound of the formula (I), tipranavir, an entry inhibitor and optionally one, two or more further NRTIs
1 st compound
2 nd compound
3 rd compound
4 th compound
FLT
TPV
Enfurvirtide
FLT
TPV
T-1249
FLT
TPV
AMD-070
FLT
TPV
BlockAide/CR
FLT
TPV
BMS 806
FLT
TPV
KRH-1636
FLT
TPV
ONO-4128
FLT
TPV
Pro-140
FLT
TPV
PRO-542
FLT
TPV
SCH-D
FLT
TPV
TAK-220
FLT
TPV
TNX-355
FLT
TPV
UK-427,857
FLT
TPV
Ritonavir
Enfurvirtide
FLT
TPV
Ritonavir
T-1249
FLT
TPV
Ritonavir
AMD-070
FLT
TPV
Ritonavir
BlockAide/CR
FLT
TPV
Ritonavir
BMS 806
FLT
TPV
Ritonavir
KRH-1636
FLT
TPV
Ritonavir
ONO-4128
FLT
TPV
Ritonavir
Pro-140
FLT
TPV
Ritonavir
PRO-542
FLT
TPV
Ritonavir
SCH-D
FLT
TPV
Ritonavir
TAK-220
FLT
TPV
Ritonavir
TNX-355
FLT
TPV
Ritonavir
UK-427,857
FLG
TPV
Enfurvirtide
FLG
TPV
T-1249
FLG
TPV
AMD-070
FLG
TPV
BlockAide/CR
FLG
TPV
BMS 806
FLG
TPV
KRH-1636
FLG
TPV
ONO-4128
FLG
TPV
Pro-140
FLG
TPV
PRO-542
FLG
TPV
SCH-D
FLG
TPV
TAK-220
FLG
TPV
TNX-355
FLG
TPV
UK-427,857
FLG
TPV
Ritonavir
Enfurvirtide
FLG
TPV
Ritonavir
T-1249
FLG
TPV
Ritonavir
AMD-070
FLG
TPV
Ritonavir
BlockAide/CR
FLG
TPV
Ritonavir
BMS 806
FLG
TPV
Ritonavir
KRH-1636
FLG
TPV
Ritonavir
ONO-4128
FLG
TPV
Ritonavir
Pro-140
FLG
TPV
Ritonavir
PRO-542
FLG
TPV
Ritonavir
SCH-D
FLG
TPV
Ritonavir
TAK-220
FLG
TPV
Ritonavir
TNX-355
FLG
TPV
Ritonavir
UK-427,857
Table 4 illustrating combinations of a compound of the formula (I), tipranavir, a NNRTI, an entry inhibitor and optionally one, two or more further NRTIs
1 st
2 nd
3 rd
4 th
5 th
compound
compound
compound
compound
compound
FLT
TPV
Delavirdine
Enfurvirtide
FLT
TPV
Delavirdine
T-1249
FLT
TPV
Delavirdine
AMD-070
FLT
TPV
Delavirdine
BlockAide/CR
FLT
TPV
Delavirdine
BMS 806
FLT
TPV
Delavirdine
KRH-1636
FLT
TPV
Delavirdine
ONO-4128
FLT
TPV
Delavirdine
Pro-140
FLT
TPV
Delavirdine
PRO-542
FLT
TPV
Delavirdine
SCH-D
FLT
TPV
Delavirdine
TAK-220
FLT
TPV
Delavirdine
TNX-355
FLT
TPV
Delavirdine
UK-427,857
FLT
TPV
Efavirenz
Enfurvirtide
FLT
TPV
Efavirenz
T-1249
FLT
TPV
Efavirenz
AMD-070
FLT
TPV
Efavirenz
BlockAide/CR
FLT
TPV
Efavirenz
BMS 806
FLT
TPV
Efavirenz
KRH-1636
FLT
TPV
Efavirenz
ONO-4128
FLT
TPV
Efavirenz
Pro-140
FLT
TPV
Efavirenz
PRO-542
FLT
TPV
Efavirenz
SCH-D
FLT
TPV
Efavirenz
TAK-220
FLT
TPV
Efavirenz
TNX-355
FLT
TPV
Efavirenz
UK-427,857
FLT
TPV
Nevirapine
Enfurvirtide
FLT
TPV
Nevirapine
T-1249
FLT
TPV
Nevirapine
AMD-070
FLT
TPV
Nevirapine
BlockAide/CR
FLT
TPV
Nevirapine
BMS 806
FLT
TPV
Nevirapine
KRH-1636
FLT
TPV
Nevirapine
ONO-4128
FLT
TPV
Nevirapine
Pro-140
FLT
TPV
Nevirapine
PRO-542
FLT
TPV
Nevirapine
SCH-D
FLT
TPV
Nevirapine
TAK-220
FLT
TPV
Nevirapine
TNX-355
FLT
TPV
Nevirapine
UK-427,857
FLT
TPV
GW-695634
Enfurvirtide
FLT
TPV
GW-695634
T-1249
FLT
TPV
GW-695634
AMD-070
FLT
TPV
GW-695634
BlockAide/CR
FLT
TPV
GW-695634
BMS 806
FLT
TPV
GW-695634
KRH-1636
FLT
TPV
GW-695634
ONO-4128
FLT
TPV
GW-695634
Pro-140
FLT
TPV
GW-695634
PRO-542
FLT
TPV
GW-695634
SCH-D
FLT
TPV
GW-695634
TAK-220
FLT
TPV
GW-695634
TNX-355
FLT
TPV
GW-695634
UK-427,857
FLT
TPV
Ritonavir
Delavirdine
Enfurvirtide
FLT
TPV
Ritonavir
Delavirdine
T-1249
FLT
TPV
Ritonavir
Delavirdine
AMD-070
FLT
TPV
Ritonavir
Delavirdine
BlockAide/CR
FLT
TPV
Ritonavir
Delavirdine
BMS 806
FLT
TPV
Ritonavir
Delavirdine
KRH-1636
FLT
TPV
Ritonavir
Delavirdine
ONO-4128
FLT
TPV
Ritonavir
Delavirdine
Pro-140
FLT
TPV
Ritonavir
Delavirdine
PRO-542
FLT
TPV
Ritonavir
Delavirdine
SCH-D
FLT
TPV
Ritonavir
Delavirdine
TAK-220
FLT
TPV
Ritonavir
Delavirdine
TNX-355
FLT
TPV
Ritonavir
Delavirdine
UK-427,857
FLT
TPV
Ritonavir
Efavirenz
Enfurvirtide
FLT
TPV
Ritonavir
Efavirenz
T-1249
FLT
TPV
Ritonavir
Efavirenz
AMD-070
FLT
TPV
Ritonavir
Efavirenz
BlockAide/CR
FLT
TPV
Ritonavir
Efavirenz
BMS 806
FLT
TPV
Ritonavir
Efavirenz
KRH-1636
FLT
TPV
Ritonavir
Efavirenz
ONO-4128
FLT
TPV
Ritonavir
Efavirenz
Pro-140
FLT
TPV
Ritonavir
Efavirenz
PRO-542
FLT
TPV
Ritonavir
Efavirenz
SCH-D
FLT
TPV
Ritonavir
Efavirenz
TAK-220
FLT
TPV
Ritonavir
Efavirenz
TNX-355
FLT
TPV
Ritonavir
Efavirenz
UK-427,857
FLT
TPV
Ritonavir
Nevirapine
Enfurvirtide
FLT
TPV
Ritonavir
Nevirapine
T-1249
FLT
TPV
Ritonavir
Nevirapine
AMD-070
FLT
TPV
Ritonavir
Nevirapine
BlockAide/CR
FLT
TPV
Ritonavir
Nevirapine
BMS 806
FLT
TPV
Ritonavir
Nevirapine
KRH-1636
FLT
TPV
Ritonavir
Nevirapine
ONO-4128
FLT
TPV
Ritonavir
Nevirapine
Pro-140
FLT
TPV
Ritonavir
Nevirapine
PRO-542
FLT
TPV
Ritonavir
Nevirapine
SCH-D
FLT
TPV
Ritonavir
Nevirapine
TAK-220
FLT
TPV
Ritonavir
Nevirapine
TNX-355
FLT
TPV
Ritonavir
Nevirapine
UK-427,857
FLT
TPV
Ritonavir
GW-695634
Enfurvirtide
FLT
TPV
Ritonavir
GW-695634
T-1249
FLT
TPV
Ritonavir
GW-695634
AMD-070
FLT
TPV
Ritonavir
GW-695634
BlockAide/CR
FLT
TPV
Ritonavir
GW-695634
BMS 806
FLT
TPV
Ritonavir
GW-695634
KRH-1636
FLT
TPV
Ritonavir
GW-695634
ONO-4128
FLT
TPV
Ritonavir
GW-695634
Pro-140
FLT
TPV
Ritonavir
GW-695634
PRO-542
FLT
TPV
Ritonavir
GW-695634
SCH-D
FLT
TPV
Ritonavir
GW-695634
TAK-220
FLT
TPV
Ritonavir
GW-695634
TNX-355
FLT
TPV
Ritonavir
GW-695634
UK-427,857
FLG
TPV
Delavirdine
Enfurvirtide
FLG
TPV
Delavirdine
T-1249
FLG
TPV
Delavirdine
AMD-070
FLG
TPV
Delavirdine
BlockAide/CR
FLG
TPV
Delavirdine
BMS 806
FLG
TPV
Delavirdine
KRH-1636
FLG
TPV
Delavirdine
ONO-4128
FLG
TPV
Delavirdine
Pro-140
FLG
TPV
Delavirdine
PRO-542
FLG
TPV
Delavirdine
SCH-D
FLG
TPV
Delavirdine
TAK-220
FLG
TPV
Delavirdine
TNX-355
FLG
TPV
Delavirdine
UK-427,857
FLG
TPV
Efavirenz
Enfurvirtide
FLG
TPV
Efavirenz
T-1249
FLG
TPV
Efavirenz
AMD-070
FLG
TPV
Efavirenz
BlockAide/CR
FLG
TPV
Efavirenz
BMS 806
FLG
TPV
Efavirenz
KRH-1636
FLG
TPV
Efavirenz
ONO-4128
FLG
TPV
Efavirenz
Pro-140
FLG
TPV
Efavirenz
PRO-542
FLG
TPV
Efavirenz
SCH-D
FLG
TPV
Efavirenz
TAK-220
FLG
TPV
Efavirenz
TNX-355
FLG
TPV
Efavirenz
UK-427,857
FLG
TPV
Nevirapine
Enfurvirtide
FLG
TPV
Nevirapine
T-1249
FLG
TPV
Nevirapine
AMD-070
FLG
TPV
Nevirapine
BlockAide/CR
FLG
TPV
Nevirapine
BMS 806
FLG
TPV
Nevirapine
KRH-1636
FLG
TPV
Nevirapine
ONO-4128
FLG
TPV
Nevirapine
Pro-140
FLG
TPV
Nevirapine
PRO-542
FLG
TPV
Nevirapine
SCH-D
FLG
TPV
Nevirapine
TAK-220
FLG
TPV
Nevirapine
TNX-355
FLG
TPV
Nevirapine
UK-427,857
FLG
TPV
GW-695634
Enfurvirtide
FLG
TPV
GW-695634
T-1249
FLG
TPV
GW-695634
AMD-070
FLG
TPV
GW-695634
BlockAide/CR
FLG
TPV
GW-695634
BMS 806
FLG
TPV
GW-695634
KRH-1636
FLG
TPV
GW-695634
ONO-4128
FLG
TPV
GW-695634
Pro-140
FLG
TPV
GW-695634
PRO-542
FLG
TPV
GW-695634
SCH-D
FLG
TPV
GW-695634
TAK-220
FLG
TPV
GW-695634
TNX-355
FLG
TPV
GW-695634
UK-427,857
FLG
TPV
Ritonavir
Delavirdine
Enfurvirtide
FLG
TPV
Ritonavir
Delavirdine
T-1249
FLG
TPV
Ritonavir
Delavirdine
AMD-070
FLG
TPV
Ritonavir
Delavirdine
BlockAide/CR
FLG
TPV
Ritonavir
Delavirdine
BMS 806
FLG
TPV
Ritonavir
Delavirdine
KRH-1636
FLG
TPV
Ritonavir
Delavirdine
ONO-4128
FLG
TPV
Ritonavir
Delavirdine
Pro-140
FLG
TPV
Ritonavir
Delavirdine
PRO-542
FLG
TPV
Ritonavir
Delavirdine
SCH-D
FLG
TPV
Ritonavir
Delavirdine
TAK-220
FLG
TPV
Ritonavir
Delavirdine
TNX-355
FLG
TPV
Ritonavir
Delavirdine
UK-427,857
FLG
TPV
Ritonavir
Efavirenz
Enfurvirtide
FLG
TPV
Ritonavir
Efavirenz
T-1249
FLG
TPV
Ritonavir
Efavirenz
AMD-070
FLG
TPV
Ritonavir
Efavirenz
BlockAide/CR
FLG
TPV
Ritonavir
Efavirenz
BMS 806
FLG
TPV
Ritonavir
Efavirenz
KRH-1636
FLG
TPV
Ritonavir
Efavirenz
ONO-4128
FLG
TPV
Ritonavir
Efavirenz
Pro-140
FLG
TPV
Ritonavir
Efavirenz
PRO-542
FLG
TPV
Ritonavir
Efavirenz
SCH-D
FLG
TPV
Ritonavir
Efavirenz
TAK-220
FLG
TPV
Ritonavir
Efavirenz
TNX-355
FLG
TPV
Ritonavir
Efavirenz
UK-427,857
FLG
TPV
Ritonavir
Nevirapine
Enfurvirtide
FLG
TPV
Ritonavir
Nevirapine
T-1249
FLG
TPV
Ritonavir
Nevirapine
AMD-070
FLG
TPV
Ritonavir
Nevirapine
BlockAide/CR
FLG
TPV
Ritonavir
Nevirapine
BMS 806
FLG
TPV
Ritonavir
Nevirapine
KRH-1636
FLG
TPV
Ritonavir
Nevirapine
ONO-4128
FLG
TPV
Ritonavir
Nevirapine
Pro-140
FLG
TPV
Ritonavir
Nevirapine
PRO-542
FLG
TPV
Ritonavir
Nevirapine
SCH-D
FLG
TPV
Ritonavir
Nevirapine
TAK-220
FLG
TPV
Ritonavir
Nevirapine
TNX-355
FLG
TPV
Ritonavir
Nevirapine
UK-427,857
FLG
TPV
Ritonavir
GW-695634
Enfurvirtide
FLG
TPV
Ritonavir
GW-695634
T-1249
FLG
TPV
Ritonavir
GW-695634
AMD-070
FLG
TPV
Ritonavir
GW-695634
BlockAide/CR
FLG
TPV
Ritonavir
GW-695634
BMS 806
FLG
TPV
Ritonavir
GW-695634
KRH-1636
FLG
TPV
Ritonavir
GW-695634
ONO-4128
FLG
TPV
Ritonavir
GW-695634
Pro-140
FLG
TPV
Ritonavir
GW-695634
PRO-542
FLG
TPV
Ritonavir
GW-695634
SCH-D
FLG
TPV
Ritonavir
GW-695634
TAK-220
FLG
TPV
Ritonavir
GW-695634
TNX-355
FLG
TPV
Ritonavir
GW-695634
UK-427,857
Table 5 illustrating combinations of a compound of the formula (I), tipranavir, an integrase inhibitor and optionally one, two or more further NRTIs
1 st
2 nd
3 rd
4 th
compound
compound
compound
compound
FLT
TPV
L-870810
FLT
TPV
c-2507
FLT
TPV
S(RSC)-
1838
FLT
TPV
Ritonavir
L-870810
FLT
TPV
Ritonavir
S(RSC)-1838
FLG
TPV
L-870810
FLG
TPV
c-2507
FLG
TPV
S(RSC)-
1838
FLG
TPV
Ritonavir
L-870810
FLG
TPV
Ritonavir
S(RSC)-1838
Table 6 illustrating combinations of a compound of the formula (I), tipranavir, a NNRTI, an integrase inhibitor and optionally one, two or more further NRTIs
1 st
2 nd
3 rd
4 th
5 th
compound
compound
compound
compound
compound
FLT
TPV
Delavirdine
L-870810
FLT
TPV
Delavirdine
c-2507
FLT
TPV
Delavirdine
S(RSC)-1838
FLT
TPV
Efavirenz
L-870810
FLT
TPV
Efavirenz
S(RSC)-1838
FLT
TPV
Nevirapine
L-870810
FLT
TPV
Nevirapine
c-2507
FLT
TPV
Nevirapine
S(RSC)-1838
FLT
TPV
(+)-
S(RSC)-1838
Calanolide
A or B
FLT
TPV
(+)-
c-2507
Calanolide
A or B
FLT
TPV
(+)-
L-870810
Calanolide
A or B
FLT
TPV
Capravirine
S(RSC)-1838
FLT
TPV
Capravirine
L-870810
FLT
TPV
Capravirine
c-2507
FLT
TPV
GW-695634
S(RSC)-1838
FLT
TPV
GW-695634
L-870810
FLT
TPV
GW-695634
c-2507
FLT
TPV
MIV-150
S(RSC)-1838
FLT
TPV
MIV-150
L-870810
FLT
TPV
MIV-150
c-2507
FLT
TPV
MV026048
S(RSC)-1838
FLT
TPV
NV-05
L-870810
FLT
TPV
NV-05
c-2507
FLT
TPV
NV-05
S(RSC)-1838
FLT
TPV
R-278474
L-870810
FLT
TPV
R-278474
c-2507
FLT
TPV
R-278474
S(RSC)-1838
FLT
TPV
RS-1588
L-870810
FLT
TPV
RS-1588
S(RSC)-1838
FLT
TPV
TMC-120/125
S(RSC)-1838
FLT
TPV
TMC-120/125
c-2507
FLT
TPV
TMC-120/125
L-870810
FLT
TPV
TMC-125
S(RSC)-1838
FLT
TPV
TMC-125
L-870810
FLT
TPV
TMC-125
c-2507
FLT
TPV
UC-781
S(RSC)-1838
FLT
TPV
UC-781
L-870810
FLT
TPV
UC-781
c-2507
FLT
TPV
YM-215389
S(RSC)-1838
FLT
TPV
YM-215389
L-870810
FLT
TPV
YM-215389
c-2507
FLT
TPV
Ritonavir
Delavirdine
L-870810
FLT
TPV
Ritonavir
Delavirdine
S(RSC)-1838
FLT
TPV
Ritonavir
Efavirenz
L-870810
FLT
TPV
Ritonavir
Efavirenz
S(RSC)-1838
FLT
TPV
Ritonavir
Nevirapine
L-870810
FLT
TPV
Ritonavir
Nevirapine
S(RSC)-1838
FLT
TPV
Ritonavir
(+)-
S(RSC)-1838
Calanolide A
or B
FLT
TPV
Ritonavir
(+)-
L-870810
Calanolide A
or B
FLT
TPV
Ritonavir
Capravirine
S(RSC)-1838
FLT
TPV
Ritonavir
Capravirine
L-870810
FLT
TPV
Ritonavir
GW-695634
S(RSC)-1838
FLT
TPV
Ritonavir
GW-695634
L-870810
FLT
TPV
Ritonavir
MIV-150
S(RSC)-1838
FLT
TPV
Ritonavir
MIV-150
L-870810
FLT
TPV
Ritonavir
MV026048
S(RSC)-1838
FLT
TPV
Ritonavir
NV-05
L-870810
FLT
TPV
Ritonavir
NV-05
S(RSC)-1838
FLT
TPV
Ritonavir
R-278474
L-870810
FLT
TPV
Ritonavir
R-278474
S(RSC)-1838
FLT
TPV
Ritonavir
RS-1588
L-870810
FLT
TPV
Ritonavir
RS-1588
S(RSC)-1838
FLT
TPV
Ritonavir
TMC-120/125
S(RSC)-1838
FLT
TPV
Ritonavir
TMC-120/125
L-870810
FLT
TPV
Ritonavir
TMC-125
S(RSC)-1838
FLT
TPV
Ritonavir
TMC-125
L-870810
FLT
TPV
Ritonavir
UC-781
S(RSC)-1838
FLT
TPV
Ritonavir
UC-781
L-870810
FLT
TPV
Ritonavir
YM-215389
S(RSC)-1838
FLT
TPV
Ritonavir
YM-215389
L-870810
FLG
TPV
Delavirdine
L-870810
FLG
TPV
Delavirdine
S(RSC)-1838
FLG
TPV
Efavirenz
L-870810
FLG
TPV
Efavirenz
S(RSC)-1838
FLG
TPV
Nevirapine
L-870810
FLG
TPV
Nevirapine
S(RSC)-1838
FLG
TPV
(+)-
S(RSC)-1838
Calanolide
A or B
FLG
TPV
(+)-
L-870810
Calanolide
A or B
FLG
TPV
Capravirine
S(RSC)-1838
FLG
TPV
Capravirine
L-870810
FLG
TPV
GW-695634
S(RSC)-1838
FLG
TPV
GW-695634
L-870810
FLG
TPV
MIV-150
S(RSC)-1838
FLG
TPV
MIV-150
L-870810
FLG
TPV
MV026048
S(RSC)-1838
FLG
TPV
NV-05
L-870810
FLG
TPV
NV-05
S(RSC)-1838
FLG
TPV
R-278474
L-870810
FLG
TPV
R-278474
S(RSC)-1838
FLG
TPV
RS-1588
L-870810
FLG
TPV
RS-1588
S(RSC)-1838
FLG
TPV
TMC-120/125
S(RSC)-1838
FLG
TPV
TMC-120/125
L-870810
FLG
TPV
TMC-125
S(RSC)-1838
FLG
TPV
TMC-125
L-870810
FLG
TPV
UC-781
S(RSC)-1838
FLG
TPV
UC-781
L-870810
FLG
TPV
YM-215389
S(RSC)-1838
FLG
TPV
YM-215389
L-870810
FLG
TPV
Ritonavir
Delavirdine
L-870810
FLG
TPV
Ritonavir
Delavirdine
S(RSC)-1838
FLG
TPV
Ritonavir
Efavirenz
L-870810
FLG
TPV
Ritonavir
Efavirenz
S(RSC)-1838
FLG
TPV
Ritonavir
Nevirapine
L-870810
FLG
TPV
Ritonavir
Nevirapine
S(RSC)-1838
FLG
TPV
Ritonavir
(+)-
S(RSC)-1838
Calanolide A
or B
FLG
TPV
Ritonavir
(+)-
L-870810
Calanolide A
or B
FLG
TPV
Ritonavir
Capravirine
S(RSC)-1838
FLG
TPV
Ritonavir
Capravirine
L-870810
FLG
TPV
Ritonavir
GW-695634
S(RSC)-1838
FLG
TPV
Ritonavir
GW-695634
L-870810
FLG
TPV
Ritonavir
MIV-150
S(RSC)-1838
FLG
TPV
Ritonavir
MIV-150
L-870810
FLG
TPV
Ritonavir
MV026048
S(RSC)-1838
FLG
TPV
Ritonavir
NV-05
L-870810
FLG
TPV
Ritonavir
NV-05
S(RSC)-1838
FLG
TPV
Ritonavir
R-278474
L-870810
FLG
TPV
Ritonavir
R-278474
S(RSC)-1838
FLG
TPV
Ritonavir
RS-1588
L-870810
FLG
TPV
Ritonavir
RS-1588
S(RSC)-1838
FLG
TPV
Ritonavir
TMC-120/125
S(RSC)-1838
FLG
TPV
Ritonavir
TMC-120/125
L-870810
FLG
TPV
Ritonavir
TMC-125
S(RSC)-1838
FLG
TPV
Ritonavir
TMC-125
L-870810
FLG
TPV
Ritonavir
UC-781
S(RSC)-1838
FLG
TPV
Ritonavir
UC-781
L-870810
FLG
TPV
Ritonavir
YM-215389
S(RSC)-1838
FLG
TPV
Ritonavir
YM-215389
L-870810
Table 7 illustrating combinations of a compound of the formula (I), tipranavir and a further antiviral
1 st
2 nd
3 rd
4 th
compound
compound
compound
compound
FLT
TPV
PA-457
FLT
TPV
KPC-2
FLT
TPV
HGTV-43
FLT
TPV
Amprenavir
FLT
TPV
Atazanavir
FLT
TPV
Indinavir
Sulfate
FLT
TPV
Lexiva
FLT
TPV
Lopinavir
FLT
TPV
Nelfinavir
Mesylate
FLT
TPV
Saquinavir
FLT
TPV
AG-1776
FLT
TPV
AG-1859
FLT
TPV
DPC-
681/684
FLT
TPV
GS224338
FLT
TPV
KNI-272
FLT
TPV
Nar-DG-35
FLT
TPV
P(PL)-100
FLT
TPV
P-1946
FLT
TPV
R-944
FLT
TPV
RO-0334649
FLT
TPV
TMC-114
FLT
TPV
VX-385
FLT
TPV
VX-478
FLT
TPV
ritonavir
PA-457
FLT
TPV
ritonavir
KPC-2
FLT
TPV
ritonavir
HGTV-43
FLT
TPV
ritonavir
Amprenavir
FLT
TPV
ritonavir
Atazanavir
FLT
TPV
ritonavir
Indinavir
Sulfate
FLT
TPV
ritonavir
Lexiva
FLT
TPV
ritonavir
Lopinavir
FLT
TPV
ritonavir
Nelfinavir
Mesylate
FLT
TPV
ritonavir
Saquinavir
FLT
TPV
ritonavir
AG-1776
FLT
TPV
ritonavir
AG-1859
FLT
TPV
ritonavir
DPC-681/684
FLT
TPV
ritonavir
GS224338
FLT
TPV
ritonavir
KNI-272
FLT
TPV
ritonavir
Nar-DG-35
FLT
TPV
ritonavir
P(PL)-100
FLT
TPV
ritonavir
P-1946
FLT
TPV
ritonavir
R-944
FLT
TPV
ritonavir
RO-0334649
FLT
TPV
ritonavir
TMC-114
FLT
TPV
ritonavir
VX-385
FLT
TPV
ritonavir
VX-478
FLG
TPV
PA-457
FLG
TPV
KPC-2
FLG
TPV
HGTV-43
FLG
TPV
Amprenavir
FLG
TPV
Atazanavir
FLG
TPV
Indinavir
Sulfate
FLG
TPV
Lexiva
FLG
TPV
Lopinavir
FLG
TPV
Nelfinavir
Mesylate
FLG
TPV
Saquinavir
FLG
TPV
AG-1776
FLG
TPV
AG-1859
FLG
TPV
DPC-
681/684
FLG
TPV
GS224338
FLG
TPV
KNI-272
FLG
TPV
Nar-DG-35
FLG
TPV
P(PL)-100
FLG
TPV
P-1946
FLG
TPV
R-944
FLG
TPV
RO-0334649
FLG
TPV
TMC-114
FLG
TPV
VX-385
FLG
TPV
VX-478
FLG
TPV
ritonavir
PA-457
FLG
TPV
ritonavir
KPC-2
FLG
TPV
ritonavir
HGTV-43
FLG
TPV
ritonavir
Amprenavir
FLG
TPV
ritonavir
Atazanavir
FLG
TPV
ritonavir
Indinavir
Sulfate
FLG
TPV
ritonavir
Lexiva
FLG
TPV
ritonavir
Lopinavir
FLG
TPV
ritonavir
Nelfinavir
Mesylate
FLG
TPV
ritonavir
Saquinavir
FLG
TPV
ritonavir
AG-1776
FLG
TPV
ritonavir
AG-1859
FLG
TPV
ritonavir
DPC-681/684
FLG
TPV
ritonavir
GS224338
FLG
TPV
ritonavir
KNI-272
FLG
TPV
ritonavir
Nar-DG-35
FLG
TPV
ritonavir
P(PL)-100
FLG
TPV
ritonavir
P-1946
FLG
TPV
ritonavir
R-944
FLG
TPV
ritonavir
RO-0334649
FLG
TPV
ritonavir
TMC-114
FLG
TPV
ritonavir
VX-385
FLG
TPV
ritonavir
VX-478
In the above given Tables 1 to 7 the term “FLG” is 2′,3′-dideoxy-3′-fluoroguanosine, or a pharmaceutically acceptable salt or prodrug thereof, in particular 3′-deoxy-3′-fluoro-5-O-[2-(L-valyloxy)-propionyl]guanosine, or a pharmaceutically acceptable salt thereof. | In accordance with the present invention there is provided a pharmaceutical composition useful for the treatment or prophylaxis of viral infections comprising tipranavir and at least one antiviral active compound of formula (I)
wherein Base is selected from the group consisting of thymine, cytosine, adenine, guanine, inosine, uracil, 5-ethyluracil and 2,6-diaminopurine, or a pharmaceutically acceptable salt or prodrug thereof. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims the benefits of and priority to U.S. Provisional Application Ser. No. 61/327,329 filed on Apr. 23, 2010. The entire contents of which are incorporated herein by reference.
BACKGROUND
[0002] The present disclosure relates to an exercise device, method of use, and method of treating an individual. In particular, the exercise pad or device includes a self help body treatment device and/or an exercise device.
[0003] This device is configured to allow an individual to be positioned thereon and to pivot thereon, for example, which allows their muscles, joints and/or soft tissue structures of many regions of the body to relax, stretch and improve mobility. The device also promotes and enhances strength and core stability. The shape/size of various dimensions of the device may vary (e.g., small, medium and large sizes) to accommodate various body types and sizes.
[0004] The device is generally disc-shaped including a first portion and a second portion. The device is intended to be used by an individual either with the first or second portion facing upward, and with at least a portion of the other surface resting on a substantially flat surface.
SUMMARY
[0005] The present disclosure relates to an exercise device. The exercise device includes a first portion and a second portion. The first portion includes a first substantially planar surface and is configured to support a portion of a patient. The second portion includes a second substantially planar surface and is configured to support a portion of a patient. The second substantially planar surface is oppositely disposed of the first substantially planar surface. The first substantially planar surface includes a diameter, and the second substantially planar surface includes a diameter. The diameter of the first substantially planar surface is smaller than the diameter of the second substantially planar surface.
[0006] The present disclosure also relates to a method of treating a patient. The method comprises providing an exercise device. The exercise device includes a first portion and a second portion. The first portion includes a first substantially planar surface and is configured to support a portion of a patient. The second portion includes a second substantially planar surface and is configured to support a portion of a patient. The second substantially planar surface is oppositely disposed of the first substantially planar surface. The first substantially planar surface includes a diameter, and the second substantially planar surface includes a diameter. The diameter of the first substantially planar surface is smaller than the diameter of the second substantially planar surface. The method also comprises providing instructions to the patient regarding use of the exercise device.
[0007] The present disclosure also relates to a method of using an exercise device. The exercise device includes a first portion and a second portion. The first portion includes a first substantially planar surface and is configured to support a portion of a patient. The second portion includes a second substantially planar surface and is configured to support a portion of a patient. The second substantially planar surface is oppositely disposed of the first substantially planar surface. The first substantially planar surface includes a diameter, and the second substantially planar surface includes a diameter. The diameter of the first substantially planar surface is smaller than the diameter of the second substantially planar surface. The method also comprises placing a portion of a body in contact with one of the first portion and the second portion.
BRIEF DESCRIPTION OF DRAWINGS
[0008] Embodiments of the presently disclosed device are disclosed herein with reference to the drawings, wherein:
[0009] FIG. 1 is a side view of the device with a first portion facing upward.
[0010] FIG. 2 is a side view of the device with a second portion facing upward.
[0011] FIG. 3 is a top view of the device with the first portion facing upward.
[0012] FIG. 4 is a top view of the device with the second portion facing upward.
[0013] FIG. 5 is a perspective view of the device with the first portion facing upward.
[0014] FIG. 6 is a perspective view of the device with the second portion facing upward.
[0015] FIGS. 7-10 show the device in use in connection with a model spine.
[0016] FIGS. 11-18 show the device in use located at various locations of a human model.
[0017] FIG. 19 illustrates the device under an individual with the first portion facing upward.
[0018] FIG. 20 illustrates the device under an individual with the second portion facing upward.
DETAILED DESCRIPTION
[0019] Embodiments of the presently disclosed device and methods are now described in detail with reference to the drawings wherein like reference numerals identify similar or identical elements. It shall be noted that all dimensions shown in the accompanying figures and described herein are included as examples, and the scope of the present disclosure is not intended to be limited thereby. As used herein, the term “exercise,” as in “exercise device” or “exercise pad”, for example, includes “therapy,” “therapeutic,” etc.
[0020] Various embodiments of the device 100 of the present disclosure are described herein. It is envisioned that the device 100 may include a diameter of between about 4″ and about 10″ (e.g., between about 6″ and about 7″), for example. The device 100 may include a height of between about 1″ and about 3.5″ (e.g., between about 1.75″ and about 2.25″), for example. The first portion 110 of the device may include a flat (e.g., substantially planar) surface 112 having a diameter of between about 1.5″ and about 3.5 (e.g., between about 2.25″ and about 2.75″), for example. The second portion 120 of the device may include a flat (e.g., substantially planar) surface 122 having a diameter of between about 3.5″ and about 6.5″ (e.g., between about 4.25″ and about 5.25″), for example.
[0021] The first portion 110 and second portion 120 are shown as being separated by a substantially vertical sidewall 130 . It is envisioned that the height of vertical sidewall 130 is between about 0.25″ and about 1.0.″ It is further envisioned that the height of vertical sidewall 130 is between about 0.5″ and about 0.75″. A first angled surface 114 is defined between the vertical sidewall 130 and an outer edge of first flat surface 112 . It is envisioned that first angle surface 114 is substantially flat along its entire length. Additionally, with reference to FIG. 3 , it is envisioned that angled surface 114 includes a plurality of sections 114 a, 114 b, etc. (a total of 13 sections (i.e., 114 a - 114 m ) are shown), which may facilitate incremental rotational movement, or instance. As can be appreciated, more or fewer sections are contemplated by the present disclosure. It is envisioned that the first angled surface 114 defines a first angle α 1 of between about 20° and about 25°, for example. This angle/surface 114 creates a pyramidal shape, which allows for rotation and/or pivoting around/about the smaller-diameter flat surface 122 , e.g. in a 360° motion.
[0022] A second angled surface 124 is defined between the vertical sidewall 130 and an outer edge of second flat surface 114 . It is envisioned that the second angled surface 124 is substantially rounded or substantially flat. It is envisioned that the second angled surface 124 defines a second angle α 2 of between about 25° and about 45°, for example, and may be equal to about 30°.
[0023] The device 100 may include a contoured shape; may be made of injection molded high density foam, rubber, or another suitable material; and/or may be disc-shaped, e.g., to allow for multiple functions.
[0024] In use, with the first portion 110 (e.g., flat surface 112 ) of the device 100 facing upwards, a user will be able to actively “tilt” and/or “rotate” the region of the body, e.g., in a clock-type motion or any functional body movement that promotes increased mobility at the region around the device 100 . This will allow the joints of the region (e.g., the sacro-iliac SI of the pelvic and lumbar, thoracic, knee, hip, shoulder, etc.) to be exercised, which will increase range of motion (“ROM”) and/or flexibility. Use of the device 100 may also promote decreased pain through the use of isolated movement, allow for activation of the core musculature of the spine, and/or promote proprioceptive training for the joints of the body. Additionally, it is envisioned that the device 100 allows the individual to loosen soft tissue structures (e.g., fascia, muscles, tendons and joints) and/or promotes improved flexibility, range of motion, strength and core stability.
[0025] In use, with the flat surface 112 of first portion 110 of the device 100 facing upwards, a user will be able to pivot their body (or portions of their body) about the device 100 , which may remain substantially stationary during use in this embodiment.
[0026] It is envisioned that the device 100 can used both passively and actively with the device 100 in either position, i.e., with either first portion 110 or second portion 120 facing up. It is envisioned that the device 100 can be used as an exercise device to help any individual who desires or needs to increase the mobility of their soft tissues, muscles, tendons, joints and/or other structures. Use of the device 100 by any individual may also help improve flexibility, strength and/or core stability. It is also envisioned that the device 100 may be used by the general public, who are not necessarily in need of rehabilitation.
[0027] The present disclosure also includes method of using the device 100 and method of treating individuals (e.g., patients). Individuals can use this device 100 to release or loosen their muscles, tissues and/or joints while promoting their flexibility, range of motion and core stability. This can be accomplished, for example, by doing certain exercises while lying on top of the device 100 with either the first portion 110 or second portion 120 facing upwards. Additionally, the individual can passively lie on the device 100 or in the same position and do a pelvic clock motion which is aided by the device's shape (see FIG. 15 , for example). The device 100 allows the individual to move 360° around the pivot (e.g., flat surface 112 or 122 ) of the device 100 . Additionally, by positioning the device 100 under the thoracic spine or mid back at various levels and lying over it, the individual can loosen the structures in this region of the body. This can be enhanced by initiating active exercises like the pelvic clock or upper extremity raises (see FIGS. 11-14 , for example).
[0028] The device 100 may also be used by an individual while performing lower extremity exercises. In FIGS. 17-18 , for example, the individual is using the device 100 to loosen the muscle in the lower quadriceps and enhancing the release by actively flexing and extending the lower extremity over the device. Putting the device 100 under the lateral thigh or Iliotibial band, the tissues can passively loosen, or active exercise can enhance the release of the individual's muscles and/or tissues.
[0029] The device 100 may also be used by an individual while performing core stabilization exercises. For example, the device 100 may be used to improve overall mobility, flexibility and/or strength of and individual. It is envisioned that individuals would experience decreased pain in regions where the device 100 is used. The device 100 may also promote enhanced proprioceptive awareness or the awareness of the individual's body movements and improved core stability as well.
[0030] The present disclosure also includes methods of treating an individual. A disclosed method includes providing the device 100 , providing an individual with access to the device 100 , providing an individual with instructions for using the device 100 , and/or providing an individual with instructions to use the device 100 . The present disclosure also includes an instruction manual and an instructional video for using the device 100 , including providing description and/or figures, such as those included herein and/or similar description and/or figures.
[0031] It is to be understood that the foregoing description is merely a disclosure of particular embodiments and is in no way intended to limit the scope of the disclosure. For example, it is envisioned that all edges, e.g., between adjacent surfaces, are either rounded or include a point. Additionally, while the device 100 is shown in use in connection to particular portions of the body, the device 100 may be used in connection with any body part. Other possible modifications will be apparent to those skilled in the art and are intended to be within the scope of the present disclosure. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto. | An exercise device is disclosed. The exercise device includes a first portion and a second portion. The first portion includes a first substantially planar surface and is configured to support a portion of a patient. The second portion includes a second substantially planar surface and is configured to support a portion of a patient. The second substantially planar surface is oppositely disposed of the first substantially planar surface. The first substantially planar surface includes a diameter, and the second substantially planar surface includes a diameter. The diameter of the first substantially planar surface is smaller than the diameter of the second substantially planar surface. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates broadly to scaffolding and modular and temporary frames or constructions. It relates in particular, though not exclusively, to modular, quick assembly and disassembly, scaffolding.
BACKGROUND OF THE INVENTION
[0002] A number of modular scaffolding frames are currently available. These modular frames typically enable the speed and ease of scaffolding assembly and disassembly to be improved. It is desirable however to provide improved scaffolding methods, components and/or frames to further improve one or more of:
a. Distribution of forces by the scaffolding b. The speed or ease of scaffolding assembly and disassembly c. The versatility of scaffolding components.
SUMMARY OF THE INVENTION
[0006] According to one aspect of the present invention there is provided a method of erecting scaffolding comprising the steps of:
a. considering whether to attach a scaffolding frame main support member to a top plate of an unlined building frame from a position which is inside an unlined wall of the building frame, and alternatively, from a position which is outside the building frame wall, the scaffolding frame main support member having an elongate portion and being arranged for connecting a platform support member of a scaffolding frame to a top plate of a building frame for support of the platform support member outside the building frame via the top plate; and b. attaching the scaffolding frame main support member to the top plate so that the elongate portion of the main support member is positioned on the side of the building frame wall from which the main support member was attached.
[0009] The method preferably further comprises attaching the main support member to a top plate of a building frame so that it is positioned either substantially over a wall stud or any other position along the top plate.
[0010] The platform support is preferably attached to the main support before the main support is attached to the top plate. However, the platform support may alternatively be attached to the main support after the main support is attached to the top plate.
[0011] The method preferably further comprises the step of attaching a main support load distribution member to the main support member wherein the main support load distribution member is arranged to distribute load transferred to the main support member from the platform support to at least two wall studs. The main support load distribution member is preferably attached to the main support member after the main support is attached to the top plate. However, it may alternatively be attached to the main support member before the main support member is attached to the top plate.
[0012] According to another aspect of the present invention there is provided a method of erecting scaffolding comprising the steps of:
a. attaching a scaffolding frame main support member to a top plate of an unlined building frame, the scaffolding frame main support member being arranged for connecting a platform support member of a scaffolding frame to a top plate of a building frame for support of the platform support member via the top plate; and b. attaching a main support load distribution member to the main support member, either before or after the main support member is attached to the top plate, wherein the main support load distribution member is arranged to distribute load transferred, to the main support from the platform support, to at least two wall studs.
[0015] The method preferably further comprises the step of supporting the platform support member outside the building frame. In another preferred form the method of this other aspect of the present invention further comprises the step of attaching the scaffolding frame main support member to the top plate from a position which is inside an unlined wall of the building frame, and alternatively, from a position which is outside the building frame wall. The scaffolding frame main support member preferably comprises an elongate portion and the method preferably further comprises the step of attaching the scaffolding frame main support member to the top plate so that the elongate portion of the main support member is positioned on the side of the building frame wall from which the main support member was attached.
[0016] According to another aspect of the present invention there is provided a scaffolding frame main support member arranged for connecting a platform support member of a scaffolding frame to a top plate of a building frame and support of the platform support member via the top plate wherein the scaffolding frame main support member is arranged for attachment to the top plate from inside, and alternatively, outside the building frame and support of the platform support outside the building frame.
[0017] The scaffolding frame main support member preferably further comprises a main support load distributor arranged for attachment to the main support member and distribution, across at least two studs of the building frame, of load transferred, when the main support member is attached to the top plate and supporting the platform support, from the platform support to the main support.
[0018] According to a another aspect of the present invention there is provided a scaffolding frame main support load distribution member arranged for attachment to a main support member of a scaffolding frame, the main support member being arranged for connecting a platform support member of a scaffolding frame to a top plate of a building frame and support of the platform support member via the top plate, wherein the main support load distribution member is arranged for distributing across at least two studs of the building frame load transferred, when the main support member is attached to the top plate and supporting the platform support, from the platform support to the main support.
[0019] According to another aspect of the present invention there is provided a modular apparatus for constructing scaffolding, the modular apparatus comprising:
a. a scaffolding frame main support member for supporting a scaffolding frame via a top plate of a building frame; and b. a platform support member for supporting a platform; wherein
the scaffolding frame main support member is arranged for attachment to the top plate from inside, and alternatively, outside the building frame and connection to the platform support member for support of the platform support member outside the building frame.
[0022] According to another aspect of the present invention there is provided a scaffolding frame assembly comprising:
a. a scaffolding frame main support member for supporting a scaffolding frame via a top plate of a building frame; and b. a platform support member for supporting a platform; wherein
the scaffolding frame main support member is arranged for attachment to the top plate from inside, and alternatively, outside the building frame and connection to the platform support member for support of the platform support member outside the building frame.
[0025] The scaffolding frame assembly is preferably modular.
[0026] The modular apparatus and scaffolding frame assembly preferably further comprise a main support load distribution member arranged for attachment to the main support member and distribution, across at least two studs of the building frame, of load transferred, when the main support member is attached to the top plate and supporting the platform support, from the platform support to the main support.
[0027] The modular apparatus and scaffolding frame assembly preferably further comprise a platform rail support member arranged for supporting one or more platform rails relative to the platform support member and thereby preventing a person falling from the platform. The platform rail support member is preferably arranged for attachment to the platform support. The platform rail support member may be arranged for detachable attachment to the platform support for adjustment of its position relative to the platform support thereby allowing adjustment of platform rail positions. The modular apparatus and scaffolding frame assembly preferably further comprise both fixed and detachable platform rail support members.
[0028] The platform rail support member is preferably also arranged for attachment thereto of a rail support post. For this purpose the platform rail support member preferably comprises a platform rail support post tube designed to slideably receive a platform rail support post. The platform rail support post is preferably a tube having a section corresponding to that of the platform rail support post tube.
[0029] The modular apparatus and scaffolding frame assembly preferably further comprise one or more of the platform rails.
[0030] The main support member preferably comprises a U-Shaped attachment portion. The U-shaped attachment portion preferably comprises a U-shaped channel. However, the U shaped attachment portion, may, for example, comprise at least one U shaped strap. The U-shaped attachment portion preferably further comprises main support location means for locating and preferably securing the main support relative to the top plate. The main support location means preferably comprises one or more bolts arranged for threadable engagement with the attachment portion.
[0031] The main support member preferably further comprises an elongate portion. The attachment portion preferably extends from one end of the elongate portion. The elongate portion preferably comprises a tube. In one preferred form of the present invention the tube is square or rectangular in section. However, it may also, for example, be round.
[0032] The main support member is preferably arranged for attachment to a top plate of a building frame so that it is positioned either substantially over a wall stud or any other position along the top plate.
[0033] The main support load distributor and main support load distribution member preferably comprise a load distribution rail arranged for contacting the two or more studs when the main support is attached to the building frame top plate. In one preferred form the load distribution rail is arranged for removable slidable engagement with the remainder of the main support load distribution member.
[0034] The main support load distribution member and platform support member are each preferably arranged for detachable attachment to the main support member. However, in an alternative embodiment one or both of them may be integrally formed with the main support member.
[0035] The main support load distribution member and platform support member are each preferably arranged for engagement with the elongate portion of the main support. In one preferred form the main support load distribution member and platform support member comprise engagement portions arranged for engagement with the elongate portion of the main support. The rail support member preferably similarly comprises an engagement portion for engagement with and attachment to the platform support. The engagement portions preferably, comprise, in the case of the main support load distribution member and platform support, tubes corresponding in cross section to the elongate portion and arranged for slidably receiving the elongate portion. The engagement portion of the rail support preferably comprises an engagement channel. The engagement portions and corresponding portions of the main support and platform support members preferably comprise corresponding holes for passage of, for example, one or more bolts or pins there through to adjustably locate and preferably secure the engagement portions relative to the corresponding members.
[0036] The main support load distribution member preferably further comprises another engagement portion. The other engagement portion is preferably arranged for engagement with the main support member when the main support member is attached to a top plate of a building frame so that the main support member is in an alternate orientation with respect to the building frame. For example, the main support member can be positioned for attachment to a top plate of a building frame from a position which is outside the building frame. The main support can alternately be positioned for attachment to a top plate of a building frame from a position which is inside the building frame. The other engagement portion is preferably substantially identical to the engagement portion but offset relative to it for engagement with the main support when it is alternately orientated relative to the building frame. The other engagement portion is preferably arranged for engagement with the main support so that the position of the main support load distribution member, when it is attached to the main support member and the main support member is attached to a top plate of a building frame, is substantially the same as for the engagement portion.
[0037] In one preferred form the platform support member comprises a platform support arm.
[0038] According to a another aspect of the present invention there is provided a rail joiner, the rail joiner having one or more receptacles arranged to join end portions of substantially collinear rails in abutting, and alternatively, overlapping relationship to provide a joined rail.
[0039] According to another aspect of the present invention there is provided a modular apparatus for constructing rails, the modular apparatus comprising:
a. a rail joiner; and b. corresponding rails; wherein
the rail joiner having one or more receptacles arranged to join end portions of substantially collinear rails in abutting, and alternatively, overlapping relationship to provide a joined rail.
[0042] According to another aspect of the present invention there is provided a rail assembly comprising:
a. a rail joiner; and b. corresponding rails; wherein
the rail joiner having one or more receptacles arranged to join end portions of substantially collinear rails in abutting, and alternatively, overlapping relationship to provide a joined rail.
[0045] The one or more rail joiner receptacles preferably comprise connected bands for connecting two or more rails, one of the bands being arranged for location within or passage there through of an end of a rail, and alternatively, an end of the rail and ends of one or more other rails, and the other band being arranged for location within or passage there through of ends of the one or more other rails, and alternatively, ends of the one or more other rails and an end of the rail. The bands may in an alternative embodiment comprise ends of a tube. However, in this alternative embodiment it is preferred that the tube is at least partially transparent or translucent to facilitate assembly of the rails and rails joiner.
[0046] The bands are preferably rectangular in cross section.
[0047] According to a another aspect of the present invention there is provided another rail joiner, the other rail joiner being arranged to join end portions of rails lying in substantially transverse planes and comprising engagement portions for engaging the rails to provide a joined rail, wherein at least one of the engagement portions is arranged for axial movement relative to the corresponding rail to facilitate adjustment of a position of an end of that rail.
[0048] According to another aspect of the present invention there is provided a modular apparatus for constructing a rail, the modular apparatus comprising:
a. another rail joiner; and b. corresponding rails; wherein
the other rail joiner is arranged to join end portions of rails lying in substantially transverse planes and comprises engagement portions for engaging the rails to provide a joined rail wherein at least one of the engagement portions is arranged for axial movement relative to the corresponding rail to facilitate adjustment of a position of an end of that rail.
[0051] According to another aspect of the present invention there is provided a rail assembly comprising:
a. another rail joiner; and b. corresponding rails; wherein
the other rail joiner is arranged to join end portions of rails lying in substantially transverse planes and comprises engagement portions for engaging the rails to provide a joined rail wherein at least one of the engagement portions is arranged for axial movement relative to the corresponding rail to facilitate adjustment of a position of an end of that rail.
[0054] One of the engagement portions preferably comprises opposed hooks arranged for location there between of an end portion of a rail. The hooks are preferably U shaped brackets. In one preferred embodiment the U shaped brackets are connected by a strap of the same width to form a C shaped engagement portion. The strap and U shaped brackets may comprise a single homogeneous member.
[0055] The other engagement portion preferably comprises a protrusion arranged for receipt within an end portion of a rail. The protrusion preferably comprises a tube. The tube is preferably square in section for receipt within a square sectioned rail.
[0056] The rail joiner and other rail joiner are preferably arranged to join two or more connected rails which collectively form a balustrade. In a more preferred form the rail joiner and other rail joiner are corresponding kick board joiners arranged to join kick boards. The kick board may, for example, comprise a scaffolding frame kick board.
[0057] According to a another aspect of the present invention there is provided a deck joiner, the deck joiner having one or more receptacles arranged to join edges of two or more substantially coplanar decks in abutting relationship to provide a joined deck.
[0058] According to another aspect of the present invention there is provided a modular apparatus for constructing decking, the modular apparatus comprising:
a. a deck joiner; and b. corresponding decks; wherein
the deck joiner has one or more receptacles arranged to join edges of two or more substantially coplanar decks in abutting relationship to provide a joined deck.
[0061] According to another aspect of the present invention there is provided a decking assembly comprising:
a. a deck joiner; and b. corresponding decks; wherein
the deck joiner has one or more receptacles arranged to join edges of two or more substantially coplanar decks in abutting relationship to provide a joined deck.
[0064] The one or more receptacles of the deck joiner preferably comprise a sleeve arranged to receive and locate therein the deck edges. In a further preferred embodiment the deck joiner comprises a deck edge locator which is arranged to locate ends of the deck edges substantially midway along the longitudinal length of the sleeve. The deck joiner preferably further comprises an inspection hole.
[0065] The sleeve is preferably rectangular in section.
[0066] The deck joiner is preferably a plank joiner arranged to join end edges of two substantially coplanar planks in abutting relationship to provide joined planks.
BRIEF DESCRIPTION OF THE FIGURES
[0067] A preferred embodiment of a modular scaffolding frame of the present invention will now be described, by way of example only, with reference to the accompanying figures in which:
[0068] FIG. 1 is a perspective view of one example of an assembled modular scaffolding frame;
[0069] FIG. 1 a is a plan view of the assembled modular scaffolding frame of FIG. 1 ;
[0070] FIG. 1 b is a side view of the assembled modular scaffolding frame of FIG. 1 ;
[0071] FIG. 1 c is a rear elevational view of the assembled modular scaffolding frame of FIG. 1 attached to a building frame;
[0072] FIG. 2 is a perspective view of the assembled modular scaffolding frame of FIG. 1 attached to a building frame;
[0073] FIG. 3 is a perspective view of two assembled modular scaffolding frames of FIG. 1 attached to adjacent walls of a building frame;
[0074] FIG. 3 a is a perspective view similar to that of FIG. 3 but viewed from the inside of the building frame;
[0075] FIG. 3 b is a plan view of the modular scaffolding frame of FIG. 3 ;
[0076] FIG. 3 c is an elevational view of the modular scaffolding frame of FIG. 3 ;
[0077] FIG. 3 d is another elevational view of the modular scaffolding frame of FIG. 3 ;
[0078] FIG. 4 is a perspective view of the assembled modular scaffolding frame of FIG. 1 attached to a building frame from inside rather than outside the building frame;
[0079] FIG. 4 a is a plan view of the assembled modular scaffolding frame of FIG. 4 ;
[0080] FIG. 4 b is a side elevational view of the assembled modular scaffolding frame of FIG. 4 ;
[0081] FIG. 4 c is a rear elevational view of the assembled modular scaffolding frame of FIG. 4 ;
[0082] FIG. 5 is a perspective view similar to that of FIG. 4 but viewed from outside, rather than inside, the building frame;
[0083] FIG. 6 is a perspective view of the assembled modular scaffolding frame of FIGS. 1 and 4 ;
[0084] FIGS. 7 and 8 are respective side and front elevational views of the assembled frame of FIG. 6 ;
[0085] FIG. 9 is a perspective view of one example of a main support load distributor or main support load distribution member of the modular scaffolding frame of Figures and 1 and 4 ;
[0086] FIGS. 10 and 11 are respective side and plan views of the main support load distributor or distribution member of FIG. 9 ;
[0087] FIG. 12 is a perspective view of a platform support arm of the modular scaffolding frame of FIGS. 1 and 4 ;
[0088] FIGS. 13 and 14 are respective side and plan views of the platform support arm of FIG. 12 ;
[0089] FIG. 14 a is an underneath view of the platform support arm of FIG. 12 ;
[0090] FIGS. 15 , 16 and 17 are respective side, rear and plan views of a platform rail support of the modular scaffolding frame of FIGS. 1 and 4 ; and
[0091] FIG. 17 b is an underneath plan view of the platform rail support;
[0092] FIGS. 18 and 19 are respective front and side views of a platform rail support post of the modular scaffolding frame of FIGS. 1 and 4 .
[0093] FIG. 18 a is a perspective view of the platform rail support post;
[0094] FIG. 18 b is a rear elevational view of the platform rail support post;
[0095] FIG. 20 is a perspective view of the main support of the modular scaffolding frame of FIGS. 1 and 4 ;
[0096] FIG. 21 is a side elevational view of the main support of FIG. 20 ;
[0097] FIG. 22 is a plan view of the main support of FIG. 20 ;
[0098] FIG. 23 is a perspective view of one example of a plank sleeve of the present invention;
[0099] FIG. 24 is a plan view of the plank sleeve of FIG. 23 ;
[0100] FIG. 25 is an end elevational view of the plank sleeve of FIG. 23 ;
[0101] FIG. 26 is a perspective view of one example of a corner sleeve of the present invention;
[0102] FIG. 27 is a plan view of the corner sleeve of FIG. 26 ;
[0103] FIG. 28 is a side elevational view of the corner sleeve of FIG. 26 ;
[0104] FIG. 29 is an underneath view of the corner sleeve of FIG. 26 ;
[0105] FIG. 30 is a perspective view of one example of a slide chassy of the present invention;
[0106] FIG. 31 is an end elevational view of the slide chassy of FIG. 30 ;
[0107] FIG. 32 is a side view of the slide chassy of FIG. 30 ;
[0108] FIG. 33 is a perspective view of one example of a kickboard of the present invention;
[0109] FIG. 34 is a side elevational view of the kickboard of FIG. 33 ;
[0110] FIG. 35 is a perspective view of one example of a corner slide of the present invention;
[0111] FIG. 36 is a plan view of the corner slide of FIG. 35 ;
[0112] FIG. 37 is a side elevational view of the corner slide of FIG. 35 ;
[0113] FIG. 38 is an exploded perspective view of a slide chassy and kickboards prior to assembly;
[0114] FIG. 39 is a plan view of the slide chassy and kickboards of FIG. 38 ;
[0115] FIG. 40 is a perspective view of assembled slide chassy and kickboards of FIG. 38 ;
[0116] FIG. 41 is a plan view of the assembled slide chassy and kickboards of FIG. 38 ;
[0117] FIG. 42 is a perspective view similar to that of FIG. 38 but in relation to a corner slide and corresponding kickboards;
[0118] FIG. 43 is a plan view of the corner slide and kickboards of FIG. 42 ;
[0119] FIG. 44 is a perspective view similar to that of FIG. 40 but showing assembly of a corner slide and kickboards;
[0120] FIG. 45 is a plan view of the assembled corner slide and kickboards of FIG. 42 ;
[0121] FIG. 46 is a perspective view of one example of a corner sleeve of the present invention supporting kickboards connected via a corner slide;
[0122] FIG. 47 is a plan view of the assembled corner sleeve, kickboards and corner slide of FIG. 46 ;
[0123] FIG. 48 is an elevational view of the assembly of FIGS. 46 and 47 ;
[0124] FIG. 49 is another elevational view of the assembled components of FIGS. 46 , 47 and 48 ;
[0125] FIG. 50 is an exploded perspective view of the plank sleeve of FIGS. 23 to 25 showing one example of planks of the current invention positioned for assembly with the plank sleeve;
[0126] FIG. 51 is a plan view of the components of FIG. 50 positioned for assembly;
[0127] FIG. 52 is a perspective view of the plank sleeve and planks of FIG. 50 assembled; and
[0128] FIG. 53 is a plan view of the assembled plank sleeve and planks of FIG. 52 .
DETAILED DESCRIPTION OF THE INVENTION
[0129] Referring to FIGS. 1 , 2 and 3 one example of a modular scaffolding frame assembly of the present invention comprises modular scaffolding frame 10 . The scaffolding frame 10 generally comprises a main support member, which in this particular example comprises main support 12 , a main support load distributor or load distribution member in the form of main support load distributor 14 and a platform support member in the form of support arm 16 . The main support load distributor 14 and support arm 16 are shown in more detail in respective FIGS. 9-11 and 12 - 15 . The modular scaffolding frame further comprises platform rail supports which in this particular example comprise rail support 20 , platform rail posts in the form of rail posts 22 , and platform rails 24 . The support arm supports platform 30 .
[0130] Referring to FIGS. 6 , 7 and 8 the main support 12 comprises a main support attachment portion in the form of attachment bracket 32 . The attachment bracket 32 is designed to hook over a top plate 35 of building frame 38 (see FIGS. 2 and 3 ). An elongate portion of the main support in the form of a tube 34 extends downwardly away from the attachment bracket 32 when the main support 12 is appropriately attached to the top plate 35 . Referring also to FIGS. 1 and 12 - 15 , the support arm 16 attaches to the main support 12 via the tube 34 . The support arm 16 comprises tube 36 having a cross section corresponding to that of the tube 34 and is thereby designed to slideably receive that tube. The support arm 16 is located relative to the main support 12 by bolts which threadably engage the support arm 16 and engage the tube 34 via threaded holes of the tube 36 .
[0131] As can been seen from FIGS. 1-3 and 6 - 8 , when platform 30 is supported by the support arm 16 , a downward force is applied to the support arm. The support arm 16 in turn applies a rotational force to the main support 12 via the tube 34 and about the attachment bracket 32 . This forces the tube 34 of the main support 12 toward the building frame 38 . This force applied to the tube 34 is spread over at least two wall studs 39 (see FIG. 2 ) by a load distributor rail which in this preferred embodiment is load distributor bar 40 (best seen in FIGS. 1 and 2 ). As will be readily appreciated by persons skilled in the relevant art, the load distributor rail could alternatively, for example, comprise a load distributor strap or shaft. The Load distributor bar 40 slidably engages the remainder of the main support load distributor 14 . The main support load distributor 14 is slidably attached to the main support 12 via tube 56 of the main support load distributor 14 (best seen in FIGS. 1 and 9 ). The main support load distributor 14 is located and secured relative to the main support 12 in a similar manner to that described in relation to the support arm 14 and main support 12 .
[0132] The slidable nature of the load distributor bar 40 enables its position relative to the tube 34 of the main support 12 to be adjusted to appropriately contact wall studs 42 of the building frame 38 . This feature, in combination with the length of the load distributor bar 40 , ensures the bar 40 can be positioned to contact at least three wall studs 39 regardless of the position along the top plate where the attachment bracket 32 is attached. In this way the rotational force applied to the main support 12 can be spread over three wall studs. The load distributor bar 40 is located and secured relative to the main support load distributor 14 in a similar manner to that described in relation to the support arm 14 and main support 12 . A threaded hole 41 designed to receive a locating bolt (not shown) is shown in FIGS. 10 and 11 .
[0133] Referring again to FIGS. 1-3 and 6 - 8 , the rail supports 20 are designed for detachable attachment to the support arm 16 . An alternative platform support member comprises a support arm (not shown) having a rail support which is integrally formed with the support arm.
[0134] Referring to FIGS. 15-17 the rail supports 20 comprise a channel 42 which is designed to fit over a tube 44 of the support arm 16 . The rail supports 20 also include a tube 46 which extends transversely of the channel 42 . The channel 42 enables the position of the rail supports 20 to the adjusted relative to the tube 44 . This adjustment in turn enables the position of the rails 24 to be adjusted. The rail supports 20 are secured to the support arm 16 in a similar manner to that which the support arm 14 is secured to the main support 12 .
[0135] FIGS. 4 and 5 represent another example of the modular scaffolding frame assembly 10 , in the form of modular scaffolding frame assembly 48 . This other example involves assembly of the frame so that the main support is positioned inside building frame 38 . A main support 50 of the modular scaffolding frame assembly 48 is orientated 180 degrees relative to the main support 12 of the modular scaffolding frame assembly 10 . A main support load distributor 52 is also orientated 180 degrees relative to its orientation in FIGS. 1-3 so that tube 54 rather than tube 56 slideably receives the main support tube 34 (see also FIGS. 1 and 9 - 11 ). In this way a strap holder 58 (best seen in FIGS. 1 and 9 ) of the main support load distributor 52 is positioned so that the load distributor strap 40 still contacts outer surfaces of the wall studs 42 .
[0136] The modular scaffolding frame assembly 10 is designed for fitting to building frame 38 from outside the frame. However, the modular scaffolding frame assembly 48 is designed as shown in FIGS. 4 and 5 , to be fitted to building frame 38 from inside. In some situations it is difficult to attach the modular scaffolding frame assembly to a building frame from outside the frame. It may, for example, be difficult if the terrain surrounding the building frame is unlevel or drops sharply away. It is also difficult if the scaffolding relates to a second story or higher of a multistory building. The modular scaffolding frame assembly 48 therefore facilitates scaffolding erection in these types of situations by enabling it to be erected from an internal floor of the building to which the scaffolding is to be attached.
[0137] Referring to FIGS. 1 to 5 and 50 to 53 it can be seen that scaffolding frame assemblies 10 and 48 also include planks 70 and plank joiners in the form plank sleeves 72 . It can be seen from these figures that the plank sleeves 72 have deck edge locators in the form of separator tags 74 and an inspection hole in the form of hole 76 . The plank sleeves enable planks to be securely joined as is readily evident from the figures to a person skilled in the relevant art.
[0138] Scaffolding frame assemblies 10 and 48 also include kick boards 80 (see FIGS. 1 to 5 and 33 and 34 ). Referring to FIGS. 30 to 32 and 35 to 45 , the kick boards 80 are joined by a kick board joiner and another kick board joiner in the form of slide chassis 84 and corner slide 86 respectively. The slide chassis 84 comprises bands in the form of straps 88 . The corner slide 86 comprises opposed hooks and tubes in the form of strap 90 and square sectioned tubes 92 . It will be readily apparent from the figures to a person skilled in the relevant art how the kick boards are assembled.
[0139] Referring to FIGS. 26 to 29 and 46 to 49 , scaffolding frame assemblies 10 and 48 can also include a corner sleeve 100 and corresponding support post (not shown). One example of a corner sleeve 100 is visible in FIGS. 3 a and 3 b and slidably receives a plank 70 and support post in a manner that will be readily apparent to a person skilled in the relevant art. It will be appreciated by a person skilled in the relevant art that the invention in at least its preferred form has at least the following advantages:
1. A main support of the modular scaffolding frame assembly of the present invention can be attached to a top plate of a building frame from either inside or outside the building frame 2. The modular scaffolding frame assembly comprises a main support load distributor or load distribution member which transfers load supported by the main support to two or more wall studs of the building frame 3. The modular scaffolding frame comprises an adjustable rail support for adjustment of rails which are positioned above a platform of the modular scaffolding frame assembly so that they are positioned either closer to or further away from a wall frame which the modular scaffolding frame assembly is mounted to 4. A support arm of the modular scaffolding frame is designed for detachment from a main support of the modular scaffolding frame assembly facilitating attachment of the frame assembly to a building frame 5. The main support load distributor is also detachable from the main support to further facilitate attachment of the frame assembly to a building frame 6. The support arm is adjustable along the length of the main support tube to enhance platform support adjustability 7. Plank joiners that enable planks, for example those of a scaffolding frame, to be readily and securely joined 8. Kick board joiners that enable kick boards, for example those of a scaffolding frame, to be readily and securely joined.
[0148] It will appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in specific embodiments without departing from the spirit or scope of the invention broadly described. For example, different members of a preferred embodiment of the modular scaffolding frame assembly such as the main support and support arm could be foldably connected. This foldable connection should also enable the support arm to be unfolded to a platform support position. It would also preferably allow the main support to be alternately orientated relative to the support arm for attachment of the main support to a top plate of a building frame either from inside or outside the building frame. Other alternative embodiments include, for example, different shaped support arms. They could also comprise members similar to those of preferred embodiments of the modular scaffolding frame assembly but, for example, with tubes of different shaped cross sections or, where appropriate, equivalent solid components. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive. | The present invention provides scaffolding erection methods. One method includes considering whether to attach a scaffold frame support to a building frame from inside, and alternatively, outside the building frame wall. Another comprises attaching a load distribution member to distribute transferred load to at least two wall studs. The present invention also provides scaffolding frame members. One is arranged for connection to a top plate from inside, and alternatively, outside a building frame. Another is a load distributor arranged for distribution across at least two studs of the building frame. The present invention also provides kick board and plank joiners. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to siding panels suitable for surfacing exterior walls and roofs of buildings. While conventional siding panels produced from thermo-plastic such as polyvinylchloride (PVC) are well known and have been manufactured in many various shapes, difficulties have continued to be encountered due to the fact that satisfactory profile designs frequently are difficult or expensive to manufacture. It is difficult for instance to extrude wide, nonuniform, unsymetric profiles from thermoplastics. Complex dies are required to produce a product of acceptable tolerance from a well-mixed uniform extrudate which contains a minimum of internal stresses. Furthermore, exacting coordination between the downstream profile shaping equipment and die operation must be maintained to make marketable products. Hence, output from an extrusion process for complex profiles is significantly below the output for profiles of uniform, symetrical shape. Nonsymetrical shapes also increase the difficulty of laminating plastic film to siding panels. Conventional siding must also be installed by pressing each panel upwardly into place while the upper portion of the panel is nailed to the substrate. Conventional siding panels and panel assemblies of the type referred to above and which are subject to the disadvantages mentioned above include for instance those described in U.S. Pat. Nos. 3,473,274, 3,552,078, 3,520,099 etc.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide siding panels which are easily manufactured and installed and are not subject to the various disadvantages mentioned above. In accordance with the invention, an elongated siding panel is provided which has first and second longitudinally extending edge portions and first and second surfaces.
A first pair of parallel, spaced ridges is provided on the first surface of the first edge portion of the panel. The first pair of ridges is adjacent to but spaced from the edge of such edge portion and is parallel therewith. A flange extends from the first surface of the second edge portion adjacent the edge of the second edge portion. The flange terminates in a generally U-shaped opening which is coplanar with the first edge portion of the panel and which opens in a direction away from the first edge portion. In a preferred embodiment, a second pair of spaced parallel ridges is positioned on the second surface of the panel parallel with and opposite the first pair of ridges.
The invention also provides a lapped siding assembly comprising a plurality of lapped, elongated horizontal siding panels of the type described above on a generally vertical substrate. The U-shaped opening of a flange connected to the bottom edge of each panel engages the upper edge portion of the next lower adjacent panel of the assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view showing a typical building panel constructed in accordance with the invention.
FIG. 2 is a sectional view taken as indicated by line 2--2 of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
As mentioned above, the invention includes individual siding panels and a siding panel assembly utilizing such panels. While panels of the invention may be constructed from any suitable materials, the invention is particularly applicable to rigid plastic building panels manufactured from conventional thermoplastic materials such as polyolefin (e.g. polyethylene), polycarbonate, polyvinyl chloride (PVC), polyvinyl flouride, acrylic resins, acrylonitrile, butadiene, styrene, copolymers of acrylonitrile, butadiene and styrene (ABS), etc. PVC is a preferred plastic for the panels of the invention. While rigid plastics are preferred, other materials such as metals may be used.
The panels of the invention may be constructed by any suitable conventional techniques. Profile extrusion is preferred since this is an economical manufacturing technique and the design of the panels of the invention is readily adaptable to this method of manufacture. Other manufacturing techniques suitable for manufacture of panels of the invention include, for instance, conventional vacuum forming operations as well as the air system described in U.S. Pat. No. 3,776,672.
A particularly desirable embodiment of the invention is an extruded profile of the thermoplastic material containing a filler such as calcium carbonate, talc, asbestos, glass fibers, silicates, wood flour or any other suitable material. Also panels of the invention can be laminated with films such as polyvinyl flouride, acrylics, etc. in a conventional manner to improve weatherability.
As will be apparent from the more detailed description of the invention given below, panels of the invention can be installed to form lapped siding assemblies much more easily than more conventional siding products having more complicated profiles. Also the design of the panels of the invention allows a greater range of thermoplastic materials to be used with the same design, since die design is not as critical as with more complicated profiles.
For a more complete understanding of the invention reference may be had to the drawings which show a lapped siding assembly 10 comprising a substrate 12 and a plurality of panels 14 constructed in accordance with the invention and fastened to the substrate by fastener means in the form of conventional nails 16.
As indicated in the drawings, each of the panels 14 has first and second longitudinally extending edge portions indicated generally as upper and lower edge portions 18 and 20 respectively and first and second surfaces indicated as inner and outer surfaces 22 and 24 respectively. Each panel has a first pair of parallel, spaced ridges 26 and 28 adjacent to but spaced from the upper edge 30 of the panel. A second pair of spaced, parallel ridges 32 and 34 is provided on the inner surface 22 opposite the ridges 26 and 28. As can be seen from FIG. 2, the nails 16 extend through slots 36 (best shown in FIG. 1), the heads of the nails being flush with the tops of the ridges 26 and 28.
The outer surface 24 of each panel 14 extends downwardly and outwardly with respect to the substrate 12 from the upper edge portion 18 of the panel to the lower edge portion 20 thereof. As best shown in FIG. 2, the lower edge portion 20 of each panel includes a flange, indicated generally at 38, extending from the inner surface 22 of the panel and terminating in an inverted, generally U-shaped opening 40. The U-shaped opening 40 is coplanar with the upper edge portion 18 of the panel and engages the upper edge portion 18 of the adjacent lower panel in the siding assembly. The flange 38 further includes a generally horizontal member 42 which may contain conventional weep holes 44. The flange also includes a vertical portion 46 which is directly adjacent to and overlaps substantially the entire outer surface 24 of the upper edge portion of the next lower panel in the siding assembly, the upper edge of which is engaged by the U shaped opening 40.
While the invention has been described above with respect to preferred embodiments thereof, it will be understood that various changes and modifications may be made without departing from the spirit and scope of the invention. | A siding panel and siding panel assembly. Each panel has a pair of ridges near the top edge so that the top edge of the panel can be nailed to a substrate while remaining spaced therefrom. The bottom edge of each panel is provided with a flange terminating in an inverted U-shaped opening adapted to engage the upper edge of an adjacent panel. | 4 |
SCOPE OF THE INVENTION
This invention relates to the domain of balancing low and medium tonnage ships such as launches, and particularly balancing in roll, in other words in list.
PRIOR ART AND PROBLEM THAT ARISES
French patent application 2 687 978 deposited by the same applicant describes a device for balancing a ship, particularly for balancing in roll, using a track along which a train of solid weights can move. With reference to FIG. 1 reproducing the system used in this document, the balancing elements are composed of two trains of series of rollers 19 rolling along a track, for example composed of two side rails 25 and 26 . A cable 4 driven by a motor 10 through a motor driven drum 9 , displaces the rollers 19 on each side of the ship. A blocking system 34 fixing the position using two jaws 37 is placed between the two series of rollers 19 , and is controlled by the cable 4 . The assembly is fixed in place by bringing the jaws 34 close into contact with a central positioning rail 30 placed longitudinally above the device. When the cable is not tight, the jaws 34 clamp the central positioning rail 30 . Two electrical lateral jacks 14 are also used on this device to tension the cable at its two ends through a pulley 5 fixed to the jack rod. Several of these devices may be mounted in parallel to each other in the compartments of the same ship, forming part of the ship deck structure.
It is easy to understand that when the cable is tensioned, the two clamping jaws 37 move apart from each other to release the device from the central positioning rail 30 . The set of rollers 19 can then be moved by applying tension to one or the other end of the cable 4 . If the tension is removed deliberately or accidentally by the breakage of a strand of the cable 4 , the clamping jaws 37 will automatically be blocked in contact with the central positioning rail 30 , in the closed position.
Furthermore, French patent application 2 802 504 deposited by the same applicant describes an improvement to this device as shown in FIG. 2 . It also comprises a set of moving lead masses 12 , together with a pair of jaws 16 at each end bearing on the side rails of a compartment. A single cable 2 pulls the train and controls loosening of the jaws 16 .
These ship balancing devices are adapted for high tonnage ships. Application of these devices to medium tonnage and particularly to low tonnage ships would cause a significant loss of volume inside the ship, due to their size. Furthermore, the cable winch control system and the cable tension control system are relatively sophisticated and are not necessary in low tonnage ships. Therefore, the purpose of the invention is to overcome these disadvantages by proposing another ship balancing device applicable to and adapted to low tonnage ships.
SUMMARY OF THE INVENTION
Therefore, the main purpose of the invention is a device for balancing a ship, particularly in roll, comprising:
a train of rolling moving masses forming the links of a chain forming a train;
train immobilization means;
a train tension and immobilization means control cable;
at least one motor to activate the train; and
means of adjusting the cable tension in order to control the immobilization means and comprising two moving pulleys to adjust the cable tension.
According to the invention, the moving masses are preformed so that they can wind around at least one drive wheel with teeth that engage in the corresponding complementary housings machined on the side of the moving masses, each of these moving masses rolling on at least two side rails on at least four rollers, the at least two rails forming a U track with two lateral branches each extending along a wall of the ship, and a central horizontal segment, the at least one drive wheel being located inside the turning point formed by the central segment and a first of the two side segments.
In a first preferred embodiment of the invention, it comprises two chain drive wheels, the second being located at the second turning point formed by the central segment and the second of the two side branches.
In one particular embodiment of the invention, the rails are composed of two opposite sides of a section.
In a first embodiment of the invention, the side branches are horizontal, in other words the U formed by the track composed of the two rails is horizontal.
In this case, the moving masses preferably have four wheels and the track is composed of two side rails.
In a second embodiment of the invention, the side branches are vertical, each of the rails is composed of a vertical compartment, in other words the U formed by the track composed of the rails is vertical.
Consequently in this case, the moving masses preferably have eight wheels rolling in sets of four on two inside faces of two opposite sides of the compartment.
LIST OF FIGURES
The invention and its technical characteristics will be better understood after reading the following description accompanied by several figures:
FIG. 1, already described, showing an exploded view of a first balancing device according to prior art;
FIG. 2 showing a top view of part of a second balancing device according to prior art;
FIG. 3, showing a first manner by which the device according to the invention may be installed in a ship;
FIG. 4, showing a detail of the construction of this first version of the invention;
FIG. 5, showing a section through the detail in FIG. 4; and
FIG. 6, showing a top view of a second manner in which the device according to the invention may be installed in a ship.
DETAILED DESCRIPTION OF THE INVENTION
The device according to the invention is still based on a train system formed by individual rolling blocks each composed of a mass that moves from one side of the ship to the other.
FIG. 3 contains a top or bottom view, showing how the device according to the invention must be installed. It can be seen that the train of moving masses moves along a U track. This track is placed horizontally in the ship, so that the two side branches 50 of the U are parallel to and close to the edges of the ship, in other words each is in contact with an inside wall of the ship. A central segment 52 connects the two side branches 50 of the U. The angle between the two side branches 50 and the central segment 52 of the track is 90°. In order to form the corresponding turning point, there are two sprocket wheels 60 , at least one of which and preferably both are driving wheels, and around which the masses train 40 will wind when it moves from the central segment 52 to one of the two side branches 50 .
Movements of the train 40 are controlled using the drive wheels 60 . A tension cable 70 connects the two ends of the train 40 . Its circuit is composed of a loop that is closed and forms a U inside the circuit followed by the train 40 . The cable is tensioned at the ends of the two side branches 50 of the U by a mobile pulley 73 around which the cable 70 makes a half turn. In its inner path, the cable 70 makes the U trajectory around two inside detour wheels 74 . The mobile pulleys 73 are held in place elastically, each using a tension jack 71 , through a spring 72 . Thus, the cable is held at a given tension, depending on whether the train 40 must be immobilised or displaced.
Indeed, an increasing the tension in the cable 70 can loosen the train immobilisation system 40 . In this case, rotation of the drive wheels 60 enables the train 40 to move along the three parts 50 and 52 of the U. If the tension in cable 70 is released, then the train 40 can be blocked in the required position once it reaches it, by relaxation of the clamping system which returns to its natural blocking position. Details of operation of this system are described in detail in French patent application published under number 2 802 504.
Two systems are shown in the same ship in FIG. 3 . This is simply one example embodiment, and a single system, or more than two systems, could be installed inside the same ship.
FIG. 4 shows in detail of part of the path of the moving masses train, particularly around a drive wheel 60 . The drive wheel is shown with a given number of teeth 63 projecting outside the wheel. There is a toothed ring 64 on the inside of the drive wheel 60 , within which a drive pinion 62 engages with a much smaller number of teeth than in the inner ring 64 , in order to form a reduction gear.
The different moving masses 41 forming the train are attached to each other by a linking pin 42 around which each can pivot with respect to each other. They thus form part of a long chain that can be pulled to one side or the other. Each moving mass 41 on each side of the drive wheel 60 possesses a housing 43 , the shape of which corresponds to the shape of the teeth 63 of the drive wheel 60 , and more precisely corresponds to the movement of each tooth 63 in each cavity 43 , while the moving masses 41 pivot about the turning point around which the train passes. When the moving mass train 41 moves around the drive wheel 60 , each moving mass 41 pivots by 90° so that it can pass from one of the side branches 50 to the central horizontal segment 52 .
Two opposite sides of a section are used to guide each moving mass 41 during its displacements along the side branches and the horizontal segment. Four rollers 44 on each moving mass 41 roll along these two opposite sides. Thus, the sections act as rails for the moving masses train 41 .
FIG. 5 shows a section along line V—V in FIG. 4, and gives a better view of how these moving masses are arranged. This figure shows the rollers 44 rolling along the top of the opposite sides 51 of the section and installed free to rotate in the base of a moving mass 41 . This FIG. 5 also shows a tooth 63 of the drive area 60 that penetrates into the corresponding housing 43 of the moving mass, the drive gear 62 and the inner ring 64 of the same drive wheel 60 .
FIG. 6 shows a second way of installing the device according to the invention in a ship. In this case, the said devices 80 have been installed. The main difference compared with the installation described with reference to the previous figures, is that the side branches are placed vertically. It can be observed that side compartments 82 are located on the inside wall 85 of the ship's hull. Each surrounds a moving mass 81 symbolising the train of circulating moving masses. Note that in this version eight rollers are essential for support on both sides of the side compartments 82 . Note that in this installation mode, the motor drive must be slightly more powerful to take account of the weight of the moving masses 81 that have to be installed on the inside of the side compartments 82 .
In the two embodiments described, it is useful to be able to drive the drive wheels 60 using reversible hydraulic motors powered by a pressure generation system capable of supplying the power necessary for acceleration and starting, and for storing braking energy. The hydraulic motors can be recharged at any time by a pump. The fact that two drive wheels 60 are used means that the drive system can be made redundant if there is a deficiency of a failure in either of them. | The balancing device makes it easy to balance low and medium tonnage ships without needing to use high power. It comprises mainly one or several trains of moving masses mounted on a U track of which the side branches are parallel to the side walls of the ship, the central segment being perpendicular to the center line of the ship. Two drive wheels placed inside the turning points of the U enable driving of the train of moving mass. Application to low and medium tonnage ships. | 1 |
FIELD OF THE INVENTION
This is a continuation-in-part of U.S. application Ser. No. 402,607, filed July 28, 1982, abandoned.
This invention relates to a method and an apparatus for creating, laying out on and cutting patterns from laminar sheets of material and, in particular, relates to a method and apparatus which is of particular utility in the sheet metal working arts where custom patterns are required for fittings or other parts on a job-by-job basis and where the production run extends to a single set of patterns or to a relatively small number of sets of specially configured patterns.
While not limited thereto, the present invention finds particular application in the manufacture of duct work, such as air conditioning ducting, fresh-air or exhaust air ducting, or in ducting employed for conveying fluidized particulate materials.
Any suitable laminar material may be employed in the practice of the present invention, such as, for example, metal sheeting, such as a galvanized iron sheeting, or iron sheeting which has been otherwise coated to render it resistant to rusting and corrosion. Copper or aluminum sheeting, and other sheet materials, such as fiberglass sheeting and the like have also been found to be particularly suitable.
Broadly, the present invention is directed to an improvement in the sheet metal arts which is uniquely suitable to circumstances where mass-production is not economically feasible or, where mass-production although feasible, first requires the design of templates or masters of the patterns.
In the air conditioning and ventilation industries the ducting is designed to the specific dimensions of an architectural structure either under construction, renovation or improvement, and the ducts must be tailored or custom designed for each project, particularly since the ducts generally must occupy the residual space and not encroach on the space required for plumbing and electrical lines.
Compared to other manufacturing requirements of the construction industry, duct fabrication is unique in that it still employs one piece at a time custom pattern development and manually controlled cutout of the development patterns. In the space allocated for installation, such as the hung ceiling space in office buildings, the plumbing, sprinkler systems, steam fittings, electrical conduits and air conditioning ducts must all inter-fit and be coordinated to conjointly occupy the available space.
The plumbing lines, sprinkler lines, and steam lines must be arranged in uninterrupted planes, or otherwise drainage of water therefrom is precluded. The size and location of electrical conduits is mandated by the wiring requirements and the pragmatic prohibition which does not permit it to be bent more than a few times or it becomes impossible to pull the wires through the conduits in the usual manner.
In constrast, air ducting can be arranged to extend about and around the work of others. This inter-fitting of the ducting around the other, generally straight-line, structures can be achieved by raising, lowering, changing the direction of or modifying the cross sectional dimensions of the ducting. There is, therefore, a requirement for three-dimensional customized fittings between straight sections of ducting.
Architects and engineers have taken full advantage of the ability to modify ducting location to maximize usable space. Their designs provide relatively complex spatial allocation for duct work, even though the consequent need for non-standard fittings results in costly customizing of ducts. Economically, it has been determined that it is a far better choice to have ten floors of rentable space in a 100-foot high building by employing intricately arranged ducting, instead of eight floors of space with less complex ducting. The initial relatively high installation cost is greatly compensated for by the resultant gain in rentable space.
This extremely high use of non-standard fittings, which must be produced one piece at a time, has prevented the application of automation techniques from significantly impacting the ducting industry. By and large, the fittings are produced by the age-old process of having a highly skilled artisan determine what components are required to create the three-dimensional fitting from flat sheet stock. Each component piece (generally four patterns adapted to interfit) must then be marked out on the sheet metal. The marking out, in addition to being time consuming and laborious, requires the skill of a sheet metal layout technician for laying out the pattern on sheet material.
By and large, little or no attempt is made to optimize material usage and, in fact, the layout is generally a one piece at a time operation. Little time is spent assessing optimum stock widths, positioning of patterns and minimizing severing lines.
Since the sheet metal layout technician must mark out the outline of the four patterns by hand, these four patterns, together, forming the fitting, significant compromises are made as, for example, in not maximizing material usage.
In the late 1950's, a machine called a Coil Line Duct Maker became available. It permitted automation of the manufacture of standard straight duct sections. This machine, now standard shop equipment for virtually all major duct fabricators, permits mass-production of standard straight duct sections and has become the common manner of manufacture.
This has exacerbated the problem attendant upon the tedious and time consuming steps required for the production of the non-standard fittings which now have become the paramount limiting and cost factor in the production capability of duct work fabricators.
It is commonly known in the industry that each hour's output of shop fabrication supports about two hours of field installation work, i.e., every hour gained in shop productivity generates two hours of new work opportunity in field installation.
It would thus seem obvious that fabricators seek to train and employ more layout technicians, but this has not been possible and there presently exists a worldwide shortage of layout technicians. A 1975 survey of the Northeast United States reported that the then average age of a layout technician was 55 years. Although layout technicians represent only 4 to 5 percent of total industry employees, the shortage of technicians has directly accounted for a reduction in the work opportunity for the entire industry.
Some have suggested means for the possible automation of at least part of the layout technician's function, but none were truly beneficial as none could provide a means to create the initial patterns for the components of the fittings which meets the requirements hereinabove set forth.
For example, the use of an electrically driven and controlled marking table has been proposed in the manufacture of patterns, such a marking table being controlled by a scanning arrangement which enables the scaling up of the sets of patterns from reduced scale drawings of those patterns, such drawings commonly being to quarter scale.
However, this technology has, heretofore, not been employed in the ducting fabrication industry because all the layout technician receives is a rough sketch dimension layout of the particular customized piece required, from which the technician must, on a customized basis, create the patterns on the sheet material.
While, heretofore the automation of the production of patterns for nonstandard duct work fittings has been considered as being totally impractical or impossible, considerable attention has been given in other industries to the production of patterns, particularly in the clothing industry, in which extensive developments have been made in automating the cutting of fabric panels for subsequent assembly into garments.
Typical of such applications are U.S. Pat. Nos. 4,327,615 to Gerber et al, issued May 4, 1982; 4,178,820 to Gerber, issued Dec. 18, 1979; 3,610,081 to Gerber, issued Oct. 5, 1971; and 3,477,322 to Gerber et al, issued Nov. 11, 1969, which teach the use of a computer-controlled cutter which is employed to sever layers of material secured to the bed of a cutting table, the cutter being moved under the control of the computer simultaneously in first and second directions longitudinally and laterally of the table along X and Y axes.
Such an operation, however, still involves the initial drawing of the respective patterns to full or reduced scale by a skilled layout draftsman, who must also maximize utilization of the material, after which the drawing is scanned to convert the information contained thereon into digital signals which are stored and subsequently used to control movement of the cutter. Despite the accuracy with which the drawings are prepared, any errors can appear at the cutting head, and can reappear in amplified form in the event that movement of the cutter is scaled up from reduced scale drawings.
Sophistication of the electronics industries, made possible by the availability of computers, has permitted the elimination of repetitive hand drafting but the original drawings must still be created by hand. Electronic scanning now permits the development of the patterns on a cathode ray tube. The storage, in memory, of those patterns in the form of digital information, can then be subsequently recovered and utilized to control the cutter head. This system has the advantage of permitting corrections to be made of any errors which occur in the developed pattern, but do not solve the problem of creating the initial patterns. This still requires the skill of a technician.
For example, U.S. Pat. No. 3,596,068 to Doyle, issued July 27, 1971, recognizes the disadvantage of manually laying out patterns to maximize material usage and proposes converting manually developed patterns to digital signals and the subsequent comparison of the digitized information, including rotation of the stored pattern information, to optimize material usage. Similarly, U.S. Pat. No. 3,875,389 to McFadden et al., issued April 1, 1975, discloses a system the object of which is to optimize a single pattern to permit its production in quantity by interfitting facsimiles of that pattern and rotating the assemblage until maximized material usage is achieved. Both of these teachings still require a separate hand drawing for each pattern to be produced as the basis for digitization, comparison and pattern rotation.
Once the patterns have been established and laid out, automated methods for cutting have been suggested. Again, and more particularly as related to the clothing industry, it is recognized in U.S. Pat. No. 3,761,675 to Mason et al, issued Sept. 25, 1973, that the cutting of fabric is feasible using a laser beam as a cutter.
However, these advances found little applicability in the duct work fabricating industry. Creation of the master pattern was still subject to the individual skill of an artisan and, lacking mass production needs, automation was conceived of as being economically impractical.
THE INVENTIVE CONCEPT
According to the present invention, each of the operations, heretofore requiring the judgment and skill of the technician, are fully automated, including the initial determination of the number and size of pattern required for each nonstandardized fitting; the placement of the patterns or pattern on the sheet material, both optimizing material usage and cutting patterns; and, in its most preferred form, to scribe or mark out; tag and, if desired, cut out the pattern or patterns for ready assembly.
Basically, the present invention affords a method and an apparatus for creating patterns for a three-dimensional product which can then be fabricated from patterns of laminar sheet material, the method including the steps of:
electronically creating, through mathematical calculation, the shape (or pattern) of a selected portion of the end product on the basis of dimensional information;
electronically creating, through mathematical calculation, the others of the shapes of the portion of the end product;
positioning all the shapes required for such end product in a grouping such that the grouping when aligned on said sheet material may be severed from the sheet material by a single substantially straight cut across the sheet material;
positioning selected pairs of shapes in said grouping with like edge configurations in relative juxtaposition;
rotating said pairs of shapes to yield a juxtaposition which provides for optimum material usage and for severance of the shapes with a minimum of cutting steps; and
converting the shape into physical form onto a sheet of planar material.
In accordance with the present invention, microprocessing and plotting equipment under the control of an algorithm program performs all the steps required without the intervention on the part of the operator other than the supplying of information which identifies the basic type of the fitting, and its dimensional parameters.
Preferably, the invention comprises a method for producing the customized patterns of the closed sides of a three dimensional product which can be fabricated from sheet material, such as a ventilating duct fitting, comprising the steps of:
storing, in digital form in memory means, the configurations of a group of basic pattern types having nominal dimensions from which substantially all variations of the product can be developed;
entering input data including the actual dimensions of the patterns to be formed and the pattern type;
generating, from the actual dimensional and pattern type data, the pattern of each side of the product, each of the patterns developed from selected ones of the basic pattern types in response to the input dimensional and pattern type data;
positioning the developed patterns in a series of groupings;
determining which of the groupings yields the minimum surface area so as to provide for optimum material usage and generating digital data representing the optimum grouping;
supplying the digital data representing the optimum grouping to an X-Y plotting table, the data being in block format and including digital data representing the starting point for each pattern in X-Y format and sequential digital data in X-Y format representing the contour of each pattern; and
plotting the patterns in accordance with the digital data on a sheet of material on the plotting table.
In preferred embodiments, the apparatus and method comtemplate means to evaluate, and to optimize usage on the basis of the likely stock sizes of sheet material available to the fabricator and to automatically suggest the stock which will result in the least waste.
If desired, the program can include such additional features as the fabrication of configurations which exceed the maximum width size of the sheet stock by computing combinations of pieces. Further, in accordance with the present invention, printed records for all patterns in inventory for possible recall may be maintained. The present invention is not only capable of designing nonstandard fitting patterns but in addition, includes, within the pattern configuration, modifications which adapt the patterns to the tooling of the fabricator so as to optimize the assembly process.
These benefits and others which will be apparent to one skilled in the art, have been made possible by the discovery that all shapes and dimensions of patterns employed in the duct work industry may be expressed in terms of a small number of geometric shapes which may be three but is preferably four, which can be modified on the basis of predetermined equations to the shape and dimension of a component of the desired fitting, the program or algorithm being employable to produce any required permutation or combination of the basic geometric figures. When provided with the desired dimensions of the fitting, the program algorithm of the present invention enables a complete set of patterns to be automatically produced, including sets of patterns for ducts having bends, dual or multiple bends of any required radius and radial extent, including bends which decrease or increase in radial width and with simultaneous increase or decrease in axial width, and any combination of such bends with rectilinear portions of converging or diverging construction, any of such fitting sections terminating in either right or offset ends. The four geometric figures can be expressed as an annular segment of a circle; dual interconnected annular segments of circles taken about centers of generation which are spaced from each other; a rhomboid, and a trapezoid. The latter two configurations, i.e., the rhomboid and the trapezoid, may be expressed as a single shape as each can be developed from the same configuration through modification of dimensions. However, in order to utilize a predetermined set of algorithms, it is desirable to treat the rhomboid and trapezoid separately.
Further, after having been provided with the required dimensions and number of patterns, the algorithm preferably rotates and orients the forms with respect to each other to yield, on the basis of the stock sheet material being employed, a grouping which aligns all patterns required for a fitting such that a single width wide cut of the sheet will yield a sheet with all the required patterns for a single fitting and additionally maximizes the sheet material usage and provides optimization of the cutting steps in severing the patterns from the sheet stock.
Having finalized calculations on the basis of the algorithm and the specific dimensions of the set of patterns to be produced, the entire process of fabrication of the respective patterns can be effected automatically, by computer-generated sets of patterns fed to a computer controlled layout plotting table and, in its most preferred form by providing a laser means for severance of the patterns.
Ancillary to the cutting of the patterns or the marking thereof for subsequent cutting is the capability of the algorithm of the present invention to produce a complete inventory of the sets of patterns, a costing thereof, and the location thereof within the ducting system with such information being delivered for subsequent use as hard copy by means of a conventional print-out device.
While the present invention is able to develop sets of patterns for any desired shape or dimension of fitting based upon these geometrically expressed figures, it should be understood that the number of patterns required to create a three-dimensional rectilinear fitting need not be comprised of four separate patterns. In some instances, the fitting would be comprised of only two patterns each of which is subsequently bent to provide the four sides of the fitting or one of which is subsequently bent to provide three sides of the fitting.
As will be readily understood, proceeding from a planar square, any desired geometric variation therefrom can be obtained by varying the length of one side to zero or by modifying the angle between adjacent sides. Similarly, any combination of curves can be produced by modifying the radius and arcuate extent of an annular segment, and by adding thereto one or more segments of the same or differing dimensions, either in juxtaposition with each other or in juxtaposition with a rectilinear section. All of these variations are within the capability of the present invention, including simultaneous combination of rectilinear and arcuate segments to produce non-arcuate curvilinear segments.
While the sizes and lengths of duct fittings are infinite in number and in variation, in rectangular duct construction there are basically four general types of fittings within the industry. There are transition fittings, which are fittings between ducts of differing outer perimeter dimensions; offset fittings, in which ducts of the same perimeter lying along parallel planes are sought to be connected; elbow fittings, which are fittings for right angle turns; and bevel fittings which are fittings for turns other than ninety degrees.
In accordance with the present invention, once the type of fitting is identified and the dimensional information provided, the optimum construction type in accordance with approved industry standards will be calculated. The algorithms of the present invention mathematically create the shapes for each of the four sides required for the fitting type and provide the most efficient method of laying out the requisite patterns. The results may indicate the desirability of a two piece construction, three piece construction or four piece construction.
Irrespective of the complexity of the fitting the shape of the fitting sought to be designed is generated on the basis of one of the mathematically expressed geometric shapes, i.e., an annular segment of a circle, dual interconnected annular segments of circles taken about centers of generation which are spaced from each other; a rhomboid, and a trapezoid.
Having established the dimensions of the four sides of the fitting, the algorithm of the present invention through sequential rotation and positional orientation of the mathematically expressed dimensional representations of the patterns stored in the memory of the microprocessor, which also carries within its memory the basic mathematical geometric configurations, then positions the configurations A, B, C, and D, which represent the four sides of the fitting, with respect to each other on the basis of the following, in which "X" indicates the positioning of the forms in one direction along a first axis and "Y" indicates the positioning of the forms along another axis, the suffix "r" indicates the rotation of the particular form through ninety degrees, the suffix "1" indicating the forms are tried in a single position, and the suffix "1:2" indicating the forms are tried in mirror image and inverted mirror image:
______________________________________Position 1: X = A1, B1, C1; Y = B1, D1.Position 2: X = A1, B1, C1r; Y = B1, D1.Position 3: X = A1, B1, C1; Y = B1, D1r.Position 4: X = A1, B1, C1r; Y = B1, D1r.Position 5: X = A1, B1, D1; Y = B1, C1.Position 6: X = A1, B1, D1r; Y = B1, C1.Position 7: X = A1, B1, D1; Y = B1, C1r.Position 8: X = A1, B1, D1r; Y = B1, C1r.Position 9: X = A1:2, B1:2 + C1:2, D1:2; Y = A1:2, C1:2 + B1:2, D1:2.Position 10: X = A1, B1 +C1r. D1r; Y = A1, C1r + B1, D1r.Position 11: X = A1, B1 + C1r, D1; Y = A1, C1r + B1, D1.Position 12: X = A1, B1 + C1, D1r; Y = A1, C1 + B1, D1r.Position 13: X = A1, B1 + D1 + C1; Y = A1 + B1, D1, C1.Position 14: X = A1, B1, + D1 + C1r; Y = A1 + B1, D1, C1r.Position 15: X = A1, B1 + D1r + C1; Y = A1 + B1, D1r, C1.Position 16: X = A1:2, B1:2 + D1:2r + C1:2r; Y = A1:2 + B1:2, D1:2r, C1:2r.Position 17: X = A1, B1, D1 & C1; Y = A1 + B1 + D1, C1.Position 18: X = A1, B1, D1r & C1; Y = A1 + B1 + D1r, C1.Position 19: X = A1, B1, D1r + C1r; Y = A1 + B1 + D1r, C1r.Position 20: X = A1, B1, D1 + C1r; Y = A1 + B1 + D1, C1r.Position 21: X = A1:2, B1:2, C1:2, D1:2; Y = A1:2 + B1:2 + C1:2 + D1:2.Position 22: X = A1, B1, C1R, D1; Y = A1 + B1 + C1R + D1.Position 23: X = A1, B1, C1, D1r; Y = A1 + B1 + C1 + D1r.Position 24: X = A1, B1, C1r, D1r; Y = A1 + B1 + C1r + D1r.Position 25: X = B1r + A1r, C1 + D1; Y = B1r, A1r, D1 + C.Position 26: X = B1r + A1r, C1r + D1; Y = B1r, A1r, D1 + C1r.Position 27: X = B1r + A1r, C1 + D1r; Y = B1r, A1r, D1r + C1.Position 28: X = B1r, A1r, C1r + D1r; Y = B1r, A1r, D1r + C1r.Position 29: X = B1r + A1r, D1 +C1; Y = B1r, A1r, C1 + D1.Position 30: X = B1r + A1r, D1r, C1; Y = B1r, A1r, C1 + D1r.Position 31: X = B1r + A1r, D1 + C1r; Y = B1r, A1r, C1r + D1.Position 32: X = B1r + A1r, D1r + C1r; Y = B1r, A1r, C1r + D1r.Position 33: X = B1:2r + A1:2r + C1:2, D1:2; Y = B1:2r, A1:2 r, C1:2 + D1:2.Position 34: X = B1r + A1r + C1r, D1r; Y = B1r, A1r, C1r + D1r.Position 35: X = B1r + A1r + C1r, D1; Y = B1r, A1r, C1r + D1.Position 36: X = B1r + A1r + C1, D1r; Y = B1r, A1r, C1 + D1r.Position 37: X = B1r + A1r + D1 + C1; Y = B1r, A1r, D1, C1.Position 38: X = B1r + A1r + D1 + C1r; Y = B1r, A1r, D1, C1r.Position 39: X = B1r + A1r + D1r + C1; Y = B1r, A1r, D1r, C1.Position 40: X = B1:2r + A1:2r + D1:2r + C1:2r; Y = B1:2r, A1:2r, D1:2r, C1:2r.Position 41: X = B1r, D1 + A1r, C1; Y = B1r, A1r + D1, C1.Position 42: X = B1r, D1r + A1r, C1; Y = B1r, A1r + D1r, C1.Position 43: X = B1:2r, D1:2r + A1:2r, C1:2r; Y = B1:2r, A1:2r + D1:2r, C1:2r.Position 44: X = B1r, D1 + A1r, C; Y = B1r, A1r + D1, C1r.Position 45: X = B1:2r +I A1:2r, C1:2, D1:2; Y = B1:2r, A1:2r + C1:2 + D1:2.Position 46: X = B1r + A1r, C1r, D1; Y = B1r, A1r + C1r + D1.Position 47: X = B1r + A1r, C1, D1r; Y = B1r, A1r + C1 + D1r.Position 48: X = B1r + A1r, C1r, D1r; Y = B1r, A1r + C1r + D1r.Position 49: X = A1r, B1r, C1 + D1; Y = A1r + B1r, D1 + C1.Position 50: X = A1r, B1r, C1r + D1; Y = A1r + B1r, D1 + C1r.Position 51: X = A1r, B1r, C1 + D1r; Y = A1r + B1r, D1r + C1.Position 52: X = A1r, B1r, C1r + D1r; Y = A1r + B1r, D1r + C1r.Position 53: X = A1r, B1r, D1 + C1; Y = A1r + B1r, C1 + D1.Position 54: X = A1r, B1r, D1r + C1; Y = A1r + B1r, C1 + D1r.Position 55: X = A1r, B1r, D1 + C1r; Y = A1r + B1r, C1r + D1.Position 56: X = A1r, B1r, D1r + C1r; Y = A1r + B1r, C1r + D1r.Position 57: X = A1:2r, B1:2r + C1:2, D1:2; Y = A1:2r, C1:2 + B1:2r, D1:2.Position 58: X = A1r, B1r + Clr, D1r; Y = A1r, C1r + B1r, D1r.Position 59: X = A1r, B1r + C1r, D1; Y = A1r, C1r + B1r, D1.Position 60: X = A1r, B1r + C1, D1r; Y = A1r, C1 + B1r, D1r.Position 61: X = A1r, B1r + D1 + C1; Y = A1r, B1r, D1, C1.Position 62: X = A1r, B1r + D1 + C1r; Y = A1r + B1r, D1, C1r.Position 63: X = A1r, B1r + D1r + C1; Y = A1r + B1r, D1r, C1.Position 64: X = A1r, B1r + D1r + C1r; Y = A1r + B1r, D1r, C1r.Position 65: X = A1r, B1r, D1 + C1; Y = A1r + B1r + D1, C1.Position 66: X = A1r, B1r, D1r + C1; Y = A1r + B1r + D1r, C1.Position 67: X = A1:2r, B1:2r, D1:2r, C1:2r; Y = A1:2r + B1:2r + D1:2r, C1:2r.Position 68: X = A1r, B1r, D1 + C1r; Y = A1r + B1r + D1, C1r.Position 69: X = A1:2r, B1:2r, C1:2, D1:2; Y = A1:2r + B1:2r + C1:2 + D1:2.Position 70: X = A1r, B1r, C1r, D1; Y = A1r + B1r + C1r + D1.Position 71: X = A1r, B1r, C1, D1r; Y = A1r + B1r + C1 + D1r.Position 72: X = A1r, B1r, C1r, D1r; Y = A1r + B1r + C1r + D1r.Position 73: X = A1 + B1, C1 + D1; Y = A1, B1, D1 + C1.Position 74: X = A1 + B1, C1r + D1; Y = A1, B1, D1 + C1r.Position 75: X = A1 + B1, C1 + D1r; Y = A1, B1, D1r + C1.Position 76: X = A1, C1r + B1 + D1r; Y = A1, B1, D1r + C1r.Position 77: X = A1 + B1, D1 + C1; Y = A1, B1, C1 + D1.Position 78: X = A1 + B1, D1r + C1; Y = A1, B1, C1 + D1r.Position 79: X = A1 + B1, D1 + C1r; Y = A1, B1, C1r + D1.Position 80: X = A1 + B1, D1r + C1r; Y = A1, B1, C1r + D1r.Position 81: X = A1:2 + B1:2 + C1:2, D1:2; Y = A1:2, B1:2, C1:2 + D1:2.Position 82: X = A1 + B1 + C1r, D1r; Y = A1, B1, C1r + D1r.Position 83: X = A1 + B1 + C1r, D1; Y = A1, B1, C1r + D1.Position 84: X = A1 + B1 + C1, D1r; Y = A1, B1, C1 + D1r.Position 85: X = A1 + B1 + D1 + C1; Y = A1, B1, D1, C1.Position 86: X = A1 + B1 + D1 + C1r; Y = A1, B1, D1, C1r.Position 87: X = A1 + B1 + D1r + C1; Y = A1, B1, D1r, C1.Position 88 X = A1:2 + B1:2 + D1:2r + C1:2r; Y = A1:2, B1:2, D1:2r, C1:2r.Position 89: X = A1, D1 + B1, C1; Y = A1, B1 + D1, C1.Position 90: X = A1, D1r + D1, C1; Y = A1, B1 + D1r, C1.Position 91: X = A1:2, D1:2r + B1:2, C1:2r; Y = A1:2, B1:2 + D1:2r, C1:2r.Position 92: X = A1, D1 + B1, C1r; Y = A1, B1 + D1, C1r.Position 93: X = A1:2, C1:2, D1:2 + B1:2; Y = A1:2, B1:2 + C1:2 + D1:2.Position 94: X = A1, C1r, D1 + B1; Y = A1, B1 + C1r + D1.Position 95: X = A1, C1, D1r + B1; Y = A1, B1 + C1 + D1r.Position 96: X = A1 + B1, C1r, D1r; Y = A1, B1 + C1r + D1r.______________________________________
The symbol "+" above indicates that the forms are tried in more than one row or column in the direction indicated. For example, Position 9 indicates that forms A and B are positioned next to each other in the X direction; Forms C and D are then also positioned next to each other in the X direction. The Y direction indicates that Forms A and C are positioned next to each other in the Y direction and that forms B and D are likewise positioned next to each other in the Y direction. Accordingly, the forms are tried in the arrangement ##EQU1## if X indicates the vertical axis and Y indicates the horizontal axis (see Table below). Position 9 also indicates the forms A, B, C and D are arranged in mirror image and inverted mirror image. This method of arranging the forms will become clearer in the more detailed description below with reference to the drawings and the Table.
In addition, the following extra positions permit the mathematical positioning of dimensional representations E, which are larger in at least one dimension than the sheet stock available, so as to require more than a single sheet to produce a side of a particular pattern, on the basis of the following additional positions:
______________________________________Position 97: X = E1, E1 + C1, D1; Y = E1, C1 + E1, D1.Position 98: X = E1, E1 + C1r, D1r; Y = E1, C1r + E1, D1r.Position 99: X = E1, E1 + C1, D1r; Y = E1, C1 + E1, D1r.Position 100: X = E1, E1 + C1r, D1; Y = E1, C1r + E1, D1.Position 101 X = E1:2, E1:2, C1:2, D1:2; Y = E1:2 + E1:2 + C1:2 + D1:2.Position 102: X = E1, E1, C1r, D1; Y = E1 + E1 + C1r + D1.Position 103: X = E1, E1, C1r, D1r; Y = E1 + E1 + C1r + D1r.Position 104: X = E1, E1, C1, D1r; Y = E1 + E1 + C1 + D1r.______________________________________
The above positions represent the essential positional combinations which will yield a group of patterns for a fitting which can be severed from a sheet by a single cut across the sheet and in which the patterns are laid out for minimum waste of material and optimum severance.
A microprocessor performs the mathematical calculations with the microprocessor having stored in its memory the basic geometric configurations and a program for implementing the mathematical positioning.
Preferably, the computer-generated patterns and other data developed and stored in the microprocessor are converted to a form, such as a paper tape which may be used to actuate automated plotting equipment, which automatically marks out physical representations on planar sheeting by selective traversing of its plotting head along predetermined axes under the control of independently driven motors.
In its most preferred form the method and apparatus of the present invention further includes integral means on the plotting aparatus which is responsive to the information provided by the microprocessor for cutting the patterns by the use of a laser.
The present invention thus describes a method and apparatus for automatically producing the data required for laminar patterns and the production of the patterns by a mechanically driven plotting apparatus which marks-out or carries along the cutting tools for severance of the patterns on a sheet of material positioned on the plotting bed of the plotting apparatus.
Preferably, the plotting apparatus includes a plotting head supported for independent movement parallel to the plotting bed along preferably mutually perpendicular X and Y axes, the plotting head being driven selectively along the respective X and Y axes by dual independently driven motors under the control of a microprocessor and wherein the microprocessor has stored within its memory at least one basic geometric configuration of at least one of a plurality of laminar patterns of an interrelated series of such patterns. Once the microprocessor is provided with information relative to the required ultimate dimensions of the pattern, it correlates the dimensions of the pattern to the dimensions of other complementary patterns which are required to form a series of interrelated patterns which, when interfit, will create a fitting. Furthermore, through selective rotation and positioning of the series of patterns to orient the dimensional representations of the series of the patterns as stored in the microprocessor, the apparatus determines representations of the series of the patterns which results in the smallest required surface area of at least a portion of a sheet material of stock dimensions, considering the optimum desirable cutting lines between the patterns and the requirement that patterns of a fitting be grouped such that the group can be severed by a single, preferably widthwide cut. The data thus developed and stored in the microprocessor is thereafter used to control the drive motors of the plotter to mark out or sever physical representations of the patterns on the sheet of material.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described in greater detail in the following detailed description with reference to the drawings, in which:
FIG. 1 is a block diagram of an apparatus for plotting out and marking patterns of a fitting according to the present invention.
FIG. 2 is a block diagram of an alternate form of the present invention further including a laser cutting apparatus.
FIGS. 3-1-3-15 are schematic representation of the transition, offset, elbow and bevel fitting types in accordance with the present invention.
FIGS. 4A-4D are schematic representations of mathematically generated geometric patterns in accordance with the present invention.
FIGS. 5-11 are schematic representations illustrating the method by which the present invention calculates the optimum positioning of patterns to minimize material usage and optimize cutting.
FIG. 12 is a schematic representation of two of the various mathematical positions in which the microprocessor tries the patterns to determine optimal positioning for laying out and cutting the patterns.
FIG. 13 illustrates, in perspective view, a typical fitting.
FIG. 14 illustrates the prior art method of ordering and laying out the fitting of FIG. 13.
FIG. 15 illustrates the same fitting as illustrated in FIG. 13 as developed and layed out in accordance with the present invention.
FIG. 16 is a schematic representation of a plotting apparatus in accordance with the present invention.
FIG. 17 is a perspective view of the apparatus of the present invention including a laser cutting apparatus.
FIG. 18 is a detailed, partially sectional view, of the laser cutting nozzle assembly of the apparatus of FIG. 17.
FIG. 19 is a plan view of a typical pattern showing optimization of material and cutting alignment in accordance with the present invention with spaces shown between the patterns for clarity.
FIGS. 20A & 20B in combined form represent a flowchart of the computer program implementing the preferred mathematical optimization in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates the general means for the retention of information, generation of data, and the production of plotted out patterns on sheet metal stock in accordance with the present invention. The algorithm storage and comparator drive for the computer can be selected from any readily available commercial equipment. Preferably a computer system is employed which includes a display, magnetic tape, disk or other storage and a keyboard to permit inputting of information. It is preferable that at least 32K of random access memory capability to included within the system.
The system shown in FIG. 1 includes memory 10 wherein the preferred program for implementing the optimization listing described above is stored. The preferred optimization program must be stored in random access computer memory because of the speed with which the optimization must be done. Storage on disks would be too slow to implement the program efficiently. Disk storage, however, might, of course, be used to store the computer operating system program. Should limitations of computer hardware (e.g., insufficient random access memory) preclude the preferred optimization described above, other less sophisticated optimization procedures such as the outside rectangle technique to be described later, could be used, with the accompanying reduction in memory requirements. Furthermore, memory 10 should be non-volatile, so that the contents are not lost if the system is powered down. For example, magnetic core storage can be used or a battery back-up provided for enabling orderly shut down of the system and storage on permanent media (disk or tape) after a power down.
Computer 20 is coupled to I/O devices 30 which preferably include a keyboard, printer and CRT display. Once the fitting type and dimensional data are inputted into the system via the keyboard, the computer 20 will determine which orientation of the duct pattern sides is optimum, preferably in accordance with the optimization program described above, and will output the data which determines orientation of the pattern in X-Y format to an output device 40, such as a paper tape punch or magnetic tape unit. The magnetic tape unit may also be used for back-up protection in the event of a power failure.
The paper or magnetic tape bearing the output data can later be read by an appropriate playback and information retrieval device 50, such as a paper-tape reader or magnetic tape unit. Alternatively, data from computer 20 may also be fed electronically to the X-Y plotting table 103 instead of utilizing the intermediate paper or magnetic tape medium. Paper tape, however, provides a convenient means for storing the data indefinitely prior to use on the shop floor. This data controls metal stock feed control 70 and cutter control 80, which controls coil feed 90 and cutter 95, which might comprise a flying shear cutter, for example. The cut sheet metal stock is then transferred, preferably by a conveyor 110, to an X-Y plotting table 103, also controlled by information retrieval device 50. At the X-Y plotting device, the sheet metal stock is either marked with the patterns for a particular duct fitting or the patterns are directly cut, preferably by a laser cutting device, to be described below.
While the data generated by the computer could be inputted directly to the plotting table, it is preferable that the data be converted to a storage form such as magnetic tape, paper tape or other memory medium for later use, as described.
Upon the inputting of a command for calling up from storage memory 10 a particular stored fitting layout or any number of layouts up to and including the total number required for a given shipment such as when using tape playback information retrieval equipment, the information can then be provided to the automated plotting table which will plot on X and Y axes as hereinafter more particularly described, the pattern or patterns.
It has been found particularly convenient to employ a paper tape output for the computer and a paper tape reader to control the plotting table.
It has also been found particularly desirable, where the fabricator has automated equipment for the feeding of the sheet material, to directly control the sheet metal feed to the plotting table by the microprocessor 20. This permits the feeding out of the sheet material to the plotting table and placing indicia on the sheet for cutting of the sheet into segments after the plotting of the patterns of a particular fitting. While any known means may be employed for feeding the sheet stock, transferring it to the plotting table and cutting it, it is particularly desirable if the equipment includes a tape reader compatible with the tape reader which controls the plotting table.
In its preferred form, the tape playback information retrieval apparatus, preferably, also includes a label stock list printer 60 which prints the labels for each of the patterns and identifies those common to a given fitting. As hereinbefore set forth, the preferred program or algorithm of the present invention maintains all components of each fitting piece in adjoining relationship so as to ensure that all patterns of a fitting can preferably be separated from the patterns of other fittings with a straight cut cross the width of the sheet stock. This feature not only provides a benefit in instances where on-site separation of the patterns from the sheet stock and fabrication is desirable but also provides benefits to fabricators who cut out the patterns immediately and assemble the fitting so that they can be delivered to the job site in finished form.
FIG. 2 illustrates a preferred form of the invention which further includes automated equipment to cut out the patterns on the plotting table through the use of a laser. Like components are indicated with the same reference numerals as used in FIG. 1. The embodiment shown in FIG. 2 further comprises Y motor drive controller 122, X motor drive controller 124, velocity comparator 150, laser cutter power generator 130 and laser cutter intensity control 140.
The method and apparatus for a laser equipment will be set forth in greater detail, particularly with regard to FIGS. 17 & 18. In general, a focused laser beam delivery nozzle is mounted on the carriage of the plotting table which carriage is driven by an X-drive controller 124 in a first direction and a Y-drive controller 122 in a second direction, generally at right angles to each other. The computer generates pulses respectively to the X and Y motors via playback information retrieval device 50 with the pulses supplied to the X motor being sufficient to move the carriage along the table a distance equal to the X component of the desired movement, and the number of pulses supplied to the Y motor sufficient to move the focused laser beam along the carriage a distance equal to the Y component of the desired movement. A velocity comparator 150 regulates and X and Y drive and a laser power control generator 130, which provides a linear power output signal, preferably coupled with a laser intensity control 140, coordinates the intensity of the laser beam with the speed of movement as generated by the X and Y motors. In this manner, the desired laser beam intensity, given the speed of movement of the laser beam relative to the sheet stock, is controlled for proper energy delivery at the cutting point. This is necessary so that the appropriate amount of laser cutting power is supplied to the sheet metal stock depending on the speed of movement of the carriage on which the laser head is mounted.
While the size and lengths of duct fittings are infinite in number and variety, it has been discovered that rectangular duct construction fittings can be reduced to fifteen varieties of the four general construction types as illustrated in FIGS. 3-1-3-15.
FIGS. 3-1, 3-2 and 3-4 represent the fitting type generally referred to in the industry as an elbow, which is a fitting which turns ninety degrees. FIG. 3-3 represents a fitting which turns other than ninety degrees and is generally referred to in the industry as a bevel.
FIGS. 3-5, 3-6, and 3-7 represent various forms of the fitting type generally referred to in the industry as offset fittings. FIGS. 3-8 through 3-15 are generally referred to as transition fittings. They connect ducts of differing perimeter dimensions either in general linear alignment, such as in FIGS. 3-8 through 3-11 and 3-14 through 3-15 or in offset relationship, such as in FIGS. 3-12 and 3-13.
As is noted in FIGS. 3-8 through 3-15, it is possible to fabricate transition fittings either as two-piece constructions as shown in FIG. 3-8, three-piece constructions as shown in FIGS. 3-9 and 3-10 or four-piece constructions as shown in FIGS. 3-11 through 3-15.
Each side of the fitting is identified in FIG. 3 by the letters A, B, C and D. Curvature information, such as a throat radius, is identified as TR and throat length is identified as T1 and T2. End widths are identified as E1 and E2. Width and height are identified by WC and HC, respectively.
In the practice of the present invention, an operator will input information to the microprocessor 20 by typing on the keyboard an identification as to which type of fitting is desired. For example, by typing a "T", a transition fitting is identified, as an "O" for an offset fitting, or a "B" for a bevel fitting, or an "E" for an elbow fitting. The computer will then request dimensional information and, based upon the inputted dimensions, the computer will mathematically create the pattern shapes, as hereinafter more particularly explained, and then request information regarding the next piece.
In order to perform the selection process, the computer must mathematically create configurations which will, when combined, represent each side of the desired fitting and then compute the position of the patterns with respect to the stock material to result in least waste.
As illustrated in FIGS. 4A-4D all rectangular duct fittings, while varying in size, can be mathematically interpreted as one of three or four shapes. The four shapes indicated are schematic in nature. S1 and S2 in combination with L1 and L2 represent the size and lock allowances for interconnection of the fittings with straight duct work. See also FIG. 13.
By modifying the dimensions A-G in any of the fittings, all required shapes common to rectangular fittings can be described, mathematically optimized and plotted out on a sheet of material.
For example, in FIG. 4A modification of the angle B from an acute to an obtuse angle can create a semi-circle. Modifications of dimensions F and G in FIG. 4C can produce a rectangle.
As can be readily appreciated from the foregoing, in rectangular duct work all shapes can be produced on the basis of the four geometric figures illustrated; specifically, an annular segment of a circle as shown in FIG. 4A; dual interconnected annular segments of circles taken about centers of generation which are spaced from each other as shown in FIG. 4B; an approximate rhomboid as shown in FIG. 4C and an approximate trapezoid as shown in FIG. 4D. While it is noted that, as illustrated, FIG. 4C is not a true trapezoid, it should be readily apparent that a trapezoid is easily generated by modification, for example, of the dimensions of F and G.
It should also be noted that variations in the dimensions of FIG. 4C will permit the creation of shapes such as shown in FIG. 4D. However, it has been found that it is preferable to identify shapes in accordance with both FIGS. 4C and 4D as operators are generally those having some training in the duct fabrication industry and are more likely to recognize FIG. 4C as a transition offset combination fitting and FIG. 4D as a reducing transition configuration.
The present invention, further recognizing that opposite sides of rectangular fittings are similar in profile, provides a computer program or algorithm for optimizing the interpositioning of patterns relative to each other to create a fitting which can be mathematically expressed on the basis of four equations.
FIGS. 5 and 6 set forth in schematic presentation the positional arrangement of two patterns generated on the basis of FIG. 4A. As illustrated in FIGS. 5 and 6, E1 represents the width of a respective end of each of the patterns, E2 represents the respective width of the other ends; T1 represents a first throat length and T2 represents a second throat length; and TR represents the throat radius size. On the basis of the above information, the optimum distance between patterns, illustrated as X' can be determined as follows:
Triangle A B C is determined: ##EQU2##
Accordingly, the computer program stored in memory 10 will position patterns of the type shown in FIG. 5 so that the distance X' equals the specific value determined by the known geometric quantities.
FIG. 5 represents a first mathematical positioning of two patterns and FIG. 6 a second, the positions of FIG. 5 and 6 representing the only two comparisons required as they are the only two possible juxtapositions of curved parts which could yield the most optimized interfittings.
FIG. 7 represents the optimum positioning of patterns geometrically created on the basis of FIG. 4B with X' again representing the optimum distance between patterns. The solution for X' is set forth below.
KNOWN:
BA=HEEL RADIUS
DE=THROAT RADIUS
<G (solved for as being a direct function of the known degree of offset) ##EQU3##
Again, the patterns are positioned so that the distance X' uniquely determined by the known geometric quantities.
As hereinbefore noted, geometrically both the shapes of FIGS. 4C and 4D are based upon the same mathematical formulation. In a like manner, the optimized positioning of the patterns of each is the same and is illustrated in FIGS. 8 & 9 on the basis of the following:
KNOWN:
AF=STRAIGHT AT END 2
BG=STRAIGHT AT END 1
L=LENGTH OF FITTING
HE=STRAIGHT AT END 1
DE=OFFSET DISTANCE
BC=BG-AF
DA=L-(AF+HE)
Triangle ABC is similar to Triangle EAD ##EQU4##
FIGS. 10 & 11 set forth the method of determining optimized positioning of paired patterns of a geometric shape based upon FIG. 4A where the fitting will be a bevel type rather than an elbow type.
It has been discovered that if the throat height TD is less than one half the heel height HD as shown in FIG. 1D, the following formula is applicable:
KNOWN:
BA=THROAT RADIUS
D=ANGLE OF BEVEL
EA=WIDTH AT END 2
EB=EA-BA
In Triangle EBF: ##EQU5##
If however, throat height TD is greater than half the heel height HD as shown in FIG. 11, the following formula is applicable:
KNOWN:
BD=END 2 WIDTH
BA=THROAT RADIUS
F=STRAIGHT ON FITTING
T1=THROAT 1 LENGTH
T2=THROAT 2 LENGTH ##EQU6##
As hereinbefore noted, it is not merely the interpositioning of parts for optimizing material usage which must be considered but also, a critical factor is the ability to easily and efficiently separate the parts. Ideally, as many common edges as possible which permit a clear cutting path should be employed.
In accordance with the present invention it has been discovered that certain basic positions in combinations will yield a maximized material usage and cutting pattern. FIG. 12 schematically represents a hypothetical problem of positioning four mathematically created pattern shapes A, B, C and D which represent the components of a transition fitting.
Having created the mathematical patterns A, B, C and D, the various orientations of the patterns to each other are compared in accordance with the protocol set forth in the Table below. This Table represents, in graphic form, the information described in the program listing above with respect to the positioning of the patterns for optimizing material usage. For example, Table box A1 corresponds to position 1 above, Table box A8 corresponds to position 8 above, Table box B1 corresponds to position 9 above and Table box B8 corresponds to position 16 above, etc.
TABLE__________________________________________________________________________ ##STR1## ##STR2## ##STR3## ##STR4## ##STR5## ##STR6## ##STR7## ##STR8## ##STR9## ##STR10## ##STR11## ##STR12## ##STR13##__________________________________________________________________________
The orientation of the letters A, B, C and D represents the positions being computed. Thus, FIG. 12 illustrates the orientation of Table boxes B1 and B2.
As used in the above Table the numerals 1 or 2 represent an additional position rotation which has been found advantageous for patterns mathematically created on the basis of FIGS. 4C and 4D. The numeral 1 indicates that A and B will also be evaluated both in mirror image and in inverted mirror image. The numeral 2 indicates that C and D will be evaluated in mirror image and inverted mirror image.
The Table, with respect to patterns A, B, C and D, sets forth 96 basic arrangements (rows A-L×columns 1-8), but due to mirror image and reverse mirror image combinations, many more comparisons are made. Further, based upon the fact that certain kinds of construction permit a pairing of identical patterns or at least patterns with a single common edge, a number of comparisons are made as paired comparisons.
Thus, in instances where A and B can be combined and D and C can be combined and, as "doubles", compared one to the other, side to side or top to bottom, or a paired A and B could be combined with an individual C and D either in side by side relationship with respect to A and B generally or parallel to adjacent sides of the combined A and B or along a line beneath A and B, many additional combinations are possible. In all, 192 possible combinations are computed and the optimum position, once located, is selected. It must also be noted that other optimization schemes known in the art may also be utilized instead of the particular preferred optimization scheme described in detail here. Although the invented optimization scheme is particularly efficient, other, simpler techniques which require less computer memory capacity may be used, for example, the "outside rectangle" technique, wherein the rectangle within which each particular pattern fits is compared and optimized with the others. Additionally, once the technique for optimizing is described, such as is shown herein, it will be within the skill of one skilled in the art of computer programming to program a general purpose digital computer of sufficient memory capacity to accomplish the described optimization.
The letter E in the Table indicates an oversized pattern that cannot be rotated on the sheet material as one dimension is longer than the stock width. There are, as illustrated in Table boxes M1 through M8, eight additional possible basic positions relative to either an oversized A or B pattern as combined with C and D patterns with mirror images, and therefore eight additional basic positions are compared.
In all, the Table reflects 208 positions which mathematically compare those combinations which will yield the optimized material usage and severance with a minimum of cutting steps for all the patterns of a fitting on a sheet and which preferably lays out such patterns so that the patterns which make up the fitting can be separated as a group of patterns by a single, widthwise cut across the sheet material.
The sequential steps of the above-described selection is illustrated in the flowcharts shown in FIGS. 20A and 20B.
FIGS. 20A and 20B, taken together, are a flowchart of the program stored in memory 10. As shown, in response to a detailer's input of fitting type and dimensional data concerning the particular fitting, the computer will select the appropriate optimization routine based on the fitting type. As shown, if the fitting type is an elbow (shape #1) the program will enter the subroutine shown on the lefthand side of FIG. 20A. If the fitting type is one of the other three types, the program will enter the particular subroutine for that type fitting, as indicated on the right-hand side of FIG. 20A. For the sake of clarity, only the subroutine for one of the other fitting types is shown on the right-hand side of FIG. 20A, although there are other subroutines as discussed above for the remaining fitting types. The program will then cycle through the entire subroutine for the particular fitting type and select the optimum arrangement for the positioning of two patterns of the fitting. At this point, only two sides of the fitting have been optimized in accordance with the mathematical relations described above with respect to FIGS. 5 through 11.
Once the optimum A and B combination has been obtained, the program then selects the remaining sides of the fitting. The remaining sides can never be in the shape of an elbow or bevel fitting if the A and B sides are already configured as elbows or bevel fittings. The program then repeats the subroutines on the right-hand side of FIG. 20A for the remaining sides of the fitting and selects the optimum combination in accordance with the mathematical relations described earlier.
The two combinations thus obtained are then compared as shown in FIG. 20B. FIG. 20B is an abbreviated version of the optimization steps shown in the Table and program listing above. The lefthand side of FIG. 20B shows a number of optimization steps wherein "doubles" or the groupings of two pattern sides are compared to each other. Although only eight comparisons are shown for sake of clarity, the program will cycle through all the steps indicated in the Table or program listing above.
In addition to comparing "doubles", the combination of a "double" with individual ones of the remaining patterns is also tried, as shown by the right-hand side of FIG. 20B. This is also indicated in the above chart by optimization steps D1 through D8, G1 through G8 and J1 through J8.
The reason why this is done is related to the heating and ventilating industry. Of the 4 fitting types described--both the elbow or bevel (FIG. 4A) and the radius offset (FIG. 4B) are such that the remaining two sides will virtually always be rectangles, appropriately bent to shape, and offer little, if any combined optimization.
In the 2 remaining fitting types, offset (FIG. 4C) and converging transition fittings (FIG. 4D), it is common practice to present the fitting in its most dramatically offset or converging view, so that the angular variance (and potential optimization) is normally greatest in the top and bottom pieces. The results of this is that far less optimization saving can be expected in the combining of side pieces as compared to the top and bottom pieces.
Due to the limitations of standard industry stock sizes, it is often impossible to accommodate two "pairs" of combined blanks and it becomes practical to also compare the side pieces individually to the top and bottom combination.
Through this procedure it is insured that the sides (offering less optimization saving) are given priority if separation is required.
Once the optimum stock selection for the particular fitting entered is determined, the resultant "stock length" is evaluated with the previous piece processed to determine if it will also fit on the same stock cut up to the table length maximum, which is normally about 8 to 10 feet long.
Should it be such that the stock for two or more fittings is less than the stock length maximum, it becomes practical to have as many such fittings as possible plotted or cut out of one large length of stock to save cutting and handling time. This is accomplished by adjusting the "starting point" of each plot, to be described later.
If the piece being processed can also fit on the same blank in the X direction or plotting table maximum length, the X dimension of each pattern starting point is increased by the length of the previous piece plotted.
Should two pieces or more be possible to combine across the Y direction (shorter stock width--usually approximately 5 feet), the Y dimension of each starting point is increased by the total Y dimension of the previous piece plotted.
Once the optimum arrangement has been selected, the data is transmitted, either directly or via another medium, such as paper tape, to the plotting table 120.
The benefit of the present invention illustrated using as an example the transition fitting shown in FIG. 13. Prior to the present invention, a technician would be provided with basic dimensional information for each of the four sides of the fitting. The technician would either hand sketch a drawing or fill in the dimensions on a pre-printed form. The form would then be passed to a skilled technician who, employing mathematics, charts and drafting tools, would compute the exact pattern size for each of the four parts with allowances for a pitch or angle. Assuming the technician selects the correct stock, which, in the example of FIG. 13 is a 48 inch wide sheet, the patterns would have been laid out and cut. The prior art layout is shown in FIG. 14 and assuming appropriate skill by the technician, these patterns could be laid out in approximately 15 minutes and use approximately 38.41 square feet of sheet metal.
In accordance with the present invention, the same information which was handwritten and given for the initial sketch is provided to an operator who inputs the same by answering a series of questions which request the data. The operator merely identifies the type of fitting, which in this case is a transition fitting and the computer requests sequentially the dimensions required to create the fitting according to the program stored in memory. In accordance with the present invention, the appropriate sheet stock is selected and the entire plotting time is 15 seconds with a material usage of 31.75 square feet. The layout in accordance with the present invention is shown in FIG. 15.
In addition to optimizing the usage of the sheet material, the microprocessor is programmed to identify groups of patterns of a common job lot so that a job lot can be identified and an inventory created. It lists the patterns in the order they are to be plotted on the plotting table and, where fabricators have numerical control tape readers at the coil line which feeds out the sheet material, the computer can also punch out a tape to directly operate the metal feed onto the plotting surface.
Referring to FIG. 16, there is illustrated schematically, a preferred form of the invention including a coil line feed 100 which feeds coil from the coil line 102 to the plotting table 103. A first length 104 if metal required to form the first fitting is advanced by the coil feed 100 onto the plotting table 103. The plotting table 103 is particularly configured for use with sheet metal. A series of electromagnetic devices 105, preferably a series of fifteen, are built into the surface of the plotting table 103 to securely retain the sheet metal against untoward movement during the plotting step. Where the fabrication material does not lend itself to magnetic securement, such as where the material is aluminum or fiberglass, other securement means such as clamps or vacuum tubes (not shown) may be employed.
The top of the plotting table is preferably made of a material such as stainless steel, which can withstand the weight and wear of sheet metal and preferably is scribed or etched so that it contains indicia conforming to standard widths of stock sheet ordinarily used in the industry. The coil feed mechanism 100, having advanced the length of metal required for the laying out of a first fitting, a plotter, which operates in accordance with the data generated by the microprocessor either directly or through a paper tape input, plots out the patterns required for the fitting.
Preferably an X-Y plotter of the type customarily used for drawing or plotting lines or other information on a sheet of paper or the like is employed, with a pen, scribe or printing mechanism of the type which will write on sheet metal being carried by a carriage 106. The carriage 106 is supported for movement relative to the plotting table 103 in the direction of the X axis and movable relative to the carriage in the Y axis.
By moving the carriage 106 relative to the top of the plotting table and by moving the scribe relative to the carriage 106, the patterns can be drawn on the sheet metal.
Once a first set of patterns for a fitting has been laid out, the coil line feed mechanism 100 advances a further length of metal required for a second fitting. Plotting of the second fitting is now accomplished in the same manner as that of the first.
A separating mechanism, often in the form of a flying shear (not shown) separates the first set of patterns which made up the first fitting and the same can be cut and assembled either at the fabricator's plant or on site. The separating mechanism may either precede or follow the plotting table.
For those fabricators who do not have automatic coil line feeding, pre-cut sheets of metal, cut in accordance with the instructions provided by the microprocessor, may be placed on the plotting table and laid out in the manner heretofore described.
FIG. 19 illustrates a typical positioning of patterns on the plotting table in accordance with the present invention. Spaces between patterns are shown for clarity, but as actually laid out, the patterns having common lines touch so that a single cutting severs a side or a portion of the side of two patterns. In FIG. 19, a plurality of groupings of patterns (1A-1D; 2A-2D; 3A-3D and 4A-4D) for four fittings are shown, with a single widthwise severance of the sheet metal possible to effect the severing of a group of patterns which comprise an individual fitting.
The data read from information retrieval device 50 is fed to the X-Y plotting table 103 in sequential form. For each pattern or side of the fitting, a starting reference point is established. All data with respect to the outline of the pattern is based upon this starting point. The data is transferred in block format. A first block includes digital data concerning the location of the reference or starting point for the first pattern to be marked or cut. Once the reference or starting point has been determined, the marking or cutting device moves to this location on the plotting table. The next block of data gives information in digital form concerning the X and Y movement of the plotting head from the starting point. The plotting head moves in small straight line increments, although these increments are too small to result in any noticeable disparity from the desired pattern. Thus, the curved side patterns of an elbow fitting are actually formed by a large series of interconnected line segments. Once one pattern has been marked or cut, the next pattern of the same fitting is marked or cut. Again, a starting or reference point is first obtained and all the remaining points are then plotted.
FIG. 17 illustrates the apparatus of the present invention further including laser cutting means. As illustrated, a laser beam generating apparatus is provided and initiates a laser beam which is operably linked to the carriage 106 through use of mirrors which are preferably water cooled (not shown). As illustrated in FIG. 18, in lieu of a scribing instrument, a laser cutting attachment 201 is affixed to the carriage. The laser beam 202 is directed by mirror 203 through a series of lenses 204 through a nozzle 205 so that a focused laser beam will sever the sheet metal. Preferably the laser is a CO 2 laser with the gas inlet illustrated by 206.
The laser beam is shielded by beam covers 207 and 28 with the beam cover 208 carried by the carriage 106.
The energy required for the laser to cut (melt; atomize) must be coordinated with the speed at which the material is being cut. As hereinbefore described, the plotter employs two independently driven motors, one for the X-axis movement and one for the Y-axis movement. The speed of each motor will vary in accordance with the angle or curve of the line being described.
By providing a linear power output signal for the laser which is related to the combined speeds of the X and Y axes motors, the intensity of the laser beam can be modified and, as modified, correlated to the plotting movement of the nozzle of the laser as it traverses the plotting table as carried by the carriage 106.
In order to laser-cut the material on the plotting table a space separation is provided to permit energy focus, and this is illustrated in FIG. 18, where grid separators 300 support and maintain the sheet metal 302 in spaced-apart relationship from the steel table top 301. The space which is so provided allows for sufficient dissipation of the energy of the laser to avoid injury to the top 301 and yet allows sufficient energy to be focused at the sheet metal 302 to permit cutting.
Examples of components which can be used to implement the preferred embodiment of the invention include the following:
10--32K non-volatile RAM or Magnetic Core storage;
20--Digital Equipment Corp. Model 8A400;
30--Digital Equipment Corp. Model LA120 printer/keyboard
40--Digital Equipment Corp. TU--60 magnetic tape unit and PC--8--E paper tape punch/reader;
50--Gerber 4000 controller with paper tape reader;
60--part of LA 120 printer/keyboard;
70, 80, 90, 95 and 110--Coil Line feed controller and cutter (Iowa Precision Instruments);
120--Gerber 77 Plotting Table and Model 4000 controller modified as discussed herein;
122, 124, 130, 140 and 150--Coherent Model 46 CO 2 Laser Cutter and Controller modified as discussed herein.
There is thus provided a method apparatus by which an operator, ordinarily unskilled in the field can, in response to simple requests posed by a computer, provide basic pattern type and dimensional information which, in accordance with the program or algorithm of the present invention, will yield the patterns required for creation of a three-dimensional duct fitting, which patterns are laid out in a spatial relationship and which optimizes the use of material; positions all components of a fitting into relative juxtaposition; provides optimized cutting paths so that the least amount of cuts need be made to separate the patterns; preferably provides indicia to identify the patterns and the job to which they relate; preferably separates the patterns either in the form of individual patterns or by a single widthwise cut into a group of patterns which together form a fitting; and preferably provides hard copy information for use for on-the-job fabrication. The entire operation is accomplished with greater accuracy than heretofore permitted even with the intervention of the most skilled artisan and in a fraction of the time heretofore required.
It will be understood that the above description is exemplary of that which falls within the scope of the appended claims and that various modifications may be made without departing from the scope of the invention. | The present invention relates to a method and apparatus for creating, laying out and cutting patterns on laminar sheet material having particular application to air handling ducting which permits the fully automated creation of the patterns required to subsequently construct three-dimensional products such as fittings, which have heretofore only been designed by skilled technicians. Information representative of the geometric configurations of a group of basic pattern types, including mathematical relationships, is stored in digital form in a memory. From the basic pattern types, substantially all variations of the three-dimensional product can be developed. An operator specifies the type of fitting required and inputs selected actual basic dimensions of the product, the basic dimensions being those dimensions necessary to specify the overall dimensions of the product. The patterns for the closed sides of the product are developed from the mathematical relationships specifying the geometry of the basic pattern types in response to the input basic dimensions. The patterns so developed are then computed for optimum positioning with other developed patterns, most preferably with alignment of similarly shaped edges for sheet material optimization, and preferably with adjacent grouping of the patterns for each end product to facilitate location and assembly and, most preferably, in such a manner that each grouping can be severed from the sheet material with a single cut to facilitate use of sheet or coil stock shearing machinery. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S. Provisional Application Serial No. 60/025,858, filed Sep. 9, 1996, and entitled Improved Rock Drill Bit, which is incorporated herein by reference, and of U.S. Provisional Application Serial No. 60/051,373 filed Jul. 1, 1997, and entitled Protected Lubricant Reservoir For Sealed Bearing Earth Boring Drill Bit.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] The invention relates generally to sealed bearing earth boring drill bits, such as rotary cone rock bits, that utilize a fluid circulation medium. More particularly, the invention relates to such drill bits that include a protected lubricant reservoir.
[0004] More specifically, drill bits are generally known, and fall into at least two categories. Drill bits used for drilling petroleum wells and drill bits used in the mining industry are both well known in the art. While these two types of bits superficially resemble each other, the parameters that affect the operation of each are completely different. Petroleum drill bits typically use a viscous, heavy drilling fluid (mud) to flush the cuttings from the vicinity of the bit and carry them out of the hole, whereas mining bits typically use compressed air to achieve the same purpose. Petroleum bits typically drill deep holes, on the order of thousands of feet, and an average bit typically drills several hundreds or thousands of feet before being removed from the hole. In many instances, a petroleum bit is not withdrawn from the hole until it has exhausted its useful life. In contrast, mining bits are each used to drill several relatively shallow holes, typically only 30-50 feet deep, and must be withdrawn from each shallow hole before being shifted to the next hole. Thus, the effect of withdrawal and backreaming wear on the body of a mining bit are much more important considerations than they are for petroleum bits. In addition, because petroleum bits drill near the surface they are more frequently subjected to cave-ins, and must ream their way backwards out of the hole through the caved-in material. For these reasons, the factors that affect the design of mining bits are very different from those that affect the design of petroleum bits.
[0005] For instance, the viscosity and density of the drilling mud makes it possible to flush the cuttings from the hole even at relatively low fluid velocities. The air used to flush cuttings from mining holes, in contrast, is much less viscous and dense and therefore must maintain a rapid velocity in order to successfully remove the rock chips. This means that the cross-sectional area through which the air flows at each point along the annulus from the bit to the surface must be carefully maintained within a given range. Similarly, the rapid flow of air across and around a rock bit greatly increases the erosive effect of the cuttings, particularly on the leading portions of the bit.
[0006] Furthermore, rock bits are now being developed with sealed lubrication systems that allow easier rotation of the bit parts. These sealed lubrication systems typically comprise a lubricant reservoir in fluid communication with the bearings. In many cases, the reservoir is created by drilling a cavity into the bit leg. Access to the reservoir is through the installation opening of this cavity, which can then be sealed with a conventional plug or vented plug. These sealed lubrication systems are particularly vulnerable to erosion of the bit body, as any breach of the sealed system can result in the ingress of cuttings and/or particles into the bearings, causing bit failure. Heretofore, the reservoir opening has been located on the main outer face of each leg, with the result that the reservoir plugs and the walls of the reservoir itself are vulnerable to wear on the leg.
[0007] Hence it is desirable to provide a mining bit that provides increased protection for the reservoir and its installation opening and plug. It is further desired to provide a bit that is capable of withstanding wear on its shoulders and legs during backreaming or as the bit is being withdrawn from a hole.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] For a detailed description of the preferred embodiments of the invention, reference will now be made to the accompanying drawings wherein:
[0009] [0009]FIG. 1 is an isometric view of a rotary cone drill bit of the present invention;
[0010] [0010]FIG. 2 is a side view of one leg of the drill bit of FIG. 1;
[0011] [0011]FIG. 3 is a cross-sectional view of a rotary cone drill bit of the prior art in a bore hole;
[0012] [0012]FIG. 4 is a front elevation view of one leg of a rotary cone drill bit having a first embodiment of a protected lubricant reservoir;
[0013] [0013]FIG. 5 is a cross-sectional view at plane 5 - 5 in FIG. 4;
[0014] [0014]FIG. 6 is a front elevation view of one leg of a rotary cone drill bit having a second embodiment of a protected lubricant reservoir;
[0015] [0015]FIG. 7 is a front elevation view of one leg of a rotary cone drill bit having a third embodiment of a protected lubricant reservoir;
[0016] [0016]FIG. 8 is a front elevation view of one leg of a rotary cone drill bit having a fourth embodiment of a protected lubricant reservoir;
[0017] [0017]FIG. 9 is a cross-sectional view at plane 9 - 9 in FIG. 8;
[0018] [0018]FIG. 10 is a front elevation view of one leg of a rotary cone drill bit having a fifth embodiment of a protected lubricant reservoir;
[0019] [0019]FIG. 11 is a cross-sectional view at plane 11 - 11 in FIG. 10;
[0020] [0020]FIG. 12 is a cross-sectional view of one leg of a rotary cone drill bit having a sixth embodiment of a protected lubricant reservoir;
[0021] [0021]FIG. 13 is an exploded view of the protected lubricant reservoir of FIG. 12;
[0022] [0022]FIG. 14 is a cross-sectional view of one leg of a rotary cone drill bit having a seventh embodiment of a protected lubricant reservoir;
[0023] [0023]FIG. 15 is a cross-sectional view of one leg of a rotary cone drill bit having an eighth embodiment of a protected lubricant reservoir;
[0024] [0024]FIG. 16 is a cross-sectional view of a rotary cone drill bit having a ninth embodiment of a protected lubricant reservoir;
[0025] [0025]FIG. 16 a is a cross-sectional view at plane 16 a - 16 a in FIG. 16;
[0026] [0026]FIG. 17 is a cross-sectional view of a rotary cone drill bit having a tenth embodiment of a protected lubricant reservoir;
[0027] [0027]FIG. 18 is a cross-sectional view of one leg of a rotary cone drill bit having an eleventh embodiment of a protected lubricant reservoir;
[0028] [0028]FIG. 19 is a front elevation view of one leg of a rotary cone drill bit having a twelfth embodiment of a protected lubricant reservoir;
[0029] [0029]FIG. 20 is a front elevation view of one leg of a rotary cone drill bit having three protected lubricant reservoirs in accordance with the present invention; and
[0030] [0030]FIG. 21 is a cross-sectional view of one leg of a rotary cone drill bit having yet another embodiment of a protected lubricant reservoir.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] Presently preferred embodiments of the invention are shown in the above-identified figures and described in detail below. In illustrating and describing the preferred embodiments, like or identical reference numerals are used to identify common or similar elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic form in the interest of clarity and conciseness.
[0032] Referring initially to FIGS. 1 - 2 , a sealed-bearing earth boring bit 10 is shown. The bit 10 illustrated is a rotary cone rock bit used for drilling blast holes in mining operations that utilizes fluid circulation to cool and clean the bit 10 and to transport earthen cuttings and debris up the bore hole to the surface (not shown). It should be understood that the present invention is not limited to rotary cone rock bits 10 for mining operations, but may be used in other types of sealed bearing earth boring drill bits for any other desirable earthen drilling applications, such as petroleum well, pipeline, sewage and electrical conduit drilling.
[0033] The bit includes a bit body 12 , a pin end 14 and a cutting end 16 . The pin end 14 includes a connector 13 , such as a threaded pin connection 15 , for connecting the bit 10 to a carrier, such as a drill string (not shown). The bit body 12 includes legs 20 extending generally between the pin end 14 and the cutting end 16 of the bit 10 . At the cutting end 16 , each leg 20 carries a cutter cone 18 having a multitude of protruding cutting elements 19 for engaging the earthen formation and boring the bore hole 17 as the bit in rotated in a clockwise direction when viewed from the pin end 14 . Typically, rotary cone drill bits 10 have three legs 20 and cones 18 , although the present invention may be used in bits 10 with any number of leg 20 /cone 18 combinations. While portions of the description of the preferred embodiments of the present invention are made herein with reference to a single leg 20 , such discussions apply equally to each leg 20 of a bit 10 in accordance with the present invention.
[0034] Still referring to FIGS. 1 and 2, a plenum 80 , having a plenum surface 82 extends through the bit 10 to allow the supply of circulation fluid (not shown) to one or more nozzles 84 formed in legs 20 , as is known in the art. The circulation fluid, such as gas or drilling mud, is provided into the plenum 80 from a fluid supply source (not shown) and through a supply conduit, such as a drill string (not shown), attached to the pin end 14 of the bit 10 . Each nozzle 84 extends from the plenum 80 to a port 86 , which opens to the exterior 70 of the bit 10 , as is known in the art. A nozzle boss 90 is disposed on the leg 20 over the nozzle 84 . The nozzles 84 operate to direct pressurized fluid against the bottom 71 of the bore hole 17 (FIG. 3) to lift earthen cuttings and other debris up through the bore hole 17 . The nozzles 84 also direct the circulation fluid over the cones 18 and cutting elements 19 to free debris accumulating thereabout.
[0035] Now referring to FIG. 5, the bit 10 includes a bearing system 50 for permitting rotation of the cone 18 about a journal 23 extending from the leg 20 . The bearing system 50 may be a roller bearing system 50 a , as is, or becomes, known in the art, such as the roller bearing system disclosed in U.S. Pat. No. 5,793,719 to Crockett et al., which is incorporated herein by reference in its entirety. The roller bearing system 50 a includes various conventional roller bearing components, such as, for example, cone bearing surfaces 52 , journal bearing surfaces 54 , roller bearings 56 and locking balls 58 , disposed in the interior 59 of the cone 18 . A roller bearing system 50 a compatible for use with the bit 10 of the present invention is also shown with respect to the prior art bit 10 a of FIG. 3. Alternately, the bearing system 50 may be a friction bearing system 50 b (FIG. 9) including conventional friction bearing system components as are or become known in the art. In either type of bearing system 50 a , 50 b , a locking ball loading hole 57 may be formed into the leg 20 for loading the locking balls 58 into the cone interior 59 . A ball retaining plug 55 (FIG. 9) is typically disposed in the hole 57 for retaining the locking balls 58 .
[0036] Referring to FIG. 9, lubricant, such as grease (not shown), is provided to the roller bearing system 50 via a lubricant reservoir system 60 . A reservoir system 60 compatible for use with the bit 10 of the present invention is also shown with respect to the prior art bit 10 a of FIG. 3. The reservoir system 60 includes one or more reservoirs 62 disposed in the bit 10 for supplying the lubricant to the bearing system 50 , such as through a lubricant passageway 68 . Any desirable number of reservoirs 62 can be disposed in a single leg 20 or elsewhere in the bit 10 . For example, FIG. 20 shows a leg 20 having three reservoirs 62 , while FIGS. 15 - 17 show lubricant reservoirs 62 disposed in the bit plenum 80 . While the following description of the preferred embodiments of the present invention is made, in part, with respect to a single reservoir 62 , it may be applied equally to each reservoir 62 of a multiple reservoir leg 20 , or bit 10 .
[0037] Still referring to FIG. 9, the reservoir 62 typically contains various reservoir system components as are known in the art, such as, for example, a flexible membrane 64 that balances the pressure between the exterior 70 of the bit 10 and the lubricated, or lubricant carrying, side 66 of the bit 10 . It should be understood, however, that the inclusion or non-use of reservoir system components in the reservoir 62 is not limiting on the present invention. To allow the 20 insertion, or loading, of the lubricant and reservoir system components into the reservoir 62 during assembly of the bit 10 , one end 76 of the reservoir is initially left accessible through a reservoir installation opening 63 . After the lubricant and: reservoir system components are inserted, or loaded, into the reservoir 62 , the installation opening 63 is typically sealed and covered, such as, for example, with a reservoir cover cap 74 held in place with a retaining, or snap, ring 75 for retaining the lubricant and reservoir system components in the reservoir 62 (see also the prior art bit 10 a of FIG. 3). The opposite end 77 of the reservoir 62 typically forms a blind hole in the leg 20 (FIG. 11).
[0038] Again referring to FIG. 9, the reservoir system 60 may be configured to relieve the expansion, or excess volume, of lubricant (not shown) contained therein. Again, any suitable technique or mechanism as is or becomes known in the art may be utilized. For example, the reservoir 62 can be configured such that there is sufficient space (not shown) in the reservoir 62 for the lubricant to expand therein, as is known in the art. For another example, excess lubricant in the reservoir system 60 may be vented from the reservoir 62 . Any suitable conventional technique may be used. For example, excess lubricant can be vented through the flexible membrane 64 , as is known in the art. Another example of venting excess lubricant from the reservoir system 60 , as shown in FIG. 9, is through a vent duct 94 extending from the reservoir 62 to the bit exterior 70 , in accordance with the present invention. According to the present invention, the opening of vent duct 94 can be located on the throat surface, the leading surface, the trailing surface, the shoulder surface, or the center panel surface, although it is preferred that the vent duct opening not be on the same surface as installation opening 63 . A control device, such as a conventional pressure relief valve 96 , may be included to enable the controlled venting of lubricant from the reservoir system 60 .
[0039] It should be understood that the aforementioned operations, configurations, components and methods have been provided to assist in understanding the context of the invention and are not necessary for operation of the invention.
[0040] Now referring to FIG. 1, each leg 20 of the bit body 12 of the bit 10 of the present invention includes a leading side 30 , a trailing side 36 , a shoulder 40 and a center panel 46 . The leading side 30 has an outer surface 32 , the trailing side 36 has an outer surface 38 , the shoulder 40 has an outer shoulder surface 42 and the center panel 46 has an outer backturn surface 48 . Surfaces 32 , 38 , 42 , 48 form part of the outer surface 100 of the leg 20 . In the embodiment shown, for example, the leading side surface 32 extends generally from the lower end 21 of the connector 13 to the lower edge 26 of the leg 20 between the edges 45 , 47 of the center panel 46 and shoulder 40 , respectively, and the edge 49 of the leg 20 . The trailing side surface 38 extends generally from the lower end 21 of the connector 13 to the lower edge 26 of the leg 20 between edge 91 of the nozzle boss 90 and edges 43 , 44 of the center panel 46 and shoulder 40 , respectively. The shoulder surface 42 is shown extending from the lower end 21 of the connector 13 to the upper edge 51 of the center panel 46 between the leading and trailing sides 30 , 36 at edges 47 , 44 , respectively. Finally, the backturn surface 48 extends between edges 45 , 43 and 51 and the lower edge 26 of the leg 20 .
[0041] Still referring to FIG. 1, as the bit 10 rotates during operations, the leading side 30 of each leg 20 leads the clockwise rotational path of the leg 20 followed by the shoulder 40 and center panel 46 , which are followed by the trailing side 36 . During drilling, as well as extraction of the bit 10 from the bore hole 17 (FIG. 2), the bit legs 20 will contact earthen cuttings (not shown) in the bore hole 17 and may also contact the bore hole wall 72 (FIG. 2). Generally, the leading side 30 , leg shoulder 40 and center panel 46 of each leg 20 will experience such contact, while the trailing side 36 is substantially blocked from significant contact with earthen cuttings and the bore hole wall 72 by the surfaces 32 , 42 and 48 and the leg mass 29 . Depending on various factors, such as the composition of the earthen formation being drilled, contact between the surfaces 100 of the legs 20 and earthen cuttings (and the bore hole wall) will cause varying degrees of wear and damage to the legs 20 . During backreaming in hard, or rocky, earthen formations, for example, the legs 20 , particularly the leg shoulders 40 and leading sides 30 , may be subject to significant contact with rock cuttings, causing significant erosive wear, cracking and fracturing of the bit legs 20 .
[0042] Referring to the prior art bit 10 a of FIG. 3, it is a concern that damage to the bit legs 20 as described above can lead to damage to the lubricant reservoir 62 , which can lead to premature bit failure. For example, the introduction of foreign material, such as earthen cuttings, into the reservoir or bearing systems 60 , 50 , will lead to contamination and deterioration of the lubricant and the reservoir and bearing system components, causing premature bit failure. It is thus an object of the present invention to provide improved protection of the reservoir 62 and reservoir opening 63 from damage caused by contact between the bit 10 and earthen cuttings (and the bore hole wall) during drilling and bit extraction.
[0043] In prior art bits 10 a , as shown in FIG. 3, the reservoir installation opening 63 was typically located on the leg shoulder 40 , or across the intersection of the shoulder and center panel (not shown), facing angularly upwardly relative to the bore hole wall 72 , or from the central axis 11 of the bit 10 a . For example, a typical prior art bit reservoir opening 63 located on the shoulder 40 was oriented with its axis at an angle 31 of about 75 degrees or less relative to the central axis 11 of the bit 10 a . The prior art reservoir opening 63 orientation has been known to subject the reservoir opening 63 and reservoir 62 to damage as described above, particularly during backreaming.
[0044] It should be understood that each of the following aspects of the invention may be utilized alone or in combination with one or more other such aspects. In one aspect of the invention, the installation opening 63 is accessible from the outer leg surface 100 , but located so as to decrease the susceptibility of the reservoir 62 and opening 63 to damage from contact between the leg 20 and bore hole debris, or the bore hole wall 72 (FIGS. 4, 7, 8 ). The installation opening 63 can be disposed anywhere on the leading side 30 (FIG. 7), trailing side 36 (FIG. 4) or center panel 46 (FIG. 8). In accordance with this aspect, as the bit 10 rotates in the bore hole 17 , particularly during extraction and backreaming, the reservoir installation opening 63 is generally more substantially blocked, or protected, from contact with the bore hole wall 72 and earthen cuttings in the bore hole 17 by the leg mass 29 , as compared to the prior art location of the installation opening 63 on the leg shoulder 40 (FIG. 3). In the preferred embodiments shown, the reservoir installation opening 63 is disposed above the bit throat level 22 . The “bit throat level” 22 refers to the cross-section of each leg 20 and the bit 10 taken generally along line 27 (FIG. 2), which extends proximate to the level of the nozzle ports 86 . The “bit throat” 33 , also shown in FIG. 2, refers to the interior, or facing, portions of each leg 20 between its lower edge 26 and the lower end 81 of the bit plenum 80 . However, the opening 63 may, in accordance with this aspect of the invention, also be disposed at, or below, the bit throat level 22 .
[0045] In another aspect of the invention, the reservoir 62 may be oriented so that the installation opening 63 is on the outer surface 100 of leg 20 , but is oriented on the shoulder 40 (FIG. 21) so that it axis is at an angle 31 of between about 76 degrees and about 180 degrees relative to the central axis 11 of the bit 10 , or disposed at any angular orientation anywhere on the leading side 30 (FIG. 7), trailing side 36 (FIG. 4), or center panel 46 (FIG. 8) of leg 20 . For example, the opening 63 in FIGS. 4 and 7 are on the trailing and leading sides 36 , 30 , respectively, oriented generally perpendicularly relative to the central axis 11 of the bit 10 , respectively. In FIG. 21, the opening 63 is oriented at an angle 31 of about 81 degrees relative to the central axis 11 of the bit 10 .
[0046] In a further aspect of the invention, as shown, for example, in FIGS. 4, 7 and 8 , the reservoir 62 and installation opening 63 may be isolated from contact with bore hole debris and the bore hole wall by recessing the installation opening 63 into the leg 20 . The reservoir opening 63 of the leg 20 of FIG. 4, for example, is shown recessed into the trailing side 36 of the leg 20 , while the opening 63 of FIG. 7 is recessed in the leading side 30 . In FIG. 8, the reservoir installation opening 63 is shown recessed into the center panel 46 . The installation opening 63 thus lies recessed relative to the shoulder and backturn surfaces 42 , 48 , respectively, and is shielded thereby and by the leg mass 29 . Further, the leg 20 may be configured so that the shoulder 40 serves as a protective ledge above the installation opening 63 , as shown, for example, in FIG. 9. In FIG. 9, the shoulder 40 extends radially outwardly from the leg 20 toward the bore hole wall 72 relative to the reservoir opening 63 by a distance 79 equal to between about 50% and about 100% of the exposed radial dimension 78 of the reservoir opening 63 , substantially blocking the reservoir opening 63 from contact with bore hole debris during backreaming.
[0047] In yet another aspect of the present invention, a protective plug 110 may be emplaced over the reservoir opening 63 , as shown, for example, in FIGS. 7 , 10 - 13 . The plug 110 protects the installation opening 63 and reservoir 62 by serving as an outer contact and wear surface and by absorbing impact energy from contact with bore hole debris and the bore hole wall 72 (FIG. 11). The plug 110 may be any suitable size and configuration, and may be constructed of any suitable material having strength, or wear, characteristics similar to, or better than, steel. For example, referring to FIG. 13, the plug 110 may have a thickness 152 of about 10% or greater of its diameter or smallest width 154 . Any suitable technique may be used to connect the plug 110 to the bit 10 , such as by welding, matable members or mechanical connectors (not shown). Still referring to FIG. 13, the bit 10 may be configured so that the plug 110 rests upon a plug base 112 formed into the leg 20 , whereby the base 112 absorbs energy from impact force to the plug 110 during drilling and bit extraction. Further, a gap 113 may be formed between the plug 110 , or plug base 112 , and reservoir opening 63 to allow space for the accumulation of excess lubricant from the reservoir 62 , or to isolate the reservoir 62 from the plug 110 . A bleed hole (not shown) may be formed in the plug 110 , or the leg 20 , and extends to the exterior 70 of the bit 10 to allow the venting of excess lubricant from the gap 113 .
[0048] Alternately, the installation opening 63 may be entirely isolated from the outer surface 100 of the legs 20 , as shown, for example, in FIGS. 14 - 18 , to reduce the susceptibility of damage to the reservoir 62 and opening 63 from contact between the bit 10 and bore hole debris or the bore hole wall 72 . FIGS. 14 - 17 , for example, show the reservoir 62 configured so that the reservoir opening 63 opens to the bit plenum 80 . In FIG. 14, the reservoir 62 and installation opening 63 are accessible via the plenum 80 and communicate with bearing system 50 of leg 20 , such as through lubricant passageway 68 . The reservoir 62 is shown as a reservoir housing 65 disposed in a cavity, or receiving pocket, 69 formed in the leg 20 . The housing 65 may be any suitable container, such as a canister, having any form and construction suitable for use as a reserved 62 is described above or as known in the art. When a housing 65 is used, it is inserted into the cavity 69 or otherwise formed into bit leg 20 during assembly of the bit 10 and may be connected to the bit 10 with any suitable conventional technique, such as a threaded matable connector 101 , retaining rings, pins, or by weld (not shown). The reservoir 62 , however, need not be a housing 65 , but can take other suitable forms. For example, the cavity, or receiving pocket, 69 can itself be used as the reservoir 62 .
[0049] In FIGS. 15 - 17 , the reservoir 62 , such as housing 65 as described above, is located within the bit plenum 80 . The reservoir housing 65 is mounted to the plenum surface 82 with pins 98 (FIG. 15), brackets 99 (FIG. 16, 16 a ) or any other suitable conventional technique, such as by weld or retaining rings (not shown). The reservoir 62 may be capable of supplying the bearing system 50 of a single leg 20 , as shown, for example, in FIG. 15, or multiple legs (FIGS. 16, 17). Further, the reservoir system 60 , such as shown in FIGS. 15 and 16, may include tubes 104 that connect the reservoir 62 with the leg bearing systems 50 , such as through passageways 68 . As illustrated in FIG. 16 a , the reservoir system 60 may have numerous tubes 104 for supplying lubricant to numerous bit legs (not shown).
[0050] Referring to the embodiment shown in FIG. 17, the reservoir 62 may be located generally proximate to the lower end 81 of the plenum 80 and in direct communication with the passageways 68 of legs 20 for supplying lubricant to the bearing systems 50 . The reservoir 62 , such as housing 65 , may be easily installed into an assembled bit 10 by inserting the reservoir 62 into the plenum 80 at the pin end 14 of the bit 10 and securing it with any suitable conventional technique, such as with a centralizing ring 120 , or by weld. Alternately, the reservoir 62 may be easily installed through a bore 162 in the lower end 81 of the plenum 80 . Using this method, once the reservoir 62 is positioned as desired, the bore 162 and reservoir 62 may be welded together at the lower end 81 of the plenum 80 to secure the reservoir 62 in the bit 10 and, if desired, to substantially seal the plenum 80 .
[0051] When the installation opening 63 opens to the bit plenum 80 , such as shown in FIGS. 14 - 17 , the reservoir system 60 may be configured to allow the flow of circulating fluid through the entire length of the plenum 80 . For example, a gap 88 (FIGS. 15, 16) can be formed between the reservoir 62 and the plenum surface 82 . For another example, the reservoir 62 can include a fluid bypass annulus (not shown), such as when the reservoir 62 is formed with a donut-shape (not shown).
[0052] Excess lubricant may be vented from the reservoir system 60 with any suitable technique, such as those described above, if venting is desired. For example, excess lubricant may be vented through a vent passage 94 extending from the passageway 68 (FIGS. 14 - 16 ) to the bit exterior 70 . Excess lubricant may additionally, or alternately, be vented from the reservoir 62 into the plenum 80 (FIGS. 15, 16) or to the bit exterior 70 (FIG. 17), such as through a vent hole 87 in the reservoir housing 65 . Further, the vent passageway 94 or vent hole 87 may be equipped with a control device, such as a pressure relief valve 96 , to enable the controlled venting of lubricant from the reservoir system 60 . The reservoir system 60 may also, or alternately, be equipped with a piston vent 138 (FIGS. 15, 16) disposed within the reservoir 62 , or housing 65 . The piston vent 138 includes a piston member 144 and biasing member, such as a spring 140 , connected between the cover, or end, 142 of the reservoir 62 and the piston member 144 . The piston member 144 substantially sealingly engages the interior wall 160 of the reservoir 62 . Pressure changes in the reservoir 62 will cause the piston member 144 to move upwardly and downwardly therein. When the pressure within the reservoir or housing 65 forces the piston member 144 above predetermined height, or level, of 3 bleed hole 150 in the reservoir 62 excess lubricant and pressure in the reservoir system 60 is released into the plenum 80 through the bleed hole 150 . It should be understood, however, that the venting of excess lubricant from the reservoir system 60 with these or any other methods and structure is not required for, or limiting upon, the present invention.
[0053] In another configuration of the present invention, such as shown in FIG. 18, the reservoir opening 63 is located in the proximity of the bit throat 33 . The reservoir 62 communicates with the leg bearing system 50 , such as through passageway 68 . By opening to the bit exterior 70 in the proximity of the bit throat 33 , the reservoir 62 and reservoir opening 63 are isolated and protected from contact between the bit 10 and bore hole debris and the bore hole wall. The reservoir 62 is shown in FIG. 18 having a housing 65 (as described above) disposed in a cavity, or receiving pocket, 69 formed in the leg 20 . The reservoir 62 , such as the housing 65 , may be connected to the bit 10 with any suitable conventional technique, such as a threaded mateable connector, retaining rings, pins, or by weld (not shown). The reservoir 62 , however, need not include a housing 65 , but can take any suitable form or configuration. For example, the cavity 69 can serve as the reservoir 62 .
[0054] In a further aspect of the invention, a hard, wear resistant material 122 may be incorporated into, or upon, the bit 10 to strengthen the bit 10 and inhibit erosive wear and contact damage to the bit 10 , reservoir 62 and reservoir opening 63 , as shown, for example in FIGS. 6 and 19. The hard wear resistant material 122 may have any suitable shape and size and may be set flush with (FIG. 14), protrude from (FIG. 9), or be recessed (not shown) in the outer surface 100 of one or more legs 20 of the bit 10 , as is desired. Further, the hard wear resistant material 122 may be attached to the bit 10 with any suitable technique that is or becomes known in the art.
[0055] The term “hard wear resistant material” as used herein generally includes any material, or composition of materials, that is known or becomes known to have strength, or wear, characteristics equal to or better than steel, and which can be affixed onto, or formed into, the drill bit 10 . The hard wear resistant material 122 may, for example, be inserts 124 (FIG. 4), as are known in the art for strengthening and inhibiting wear to the bit 10 . Inserts 124 may also be used for engaging and grinding loose rock in the bore hole during operations, such as disclosed in U.S. Pat. No. 5,415,243 to Lyon et al., which is incorporated herein by reference in its entirety. The inserts 124 may be tungsten carbide inserts, inserts constructed of a tungsten carbide substrate and having a natural or synthetic diamond wear surface, or inserts constructed of other suitable material. Any type of insert that is, or becomes, know for use with drill bits may be used with the present invention, such as “flat-top,” dome shaped, chisel shaped and conical shaped inserts. The inserts 124 may be embedded into the bit 10 as is known in the art or otherwise attached to the bit 10 with any suitable technique. For another example, the hard wear resistant material 122 may be hard facing, or deposits 134 , such as the guard member 136 of FIG. 18. As shown in FIG. 18, the hard facing or deposits 134 , such as the guard member 136 , may itself carry inserts 124 . The hard facing or deposits 134 are applied to the bit 10 with any suitable technique, such as by being brazed or welded thereto.
[0056] The hard wear resistant material 122 can be placed at any location on the bit 10 as is desirable for assisting in protecting the reservoir 62 and reservoir opening 63 . As shown, for example, in FIGS. 14 and 18, the material 122 can be located on the bit 10 outward of the entire reservoir system 60 relative to the bore hole wall 72 . FIG. 14 shown inserts 124 , while FIG. 18 shows guard member 136 , each located on the shoulder 40 to assist in protecting the reservoir 62 and reservoir system 60 located within the leg 20 . For another example, hard wear resistant material 122 , such as inserts 124 , can be embedded into, or attached to, the plug 110 of the present invention, such as shown in FIGS. 7 , 10 - 13 .
[0057] When the reservoir installation opening 63 opens to the leg surface 100 , hard wear resistant material 122 may be used to protect the reservoir 62 and installation opening 63 . For example, a protective ledge, or protrusion, 126 of hard wear resistant material 122 , such as shown in FIG. 6, may be strategically formed into or attached to the leg 20 , such as above or around the installation opening 63 . The protrusion 126 may be connected to the bit 10 with any suitable conventional method, such as by welding or mechanical attachment means (not shown). For another example, hard wear resistant material 122 , such as inserts 124 , may be placed anywhere on the outside surface 100 of the leg 20 to assist in protecting the reservoir 62 and installation opening 63 (FIGS. 6, 12). FIGS. 4 and 7 shows the use of hard wear resistant material 122 , such as inserts 124 , on the shoulder 40 and center panel 46 when the installation opening 63 is on the trailing and leading sides 36 , 30 , respectively. FIG. 20 illustrates an example of the use of inserts 124 in conjunction with a leg 20 having two reservoir openings 63 on the shoulder 40 and a third installation opening 63 on the trailing side 36 . Other examples of legs 20 having inserts 124 on the surface 100 when the installation opening 63 is on the shoulder 40 are shown in FIGS. 12, 13 and 19 . In FIG. 6, the installation opening 63 is shown located at the intersection of the shoulder 40 , center panel 46 and trailing side 36 of the leg 20 within a protrusion 126 . Hard wear resistant materials 122 , such as inserts 124 , are strategically disposed on the leg 20 , such as on the shoulder 40 and center panel 46 , to protect the reservoir 62 and installation opening 63 . FIGS. 8 and 11 show examples of the use of hard wear resistant material 122 , such as inserts 124 , to assist in protecting the reservoir 62 and installation opening 63 when the installation opening 63 is on the center panel 46 . It should be understood, however, that the particular arrangements, locations and quantities of hard wear resistant material 122 , such as inserts 124 , shown in the appended drawings are not limiting on the present invention.
[0058] Each of the foregoing aspects of the invention may be used alone or in combination with other such aspects. While preferred embodiments of the present invention have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit or teachings of this invention. The embodiments described herein are exemplary only and are not limiting of the invention. Many variations and modifications of the embodiments described herein are thus possible and within the scope of the invention. Accordingly, the scope of protection is not limited to the embodiments described herein. | A rotary cone rock bit, comprises a bit body including a plurality of legs extending therefrom, each of the legs having an outer surface that includes a leading surface and a trailing surface, a roller cone rotatably supported on each of the legs, a bearing system between each cone and the leg on which it is supported, and a lubricant reservoir in fluid communication with the bearing system. The reservoir can be provided with a wear resistant plug, if desired. In the present bit, the reservoir has at least one opening positioned in either the leg's leading surface, trailing surface, center surface, shoulder surface or some combination of these. Alternatively, the reservoir can be formed inside the bit body, preferably by means of a canister, which can be provided with venting means as desired. | 4 |
BACKGROUND
Machines such as large-capacity diesel engine systems used in connection with construction equipment, earth-moving equipment, transportation equipment (e.g., locomotives) and the like, are often implemented in adverse operating conditions. Typical operating conditions for such equipment can require extensive maintenance, repair and overhaul work to sustain the equipment and its components, including the engine systems. As a consequence of adverse equipment operating conditions, certain equipment components may be exhausted long before the expected end of their useful lives. This component exhaustion can occur despite efforts to ensure proper component installation and maintenance, including periodic maintenance of equipment oil supply and lubrication systems, for example. Extensive and premature wear of large-capacity diesel engines, for example, can be caused by a combination of factors, including inadequate lubrication of components prior to engine ignition, failure to adhere to prescribed maintenance schedules, failure to collect and analyze data associated with equipment operation, system malfunction, general misuse of the equipment, and other factors.
Methods and systems for data collection and analysis are therefore needed that can extend the useful life of equipment components. Component movement and interaction during various periods of equipment operation can impact the continued effective operation and useful life expectancy of the engine system. In connection with operation and/or maintenance of the engine system during such periods, important data such as, for example, temperature, oil pressure, time to evacuate an oil sump, and historical data regarding previous engine ignition cycles can be collected and analyzed. Conventional equipment methods and systems, however, typically do not collect and analyze data during various stages of machine operation to assist in operation or maintenance of the machine and its components.
In addition, in the context of performing machine maintenance, there is often a need for performing multiple evacuations and/or refills of fluid receptacles. Such fluid receptacles may include, for example and without limitation, oil sumps, transmission fluid reservoirs, fuel tanks, waste-receiving receptacles, hydraulic fluid reservoirs, and other like receptacles associated with machine operation and maintenance. In many situations, such fluid evacuation and fluid refill processes may not be timed and/or sequenced to maximize performance of maintenance on a machine. Furthermore, data crucial to scheduling maintenance and monitoring performance issues with machines are often neither collected nor analyzed during fluid evacuations, fluid refills, or other fluid processing activities.
Many industrial machines and equipment have requirements for fluid exchanges. Examples of these fluid exchanges include changing the oil in motors and engines or hydraulic fluid in presses and lifting equipment. Countless other examples exist, but what is generally common to these machines or equipment is the fact that the outlet port is inconveniently located. Typically this is the result of having to remove the fluid from a sump or drainage point that is located at the bottom of the machine to utilize gravity flow.
The tasks of removing and refilling machine fluids may be difficult or time consuming because of the usually inconvenient location of the fittings required to perform these fluid operations. Some machines, however, may include fluid circulation pumps that are installed and applied in locations that are external to the machine. Also, some equipment may be provided with one or more internally or externally located pre-lubrication devices that permit oil or fluid to commence circulation prior to the activation of the primary equipment or engine on which the pre-lubrication device is installed. Illustrative of such devices is the pre-lubrication device shown in U.S. Pat. No. 4,502,431, which is incorporated herein by reference, and which is typically fitted to a diesel engine used in power equipment, trucks and/or heavy equipment.
Furthermore, in certain off-road heavy equipment, reservoirs containing fluids may contain scores of gallons of fluid, which can consume unacceptably long periods of time to drain and refill. For example, in some equipment, an engine oil sump or reservoir may contain up to 150 gallons of oil; a transmission sump may contain up to 100 gallons of transmission fluid; and a separate reservoir of hydraulic fluid to power hydraulic functions may contain up to 500 gallons of hydraulic fluid. Downtime costs for relatively large machines and other pieces of equipment can be substantial. Accordingly, if downtime for maintenance in such machines can be minimized, then substantial economic benefits often result. In addition, there are numerous comparatively smaller devices and motors for which access to fluid discharge ports is difficult to reach or in which the fluid must be assisted for removal. Examples include marine engines and the like. In some small-sized pieces of equipment, the engine must be inverted to remove oil, for example, or other fluids. For example, see U.S. Pat. Nos. 5,526,782; 5,257,678; and, 4,977,978.
Thus, what are needed are improved methods and systems for performing fluid maintenance functions, such as fluid evacuation and refill processes, for example, in connection with machine operation and maintenance. What are also needed are enhanced methods and systems for sequencing and timing fluid operations, while collecting, storing and/or analyzing data pertinent to the performance and results of such fluid transfer operations.
SUMMARY
The present invention provides various embodiments of a valve assembly. The embodiments may include a first check valve structured to permit fluid flow therethrough in response to application of positive pressure at an inlet of the first check valve, further comprising an outlet of the first check valve being in fluid communication with at least a portion of a fluid system; a second check valve having an outlet in fluid communication with the inlet of the first check valve, the second check valve being structured to permit fluid flow therethrough in response to application of negative pressure at the outlet of the second check valve; and, an inlet/outlet port in fluid communication with the inlet of the first check valve and the outlet of the second check valve at a common refill/evacuation location. In certain embodiments, the fluid system portion includes at least a pre-filter portion.
The present invention provides various embodiments of a valve system. The embodiments may include a first valve assembly comprising, a first check valve structured to permit fluid flow therethrough in response to application of positive pressure at an inlet of the first check valve, further comprising an outlet of the first check valve being in fluid communication with a first portion of a fluid system; a second check valve having an outlet in fluid communication with the inlet of the first check valve, the second check valve being structured to permit fluid flow therethrough in response to application of negative pressure at the outlet of the second check valve; a first inlet/outlet port in fluid communication with the inlet of the first check valve and the outlet of the second check valve at a first common refill/evacuation location; a second valve assembly comprising, a third check valve structured to permit fluid flow therethrough in response to application of positive pressure at an inlet of the third check valve, further comprising an outlet of the third check valve being in fluid communication with a second portion of a fluid system; a fourth check valve having an outlet in fluid communication with the inlet of the third check valve, the fourth check valve being structured to permit fluid flow therethrough in response to application of negative pressure at the outlet of the fourth check valve; and, a second inlet/outlet port in fluid communication with the inlet of the third check valve and the outlet of the fourth check valve at a second common refill/evacuation location. The valve system may further include at least a third valve assembly comprising, a fifth check valve structured to permit fluid flow therethrough in response to application of positive pressure at an inlet of the fifth check valve, further comprising an outlet of the fifth check valve being in fluid communication with a third portion of a fluid system; a sixth check valve having an outlet in fluid communication with the inlet of the fifth check valve, the sixth check valve being structured to permit fluid flow therethrough in response to application of negative pressure at the outlet of the sixth check valve; and, a third inlet/outlet port in fluid communication with the inlet of the fifth check valve and the outlet of the sixth check valve at a third common refill/evacuation location.
Embodiments of a valve assembly provided in accordance with the present invention may include a first electronic valve structured to permit fluid flow therethrough in response to sensing application of positive pressure at an inlet of the first electronic valve, further comprising an outlet of the first electronic valve being in fluid communication with a first portion of a fluid system; a second electronic valve having an outlet in fluid communication with the inlet of the first electronic valve, the second electronic valve being structured to permit fluid flow therethrough in response to sensing application of negative pressure at the outlet of the electronic check valve; and, an inlet/outlet port in fluid communication with the inlet of the first electronic valve and the outlet of the second electronic valve at a common refill/evacuation location.
Embodiments of a valve system provided in accordance with the present invention may include a first electronic valve assembly comprising, a first electronic valve structured to permit fluid flow therethrough in response to sensing application of positive pressure at an inlet of the first electronic valve, further comprising an outlet of the first electronic valve being in fluid communication with a first portion of a fluid system; a second electronic valve having an outlet in fluid communication with the inlet of the first electronic valve, the second electronic valve being structured to permit fluid flow therethrough in response to sensing application of negative pressure at the outlet of the electronic check valve; a first inlet/outlet port in fluid communication with the inlet of the first electronic valve and the outlet of the second electronic valve at a first common refill/evacuation location; at least a second electronic valve assembly comprising, a third electronic valve structured to permit fluid flow therethrough in response to sensing application of positive pressure at an inlet of the third electronic valve, further comprising an outlet of the third electronic valve being in fluid communication with a second portion of a fluid system; a fourth electronic valve having an outlet in fluid communication with the inlet of the third electronic valve, the fourth electronic valve being structured to permit fluid flow therethrough in response to sensing application of negative pressure at the outlet of the fourth electronic check valve; and, a second inlet/outlet port in fluid communication with the inlet of the third electronic valve and the outlet of the fourth electronic valve at a second common refill/evacuation location.
Embodiments of a module provided in accordance with the present invention may include a first valve assembly comprising a first check valve structured to permit fluid flow therethrough in response to application of positive pressure at an inlet of the first check valve, further comprising an outlet of the first check valve being in fluid communication with a first portion of a fluid system; a second check valve having an outlet in fluid communication with the inlet of the first check valve, the second check valve being structured to permit fluid flow therethrough in response to application of negative pressure at the outlet of the second check valve; a first inlet/outlet port in fluid communication with the inlet of the first check valve and the outlet of the second check valve at a first common refill/evacuation location; at least a second valve assembly comprising, a third check valve structured to permit fluid flow therethrough in response to application of positive pressure at an inlet of the third check valve, further comprising an outlet of the third check valve being in fluid communication with a second portion of a fluid system; a fourth check valve having an outlet in fluid communication with the inlet of the third check valve, the fourth check valve being structured to permit fluid flow therethrough in response to application of negative pressure at the outlet of the fourth check valve; a second inlet/outlet port in fluid communication with the inlet of the third check valve and the outlet of the fourth check valve at a second common refill/evacuation location; and, the first and second valve assemblies being coupled together to form the module.
Embodiments of a module provided in accordance with the present invention may include a first electronic valve assembly comprising a first electronic valve structured to permit fluid flow therethrough in response to sensing application of positive pressure at an inlet of the first electronic valve, further comprising an outlet of the first electronic valve being in fluid communication with a first portion of a fluid system; a second electronic valve having an outlet in fluid communication with the inlet of the first electronic valve, the second electronic valve being structured to permit fluid flow therethrough in response to sensing application of negative pressure at the outlet of the electronic check valve; a first inlet/outlet port in fluid communication with the inlet of the first electronic valve and the outlet of the second electronic valve at a first common refill/evacuation location; at least a second electronic valve assembly comprising a third electronic valve structured to permit fluid flow therethrough in response to sensing application of positive pressure at an inlet of the third electronic valve, further comprising an outlet of the third electronic valve being in fluid communication with a second portion of a fluid system; a fourth electronic valve having an outlet in fluid communication with the inlet of the third electronic valve, the fourth electronic valve being structured to permit fluid flow therethrough in response to sensing application of negative pressure at the outlet of the fourth electronic check valve; a second inlet/outlet port in fluid communication with the inlet of the third electronic valve and the outlet of the fourth electronic valve at a second common refill/evacuation location; and, the first and second electronic valve assemblies being coupled together to form the module.
Embodiments of a method of performing at least one fluid operation in a fluid system are provided in accordance with the present invention. Embodiments of the method may include structuring a first check valve to permit fluid flow therethrough in response to application of positive pressure at an inlet of the first check valve, further structuring the first check valve with an outlet in fluid communication with a first portion of a fluid system; structuring a second check valve having an outlet in fluid communication with the inlet of the first check valve, further structuring the second check valve to permit fluid flow therethrough in response to application of negative pressure at the outlet of the second check valve; and, positioning an inlet/outlet port in fluid communication with the inlet of the first check valve and the outlet of the second check valve at a common refill/evacuation location.
Embodiments of a method of performing a fluid operation may be provided in accordance with the present invention. Embodiments of the method may include structuring a first check valve to permit fluid flow therethrough in response to application of positive pressure at an inlet of the first check valve, further structuring the first check valve with an outlet in fluid communication with a portion of a fluid system; structuring a second check valve having an outlet in fluid communication with the inlet of the first check valve, further structuring the second check valve to permit fluid flow therethrough in response to application of negative pressure at the outlet of the second check valve; positioning an inlet/outlet port in fluid communication with the inlet of the first check valve and the outlet of the second check valve at a common refill/evacuation location; applying positive pressure at the common refill/evacuation location to purge at least a pre-filter portion of the portion of a fluid system; applying negative pressure at the common refill/evacuation location to evacuate fluid through the inlet/outlet port; and, applying positive pressure at the common refill/evacuation location to refill at least one fluid through at least the portion of a fluid system.
Embodiments of a power supply system structured for use in association with a machine for which at least one fluid service operation is performed may also be provided in accordance with the present invention. Embodiments of the power supply system may include a power receptacle positioned within the vicinity of an inlet/outlet port of a fluid system of the machine; and, a power source supplying electrical power to the power receptacle, the power source being electrically operatively associated with a power source of the machine for which the fluid service operation is performed.
Embodiments of a connection/disconnection detection system structured for use in association with at least first and second coupling portions of a fluid system of a machine may be provided in accordance with the present invention. Embodiments of the detection system may include a first electrical contact operatively associated with the first coupling portion; a second electrical contact operatively associated with the second coupling portion; and, a signal processor configured to receive electrical signals from the second electrical contact of the second coupling portion representative of association or disassociation of the first and second electrical contacts of the coupling portions.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a side elevation view of one embodiment of a single-reservoir conduit system;
FIG. 2 is a plan view of the embodiment shown in FIG. 1 showing a coupling;
FIG. 3 is a plan view of a pump integrally included in a flow control means;
FIG. 4 is a side elevation of the embodiment shown in FIG. 3 ;
FIGS. 5 and 6 are two views of one embodiment of a coupling for use with various embodiments of the present systems and methods;
FIG. 7 is diagrammatic view of one embodiment of a conduit, and a coupling for oil purges;
FIG. 8 is a diagrammatic view of one embodiment of a multiple-reservoir conduit system;
FIG. 9 is an electrical schematic diagram for one embodiment of the system of FIG. 8 ;
FIG. 10 is an elevation view of one embodiment of a service panel for a fluid evacuation system;
FIG. 11 is an electrical schematic for one embodiment of the system of FIG. 10 ;
FIG. 12 is a hydraulic schematic diagram of one embodiment of a fluid evacuation system;
FIG. 13 is a diagrammatic view of one embodiment of a dual-pump multiple-reservoir conduit system;
FIG. 14 is an electrical schematic diagram for one embodiment of the system of FIG. 13 ;
FIG. 15 is an elevation view of one embodiment of a control panel for a fluid evacuation system;
FIG. 16 is an electrical diagram for one embodiment of the system of FIG. 15 ;
FIG. 17 is a hydraulic schematic diagram of one embodiment of a multiple pump fluid evacuation system;
FIG. 18 is a schematic diagram showing one embodiment of a replacement fluid conduit system;
FIG. 19 includes a schematic diagram illustrating one embodiment of a fluid system configured for performing one or more fluid processes in accordance with the present systems and methods;
FIG. 20 includes a schematic diagram displaying one embodiment of a control module and various embodiments of data devices configured for use in accordance with various embodiments of the present systems and methods;
FIG. 21 includes a schematic diagram illustrating one embodiment of an internal data module configured for use in accordance with various embodiments of the present systems and methods;
FIG. 22 includes a process flow diagram illustrating one method embodiment provided in accordance with the present systems and methods;
FIG. 23 includes a schematic diagram of one system embodiment provided in accordance with the present systems and methods;
FIG. 24 includes a schematic diagram illustrating one embodiment of a fluid system configured for performing one or more fluid processes in accordance with the present systems and methods;
FIG. 25A includes an exploded, isometric view of one illustrative embodiment of a junction block assembly structured for use in accordance with various embodiments of the present systems and methods;
FIG. 25B includes an isometric view of the junction block assembly of FIG. 23A ;
FIG. 25C includes a schematic diagram illustrating one embodiment of a fluid system including a junction block assembly, a screen and a pump installed within the fluid system;
FIG. 26 includes a schematic diagram illustrating one embodiment of a fluid system configured for performing one or more fluid processes in accordance with the present systems and methods;
FIG. 27 includes a schematic diagram illustrating one embodiment of a fluid system configured for performing one or more fluid processes in accordance with the present systems and methods;
FIG. 28 includes a schematic diagram illustrating one embodiment of a fluid system configured for performing one or more fluid processes in accordance with the present systems and methods;
FIG. 29 includes a schematic diagram illustrating one embodiment of a fluid system configured for performing one or more fluid processes in accordance with the present systems and methods;
FIG. 30 includes a schematic diagram illustrating one embodiment of a fluid system configured for performing one or more fluid processes in accordance with the present systems and methods;
FIG. 31 includes a schematic diagram illustrating one embodiment of a fluid system configured for performing one or more fluid processes in accordance with the present systems and methods;
FIG. 32 includes a schematic representation of a valve assembly structured in accordance with embodiments of the present systems and methods;
FIG. 33 includes a schematic representation of a valve system structured in accordance with embodiments of the present systems and methods;
FIG. 34 includes a schematic representation of a valve assembly structured in accordance with embodiments of the present systems and methods;
FIG. 35 includes a schematic representation of a valve system provided in accordance with embodiments of the present systems and methods;
FIG. 36 includes a schematic representation of an illustrative fluid system provided in accordance with various embodiments of the present systems and methods;
FIG. 37 includes a flow chart illustrating various aspects of fluid operations that can be performed in accordance with the present systems and methods;
FIG. 38 includes a schematic representation of a module of valve assemblies provided in accordance with the present systems and methods;
FIG. 39 includes a schematic representation of an electronic valve module provided in accordance with various embodiments shown in FIG. 38 ;
FIG. 40 includes a schematic representation of a valve module provided in accordance with various embodiments of FIGS. 38 and 39 ;
FIG. 41A through 41C illustrate various modes of operation for a schematically represented connection/disconnection detection system provided in accordance with various embodiments of the present invention; and,
FIG. 42 includes a schematic representation of a power supply system provided in accordance with various embodiments of the present invention.
DESCRIPTION
The term “machine” as applied herein may include any equipment suitable for use in accordance with the present methods and systems. Examples of “machines” as applied herein can include, without limitation, a lubrication system, engines, diesel engines, large-scale diesel engines, motors, rotating equipment, generators, aircraft engines, emergency machines, emergency generators, compressors, equipment that includes a machine (e.g., such as mining equipment, construction equipment, marine equipment, aircraft, and the like), and other like machines. In various portions of the disclosure herein, the example of an “engine” is employed for convenience of disclosure in describing various embodiments and aspects of the present systems and methods. It can be appreciated by those skilled in the art, however, that such use of “engine” as one example of a type of machine is intended merely for said convenience of disclosure and is not intended to limit the scope of application of the present systems and methods.
The term “evacuation” as applied to the systems and methods disclosed herein may include evacuation of any portion of a fluid of a machine, a receptacle, a reservoir, or other like fluid-retaining system or apparatus. Similarly, the term “refill” as applied to the systems and methods disclosed herein may include refill of any portion of the fluid capacity of a machine, receptacle, reservoir, or other like fluid-retaining system or apparatus.
The term “valve system” as applied to the systems and methods disclosed herein may include any combination of valves, pipes, disconnects, adapters and other like structural components configured for performing one or more fluid refill and/or fluid evacuation processes. Examples of valves included within a valve system may include, without limitation, single-position valves, multi-position valves (e.g., such as junction block assemblies or five-way control valves), and other types of valves with or without electronic control for actuating the various possible open/closed positions of such valves. The “multi-position valve” expression, as applied herein, can include a unitary valve mechanism (e.g., a single junction block assembly), or a reasonable combination of a unitary valve mechanism and other valve components.
Where suitable and applicable to the various embodiments of the present systems and methods discussed herein, it can be appreciated that various components, structures, elements, and other configurations may be applied or installed in a location considered external or internal to the operation of a particular machine. In applicable portions herein where the use of pumps and/or supplemental pumps is disclosed, for example, such pumps may be positioned, installed, or operated as internal components of a machine and/or as externally positioned components that assist, or otherwise operate in conjunction with, the functions of the machine.
As used herein, the term “subsequent” or variations thereof (e.g., “subsequently”) as used with respect to performance of process or method steps is not intended to exclude other potential process or method steps from occurring or being performed between steps that are considered “subsequent” with respect to each other. For example, as applied herein, if step Y occurs “subsequent to” step X, then the intended meaning of “subsequent to” is that step Y occurs at some point in time after step X occurs, but other steps may occur in the time period that elapses between the occurrence of step X and step Y. In like fashion, the term “prior” or variations thereof (e.g., “prior to”) as used with respect to performance of process or method steps described herein is not intended to exclude other potential process or method steps from occurring or being performed between steps that are considered “prior to” with respect to each other.
As employed herein, the term “type” or “kind” used with regard to various fluids discussed herein is intended to distinguish different types or kinds of fluids between/among each other. For example, oil is considered one “type” of fluid, transmission fluid is considered another, different “type” of fluid, and hydraulic fluid is considered another, different “type” of fluid. It should be noted, for example, that a used amount of a “type” of fluid is not considered different with respect to a clean or fresh fluid of the same “type” (e.g., clean oil used in a fluid refill or replacement process for a machine is not considered a different “type” of fluid with respect to the used oil drained from the machine during a fluid evacuation process).
Referring now to FIGS. 1 and 2 , a portable fluid transfer conduit 10 is shown having an inlet port 11 and outlet port 12 . Flexibly extending between inlet and outlet ports 11 and 12 is flexible tubing 13 . In various embodiments of the present systems and methods, the tubing 13 may be made from a natural or synthetic rubber material, braided stainless steel or polymeric extruded material such as polyethylene or styrene.
A coupling 14 is attached to the inlet 11 . As shown, the coupling 14 is the male mateable end of a quick disconnect coupling more clearly shown in FIGS. 5 and 6 . Alternatively, coupling 14 can be any type of fitting such as a screw in or a bayonet type coupling. In one embodiment, a fitting is adapted to the outlet of the fluid source. On devices such as a pre-lubrication pump similar to that shown in U.S. Pat. No. 4,502,431, for example, a bypass or connector means can be inserted on the pressure side of the pump to divert the oil from the engine to the fluid transfer conduit 10 . An example is disclosed in the discussion of FIGS. 5 and 6 presented hereinbelow.
Positioned adjacent outlet port 12 is flow control means 16 . Flow control means comprises, in one embodiment, an electric or mechanical valve for controlling the flow of fluid through the conduit activated by switch 17 . This embodiment is useful where the fluid source does not incorporate a pump means and/or the fluid is gravity transferred. On the other hand, in the case where means such as a pre-lubrication device is used, flow control means 16 is preferably a pass through conduit having switch 17 sealably mounted thereon. Switch 17 is electrically connected by conductor 18 to electrical connector 19 , which is adapted to connect with the pump circuit to activate the pump and control the flow of fluid. Where flow control means 16 comprises an electric valve, conductor 18 and connector 19 are typically connected to a source of electrical power such as a battery terminal, a magnetic switch, relay contacts or other electromechanical means for activating the pumping means.
To drain a fluid such as oil or hydraulic oil, for example, from a machine or other piece of equipment involves connecting coupling 14 to the outlet of the pump and initiating the pump through activation of flow control switch 17 or by use of gravity. It can be appreciated that in situations where a pre-lubrication pump is used, a valve is not usually required. The outlet port of fluid transfer conduit 10 is positioned at a remote and convenient location to discharge the fluid into a waste-receiving receptacle. Such waste-receiving receptacles are generally known in the art and may commonly comprise barrels or service vehicles, for example, or other receptacles or reservoirs adapted to receive and transport waste oil or other contaminated vehicle fluids.
In one embodiment shown in FIGS. 3 and 4 , fluid transfer conduit 20 comprises a conduit 23 having an inlet port 21 and an outlet port 22 . Inlet port 21 includes a coupling 24 , preferably a mateable coupling as shown in FIGS. 5 and 6 . In this operational example, flow control means 26 comprises a small suction, diaphragm, piston or reciprocating pump 28 and may include therein a battery pack. Flow control means 16 includes an activator switch 27 in the form of a “trigger switch” having a guard 29 and grip means 31 to facilitate holding the discharge end of the fluid transfer conduit 20 . It can be appreciated that in applications where a relatively long transfer conduit is applied such as, for example, a transfer conduit of 20 to 30 feet in length, the pump 28 can be located adjacent to, or in close proximity to, the coupling means 14 .
Many types of small portable pumps suitable for use as the pump 28 are commercially available. A number of pumps are better suited for heavier or more viscous fluids but are not capable of operating with battery power. In such cases, a power cable such as conductor 18 and connector 19 can be used in addition to the various embodiments described herein. Typically, the electrical power required to operate the pump 28 can be supplied by a vehicle storage battery or an AC pump can be connected to an AC outlet as a power source. In general, smaller pump means are suitable and applicable in the consumer market, and the comparatively larger pump means are applicable to the industrial market.
Referring now to FIGS. 5 and 6 , examples of coupling means 14 , 41 for use with various embodiments of the present systems and methods are shown. Coupling means 14 , 41 are adaptable, for example, to fluid transfer conduit embodiments shown with respect to FIG. 1 and FIG. 3 . Coupling means 41 connects to the engine oil port (not shown), whereas coupling means 14 is attached to conduit 10 . Such coupling means are well known in the art and comprise a male quick connector fitting 30 and a female mateable quick connector fitting 32 . Also shown is an electrical receptor 33 for receiving electrical connector 19 . In various embodiments, it is also possible to include a sensing means on the coupling means 14 , 41 to indicate that the sump is dry and to signal for shut down of the pump. A cap 34 is shown for protecting receptor 33 between periods of use. As shown in the embodiments of FIGS. 5 and 6 , receptor 33 and fitting 32 are mounted on a bracket 36 that is connected to a source of fluid 37 , such as a pre-lubrication pump, for example (not shown). In this embodiment, the fitting 32 is connected on the output or high-pressure side of the fluid source system. In application to a pre-lubrication system, for example, the fitting 32 is interposed in the high-pressure pump discharge line between the pump and an engine or other machine.
Referring now to FIG. 6 , one embodiment of a sampling port 39 is shown that can be used to sample oil in a pre-lubrication system where the pre-lubrication pumps flows through portion 37 . It can be appreciated that this embodiment has the advantage of being able to provide a live sample of oil, or other fluid used in this embodiment, without requiring the engine or other machine to be in a fully operational state.
As shown in the illustrative embodiment of FIG. 7 , an additional fitting 40 is attached to an external air supply 42 . In one aspect, the fitting 40 is a female fitting adapted to couple to an air supply (not shown). By attaching an air source to the fitting 40 prior to or during the removal of oil from the engine, oil resident in the channels can be removed to the sump and the oil in the filter system can be at least partially or substantially removed to facilitate removal of the filter. In many embodiments that employ such an air supply, it may be desirable to have the source of air at a pressure from about 90 to 150 pounds per square inch, for example.
It has been discovered that a vehicle or other equipment having, for example, an engine reservoir 105 , hydraulic fluid reservoir 107 and a transmission fluid reservoir 109 , may be more efficiently serviced and risks of environmental contamination may be reduced, if the various service locations for such reservoirs are in relatively close proximity. For example, and without limitation, if the service locations for such reservoirs are within about 3 to 10 feet from each other, service can usually be accomplished by relatively few technicians and within an acceptable amount of time. Also, the risks from environmental contamination caused, for example, by spillage when several lines and fluid containers are disconnected and connected, can be reduced if such close proximity of service locations is provided.
FIG. 8 illustrates one embodiment for a single-pump multiple reservoir conduit system 100 , which may be used, for example, to evacuate the engine reservoir 105 , the hydraulic reservoir 107 and the transmission or other fluid reservoir 109 of a machine through a quick connect port 112 that may be mounted on a bracket 173 or to an evacuation port 153 in a control panel 150 (see discussion hereinbelow). A pump 128 , and each of the reservoirs 105 , 107 and 109 are connected to a control valve 116 through a network of conduits 113 . In one embodiment, the pump 128 may be a dedicated evacuation pump, for example, or may be an engine pre-lubrication pump, for example. The network of conduits includes a first conduit 400 connected to the hydraulic reservoir 107 at a first end 402 by a first coupling 406 , and to the control valve 116 at a second end 404 by a second coupling 408 . Similarly, a second conduit 410 is connected at a first end 414 to the engine reservoir 105 by a first coupling 416 , and to the control valve 116 at a second end 412 by a second coupling 418 . A third conduit 420 is connected at a first end 422 to the transmission reservoir 109 by a first coupling 426 , and to the control valve 116 at a second end 424 by a second coupling 428 . A fourth conduit 430 is connected to the pump 128 at a first end 432 by a first coupling 436 and to the outlet port 112 at a second end 434 by a second coupling 438 . A fifth conduit 461 is connected to the pump 128 at a first end 463 by a first coupling 467 and to the control valve 116 at a second end 465 by a second coupling 469 .
In one example embodiment, the control valve 116 is a three-position, four-port directional valve, which controls the connection of the pump 128 with each of the conduits 410 , 400 and 420 leading to the reservoirs 105 , 107 and 109 , respectively. In one aspect, the control valve 116 has one default position, which is the engine sump 105 position. The control valve 116 and the pump 128 may be operated from a remote bracket 173 by an electrical evacuator switch attached to a connector 172 , and a toggle selector switch 174 , respectively.
As will be appreciated, in the operation of the system of FIG. 8 , the control valve 116 determines which of the reservoirs 105 , 107 or 109 will be in fluid communication with the pump 128 through the conduit network 113 . Specifically, the selector switch 174 determines the position of the control valve 116 . The switch connected at the connector 172 serves as the on-off switch for the pump 128 , and may be mounted on the bracket 173 or may be mounted on a tethered switch connected to connector 172 . In operation, the selector switch 174 controls the position of the control valve 116 to determine which reservoir 105 , 107 or 109 is evacuated. When the switch connected to connector 172 is energized, the pump 128 is energized, thereby providing negative pressure on line 461 and, in turn, to the control valve 116 . The fluid in the reservoir 105 , 107 or 109 fluidly coupled to the control valve 116 is drawn into line 461 , through pump 128 , through line 430 and to coupling 112 for discharge into a suitable receptacle and/or into a fluid line for further processing.
FIG. 9 shows one illustrative embodiment of the electrical circuitry for the embodiment of the single-pump, multiple reservoir system of FIG. 8 . A relay switch 158 is connected to the motor 162 of the pump 128 to start and stop the pump motor 162 when the start switch 172 is activated to provide power from a direct current source, for example, or other suitable power source. In one aspect, the relay switch 158 stops the motor when a low flow condition is detected in any of the conduits 400 , 410 , and 420 during evacuation by the sensor 180 . The control valve 116 is electrically operated through two solenoids 164 and 166 connected to a selector switch 174 . The selector switch 174 is also connected to the start switch 172 . In one embodiment, the start switch 172 includes a single-pole, normally open switch, and the selector switch 174 includes a single-pole double-throw switch.
Although three reservoirs are shown in the embodiment illustrated in FIG. 8 , the number of reservoirs is not limited to three. For embodiments with N reservoirs, for example, there are N reservoir conduits connecting each reservoir with the control valve, such as the conduits 400 , 410 and 420 of FIG. 8 . A pump conduit, such as conduit 461 , for example, connects the control valve 116 to the pump 128 , and an outlet conduit, such as conduit 430 , for example, connects the pump 128 to the outlet port 112 . It can be appreciated that, for N reservoirs, the control valve 116 has one default position and N−1 selector activated positions.
The control valve 116 may also be operated from a centralized location, such as a service panel. An embodiment of a remote single service panel 150 for a single pump, which includes switches for the actuation of the pump 128 and the control valve 116 in addition to switches for ignition and ports for sampling engine, transmission and hydraulic fluids, is shown in FIG. 10 . A selector switch 152 on the service panel 150 is connected to the control valve 116 to enable an operator to select the reservoir to be evacuated. A switch for controlling evacuation 154 , an emergency evacuation stop switch 156 , and an evacuation connect port 153 (coupled, for example, to the line 430 ) for connecting/disconnecting the pump 128 may also be mounted on the service panel 150 . Additionally, a transmission oil sampling port 50 , an engine oil sampling port 52 , and a hydraulic oil sampling port 54 may be mounted on the service panel 150 for with the transmission, engine and hydraulic reservoirs respectively. The service panel 150 may also include an oil filter 56 having an oil inlet line 44 , transmission oil filter, a fuel filter 58 , a fuel separator 60 , hydraulic oil filter, a remote ignition selector 62 and an ignition switch 64 . Thus, service locations, such as control panel 150 , may be provided for virtually all machine, vehicle, and/or engine fluid service needs.
An embodiment of the electrical diagram for the service panel of FIG. 10 is shown in FIG. 11 . A motor relay 76 is connected to the pump motor 80 connected to pump 128 to start and stop the pump motor 80 when the start 154 and emergency stop 156 switches, respectively, are operated. The relay switch 76 stops the motor when a low flow condition is detected by sensor 69 during evacuation. The evacuation selector switch 152 , which is electrically connected to the start switch 154 and to the emergency stop switch 156 , enables the selective evacuation of the hydraulic reservoir 107 or transmission reservoir 109 through the operation of a hydraulic reservoir solenoid valve coil 65 and a transmission reservoir solenoid valve coil 67 , respectively. The default position in FIG. 11 is the evacuation of the engine reservoir 105 , but it will be appreciated that any of the reservoirs may be chosen as the default position, and that the number of reservoirs may not be limited to three.
As shown in FIG. 12 , each of the lines 410 , 420 and 400 may also be coupled to a corresponding check valve 170 , 170 ′ or 170 ″, respectively, to allow flow in one direction only as well as a check valve 170 ′″ around pump 128 . Optionally, a line 439 (shown in dotted lines) may be provided with appropriate valving around the pump 128 , which is connected to a quick disconnect coupling 440 . In this embodiment, the truck pump 160 of a lubrication evacuation truck may be used to evacuate fluids. The truck pump 160 evacuates through permanent line 472 or quick disconnect line 474 to a truck waste tank 470 . If pump 128 is used and the truck pump 160 is not used, a conduit 460 may be connected by application of appropriate valving through the permanent line 472 or the quick disconnect 474 to the lubrication truck waste tank 470 .
FIGS. 13 through 17 illustrate embodiments for a dual-pump multiple reservoir conduit system 200 including a first pump 230 in fluid communication with an engine reservoir 505 , and a second pump 228 in fluid communication with a hydraulic reservoir 507 and a transmission reservoir 509 . However, it will be appreciated that more pumps may be used or the pumps may be connected to different reservoirs within the spirit and scope of the invention. In this embodiment, the first pump 230 evacuates the engine oil through a first outlet port 312 operated with an electrical switch connected to a connector 372 on a remote bracket 373 or mounted on a service panel 250 . A first conduit 520 is connected to the engine reservoir 505 at a first end 522 by a first coupling 524 , and to the first pump 230 at a second end 526 by a second coupling 528 . A second conduit 530 is connected at a first end 532 to the first pump 230 by a first coupling 534 , and to the first outlet port 312 at a second end 536 by a second coupling 538 . The outlet port 312 may be connected to a conduit to provide for pre-lubrication of the engine. Alternatively, the second conduit 530 may also be fluidically connected to a coupling 251 in a control panel 250 , discussed below. The second pump 228 is connected to a control valve 616 and evacuates fluid from the transmission reservoir 509 or the hydraulic reservoir 407 to a second outlet port 212 by operating the selector switch 274 and an evacuation switch connected to connector 272 which, together with the outlet port 212 , may be mounted on a second bracket 273 . The second pump 228 and each of the reservoirs 507 , 509 are connected to a control valve 616 through of a network of conduits 513 . The network of conduits 513 includes a first network conduit 540 , which is connected at a first end 542 to the hydraulic reservoir 507 by a first coupling 546 , and to the control valve 616 at a second end 544 by a second coupling 548 . A second network conduit 550 is connected at a first end 554 to the transmission reservoir 509 by a first coupling 558 , and to the valve 616 at a second end 552 by a second coupling 556 . A third network conduit 580 is connected to the pump 228 at a first end 582 by a first coupling 586 and to the outlet port 212 at a second end 584 by a second quick coupling 588 . Alternatively, the conduit 580 may be fluidically connected to a coupling 253 on the control panel 250 . A fourth network conduit 590 is connected to the second pump 228 at a first end 592 by a first coupling 596 and to the control valve 616 at a second end 594 by a second quick coupling 598 . A flexible conduit 315 may be used connect the outlet ports 312 or 212 to a waste oil container or to a port of a lubrication truck leading to a waste oil tank 570 on the lube truck, as shown in FIG. 17 . The control valve 616 provides for the selective evacuation of the transmission 509 or hydraulic reservoir 507 .
FIG. 14 illustrates an electrical diagram for an embodiment of a dual-pump multiple reservoir evacuation system illustrated in FIG. 13 . Each pump motor 263 and 262 is connected to a corresponding relay switch 258 and 259 , and each relay switch is powered, for example, by a portable source of 12V or 24V DC current. First and second motor relay switches 258 , 259 are connected to a first and second normally open start switches 372 and 272 . Between each relay and the corresponding start switch, low flow sensors 280 and 281 , respectively, may be activated to intervene and stop the corresponding motor when a low flow condition is detected. A source of electric current is connected to the second relay switch 259 , to the selector switch 274 and to the start switch 372 and 272 . A two-position control valve 216 controls flow to the hydraulic reservoir 507 and the transmission reservoir 509 , and is shown with a hydraulic reservoir as the default position, although any of the reservoirs may be the default reservoir.
It will be appreciated that the number of conduits connected to the first and second pumps need not be limited to a total of three. For example, the first pump 230 may be connected to N 1 reservoirs and the second pump 228 may be connected to N 2 reservoirs for a total number of N=N 1 +N 2 . FIG. 13 illustrates a first example of an embodiment where N 1 is equal to 1 and N 2 is equal to 2. In a second example of the same embodiment, N 1 is still equal to 1, but N 2 is a number greater that 2. In the second example, the control valve 616 is connected to N 2 reservoir conduits, such as conduits 540 and 550 . In both examples, the second pump is connected to the control valve 616 with pump conduit 590 , and to the second outlet 212 with outlet conduit 580 .
An embodiment for a remote service panel 250 including controls for a dual-pump multiple reservoir evacuation system is shown in FIG. 15 . It includes start 254 and stop 256 switches, a selector switch 252 and evacuation disconnect ports 251 , 253 for the first pump 230 and second pump 228 . A line 900 connected to the unfiltered side of the engine oil filter head may also be connected to a pressure-regulated air supply to purge the engine of used oil before adding replacement oil through the same port. On the same service panel sample ports 910 , 912 , 914 for the transmission, engine and hydraulic fluid reservoirs respectively may be mounted, as well as a remote ignition selector 918 and a remote ignition switch 916 .
An embodiment of an electrical diagram for the panel of FIG. 15 is shown in FIG. 16 . The pump motors 963 and 962 for the pumps 230 and 228 , respectively, are connected to corresponding relay switches 958 and 959 , respectively, and each relay switch is powered, for example, by a source of 12V or 24V DC current. The first and second motor relay switches 958 , 959 are connected to the selector switch 252 and a normally closed emergency stop switch 256 . Between each relay and the emergency stop switch 256 , low flow sensors 280 and 281 , respectively, intervene to stop the respective motor when a low flow condition is detected. The selector switch 252 is connected to a valve coil 966 and a normally open start switch 254 . In FIG. 16 , electrical wiring for the transmission reservoir is depicted in the selector switch 254 , corresponding to contact points including the letter “T” designation. For clarity of disclosure, some wiring for the hydraulic and engine reservoirs, corresponding to contact points “H” and “E” of the selector switch 966 , has been omitted.
FIG. 17 illustrates a hydraulic diagram for an embodiment of a dual-pump multiple reservoir evacuation system. The first and second pumps 230 and 228 evacuate fluid from each of the selected reservoirs to ports 312 and 212 , which may be mounted on brackets 373 and 273 , respectively, or to the connectors 251 and 253 on the control panel 250 . The flow from each reservoir 505 , 507 and 509 may be controlled in one-way direction by check valves downstream from each reservoir. Check valves 705 , 707 and 709 are connected downstream from the engine reservoir 505 , the hydraulic reservoir 507 and the transmission reservoir 509 respectively. Check valves 720 and 722 are also mounted on bypass pipes 711 and 712 , respectively, bypassing the first pump 230 and the second pump 228 , respectively. A control valve 216 , controls flow to the transmission reservoir 509 and to the hydraulic reservoir 507 , and is shown with default position to the hydraulic reservoir 507 . The discharge from bracket couplings 212 and 312 or control panel connectors 251 and 253 may be coupled to a discharge container or to a conduit 315 mounted on a lube truck. In that case, evacuated fluid passes through properly valved line 360 around lube truck pump 160 and directly into reservoir 570 . Alternatively, it will be appreciated that the pumps 230 and 228 may be bypassed by lines 574 and 576 , respectively, and appropriate valving provided in order that evacuation suction may be provided by the pump 160 on the lube truck. That discharge may then pass directly to the lube truck reservoir 570 via, for example, a fixed line 372 , a quick connection line 374 , a flexible conduit, or another suitable fluid system configuration.
Either single-pump multiple reservoir system (as described in connection with FIGS. 8 through 12 ) or the dual-pump multiple reservoir systems (as described in connection with FIGS. 13 through 17 ) may be used to remove fluid from any of the reservoirs on a machine or vehicle, by attaching evacuation conduits to the reservoirs as shown in the respective figures, operating the control valve to select a reservoir and actuating the pump to pump fluid from the selected reservoir to an outlet port for discharge. Additionally, after draining a selected reservoir, replacement fluid may be admitted into the appropriate cavity as shown schematically in FIG. 18 , by attaching to a conduit 972 connected to the unfiltered side of the fluid system (e.g., to the cavity's filter head 970 ), and a replacement fluid conduit 974 , by means of a coupling 976 . The coupling 976 is connected to a replacement fluid source 978 . For example, engine oil can be input into line 44 in the embodiment in FIG. 10 or into line 900 in the embodiment in FIG. 15 , in each case before the oil filter head. It can be appreciated that the fluid cavities corresponding to the other reservoirs discussed herein can also be refilled by inputting replacement fluid on the unfiltered side of the respective filters of such fluid cavities.
Referring now to FIG. 19 , one embodiment of a fluid system 1001 including a machine (wherein the machine in this example embodiment is an engine 1002 ) connected to a pump 1004 is shown. In one aspect of this embodiment, the pump 1004 may be a supplemental pump or engine pre-lubrication pump, for example, and/or may be installed and operated at a local location or a remote location with respect to the position and operation of the engine 1002 . The pump 1004 is configured for fluid communication and operation in association with an evacuation bracket 1006 . Based on the mode of operation of the engine 1002 , a fluid circuit may be completed or interrupted by a quick disconnect 1008 . During a fluid evacuation procedure, for example, the evacuation bracket 1006 can be used, in association with the operation of the pump 1004 , to evacuate various fluids from the engine 1002 . In addition, in the embodiment of FIG. 19 and in various embodiments of the present systems and methods described herein, a control module 1100 can be operatively associated with various components of the fluid system 1001 . Also, an internal data module 1200 can be operatively associated with the engine 1002 for receiving, storing and/or processing data related to functions performed within the fluid system 1001 . In another aspect, a supplemental filter system 1010 may be operatively installed in association with the evacuation bracket 1006 and the quick disconnect 1008 , for example. In various aspects of the present systems and methods, the supplemental filter system 1010 may be, for example, a fine filtration system as that term is understood in the art.
Referring now to FIG. 20 , in one illustrative embodiment, the control module 1100 includes various components for controlling and monitoring a fluid system, as well as for monitoring, collecting and analyzing data associated with various fluid system and method embodiments described herein. The control module 1100 includes a processor 1102 for executing various commands within, and directing the function of, the various components of the control module 1100 . One or more sensor inputs 1104 can be provided in the control module 1100 for receiving and processing data communicated from one or more sensors 1105 installed within a fluid system. Sensors 1105 applicable to operation of a machine can include, without limitation, sensors to detect temperature, sensors to detect pressure, sensors to detect voltage, sensors to detect current, sensors to detect contaminants, sensors to detect cycle time, flow sensors and/or other sensors suitable for detecting various conditions experienced by the machine during the various stages of operation of the machine. In addition, one or more indicators 1106 can be provided within the control module 1100 for providing alerts or notifications of conditions detected and communicated to the control module 1100 . Such indicators 1106 can be conventional audio, visual, or audiovisual indications of a condition detected within a fluid system. The control module 1100 may also include one or more data storage media 1108 for storing, retrieving and/or reporting data communicated to the control module 1100 . Data stored within the data storage media 1108 may include a variety of data collected from the condition of the fluid system including, for example and without limitation, oil condition, particle count of contaminants, cycle time data for time to evacuate or time to refill a given reservoir, fluid receptacle or other fluid storage/retention medium.
The control module 1100 further includes one or more controls 1110 for permitting manipulation of various elements of a fluid system and/or for receiving and processing data communicated from a fluid system. Machine controls 1110 A can be provided for controlling various aspects of an engine, for example, such as ignition, pre-lubrication operations, initiating a fluid evacuation process, initiating a fluid refill process, and various other machine operations. Pump controls 1110 B can be provided for controlling the action of a pump or supplemental pump operatively associated with a fluid system, such as the fluid system of a machine, for example. One or more valve controls 1110 C can be provided to actuate the position (e.g., open, closed, or other position) of one or more valves included within a fluid system. In addition, one or more multi-position valve controls 1110 D can be provided to operate a multi-way valve (e.g., a five-way valve), or another multi-position valve apparatus or system such as a junction block assembly, for example (described hereinafter). In addition, evacuation bracket controls 1110 E can be provided for the particular function of one or more evacuation brackets included within, or introduced into, a fluid system.
It can be appreciated that any portion of the above-described controls 1110 may be manually actuated by a machine operator, for example, or automatically actuated as part of execution of instructions stored on a computer-readable medium, for example. In one illustrative example, the pump controls 1110 B may be operatively associated automatically with manual actuation of the machine controls 1110 A, such as in the event of a pre-lubrication process initiated during ignition of an engine, for example.
In addition, in various embodiments described herein, it can be appreciated that the controls 1110 need not be located within the same location such as included within the same service panel, for example, or other like centralized location. It can be further appreciated that the controls 1110 may be operatively associated with a machine, a fluid system, a valve system, or other component of the present embodiments by one or more wireline and/or wireless communication methods or systems. Thus, in various embodiments described herein, it can be seen that the controls 1110 may be considered clustered for a particular application of the present embodiments while not necessarily being physically located in a single, centralized location such as installed on a service panel, for example.
Data can be communicated to the control module 1100 to and/or from a fluid system through a variety of methods and systems. In various embodiments disclosed herein, data may be communicated, for example, by a wireline connection, communicated by satellite communications, cellular communications, infrared and/or communicated in accordance with a protocol such as IEEE 802.11, for example, or other wireless or radio frequency communication protocol among other similar types of communication methods and systems. As shown in FIG. 20 , one or more data devices 1150 can be employed in operative association with the control module 1100 for the purpose of receiving, processing, inputting and/or storing data and/or for cooperating with the control module 1100 to control, monitor or otherwise manipulate one or more components included within a fluid system. Examples of data devices 1150 include, for example and without limitation, personal computers 1150 A, laptops 1150 B, and personal digital assistants (PDA's) 1150 C, and other data devices suitable for executing instructions on one or more computer-readable media.
Various types of sensors 1105 can be employed in various embodiments of the present systems and methods to detect one or more conditions of a fluid system. For example, the sensors 1105 can detect one or more of the following conditions within a fluid system: engine oil pressure, oil temperature in the engine, amount of current drawn by a pre-lubrication circuit, presence of contaminants (such as oil contaminants, for example) in the engine, amount of time that has elapsed for performance of one or more cycles of various engine operations (i.e., cycle time) such as pre-lubrication operations, fluid evacuation operations, fluid refill operations, fluid flow rates, and others. One example of a sensor 1105 that may be used in accordance with various embodiments of the present systems and methods is a contamination sensor marketed under the “LUBRIGARD” trade designation (Lubrigard Limited, United Kingdom, North America, Europe). A contamination sensor can provide information regarding oxidation products, water, glycol, metallic wear particles, and/or other contaminants that may be present in the engine oil, hydraulic oil, gearbox oil, transmission oil, compressor oil and/or other fluids used in various machines. In various aspects of the present methods and systems, the contamination sensor may be employed during one or more fluid processes, for example, such as a fluid evacuation process or a fluid refill process.
It can be appreciated that the control module 1100 can receive and store data associated with activation and deactivation of various components of a fluid system and operation of a machine, such as an engine, for example, included within the fluid system. Cycle time, for example, can be calculated from analysis of collected data to provide an indication of elapsed time for completing evacuation and/or refill operations. For a given oil temperature or temperature range (e.g., as can be detected and communicated by a temperature sensor), an average cycle time, for example, can be calculated through analysis of two or more collected cycle times. In one aspect, the present methods and systems can determine whether the most recently elapsed cycle time deviates from a nominal average cycle time, or range of cycle times, for a given oil temperature or temperature range. In addition, factors may be known such as the type and viscosity of fluids (e.g., such as oil) used in connection with operation of the machine. An unacceptable deviation from a nominal cycle time, or range of times, can result in recording a fault in a data storage medium 1108 of the control module 1100 . It can be appreciated that many other types of fault conditions may detected, analyzed and recorded in connection with practice of the present systems and methods. In other illustrative examples, conditions associated with battery voltage, current, and/or the presence of contaminants in the machine, for example, may be detected, analyzed, and one or more fault conditions recorded by the control module 1100 .
Referring now to FIG. 21 , in various embodiments of the present methods and systems, data collected from fluid system operation can be stored on an internal data module 1200 installed on or near a machine. The internal data module 1200 can include a processor 1202 with an operatively associated memory 1204 . In one aspect, the internal data module 1200 can be a “one-shot” circuit, as that term is understood by those skilled in the art. The internal data module 1200 can be configured to receive and store data related to various conditions of a fluid system, a machine, a valve, a pump, or other components of a fluid system. In one embodiment, the internal data module 1200 can store data in the memory 1204 prior to engine ignition and then transfer the stored data to the control module 1100 , for example, or another computer system, once engine ignition is initiated. In another embodiment, the internal data module 1200 can store condition data for subsequent download to the control module 1100 or another suitable computer system. In various embodiments, the internal data module 1200 can be configured for use in performing data collection and storage functions when the control module 1100 is not otherwise active (e.g., during various machine service operations). In this manner, the internal data module 1200 can be employed to store data corresponding to the electrical events associated with an oil change, for example, or another type of fluid evacuation or refill procedure and can transmit data related to the procedure to the control module 1100 . In various embodiments, the internal data module 1200 can be a stand-alone, discrete module, or can be configured for full or partial integration into the operation of the control module 1100 .
Collected and analyzed data, as well as recorded fault events, can be stored in association with the control module 1100 , the internal data module 1200 , and/or at a remote location. In various embodiments of the present methods and systems, the control module 1100 and/or the internal data module 1200 can be configured for operation as integral components of a machine or as remote components not installed locally on the machine. The collected and analyzed information can be stored in one or more of the data storage media 1108 of the control module 1100 , or on another conventional storage suitable for use in connection with the control module 1100 . The information can also be stored externally with respect to a machine and its components. As shown in FIG. 20 , data can be transmitted wirelessly by a radio frequency communication or by a wireline connection from the control module 1100 to one or more data devices 1150 . The personal digital assistant 1150 C, for example, may be configured and employed as a computer system for receiving and processing data collected from the control module 1100 during fluid evacuation and fluid refill processes.
In one illustrative example, information related to an oil change event, such as the time duration of the oil change, for example, and other engine conditions can be recorded and processed in connection with operation of the control module 1100 and/or the internal data module 1200 and/or their operatively associated storage medium or media. The date and time of the oil change event, for example, can also be recorded for one or more such oil changes. Analysis of the data may assume that a substantially constant volume of oil at a given temperature evacuates from, or refills into, the engine lubrication system in a consistent and repeatable amount of time. A calculation can be made that considers the amount of time needed for an oil change at a given temperature (as detected by an oil temperature sensor, for example), and other factors such as the type and viscosity of the oil. Using this calculation, the amount of oil evacuated from, or refilled into, the engine can be calculated. While the example of an engine is employed herein, it can be appreciated that the principles of the present methods and systems described herein can be readily applied, for example, to hydraulic fluid reservoirs, transmission fluid reservoirs, and a variety of other types of fluid reservoirs. The calculated evacuated/refilled oil amount can be compared against a nominal value for the sump capacity. If the calculated amount is greater than or less than the nominal value or tolerance range for such calculations, this information can be recorded as a fault for further investigation and/or maintenance. In one embodiment, the fault recorded can be recorded electronically, such as in association with operation of the control module 1100 . One or more notifications can be generated for an operator of the engine by use of the indicators 1106 , for example, to advise the operator that a fault has been recorded by the system. In application to various embodiments described herein, the notification can take the form of an audible signal, a visual or text signal, or some reasonable combination of such signals.
Referring now to FIG. 22 , one embodiment of a method for performing multiple fluid evacuation and refill processes is shown. In step 1222 , a need for a fluid change is identified, such as a fluid change in the fluid reservoir of a machine, for example. Identification of fluid change needs/desires and subsequent functions performed in the fluid system can be controlled in connection with a control module (in accordance with the above discussion). In step 1224 , the configuration of a valve system included within a fluid system can be adjusted to permit a fluid evacuation process to be performed in operative association with the identified fluid reservoir. It can be appreciated that adjustments to configuration of the valve system performed in step 1224 can be facilitated in an automated manner such as by operative association of the fluid system with the control module 1100 , for example, by a manual operator adjustment, or some reasonable combination of automated and manual processes. The identified fluid reservoir is evacuated in step 1226 . In optional step 1227 , which can be performed prior to the evacuation process of step 1226 , a conventional purge procedure can be performed on a fluid system associated with the reservoir to remove waste fluids, to resist spillage of fluids, to resist environmental contamination potentially caused by waste fluids, and/or to promote safety of an operator, for example, or other personnel by resisting contact between waste fluids (and potentially harmful components of waste fluids) and the operator. In one aspect, the purge procedure of step 1227 can be performed prior to performance of a subsequent fluid refill process, for example, for the reservoir. In one illustrative embodiment, the purge procedure can include an air purge procedure, for example. In step 1228 the valve system can be configured to permit a fluid refill process to be performed in connection with the identified fluid reservoir. In step 1230 , a fluid replacement source is accessed, and the identified fluid reservoir is refilled in step 1232 . In one aspect of the present methods and systems, it can be appreciated that the refill procedure of step 1232 can be performed by delivering the refill fluid pre-filter with respect to the identified fluid reservoir.
In step 1234 , a determination is made as to whether an additional fluid change process is required or desired. If it is determined that an additional reservoir does require a fluid change, then the valve system is configured in step 1236 to permit a fluid evacuation process to occur for the additionally identified reservoir, which additionally identified reservoir can include a fluid which is similar or dissimilar with respect to the fluid of the first identified reservoir. It can be appreciated that adjustments to the valve system performed in step 1236 can be facilitated in an automated manner such as by operative association of the fluid system with the control module 1100 , for example, by a manual operator adjustment, or some reasonable combination of automated and manual processes. In step 1238 , fluid within the additional reservoir is evacuated. In optional step 1227 (also described above), which can be performed prior to the evacuation process of step 1238 , a conventional purge procedure can be performed on a fluid system associated with the reservoir to remove waste fluids, to resist spillage of fluids, to resist environmental contamination potentially caused by waste fluids, and/or to promote safety of an operator, for example, or other personnel by resisting contact between waste fluids (and potentially harmful components of waste fluids) and the operator. In one aspect, the purge procedure of step 1227 can be performed prior to performance of a subsequent fluid refill process, for example, for the reservoir. In step 1240 , the valve system can be configured to permit a fluid refill process for the additional reservoir. In step 1242 , a fluid replacement source is accessed, and the additional reservoir is refilled with fluid in step 1244 to the unfiltered side of the fluid system. In one aspect of the present methods and systems, it can be appreciated that the refill procedure of step 1244 can be performed by delivering the refill fluid pre-filter with respect to the additional reservoir. The process can then return to step 1234 to identify additional reservoirs for which fluid changes may be needed or desired. It can be seen that the method shown in FIG. 22 permits multiple fluids to be evacuated and/or refilled for multiple reservoirs associated with a machine, from potentially multiple fluid replacement sources or reservoirs, in an automated or substantially automated manner.
In various embodiments of the present methods and systems, data can be collected, stored and/or analyzed for multiple reservoirs connected with, or operatively associated with, a machine. Referring again to FIG. 22 , a control module or other data device (as described hereinabove), for example, can be employed in step 1248 to collect data 1248 A, store data 1248 B, and/or analyze data 1248 C in accordance with one or more of the process steps shown in FIG. 22 , as well as other steps performed in connection with operation and/or maintenance functions of a machine. In one example aspect, it can be seen that the control module can be applied in step 1248 to collect and analyze time-stamp information associated with an event such as an evacuation/refill process performed in connection with an oil reservoir, for example. In other aspects of the present methods and systems, it can be appreciated that many types of data can be collected, analyzed, and/or stored in connection with the function of multiple reservoirs. Data such as current valve position, valve type, and/or reservoir type, for example, can be collected in connection with performance of an evacuation/refill procedure for a first reservoir. A further evacuation/refill procedure, or another process step, can then be initiated for the first reservoir or for an additionally identified reservoir. Likewise, data such as current valve position, valve type, reservoir type, for example, can be collected in association with the evacuation/refill procedure for the additionally identified reservoir, for example, or another process step.
Referring now to FIG. 23 , one embodiment of a system for performing multiple fluid evacuation and fluid refill processes is shown in schematic form. A first junction block assembly 1252 having a plurality of ports (represented by positions A,B,C,D,E and F) is connected through conventional piping or hydraulic hoses, for example, to the suction side 1254 of a pump 1256 . A second junction block assembly 1258 having a plurality of ports (represented by positions G,H,I,J,K and L) is also connected through conventional piping or hydraulic hoses, for example, to the pressure side 1260 of the pump 1256 . In one aspect, the system may include a disconnect 1262 , such as a quick disconnect and bracket assembly, for example, in the piping. In various aspects of the system, a control module 1100 can be operatively associated with various control, sensing, and monitoring functions performed in association with operation of the system. It can be appreciated that the junction block assemblies 1252 , 1258 are shown merely for purposes of illustration. One or both of the junction block assemblies 1252 , 1258 could be replaced with other multi-position valves, for example, or other suitable types of valves. It can be further appreciated that the system shown in FIG. 23 can be configured to perform multiple fluid refill and/or fluid evacuation processes in connection with one or more machine reservoirs, one or more fluid replacement sources, and/or one or more waste-receiving receptacles.
In one operational example of the valve system of FIG. 23 (which valve system includes the first and second junction block assemblies 1252 , 1258 ), ports D and G can be connected through piping to a machine 1251 such as a machine engine, for example. Port E can be configured to be a refill port that permits fluid to be introduced to the valve system such as from a fluid replacement source, for example. Port K can be configured as an evacuation port that permits fluid to be evacuated through the second junction block assembly 1258 from the machine 1251 , which evacuation may be facilitated by a quick disconnect and bracket assembly, for example. Port A is in fluid communication with the pump 1256 on the suction side 1254 of the pump 1256 , and Port J is in fluid communication with the pump 1256 on the pressure side 1260 of the pump 1256 .
In a first configuration of the illustrative valve system of FIG. 23 , all ports of the first junction block assembly 1252 are closed except for port A, which is in communication with the suction side 1254 of the pump 1256 , and port D, which is in an open position and in communication with the machine 1251 . In addition, all ports of the second junction block assembly 1258 are closed except for port J, which is in communication with the pressure side 1260 of the pump 1256 , and port K, which is in an open position in this configuration. The pump 1256 can be activated to evacuate fluid from the machine 1251 as drawn through the piping and through port D, through port A, through the pump 1256 , through port J, and ultimately through port K. Once the fluid evacuation process is completed, all ports of the first and second junction block assemblies 1252 , 1258 can be closed, except for the refill port E and ports A, J and G. The pump 1256 can be activated to draw fluid from port E through the piping and through port A, through the pump 1256 , through port J, and through port G into the machine 1251 . Based on this operational example, it can be seen how opening and closing various ports in various configurations of the valve system permits multiple evacuation and refill processes to be performed from multiple fluid replacement sources to multiple machine reservoirs in a variety of sequences. It can also be seen that a common evacuation point (e.g., port K) can be provided for various fluid processes that are performed by use of the valve system. In addition, it can be appreciated that different types of fluids (e.g., without limitation, engine oil, transmission fluid, hydraulic fluid, coolants, and other machine fluids) can be alternately and/or sequentially evacuated/refilled in connection with the various embodiments of the present methods and systems.
Various aspects of the following disclosure include operational examples for the various system and method embodiments described herein. It can be appreciated that such operational examples are provided merely for convenience of disclosure, and that no particular aspect or aspects of these operational examples are intended to limit the scope of application of the present systems and methods.
Referring now to FIGS. 24 , 25 A and 25 B, a fluid system 1301 is provided including an engine 1302 and a pump 1304 operatively connected to a junction block assembly 1400 . As shown in FIGS. 25A and 25B , the junction block assembly 1400 includes a substantially cube-shaped body 1402 having a plurality of ports, such as ports 1404 A, 1404 B, 1404 C, for example, formed therein. The junction block assembly 1400 can include any conventional material suitable for use in connection with the various fluid evacuation and refill processes described herein such as, for example and without limitation, aluminum, stainless steel, and other like materials. In the embodiment shown, the junction block assembly 1400 may possess a plurality of ports up to six ports, for example.
In one embodiment of the junction block assembly 1400 , one or more screens 1406 may be inserted between the body 1402 and one or more adapter fittings 1408 structured to be received, such as threadedly received, for example, into the junction block assembly 1400 . It can be appreciated that one or more of the screens 1406 can be positioned within the junction block assembly 1400 and/or more generally at any suitable location within the fluid systems described herein. In one embodiment, one or more of the screens 1406 may be formed as an integral assembly with one or more of the adapter fittings 1408 . In one aspect of such an integral arrangement, the screen 1406 can be positioned at a common location at which particles and other contaminants present in a fluid system may be trapped, inspected and/or removed from the fluid system. In other aspects, the screens 1406 and/or adapter fittings 1408 may be installed in conjunction with other components of a fluid system such as a pump, for example.
In one illustrative fluid system embodiment, the screen 1406 can be positioned in the junction block assembly 1400 at a common outlet port of the junction block assembly 1400 , wherein during operation of the fluid system the common outlet port is in fluid communication with the suction side or inlet port of a pump. In this embodiment, one or more fluids received into the junction block assembly 1400 from one or more fluid reservoirs can each be filtered by the screen 1406 positioned within the common outlet port of the junction block assembly 1400 .
In one aspect of the present embodiments, the adapter fitting 1408 can include a permanent or removably insertable plug that resists fluid from entering or exiting the particular port of the junction block assembly 1400 in which the adapter fitting 1408 is installed. In another aspect, the adapter fitting can include a magnetic plug, for example, to attract and capture ferrous materials, for example, and other particles or contaminants susceptible to magnetic attraction to the magnetic plug. It can be seen that, in a fluid system, a junction block assembly 1400 including an adapter fitting 1408 having a magnetic plug can be employed as a central or common location at which particles or contaminants present in the fluid system can be trapped, collected, inspected and/or analyzed. In one embodiment in which the magnetic plug is removably insertable from the junction block assembly, the magnetic plug can assist the junction block assembly 1400 in becoming a material/debris trap that allows for periodic inspections, for example, for detecting metal particles, for example, that may indicate damage, or the potential for damage, occurring in the reservoir or a related machine system.
Referring now to FIG. 25C , one example illustration of an embodiment a portion of a fluid system 1452 provided in accordance with the present methods and systems is shown. The fluid system 1452 includes a pump 1454 in fluid communication with a junction block assembly 1400 . In addition, a screen 1456 is positioned within a section of piping 1458 located between the pump 1454 and the junction block assembly 1400 on a suction side 1460 of the pump 1454 . In other aspects, it can be appreciated that the screen 1456 can be positioned to function at a variety of locations within the fluid system 1452 or other fluid systems. In the embodiment shown, it can be seen that the screen 1456 may act as a common location for collecting, trapping, and/or filtering particles, debris and/or contaminants flowing through the fluid system 1452 . During operation of the pump 1454 within the filter system 1452 , for example, particles, debris and/or contaminants are drawn from various other portions (not shown) of the fluid system 1452 through the section of piping 1458 including the screen 1456 to trap, collect, and/or filter those particles, debris, and/or contaminants, before fluid is permitted to flow to the suction side 1460 of the pump 1454 to be drawn into the pump 1454 .
Referring again to FIG. 24 , the junction block assembly 1400 can be connected to a fluid evacuation/refill port 1306 that permits fluids to exit (during a fluid evacuation process) or enter (during a fluid refill process) the fluid system 1301 . During an evacuation process, valve 1308 is actuated (such as by operation of a machine control 1110 A of the control module 1100 , for example, or by manual operation) to a closed position, and the pump 1304 is activated to evacuate fluid from the engine 1302 through the port 1306 connected to the junction block assembly 1400 . It can be seen that the junction block assembly 1400 is appropriately positioned/actuated to permit fluid to flow from the pump 1304 to the port 1306 during the evacuation procedure. During a refill procedure, the valve 1308 can be moved to an open position, and the junction block assembly 1400 can be appropriately positioned/actuated to permit fluid to flow from a reservoir and/or other apparatus (not shown) attached to the port 1306 to refill one or more fluid reservoirs via unfiltered or pre-filtered passages, for example, or other receptacles of the engine 1302 .
In various embodiments described herein, a conventional filter 1310 can be provided in association with a component such as an engine, for example, to filter contaminants or other particles that pass through the fluid system 1301 during the refill procedure and/or during normal operation of the engine 1302 . It can be appreciated that the type and/or configuration of conventional filters installed within or in association with the components of the fluid system 1301 can be provided in a variety of ways as will be evident to those skilled in the art.
The control module 1100 and the internal data module 1200 interact with the fluid system 1301 , and more generally other fluid systems described hereinafter, as previously discussed hereinabove with reference to FIGS. 20 and 21 . For convenience of disclosure, specific interaction and operation of the control module 1100 and the internal data module 1200 with fluid system embodiments described hereinafter are generally not described in detail, because such embodiments would be understood by those skilled in the art.
Referring now to FIG. 26 , in another embodiment of the present systems and methods, a fluid system 1501 is provided in which an engine 1502 is connected to a junction block assembly 1400 through a valve 1504 . A reservoir 1506 is also connected to the junction block assembly 1400 through a valve 1508 . In addition, a pump 1510 is connected to the junction block assembly 1400 , and the pump 1510 is also connected to an evacuation bracket and quick disconnect assembly 1512 in accordance with such assemblies as previously described hereinabove. In one operational example of this embodiment, a fluid evacuation process may be performed by opening valve 1504 and closing valve 1508 to evacuate fluid from the engine 1502 through an evacuation port of the junction block assembly 1400 . In one aspect, the fluid evacuation procedure can be performed by the operation of the pump 1510 to remove fluid from the engine 1502 through the evacuation bracket and quick disconnect assembly 1512 . The engine 1502 can then be refilled by connecting a fluid replacement source, for example, or another reservoir to the evacuation bracket and quick disconnect assembly 1512 . The reservoir 1506 can be evacuated by closing the valve 1504 , opening the valve 1508 , adjusting the positions of the various ports of the junction block assembly 1400 , and operating the pump 1510 to evacuate fluid from the reservoir 1506 through the evacuation bracket and quick disconnect assembly 1512 . In various embodiments of the present systems and methods, the reservoir 1506 may contain, for example and without limitation, transmission fluid, hydraulic fluid, lubricants such as oil, water, or another fluid used in addition to the operation of the engine 1502 and/or the overall function of the fluid system 1501 . In another aspect, a supplemental filter system 1514 may be operatively associated with the evacuation bracket and quick disconnect assembly 1512 . In various aspects, the supplemental filter system 1514 may be, for example, a fine filtration system as that term is understood in the art.
Referring now to FIG. 27 , in various embodiments of the present systems and methods, a fluid system 1601 is provided in which an engine 1602 is connected to a first junction block assembly 1400 through a valve 1604 . A reservoir 1606 is also connected to the junction block assembly 1400 through a valve 1608 . The junction block assembly 1400 also includes an evacuation/refill port 1610 structured for receiving fluids introduced into the fluid system 1601 , such as during a refill process, for example. In addition, a pump 1612 is connected to the first junction block assembly 1400 , and the pump 1612 is also connected to a second junction block assembly 1400 ′ through an optional valve 1614 . The second junction block assembly 1400 ′ includes an evacuation/refill port 1616 for removing/introducing fluids into the fluid system 1601 , such as by an evacuation process or by a refill process, for example. In addition, the reservoir 1606 includes a fluid connection through a valve 1618 to the second junction block assembly 1400 ′, and the engine 1602 also includes a fluid connection to the second junction block assembly 1400 ′ through a valve 1620 . It can be appreciated by those skilled in the art that the fluid system 1601 permits a variety of combinations for performing evacuation and/or refill processes. The positions of the valves 1604 , 1608 , 1614 , 1618 and 1620 , in operative interaction with the actuation of the first and second junction block assemblies 1400 , 1400 ′ provide this variety of combinations for introducing or removing fluids, respectively and where applicable, through the ports 1610 , 1616 .
In one aspect of an example of a fluid evacuation process, the engine 1602 can be identified for performance of one or more fluid refill/evacuation processes. Fluid can be evacuated from the engine 1602 , for example, by opening valves 1604 , 1614 , closing valves 1608 , 1618 , 1620 , adjusting the positions of ports associated with the first and second junction block assemblies 1400 , 1400 ′ (e.g., closing off ports not employed in a given fluid process, and other like adjustments), and activating the pump 1612 to draw fluid through the refill/evacuation port 1616 . A subsequent refill process can be performed for the engine 1602 by closing valves 1604 , 1608 , 1618 , opening valves 1614 , 1620 , adjusting the appropriate positions of the ports of the first and second junction block assemblies 1400 , 1400 ′ (e.g., closing off ports not employed in a given fluid process, and other like adjustments), and activating the pump 1612 to refill fluid into the engine 1602 by drawing the fluid from the evacuation/refill port 1610 , through the pump 1612 , to the engine 1602 . It can be appreciated that the fluid employed for the fluid refill process for the engine 1602 can be drawn from one or more fluid replacement sources (not shown) operatively connected to the evacuation/refill port 1610 of the first junction block assembly 1400 . In one aspect, the type of fluid drawn from the engine 1602 during the fluid evacuation process is of the same type as the fluid refilled into the engine 1602 during the fluid refill process.
In other steps of this operational example, the reservoir 1606 can be identified for a fluid evacuation/refill process. The valves 1604 , 1618 , 1620 can be closed, the positions of the ports of the first and second junction block assemblies 1400 , 1400 ′ can be adjusted (e.g., closing off ports not employed in a given fluid process, and other like adjustments), valves 1608 , 1614 can be opened, and the action of the pump 1612 can be employed to draw fluid from the reservoir 1606 through the evacuation/refill port 1616 of the second junction block assembly 1400 ′. In a subsequent fluid refill process, valves 1604 , 1608 , 1620 can be closed, valves 1614 , 1618 can be opened, and the pump 1612 can be employed to draw fluid through the evacuation/refill port 1610 of the first junction block assembly 1400 into the reservoir 1606 in the refill process. It can be appreciated that the fluid employed in the fluid refill process can be drawn from one or more fluid replacement sources (not shown) operatively associated with the evacuation/refill port 1610 of the first junction block assembly 1400 . In one aspect, the type of fluid drawn from the reservoir 1606 during the fluid evacuation process is of the same type as the fluid refilled into the reservoir 1606 during the fluid refill process. In various embodiments of the present systems and methods, the reservoir 1606 may contain, for example and without limitation, transmission fluid, hydraulic fluid, lubricants such as oil, water, or another fluid used in addition to the operation of the engine 1602 and/or the overall function of the fluid system 1601 .
It can be appreciated that pumps employed in connection with the various fluid systems described herein can be “on-board” or “off-board” with respect to a machine that operates in connection with the fluid system. For example, in one illustrative embodiment, an “off-board” pump could be applied in connection with the evacuation/refill port 1610 with the appropriate configuration of the valve system of the fluid system of FIG. 27 to perform one or more fluid evacuation/refill processes.
Referring now to FIG. 28 , in various embodiments of the present systems and methods, a fluid system 1701 is provided in which an engine 1702 is connected to both a first multi-position valve 1704 and a second multi-position valve 1706 . One or more reservoirs 1708 , 1709 are also fluidically connected to each of the first and second multi-position valves 1704 , 1706 . In addition, a pump 1710 is provided to facilitate one or more evacuation processes in connection with fluids contained with the engine 1702 and/or the reservoirs 1708 , 1709 . In various embodiments of the present systems and methods, the reservoirs 1708 , 1709 may contain, for example and without limitation, transmission fluid, hydraulic fluid, lubricants such as oil, water, or another fluid used in addition to the operation of the engine 1702 and/or the overall function of the fluid system 1701 . In one aspect of the operation of the fluid system 1701 , each of the multi-position valves 1704 , 1706 is actuated/positioned to permit the action of the pump 1710 to evacuate and refill fluids from the engine 1702 and the reservoirs 1708 , 1709 , in a sequence determined by an operator, for example, or by an automated determination by the control module 1100 , for example.
In one aspect of an operational example, the engine 1702 can be identified for performance of one or more fluid evacuation/refill processes. In a fluid evacuation process, appropriate ports of the multi-position valves 1704 , 1706 are actuated, in conjunction with activation of the pump 1710 , to draw fluid from the engine 1702 through the multi-position valve 1704 , through the pump 1710 , and through a selected port of the multi-position valve 1706 serving as an evacuation port. It can be appreciated that a waste-receiving receptacle, for example (not shown), may be operatively associated with the selected evacuation port of the multi-position valve 1706 to receive and/or store fluid evacuated from the engine 1702 . In a subsequent fluid refill process, appropriate ports of the multi-position valves 1704 , 1706 are actuated, in conjunction with activation of the pump 1710 , to draw fluid from a selected port of the multi-position valve 1704 serving as a refill port, through the pump 1710 , through the multi-position valve 1706 , and to the engine 1702 . It can be appreciated that a fluid replacement source, for example (not shown), may be operatively associated with the selected refill port of the multi-position valve 1704 to provide a source for fluid introduced into the fluid system 1701 and used for the refill process for the engine 1702 .
In another aspect of this operational example, the reservoir 1708 can be identified for performance of one or more fluid refill/evacuation processes. In a fluid evacuation process, appropriate ports of the multi-position valves 1704 , 1706 are actuated, in conjunction with activation of the pump 1710 , to draw fluid from the reservoir 1708 through the multi-position valve 1704 , through the pump 1710 , and through a selected port of the multi-position valve 1706 serving as an evacuation port. It can be appreciated that a waste-receiving receptacle, for example (not shown), may be operatively associated with the selected evacuation port of the multi-position valve 1706 to receive and/or store fluid evacuated from the reservoir 1708 . In a subsequent fluid refill process, appropriate ports of the multi-position valves 1704 , 1706 are actuated, in conjunction with activation of the pump 1710 , to draw fluid from a selected port of the multi-position valve 1704 serving as a refill port, through the pump 1710 , through the multi-position valve 1706 , and to the reservoir 1708 . It can be appreciated that a fluid replacement source, for example (not shown), may be operatively associated with the selected refill port of the multi-position valve 1704 to provide a source for fluid introduced into the fluid system 1701 and used for the refill process for the reservoir 1708 .
In another aspect of this operational example, the reservoir 1709 can be identified for performance of one or more fluid refill/evacuation processes. In a fluid evacuation process, appropriate ports of the multi-position valves 1704 , 1706 are actuated, in conjunction with activation of the pump 1710 , to draw fluid from the reservoir 1709 through the multi-position valve 1704 , through the pump 1710 , and through a selected port of the multi-position valve 1706 serving as an evacuation port. It can be appreciated that a waste-receiving receptacle, for example (not shown), may be operatively associated with the selected evacuation port of the multi-position valve 1706 to receive and/or store fluid evacuated from the reservoir 1709 . In a subsequent fluid refill process, appropriate ports of the multi-position valves 1704 , 1706 are actuated, in conjunction with activation of the pump 1710 , to draw fluid from a selected port of the multi-position valve 1704 serving as a refill port, through the pump 1710 , through the multi-position valve 1706 , and to the reservoir 1709 . It can be appreciated that a fluid replacement source, for example (not shown), may be operatively associated with the selected refill port of the multi-position valve 1704 to provide a source for fluid introduced into the fluid system 1701 and used for the refill process for the reservoir 1709 .
It is readily apparent to those skilled in the art that, in accordance with various aspects of the present method and system embodiments, engines, reservoirs and other like receptacles can be first evacuated and subsequently refilled in a manner that permits a pump not to encounter a refill fluid (e.g., a “clean” fluid) of a certain type, until the pump has processed an evacuated fluid (e.g., a “dirty” fluid) of the same type as the refill fluid. It can be seen that this sequence of fluid evacuation/refill processes can reduce the degree of cross-contamination for components or other elements of a fluid system that may be caused by a mixture of different types of fluids.
Referring now to FIG. 29 , in various embodiments of the present systems and methods, a fluid system 1801 is provided in which an engine 1802 is connected to both a first multi-position valve 1804 having a refill port 1806 and a second multi-position valve 1808 having an evacuation port 1810 . A reservoir 1812 is also fluidly connected to each of the first and second multi-position valves 1804 , 1808 . In addition, a pump 1814 is provided to facilitate one or more evacuation and/or refill processes in connection with fluids contained with the engine 1802 and/or the reservoir 1812 . In another aspect, an additional reservoir 1813 is connected between the first multi-position valve 1804 and the second multi-position valve 1806 . In various embodiments of the present systems and methods, the reservoirs 1812 , 1813 may contain, for example and without limitation, transmission fluid, hydraulic fluid, lubricants such as oil, water, or another fluid used in addition to the operation of the engine 1802 and/or the overall function of the fluid system 1801 .
In one example aspect of the operation of the fluid system 1801 shown in FIG. 29 , the multi-position valves 1804 , 1808 are actuated/positioned to permit the action of the pump 1814 to remove fluid from the reservoir 1812 . Then, in this operational example, the multi-position valves 1804 , 1808 can be actuated/positioned to perform a fluid refill process for the reservoir 1812 . Thereafter, the engine 1802 can be evacuated and then refilled in sequence once the fluid processes involving the reservoir 1812 have been completed.
In accordance with previous discussion hereinabove, it can be appreciated that the operative association of the fluid system 1801 , for example, with the control module 1100 permits a variety of sequences and combinations of evacuation and refill processes. Such sequencing can be facilitated by the control module 1100 through a combination of manual and/or automated processes executed in conjunction with the operation of the control module 1100 . It can be seen that such sequencing of evacuation and/or refill operations can be applied to various previously discussed embodiments of the present systems and methods, as well as embodiments discussed hereinafter.
Referring now to FIG. 30 , in various embodiments of the present systems and methods, a fluid system 1901 is provided in which an engine 1902 is connected to a junction block assembly 1400 through a valve 1904 . A first reservoir 1906 is also connected to the junction block assembly 1400 through a valve 1908 . In addition, a second reservoir 1910 is connected to the junction block assembly 1400 through a valve 1912 . The junction block assembly 1400 includes an evacuation port 1914 structured to fluidically connect with a quick disconnect 1916 . In operation of the fluid system 1901 , the quick disconnect 1916 establishes fluid connection between the junction block assembly 1400 and a pump 1918 . In addition, a waste-receiving receptacle 1920 is connected to the pump 1918 . In an example fluid evacuation process, the respective positions of the valves 1904 , 1908 , 1912 , the actuation/position of the junction block assembly 1400 , the connection of the quick disconnect 1916 to the evacuation port 1914 , and the operation of the pump 1918 work in conjunction to perform a fluid evacuation process for each of the engine 1902 and the first and second reservoirs 1906 , 1910 . For example, it can be seen that such a fluid evacuation process results in fluid flowing from the engine 1902 into the waste-receiving receptacle 1920 . It can be appreciated that the functions of the control module 1100 , working in association with the various components of the fluid system 1901 , can result in evacuating fluids, and subsequently refilling fluids, for one or more of the engine 1902 and the reservoirs 1906 , 1910 in a sequential manner. In various embodiments of the present systems and methods, the reservoirs 1906 , 1910 may contain, for example and without limitation, transmission fluid, hydraulic fluid, lubricants such as oil, water, or another fluid used in addition to the operation of the engine 1902 and/or the overall function of the fluid system 1901 .
Referring now to FIG. 31 , in various embodiments of the present systems and methods, a fluid system 2001 is provided in which an engine 2002 is connected to a junction block assembly 1400 through a valve 2004 . A first reservoir 2006 is also connected to the junction block assembly 1400 through a valve 2008 . In addition, a second reservoir 2010 is connected to the junction block assembly 1400 through a valve 2012 . The junction block assembly 1400 includes a refill port 2014 structured to fluidly connect with a quick disconnect 2016 . In operation of the fluid system 2001 , the quick disconnect 2016 establishes fluid connection between the junction block assembly 1400 and a pump 2018 . In addition, a fluid source 2020 is connected to the pump 2018 . In one aspect of the present embodiment, the fluid source may be detachably connected to the pump 2018 so that subsequent fluid sources (not shown) containing a variety of fluids can be introduced to the fluid system 2001 through the action of the pump 2018 . In an example fluid refill process, the respective positions of the valves 2004 , 2008 , 2012 , the actuation/position of the junction block assembly 1400 , the connection of the quick disconnect 2016 to the refill port 2014 , and the operation of the pump 2018 work in conjunction to perform various fluid refill processes for the engine 2002 and the first and second reservoirs 2006 , 2010 . In one example, it can be seen that such a fluid refill process can result in fluid flowing into the engine 2002 (after a prior fluid evacuation process) from the fluid source 2020 . It can be appreciated that the functions of the control module 1100 , working in association with the various components of the fluid system 2001 , can result in evacuating/refilling one or more of the engine 2002 and the reservoirs 2006 , 2010 in a sequential manner. As shown, filters 2022 , 2024 , 2026 may be employed to filter contaminants or other particles present in fluid flowing from the fluid source 2020 to the engine 2002 , the first reservoir 2006 , or the second reservoir 2010 (respectively). In various embodiments of the present systems and methods, the reservoirs 2006 , 2010 may contain, for example and without limitation, transmission fluid, hydraulic fluid, lubricants such as oil, water, or another fluid used in addition to the operation of the engine 2002 and/or the overall function of the fluid system 2001 . In addition, in another aspect, supplemental filter system 2028 can be installed between the refill port 2014 and the pump 2018 . In various aspects of the present systems and methods, the supplemental filter system 2028 may be, for example, a fine filtration system, as that term is understood in the art.
Referring now to FIG. 32 , in various embodiments of the present invention, a check valve assembly 2100 is provided in accordance with various systems and methods. The assembly 2100 includes a first check valve 2102 having an inlet 2102 A in fluid communication with a common refill/evacuation location 2104 and an outlet 2102 B in fluid communication with a portion of a fluid system 2106 . A second check valve 2108 of the assembly 2100 includes an inlet 2108 A in communication with a fluid reservoir 2110 , for example, or another similar structure included within a fluid system. The second check valve 2108 further includes an outlet 2108 B in fluid communication with the common refill/evacuation location 2104 . In addition, an inlet/outlet port 2112 may be structured for fluid communication with the common refill/evacuation location 2104 .
In various embodiments, the portion of a fluid system 2106 may include any reasonable combination of valves, pipes, reservoirs and/or other fluidic structures. In certain embodiments, the portion of a fluid system 2106 may be configured to include an operative association with at least a pre-filter portion of the fluid system. In various embodiments, the fluid reservoir 2110 may contain a quantity of a fluid such as oil, transmission fluid, hydraulic fluid, or another type of fluid described hereinabove and/or any other fluid suitable for use in accordance with the present systems and methods. In certain embodiments, a quick disconnect 2114 or other similar type of coupling may be operatively associated with the inlet/outlet port 2112 to permit operative association of various fluidic structures such as an external pump, for example, with the inlet/outlet port 2112 . In various embodiments, the inlet/outlet port 2112 may be operatively associated with a clustered service location (as described hereinabove), for example.
In various embodiments, the inlet 2102 A of the first check valve 2102 may be structured to respond to application of positive pressure (represented by arrow 2116 ) at the common refill/evacuation location 2104 , which response to the positive pressure 2116 includes actuating the first check valve 2102 and permitting fluid to flow therethrough. As applied herein with respect to pressure levels, the term “positive” means pressure which is at a level sufficient to move a fluid or fluids in the direction of the positive pressure flow 2116 (e.g., fluid moving in a direction from the inlet/outlet port 2112 to the inlet 2102 A of the first check valve 2102 ). During a filter purge operation, for example, compressed air may be introduced as positive pressure at the common refill/evacuation location 2104 and the inlet 2102 A of the first check valve 2102 . The positive pressure of the compressed air actuates the first check valve 2102 to permit the compressed air to flow to at least the portion of a fluid system 2016 and/or through passages, valves, filters, reservoirs or other fluidic structures in the fluid system that may contain old or used fluids (e.g., old or used oil). During a refill operation, for example, application of positive pressure 2116 at the common refill/evacuation location 2104 permits fluid flowing from the inlet/outlet port 2112 to flow through the first check valve 2102 to the portion of a fluid system 2106 .
Conversely, the second check valve 2108 may be structured to respond to application of negative pressure (represented by arrow 2118 ) at the common refill/evacuation location 2104 , which response to the negative pressure 2118 includes actuating the second check valve 2108 and permitting fluid to flow therethrough. As applied herein with respect to pressure levels, the term “negative” means pressure which is at a level sufficient to move a fluid or fluids in the direction of the negative pressure flow 2118 (e.g., fluid moving in a direction from the outlet 2108 B of the second check valve 2108 to the inlet/outlet port 2112 ). During an evacuation operation, for example, application of negative pressure 2118 at the common refill/evacuation location 2104 permits fluid to flow through the second check valve 2108 to the inlet/outlet port 2112 of the assembly 2100 . It can be appreciated that the present systems and methods permit alternative performance of positive pressure fluid operations or negative pressure fluid operations at the common refill/evacuation location 2104 .
In various embodiments, the inlet/outlet port 2112 may be in fluid communication with one or more fluid components, such as fluid component 2120 shown in FIG. 32 . The fluid component 2120 may include one or more of the following fluidic structures, for example and without limitation: a pump that is off-board with respect to a machine being serviced; a pump that is on-board with respect to a machine being serviced; a flow control means (in accordance with embodiments described hereinabove) such as a hand-held device, for example; and/or, a bracket or evacuation bracket (in accordance with embodiments described hereinabove). The fluid component 2120 may also be any other component suitable for supplying positive and/or negative fluid pressure to the inlet/outlet port 2112 in accordance with the various fluid operations described herein.
Referring now to FIG. 33 , in various embodiments of the present invention, a check valve system 2148 may include multiple check valve assemblies 2150 , 2170 , 2190 configured in accordance with the present invention to service multiple fluid reservoirs 2160 , 2180 , 2200 , for example, and/or multiple kinds of fluids contained in the fluid reservoirs 2160 , 2180 , 2200 . In various embodiments, one or more of the check valve assemblies 2150 , 2170 , 2190 may be structured to be part of the same fluid system, or any of the check valve assemblies 2150 , 2170 , 2190 may be structured for operation as part of an independently operating fluid system.
In the first check valve assembly 2150 , for example, a first check valve 2152 may be structured with an inlet 2152 A in fluid communication with a common refill/evacuation location 2154 and an outlet 2152 B in fluid communication with a portion of a fluid system 2156 . In certain embodiments, the portion of a fluid system 2156 may be configured to include an operative association with at least a pre-filter portion of the fluid system. A second check valve 2158 of the assembly 2150 includes an inlet 2158 A in communication with the fluid reservoir 2160 , for example, or another similar structure in fluidic association with the assembly 2150 . The second check valve 2158 further includes an outlet 2158 B in fluid communication with the common refill/evacuation location 2154 . An inlet/outlet port 2162 may be structured for fluid communication with the common refill/evacuation location 2154 . In various embodiments, the inlet/outlet port 2162 may be operatively associated with a clustered service location (as described hereinabove), for example. In certain embodiments, a quick disconnect (not shown) may be operatively associated with the common refill/evacuation location 2154 to permit ready connection and disconnection of fluidic structures in operative association with the common refill/evacuation location 2154 .
In various embodiments, the inlet 2152 A of the first check valve 2152 may be structured to respond to application of positive pressure (represented by arrow 2166 ) at the common refill/evacuation location 2154 , which response to the positive pressure 2166 includes actuating the first check valve 2152 and permitting fluid to flow therethrough. As applied herein with respect to pressure levels, the term “positive” means pressure which is at a level sufficient to move a fluid or fluids in the direction of the positive pressure flow 2166 (e.g., fluid moving in a direction from the inlet/outlet port 2162 to the inlet 2152 A of the first check valve 2152 ). During a fluid refill operation, for example, application of positive pressure 2166 at the common refill/evacuation location 2154 permits fluid flowing from the inlet/outlet port 2162 to flow through the first check valve 2152 to the portion of a fluid system 2156 .
Conversely, the second check valve 2158 may be structured to respond to application of negative pressure (represented by arrow 2168 ) at the common refill/evacuation location 2154 , which response to the negative pressure 2168 includes actuating the second check valve 2168 and permitting fluid to flow therethrough. As applied herein with respect to pressure levels, the term “negative” means pressure which is at a level sufficient to move a fluid or fluids in the direction of the negative pressure flow 2168 (e.g., fluid moving in a direction from the outlet 2158 B of the second check valve 2158 to the inlet/outlet port 2162 ). During an evacuation operation, for example, application of negative pressure 2168 at the common refill/evacuation location 2154 permits fluid to flow through the second check valve 2158 to the inlet/outlet port 2162 of the assembly 2150 . It can be appreciated that the present systems and methods permit alternative performance of positive pressure fluid operations or negative pressure fluid operations at the common refill/evacuation location 2154 .
In other aspects of the check valve system 2148 , with reference to the second check valve assembly 2170 , a third check valve 2172 may be structured with an inlet 2172 A in fluid communication with a common refill/evacuation location 2174 and an outlet 2172 B in fluid communication with a portion of a fluid system 2176 . In certain embodiments, the portion of a fluid system 2176 may be configured to include an operative association with at least a pre-filter portion of the fluid system. A fourth check valve 2178 of the assembly 2150 includes an inlet 2178 A in fluid communication with the fluid reservoir 2180 , for example, or another similar structure fluidically associated with the assembly 2170 . The fourth check valve 2178 further includes an outlet 2178 B in fluid communication with the common refill/evacuation location 2174 . An inlet/outlet port 2182 may be structured for fluid communication with the common refill/evacuation location 2174 . In various embodiments, the inlet/outlet port 2182 may be operatively associated with a clustered service location (as described hereinabove), for example. In certain embodiments, a quick disconnect (not shown) may be operatively associated with the common refill/evacuation location 2174 to permit ready connection or disconnection of fluidic structures in operative association with/from the common refill/evacuation location 2174 .
In various embodiments, the inlet 2172 A of the third check valve 2172 may be structured to respond to application of positive pressure (represented by arrow 2186 ) at the common refill/evacuation location 2174 , which response to the positive pressure 2186 includes actuating the third check valve 2172 and permitting fluid to flow therethrough. As applied herein with respect to pressure levels, the term “positive” means pressure which is at a level sufficient to move a fluid or fluids in the direction of the positive pressure flow 2186 (e.g., fluid moving in a direction from the inlet/outlet port 2182 to the inlet 2172 A of the third check valve 2172 ). During a refill operation, for example, application of positive pressure 2186 at the common refill/evacuation location 2174 permits fluid flowing from the inlet/outlet port 2182 to flow through the third check valve 2172 to the portion of a fluid system 2176 .
Conversely, the fourth check valve 2178 may be structured to respond to application of negative pressure (represented by arrow 2188 ) at the common refill/evacuation location 2174 , which response to the negative pressure 2188 includes actuating the fourth check valve 2188 and permitting fluid to flow therethrough. As applied herein with respect to pressure levels, the term “negative” means pressure which is at a level sufficient to move a fluid or fluids in the direction of the negative pressure flow 2188 (e.g., fluid moving in a direction from the outlet 2178 B of the fourth check valve 2178 to the inlet/outlet port 2182 ). During an evacuation operation, for example, application of negative pressure 2188 at the common refill/evacuation location 2174 permits fluid to flow through the fourth check valve 2178 to the inlet/outlet port 2182 of the assembly 2170 . It can be appreciated that the present systems and methods permit alternative performance of positive pressure fluid operations or negative pressure fluid operations at the common refill/evacuation location 2174 .
With reference to the third check valve assembly 2190 of the system 2148 , a fifth check valve 2192 may have an inlet 2192 A in fluid communication with a common refill/evacuation location 2194 and an outlet 2192 B in fluid communication with a portion of a fluid system 2196 . In certain embodiments, the portion of a fluid system 2196 may be configured to include an operative association with at least a pre-filter portion of the fluid system. A sixth check valve 2198 of the assembly 2190 includes an inlet 2198 A in fluid communication with the fluid reservoir 2200 , for example, or another similar structure fluidically associated with the assembly 2190 . The sixth check valve 2198 further includes an outlet 2198 B in fluid communication with the common refill/evacuation location 2194 . An inlet/outlet port 2202 may be structured for fluid communication with the common refill/evacuation location 2194 . In various embodiments, the inlet/outlet port 2112 may be operatively associated with a clustered service location (as described hereinabove), for example. In certain embodiments, a quick disconnect (not shown) may be operatively associated with the common refill/evacuation location 2194 to permit ready connection and disconnection of fluidic structures in operative association with the common refill/evacuation location 2194 .
In various embodiments, the inlet 2192 A of the fifth check valve 2192 may be structured to respond to application of positive pressure (represented by arrow 2206 ) at the common refill/evacuation location 2194 , which response to the positive pressure 2206 includes actuating the fifth check valve 2192 and permitting fluid to flow therethrough. As applied herein with respect to pressure levels, the term “positive” means pressure which is at a level sufficient to move a fluid or fluids in the direction of the positive pressure flow 2206 (e.g., fluid moving in a direction from the inlet/outlet port 2202 to the inlet 2192 A of the fifth check valve 2192 ). During a refill operation, for example, application of positive pressure 2206 at the common refill/evacuation location 2194 permits fluid flowing from the inlet/outlet port 2202 to flow through the fifth check valve 2192 to the portion of a fluid system 2196 .
Conversely, the sixth check valve 2198 may be structured to respond to application of negative pressure (represented by arrow 2208 ) at the common refill/evacuation location 2194 , which response to the negative pressure 2208 includes actuating the sixth check valve 2198 and permitting fluid to flow therethrough. As applied herein with respect to pressure levels, the term “negative” means pressure which is at a level sufficient to move a fluid or fluids in the direction of the negative pressure flow 2208 (e.g., fluid moving in a direction from the outlet 2198 B of the sixth check valve 2198 to the inlet/outlet port 2202 ). During an evacuation operation, for example, application of negative pressure 2208 at the common refill/evacuation location 2194 permits fluid to flow through the sixth check valve 2198 to the inlet/outlet port 2202 of the assembly 2190 . It can be appreciated that the present systems and methods permit alternative performance of positive pressure fluid operations or negative pressure fluid operations at the common refill/evacuation location 2194 .
It can be seen that multiple check valve assembly configurations (e.g., such as configurations that include the check valve assemblies 2150 , 2170 , 2190 ) permit multiple fluid operations such as refill operations, evacuation operations, and/or filter purge operations, for example, to be performed on multiple fluid reservoirs. It can be appreciated that any number of check valve assemblies may be provided within the scope of the present methods and systems. The illustration of three separate check valve assemblies 2150 , 2170 , 2190 in FIG. 33 , for example, is merely for purposes of convenience of disclosure. More or fewer check valve assemblies may be employed in operative association with fluid systems configured in accordance with the present invention. Each of the portions of a fluid system 2156 , 2176 , 2196 may include any reasonable combination of valves, pipes, reservoirs and/or other fluidic structures. In various embodiments, one or more of the fluid reservoirs 2160 , 2180 , 2200 may contain a quantity of a fluid such as oil, transmission fluid, hydraulic fluid, or another type of fluid described hereinabove and/or any other fluid suitable for use in accordance with the present systems and methods.
In various embodiments, any one or more of the inlet/outlet ports 2162 , 2182 , 2202 may be in fluid communication with one or more fluid components (not shown) including one or more of the following fluidic structures, for example and without limitation: a pump that is off-board with respect to a machine being serviced; a pump that is on-board with respect to a machine being serviced; a flow control means (in accordance with embodiments described hereinabove) such as a hand-held device, for example; and/or, a bracket or evacuation bracket (in accordance with embodiments described hereinabove). The fluid component may also be any other component suitable for supplying positive and/or negative fluid pressure to the inlet/outlet ports 2162 , 2182 , 2202 in accordance with various fluid operations described herein.
Referring now to FIG. 34 , in accordance with various embodiments of the present invention, an electronic valve assembly 2300 is provided in accordance with the present systems and methods. The assembly 2300 includes a first electronic valve 2302 having an inlet 2302 A in fluid communication with a common refill/evacuation location 2304 and an outlet 2302 B in fluid communication with a portion of a fluid system 2306 . In various embodiments, the portion of a fluid system 2306 may include an operative association with at least a pre-filter portion of the fluid system. A second electronic valve 2308 of the assembly 2300 includes an inlet 2308 A in communication with a fluid reservoir 2310 , for example, or another similar structure included within the fluid system 2300 . The second electronic valve 2308 further includes an outlet 2308 B in fluid communication with the common refill/evacuation location 2304 . In addition, an inlet/outlet port 2312 may be structured for fluid communication with the common refill/evacuation location 2304 .
The portion of the fluid system 2306 may include any reasonable combination of valves, pipes, reservoirs and/or other fluidic structures. In various embodiments, the fluid reservoir 2310 may contain a quantity of a fluid such as oil, transmission fluid, hydraulic fluid, or another type of fluid described hereinabove and/or any other fluid suitable for use in accordance with the present systems and methods. In certain embodiments, a quick disconnect 2314 or other similar type of coupling may be operatively associated with the inlet/outlet port 2312 to permit operative association of various fluidic structures such as an external pump, for example, with the inlet/outlet port 2312 . In various embodiments, the inlet/outlet port 2312 may be operatively associated with a clustered service location (as described hereinabove), for example.
In various embodiments, a control module 2316 may be operatively associated with one or both of the electronic valves 2302 , 2308 to actuate the valves 2302 , 2308 upon sensing a predetermined pressure level, for example, within the assembly 2300 . One or more sensors such as pressure sensors 2318 , 2320 , for example, may be operatively associated with the control module 2316 and/or the electronic valves 2302 , 2308 to provide pressure level information to the control module 2316 .
The sensor 2318 associated with the first electronic valve 2302 , for example, may be configured to communicate a signal indicative of application of positive pressure (represented by arrow 2322 ) at the common refill/evacuation location 2304 , which response to the positive pressure 2322 includes actuating the first electronic valve 2302 to permit fluid flow therethrough. As applied herein with respect to pressure levels, the term “positive” means pressure which is at a level sufficient to move a fluid or fluids in the direction of the positive pressure flow 2322 (e.g., fluid moving in a direction from the inlet/outlet port 2312 to the inlet 2302 A of the first electronic valve 2302 ). During a refill operation, for example, application of positive pressure 2322 at the common refill/evacuation location 2304 , and subsequent actuation of the first electronic valve 2302 by the control module 2316 , permit fluid to flow from the inlet/outlet port 2312 , through the first electronic valve 2302 to the portion of the fluid system 2306 .
In addition, the sensor 2320 associated with the second electronic valve 2308 , for example, may be configured to communicate a signal indicative of application of negative pressure (represented by arrow 2324 ) at the common refill/evacuation location 2304 , which response to the negative pressure 2324 includes actuating the second electronic valve 2308 and permitting fluid to flow therethrough. As applied herein with respect to pressure levels, the term “negative” means pressure which is at a level sufficient to move a fluid or fluids in the direction of the negative pressure flow 2324 (e.g., fluid moving in a direction from the outlet 2308 B of the second electronic valve 2308 to the inlet/outlet port 2312 ). During an evacuation operation, for example, application of negative pressure 2324 at the common refill/evacuation location 2304 , and subsequent actuation of the second electronic valve 2308 , permit fluid to flow through the second electronic valve 2308 to the inlet/outlet port 2312 of the assembly 2300 . It can be appreciated that the present systems and methods permit alternative positive pressure fluid operations or negative pressure fluid operations to be performed at the common refill/evacuation location 2304 .
In various embodiments, the inlet/outlet port 2312 may be in fluid communication with one or more fluid components, such as fluid component 2326 shown in FIG. 34 . The fluid component 2326 may include one or more of the following fluidic structures, for example and without limitation: a pump that is off-board with respect to a machine being serviced; a pump that is on-board with respect to a machine being serviced; a flow control means (in accordance with embodiments described hereinabove) such as a hand-held device, for example; and/or, a bracket or evacuation bracket (in accordance with embodiments described hereinabove). The fluid component 2326 may also be any other component suitable for supplying positive and/or negative fluid pressure to the inlet/outlet port 2312 in accordance with the various fluid operations described herein.
Referring now to FIG. 35 , in various embodiments of the present invention, an electronic valve system 2348 may include multiple electronic valve assemblies 2350 , 2370 , 2390 configured in accordance with the present invention to service multiple fluid reservoirs, for example, and/or multiple kinds of fluids contained in the fluid reservoirs. In various embodiments, one or more of the electronic valve assemblies 2350 , 2370 , 2390 may be structured to be part of the same fluid system, or any of the electronic valve assemblies 2350 , 2370 , 2390 may be structured for operation as part of an independently operating fluid system. In the first electronic valve assembly 2350 , for example, a first electronic valve 2352 may be structured with an inlet 2352 A in fluid communication with a common refill/evacuation location 2354 and an outlet 2352 B in fluid communication with a portion of a fluid system 2356 . In certain embodiments, the portion of a fluid system 2356 may be configured to include an operative association with at least a pre-filter portion of the fluid system. A second electronic valve 2358 of the assembly 2350 may include an inlet 2358 A in communication with a fluid reservoir 2360 , for example, or another similar structure in fluidic association with the assembly 2350 . The second electronic valve 2358 further includes an outlet 2358 B in fluid communication with the common refill/evacuation location 2354 . An inlet/outlet port 2362 may be structured for fluid communication with the common refill/evacuation location 2354 . In various embodiments, the inlet/outlet port 2362 may be operatively associated with a clustered service location (as described hereinabove), for example. In certain embodiments, a quick disconnect (not shown) may be operatively associated with the common refill/evacuation location 2354 to permit ready connection/disconnection of fluidic structures to/from operative association with the common refill/evacuation location 2354 .
In various embodiments, the inlet 2352 A of the first electronic valve 2352 may be structured to respond to application of positive pressure (represented by arrow 2366 ) at the common refill/evacuation location 2354 , which response to the positive pressure 2366 includes actuating the first electronic valve 2352 and permitting fluid to flow therethrough. As applied herein with respect to pressure levels, the term “positive” means pressure which is at a level sufficient to move a fluid or fluids in the direction of the positive pressure flow 2366 (e.g., fluid moving in a direction from the inlet/outlet port 2362 to the inlet 2352 A of the first electronic valve 2352 ). During a refill operation, for example, application of positive pressure 2366 at the common refill/evacuation location 2354 permits fluid flowing from the inlet/outlet port 2362 to flow through the first electronic valve 2352 to the portion of a fluid system 2356 .
Conversely, the second electronic valve 2358 may be structured to respond to application of negative pressure (represented by arrow 2368 ) at the common refill/evacuation location 2354 , which response to the negative pressure 2368 includes actuating the second electronic valve 2368 and permitting fluid to flow therethrough. As applied herein with respect to pressure levels, the term “negative” means pressure which is at a level sufficient to move a fluid or fluids in the direction of the negative pressure flow 2368 (e.g., fluid moving in a direction from the outlet 2358 B of the second electronic valve 2358 to the inlet/outlet port 2362 ). During an evacuation operation, for example, application of negative pressure 2368 at the common refill/evacuation location 2354 permits fluid to flow through the second electronic valve 2358 to the inlet/outlet port 2362 of the assembly 2350 . It can be appreciated that the present systems and methods permit alternative performance of positive pressure fluid operations or negative pressure fluid operations at the common refill/evacuation location 2354 .
In other aspects of the electronic valve system 2348 , with reference to the second electronic valve assembly 2370 , a third electronic valve 2372 may be structured with an inlet 2372 A in fluid communication with a common refill/evacuation location 2374 and an outlet 2372 B in fluid communication with a portion of a fluid system 2376 . In certain embodiments, the portion of a fluid system 2376 may be configured to include an operative association with at least a pre-filter portion of the fluid system. A fourth electronic valve 2378 of the assembly 2370 includes an inlet 2378 A in fluid communication with a fluid reservoir 2380 , for example, or another similar structure fluidically associated with the assembly 2370 . The fourth electronic valve 2378 further includes an outlet 2378 B in fluid communication with the common refill/evacuation location 2374 . An inlet/outlet port 2382 may be structured for fluid communication with the common refill/evacuation location 2374 . In various embodiments, the inlet/outlet port 2382 may be operatively associated with a clustered service location (as described hereinabove), for example. In certain embodiments, a quick disconnect (not shown) may be operatively associated with the common refill/evacuation location 2374 to permit ready connection or disconnection of fluidic structures to/from operative association with the common refill/evacuation location 2374 .
In various embodiments, the inlet 2372 A of the third electronic valve 2372 may be structured to respond to application of positive pressure (represented by arrow 2386 ) at the common refill/evacuation location 2374 , which response to the positive pressure 2386 includes actuating the third electronic valve 2372 and permitting fluid to flow therethrough. As applied herein with respect to pressure levels, the term “positive” means pressure which is at a level sufficient to move a fluid or fluids in the direction of the positive pressure flow 2386 (e.g., fluid moving in a direction from the inlet/outlet port 2382 to the inlet 2372 A of the third electronic valve 2372 ). During a refill operation, for example, application of positive pressure 2386 at the common refill/evacuation location 2374 permits fluid flowing from the inlet/outlet port 2382 to flow through the third electronic valve 2372 to the portion of a fluid system 2376 .
Conversely, the fourth electronic valve 2378 may be structured to respond to application of negative pressure (represented by arrow 2388 ) at the common refill/evacuation location 2374 , which response to the negative pressure 2388 includes actuating the fourth electronic valve 2388 and permitting fluid to flow therethrough. As applied herein with respect to pressure levels, the term “negative” means pressure which is at a level sufficient to move a fluid or fluids in the direction of the negative pressure flow 2388 (e.g., fluid moving in a direction from the outlet 2378 B of the fourth electronic valve 2378 to the inlet/outlet port 2382 ). During an evacuation operation, for example, application of negative pressure 2388 at the common refill/evacuation location 2374 permits fluid to flow through the fourth electronic valve 2378 to the inlet/outlet port 2382 of the assembly 2370 . It can be appreciated that the present systems and methods permit alternative performance of positive pressure fluid operations or negative pressure fluid operations at the common refill/evacuation location 2374 .
With reference to the third electronic valve assembly 2390 of the system 2348 , a fifth electronic valve 2392 may have an inlet 2392 A in fluid communication with a common refill/evacuation location 2394 and an outlet 2392 B in fluid communication with a portion of a fluid system 2396 . In certain embodiments, the portion of a fluid system 2396 may be configured to include an operative association with at least a pre-filter portion of the fluid system. A sixth electronic valve 2398 of the assembly 2390 includes an inlet 2398 A in fluid communication with a fluid reservoir 2400 , for example, or another similar structure operatively associated with the assembly 2390 . The sixth electronic valve 2398 further includes an outlet 2398 B in fluid communication with the common refill/evacuation location 2394 . An inlet/outlet port 2402 may be structured for fluid communication with the common refill/evacuation location 2394 . In various embodiments, the inlet/outlet port 2312 may be operatively associated with a clustered service location (as described hereinabove), for example. In certain embodiments, a quick disconnect (not shown) may be operatively associated with the common refill/evacuation location 2394 to permit ready connection or disconnection of fluidic structures to/from operative association with the common refill/evacuation location 2394 .
In various embodiments, the inlet 2392 A of the fifth electronic valve 2392 may be structured to respond to application of positive pressure (represented by arrow 2406 ) at the common refill/evacuation location 2394 , which response to the positive pressure 2406 includes actuating the fifth electronic valve 2392 and permitting fluid to flow therethrough. As applied herein with respect to pressure levels, the term “positive” means pressure which is at a level sufficient to move a fluid or fluids in the direction of the positive pressure flow 2406 (e.g., fluid moving in a direction from the inlet/outlet port 2402 to the inlet 2392 A of the fifth electronic valve 2392 ). During a refill operation, for example, application of positive pressure 2406 at the common refill/evacuation location 2394 permits fluid flowing from the inlet/outlet port 2402 to flow through the fifth electronic valve 2392 to the portion of a fluid system 2396 .
Conversely, the sixth electronic valve 2398 may be structured to respond to application of negative pressure (represented by arrow 2408 ) at the common refill/evacuation location 2394 , which response to the negative pressure 2408 includes actuating the sixth electronic valve 2398 and permitting fluid to flow therethrough. As applied herein with respect to pressure levels, the term “negative” means pressure which is at a level sufficient to move a fluid or fluids in the direction of the negative pressure flow 2408 (e.g., fluid moving in a direction from the outlet 2398 B of the sixth electronic valve 2398 to the inlet/outlet port 2402 ). During an evacuation operation, for example, application of negative pressure 2408 at the common refill/evacuation location 2394 permits fluid to flow through the sixth electronic valve 2398 to the inlet/outlet port 2402 of the assembly 2390 . It can be appreciated that the present systems and methods permit alternative performance of positive pressure fluid operations or negative pressure fluid operations at the common refill/evacuation location 2394 .
In various embodiments, a control module 2502 may be operatively associated with one or more of the electronic valves 2352 , 2358 , 2372 , 2378 , 2392 , 2398 to actuate the valves 2352 , 2358 , 2372 , 2378 , 2392 , 2398 upon sensing a predetermined pressure level, for example, within one or more of the assemblies 2350 , 2370 , 2390 of the electronic valve system 2348 . One or more sensors such as pressure sensors 2504 , 2506 , 2508 , 2510 , 2512 , 2514 , for example, may be operatively associated with the control module 2502 and/or the electronic valves 2352 , 2358 , 2372 , 2378 , 2392 , 2398 to provide pressure level information to the control module 2502 .
The sensor 2504 associated with the first electronic valve 2352 of the first electronic valve assembly 2350 of the system 2348 , for example, may be configured to communicate a signal indicative of application of positive pressure (represented by arrow 2366 ) at the common refill/evacuation location 2354 , which response to the positive pressure 2366 includes actuating the first electronic valve 2352 to permit fluid flow therethrough. As applied herein with respect to pressure levels, the term “positive” means pressure which is at a level sufficient to move a fluid or fluids in the direction of the positive pressure flow 2366 (e.g., fluid moving in a direction from the inlet/outlet port 2362 to the inlet 2352 A of the first electronic valve 2352 ). During a refill operation, for example, application of positive pressure 2366 at the common refill/evacuation location 2354 , and subsequent actuation of the first electronic valve 2352 by the control module 2502 , for example, together permit fluid to flow from the inlet/outlet port 2362 , through the first electronic valve 2352 to the portion of the fluid system 2356 .
In addition, the sensor 2506 associated with the second electronic valve 2358 , for example, may be configured to communicate a signal indicative of application of negative pressure (represented by arrow 2368 ) at the common refill/evacuation location 2354 , which response to the negative pressure 2368 includes actuating the second electronic valve 2358 and permitting fluid to flow therethrough. As applied herein with respect to pressure levels, the term “negative” means pressure which is at a level sufficient to move a fluid or fluids in the direction of the negative pressure flow 2368 (e.g., fluid moving in a direction from the outlet 2358 B of the second electronic valve 2358 to the inlet/outlet port 2362 ). During an evacuation operation, for example, application of negative pressure 2368 at the common refill/evacuation location 2354 , and subsequent actuation of the second electronic valve 2358 , permit fluid to flow through the second electronic valve 2358 to the inlet/outlet port 2362 of the assembly 2350 . It can be appreciated that the present systems and methods permit alternative positive pressure fluid operations or negative pressure fluid operations to be performed at the common refill/evacuation location 2354 .
It can be seen that multiple electronic valve assembly configurations (e.g., such as configurations that include the electronic valve assemblies 2350 , 2370 , 2390 ) permit multiple fluid operations such as refill operations, evacuation operations, and/or filter purge operations, for example, to be performed on multiple fluid reservoirs. It can be appreciated that any number of electronic valve assemblies may be provided within the scope of the present methods and systems. The illustration of three separate electronic valve assemblies 2350 , 2370 , 2390 in FIG. 35 , for example, is merely for purposes of convenience of disclosure. More or less electronic valve assemblies may be employed in operative association with fluid systems configured in accordance with the present invention. Each of the portions of a fluid system 2356 , 2376 , 2396 may include any reasonable combination of valves, pipes, reservoirs and/or other fluidic structures. In various embodiments, one or more of the fluid reservoirs 2360 , 2380 , 2400 may contain a quantity of a fluid such as oil, transmission fluid, hydraulic fluid, or another type of fluid described hereinabove and/or any other fluid suitable for use in accordance with the present systems and methods.
In various embodiments, any one or more of the inlet/outlet ports 2362 , 2382 , 2402 may be in fluid communication with one or more fluid components including one or more of the following fluidic structures, for example and without limitation: a pump that is off-board with respect to a machine being serviced; a pump that is on-board with respect to a machine being serviced; a flow control means (in accordance with embodiments described hereinabove) such as a hand-held device, for example; and/or, a bracket or evacuation bracket (in accordance with embodiments described hereinabove). The fluid component may also be any other component suitable for supplying positive and/or negative fluid pressure to the inlet/outlet ports 2362 , 2382 , 2402 in accordance with the various fluid operations described herein.
Referring now to FIG. 36 , an illustration of a fluid system 2600 in accordance with various aspects of the present systems and methods is provided. The fluid system 2600 includes a first check valve 2602 having an inlet 2602 A in fluid communication with a common refill/evacuation location 2604 and an outlet 2602 B in fluid communication with a pre-filter portion 2606 of the fluid system 2600 . A second check valve 2608 of the fluid system 2600 includes an inlet 2608 A in communication with an engine fluid reservoir 2610 , for example. The second check valve 2608 further includes an outlet 2608 B in fluid communication with the common refill/evacuation location 2604 . In addition, an inlet/outlet port 2612 may be structured for fluid communication with the common refill/evacuation location 2604 . In another aspect, a fluid filter 2614 is in fluid communication with the pre-filter portion 2606 and the fluid reservoir 2610 of the fluid system 2600 . It can be appreciated that the fluid filter 2614 may be, for example and without limitation, an oil filter, a transmission fluid filter, a hydraulic fluid filter or a variety of other types of suitable fluid filters for corresponding types of fluid systems. In various embodiments, a quick disconnect 2616 or other similar type of coupling may be operatively associated with the inlet/outlet port 2612 to permit operative association of various fluidic structures such as an external pump, for example, with the inlet/outlet port 2612 .
Referring now to FIG. 37 , a flow chart is provided that includes examples of various fluid operations that may be performed in accordance with the present systems and methods. In step 2702 , and in connection with the fluid system 2600 of FIG. 36 by way of example, positive pressure may be introduced at the common refill/evacuation location 2604 . A fluid such as air, for example, may be introduced through the inlet/outlet port 2612 to provide positive pressure at the common refill/evacuation location 2604 . The positive pressure actuates the first check valve 2602 and permits the contents of the fluid filter 2614 to be purged in step 2704 . The purged contents of the fluid filter 2614 may be forced by the positive pressure into the engine fluid reservoir 2610 , for example.
In step 2706 , negative pressure may be introduced at the common refill/evacuation location 2604 through the inlet/outlet port 2612 . It can be seen that such negative pressure actuates the second check valve 2608 to permit fluid to be evacuated from the engine fluid reservoir 2610 in step 2708 (which evacuated fluid includes the contents of the fluid filter purged in step 2704 ) through the second check valve 2608 to exit through the inlet/outlet port 2612 . In addition, positive pressure may be introduced in step 2710 at the common refill/evacuation location 2604 such as during performance of a refill fluid operation, for example, to refill the contents of the engine fluid reservoir 2610 in step 2712 . It can therefore be seen that the refill fluid encounters the fluid filter 2614 prior to refilling the engine fluid reservoir 2610 , and other operative components of the system 2600 , which enhances filtration of the refill fluid and which may enhance operation of a machine, for example, operatively associated with the system 2600 .
Referring now to FIG. 38 , a check valve module 2800 is provided that may include a plurality of check valve assemblies 2820 , 2840 , 2860 coupled or ganged together to form the module 2800 . The individual assemblies 2820 , 2840 , 2860 may be coupled together by a conventional device or method such as by welding the assemblies 2820 , 2840 , 2860 to each other, for example. It can be seen that the module embodiments described herein provide substantially compact and central locations for performance of various fluid operations such as fluid refill, fluid evacuation, and filter purge operations performed on a machine, for example. In various embodiments, one or more of the check valve assemblies 2820 , 2840 , 2860 may be structured to be part of the same fluid system, or any of the check valve assemblies 2820 , 2840 , 2860 may be structured for operation as part of an independently operating fluid system.
In various embodiments, with respect to the first check valve assembly 2820 , for example, a first check valve 2822 may be structured with an inlet 2822 A in fluid communication with a common refill/evacuation location 2824 and an outlet 2822 B in fluid communication with a portion of a fluid system 2826 . In certain embodiments, the portion of a fluid system 2826 may be configured to include an operative association with at least a pre-filter portion of the fluid system. A second check valve 2828 of the assembly 2820 includes an inlet 2828 A in communication with a fluid reservoir 2830 , for example, or another similar structure in fluidic association with the assembly 2820 . The second check valve 2828 further includes an outlet 2828 B in fluid communication with the common refill/evacuation location 2824 . An inlet/outlet port 2832 may be structured for fluid communication with the common refill/evacuation location 2824 . In various embodiments, the inlet/outlet port 2832 may be operatively associated with a clustered service location (as described hereinabove), for example. In certain embodiments, a quick disconnect (not shown) may be operatively associated with the common refill/evacuation location 2824 to permit ready connection and disconnection of fluidic structures in operative association with the common refill/evacuation location 2824 . In various embodiments, the check valves 2822 , 2828 may comprise cartridge type check valves, for example.
In various embodiments, the inlet 2822 A of the first check valve 2822 may be structured to respond to application of positive pressure (represented by arrow 2834 ) at the common refill/evacuation location 2824 , which response to the positive pressure 2834 includes actuating the first check valve 2822 and permitting fluid to flow therethrough. As applied herein with respect to pressure levels, the term “positive” means pressure which is at a level sufficient to move a fluid or fluids in the direction of the positive pressure flow 2834 (e.g., fluid moving in a direction from the inlet/outlet port 2832 to the inlet 2822 A of the first check valve 2822 ). During a refill operation, for example, application of positive pressure 2834 at the common refill/evacuation location 2824 permits fluid flowing from the inlet/outlet port 2832 to flow through the first check valve 2822 to the portion of a fluid system 2826 .
Conversely, the second check valve 2828 may be structured to respond to application of negative pressure (represented by arrow 2836 ) at the common refill/evacuation location 2824 , which response to the negative pressure 2836 includes actuating the second check valve 2828 and permitting fluid to flow therethrough. As applied herein with respect to pressure levels, the term “negative” means pressure which is at a level sufficient to move a fluid or fluids in the direction of the negative pressure flow 2836 (e.g., fluid moving in a direction from the outlet 2828 B of the second check valve 2828 to the inlet/outlet port 2832 ). During an evacuation operation, for example, application of negative pressure 2836 at the common refill/evacuation location 2824 permits fluid to flow through the second check valve 2828 to the inlet/outlet port 2832 of the assembly 2820 . It can be appreciated that the present systems and methods permit alternative performance of positive pressure fluid operations or negative pressure fluid operations at the common refill/evacuation location 2824 .
In other aspects of the check valve system 2800 , with reference to the second check valve assembly 2840 , a third check valve 2842 may be structured with an inlet 2842 A in fluid communication with a common refill/evacuation location 2844 and an outlet 2842 B in fluid communication with a portion of a fluid system 2846 . In certain embodiments, the portion of a fluid system 2846 may be configured to include an operative association with at least a pre-filter portion of the fluid system. A fourth check valve 2848 of the assembly 2840 includes an inlet 2848 A in fluid communication with a fluid reservoir 2850 , for example, or another similar structure fluidically associated with the assembly 2840 . The fourth check valve 2848 further includes an outlet 2848 B in fluid communication with the common refill/evacuation location 2844 . An inlet/outlet port 2852 may be structured for fluid communication with the common refill/evacuation location 2844 . In various embodiments, the inlet/outlet port 2852 may be operatively associated with a clustered service location (as described hereinabove), for example. In certain embodiments, a quick disconnect (not shown) may be operatively associated with the common refill/evacuation location 2844 to permit ready connection or disconnection of fluidic structures in operative association with/from the common refill/evacuation location 2844 . In various embodiments, the check valves 2842 , 2848 may comprise cartridge type check valves, for example.
In various embodiments, the inlet 2842 A of the third check valve 2842 may be structured to respond to application of positive pressure (represented by arrow 2854 ) at the common refill/evacuation location 2844 , which response to the positive pressure 2854 includes actuating the third check valve 2842 and permitting fluid to flow therethrough. As applied herein with respect to pressure levels, the term “positive” means pressure which is at a level sufficient to move a fluid or fluids in the direction of the positive pressure flow 2854 (e.g., fluid moving in a direction from the inlet/outlet port 2852 to the inlet 2842 A of the third check valve 2842 ). During a refill operation, for example, application of positive pressure 2854 at the common refill/evacuation location 2844 permits fluid flowing from the inlet/outlet port 2852 to flow through the third check valve 2842 to the portion of a fluid system 2846 .
Conversely, the fourth check valve 2848 may be structured to respond to application of negative pressure (represented by arrow 2856 ) at the common refill/evacuation location 2844 , which response to the negative pressure 2856 includes actuating the fourth check valve 2848 and permitting fluid to flow therethrough. As applied herein with respect to pressure levels, the term “negative” means pressure which is at a level sufficient to move a fluid or fluids in the direction of the negative pressure flow 2856 (e.g., fluid moving in a direction from the outlet 2848 B of the fourth check valve 2848 to the inlet/outlet port 2852 ). During an evacuation operation, for example, application of negative pressure 2856 at the common refill/evacuation location 2844 permits fluid to flow through the fourth check valve 2848 to the inlet/outlet port 2852 of the assembly 2840 . It can be appreciated that the present systems and methods permit alternative performance of positive pressure fluid operations or negative pressure fluid operations at the common refill/evacuation location 2844 .
With reference to the third check valve assembly 2860 of the system 2800 , a fifth check valve 2862 may have an inlet 2862 A in fluid communication with a common refill/evacuation location 2864 and an outlet 2862 B in fluid communication with a portion of a fluid system 2866 . In certain embodiments, the portion of a fluid system 2866 may be configured to include an operative association with at least a pre-filter portion of the fluid system. A sixth check valve 2868 of the assembly 2860 includes an inlet 2868 A in fluid communication with a fluid reservoir 2870 , for example, or another similar structure included within the fluid system. The sixth check valve 2868 further includes an outlet 2868 B in fluid communication with the common refill/evacuation location 2864 . An inlet/outlet port 2872 may be structured for fluid communication with the common refill/evacuation location 2864 . In various embodiments, the inlet/outlet port 2872 may be operatively associated with a clustered service location (as described hereinabove), for example. In certain embodiments, a quick disconnect (not shown) may be operatively associated with the common refill/evacuation location 2864 to permit ready connection and disconnection of fluidic structures in operative association with the common refill/evacuation location 2864 . In various embodiments, the check valves 2862 , 2868 may comprise cartridge type check valves, for example.
In various embodiments, the inlet 2862 A of the fifth check valve 2862 may be structured to respond to application of positive pressure (represented by arrow 2874 ) at the common refill/evacuation location 2864 , which response to the positive pressure 2874 includes actuating the fifth check valve 2862 and permitting fluid to flow therethrough. As applied herein with respect to pressure levels, the term “positive” means pressure which is at a level sufficient to move a fluid or fluids in the direction of the positive pressure flow 2874 (e.g., fluid moving in a direction from the inlet/outlet port 2872 to the inlet 2862 A of the fifth check valve 2862 ). During a refill operation, for example, application of positive pressure 2874 at the common refill/evacuation location 2864 permits fluid flowing from the inlet/outlet port 2872 to flow through the fifth check valve 2862 to the portion of a fluid system 2866 .
Conversely, the sixth check valve 2868 may be structured to respond to application of negative pressure (represented by arrow 2876 ) at the common refill/evacuation location 2864 , which response to the negative pressure 2876 includes actuating the sixth check valve 2868 and permitting fluid to flow therethrough. As applied herein with respect to pressure levels, the term “negative” means pressure which is at a level sufficient to move a fluid or fluids in the direction of the negative pressure flow 2876 (e.g., fluid moving in a direction from the outlet 2868 B of the sixth check valve 2868 to the inlet/outlet port 2872 ). During an evacuation operation, for example, application of negative pressure 2876 at the common refill/evacuation location 2864 permits fluid to flow through the sixth check valve 2868 to the inlet/outlet port 2872 of the assembly 2860 . It can be appreciated that the present systems and methods permit alternative performance of positive pressure fluid operations or negative pressure fluid operations at the common refill/evacuation location 2864 .
It can be seen that multiple check valve assembly configurations (e.g., such as the module 2800 that includes the check valve assemblies 2820 , 2840 , 2860 ) permit multiple fluid operations such as refill operations, evacuation operations, and/or filter purge operations, for example, to be performed on multiple fluid reservoirs. It can be appreciated that any number of check valve assemblies may be provided as a module within the scope of the present methods and systems. The illustration of three separate check valve assemblies 2820 , 2840 , 2860 in FIG. 38 , for example, is merely for purposes of convenience of disclosure. More or less check valve assemblies may be employed in operative association with fluid systems configured in accordance with the present invention. Each of the portions of a fluid system 2826 , 2846 , 2866 may include any reasonable combination of valves, pipes, reservoirs and/or other fluidic structures. In various embodiments, one or more of the fluid reservoirs 2830 , 2850 , 2870 may contain a quantity of a fluid such as oil, transmission fluid, hydraulic fluid, or another type of fluid described hereinabove and/or any other fluid suitable for use in accordance with the present systems and methods.
In various embodiments, one or more adapter fittings such as fittings 2882 , 2884 , 2886 , 2888 , 2890 , 2892 , for example, may promote operative structure of the module 2800 with one or more of the portions of a fluid system 2826 , 2846 , 2866 ; one or more of the fluid reservoirs 2830 , 2850 , 2870 ; and/or other suitable fluidic structures in operative association with the check valve module 2800 .
Referring now to FIG. 39 , an electronic valve module 2900 structured and operative substantially similarly to the check valve module of FIG. 38 (see previous discussion) is provided. In the embodiments of FIG. 39 , inserted in place of the check valves 2822 , 2828 , 2842 , 2848 , 2862 , 2868 , respectively, are a plurality of electronic valves 2822 ′, 2828 ′, 2842 ′, 2848 ′, 2862 ′, 2868 ′. In analogous accordance with the embodiments of FIG. 38 , the electronic valve assemblies 2820 ′, 2840 ′, 2860 ′ of FIG. 39 may be coupled or ganged together to form the electronic module 2900 . The individual assemblies 2820 ′, 2840 ′, 2860 ′ may be coupled together by a conventional device or method such as by welding the assemblies 2820 ′, 2840 ′, 2860 ′ to each other, for example. It can be seen that the module embodiments described herein provide substantially compact and central locations for performance of various fluid operations such as fluid refill, fluid evacuation, and filter purge operations performed on a machine, for example.
In various embodiments, a control module 3002 may be operatively associated with one or more of the electronic valves 2822 ′, 2828 ′, 2842 ′, 2848 ′, 2862 ′, 2868 ′ to actuate the valves 2822 ′, 2828 ′, 2842 ′, 2848 ′, 2862 ′, 2868 ′ upon sensing a predetermined pressure level, for example, within one or more of the assemblies 2820 ′, 2840 ′, 2860 ′ of the electronic module 2900 . One or more sensors such as pressure sensors 3004 , 3006 , 3008 , 3010 , 3012 , 3014 , for example, may be operatively associated with the control module 3002 and/or the electronic valves 2822 ′, 2828 ′, 2842 ′, 2848 ′, 2862 ′, 2868 ′, respectively, to provide pressure level information, for example, to the control module 3002 .
The sensor 3004 associated with the first electronic valve 2822 ′ of the first electronic valve assembly 2820 ′ of the module 2900 , for example, may be configured to communicate a signal indicative of application of positive pressure 2834 at the common refill/evacuation location 2824 , which response to the positive pressure 2834 includes actuating the first electronic valve 2822 ′ to permit fluid flow therethrough. As applied herein with respect to pressure levels, the term “positive” means pressure which is at a level sufficient to move a fluid or fluids in the direction of the positive pressure flow 2834 (e.g., fluid moving in a direction from the inlet/outlet port 2832 to an inlet 2822 A′ of the first electronic valve 2822 ′). During a refill operation, for example, application of positive pressure 2834 at the common refill/evacuation location 2824 , and subsequent actuation of the first electronic valve 2822 ′ by the control module 3002 , for example, together permit fluid to flow from the inlet/outlet port 2832 , through the first electronic valve 2822 ′ to the portion of the fluid system 2826 .
In addition, the sensor 3006 associated with the second electronic valve 2828 ′, for example, may be configured to communicate a signal indicative of application of negative pressure 2836 at the common refill/evacuation location 2824 , which response to the negative pressure 2836 includes actuating the second electronic valve 2828 ′ and permitting fluid to flow therethrough. As applied herein with respect to pressure levels, the term “negative” means pressure which is at a level sufficient to move a fluid or fluids in the direction of the negative pressure flow 2836 (e.g., fluid moving in a direction from an outlet 2828 B′ of the second electronic valve 2828 ′ to the inlet/outlet port 2832 ). During an evacuation operation, for example, application of negative pressure 2836 at the common refill/evacuation location 2824 , and subsequent actuation of the second electronic valve 2828 ′, permit fluid to flow through the second electronic valve 2828 ′ to the inlet/outlet port 2832 of the assembly 2820 ′. It can be appreciated that the present systems and methods permit alternative positive pressure fluid operations or negative pressure fluid operations to be performed at the common refill/evacuation location 2824 .
It can be seen that multiple electronic valve assembly configurations (e.g., such as the module 2900 that includes the electronic valve assemblies 2820 ′, 2840 ′, 2860 ′) permit multiple fluid operations such as refill operations, evacuation operations, and/or filter purge operations, for example, to be performed on multiple fluid reservoirs. It can be appreciated that any number of electronic valve assemblies may be provided in a module within the scope of the present methods and systems. The illustration of three separate electronic valve assemblies 2820 ′, 2840 ′, 2860 ′ in FIG. 39 , for example, is merely for purposes of convenience of disclosure. More or less electronic valve assemblies may be employed in operative association with fluid systems configured in accordance with the present invention.
Referring now to FIG. 40 , alternative embodiments of a module 3100 are provided in analogous structural and operative accordance with the embodiments of FIGS. 38 and 39 (see above). As shown, valves 2822 ″ and 2828 ″ may be threadedly received into a first assembly 2820 ″ of the module 3100 ; valves 2842 ″ and 2848 ″ may be threadedly received into a second assembly 2840 ″ of the module 3100 ; and/or valves 2862 ″ and 2868 ″ may be threadedly received into a third assembly 2860 ″ of the module. In various embodiments, the valves 2822 ″, 2828 ″, 2842 ″, 2848 ″, 2862 ″, 2868 ″ may be, where operatively appropriate for the module 3100 , check valves, electronic valves, or a combination of both check valves and electronic valves.
In various embodiments, a control module 3202 may be operatively associated with the module 3100 . As shown in FIG. 40 by way of illustration, the control module 3002 may be operatively associated with one or more of the valves 2822 ″, 2828 ″, 2842 ″, 2848 ″, 2862 ″, 2868 ″ (which comprise electronic valves in this example) to actuate the valves 2822 ″, 2828 ″, 2842 ″, 2848 ″, 2862 ″, 2868 ″ upon sensing a predetermined pressure level, for example, within one or more of the assemblies 2820 ″, 2840 ″, 2860 ″ of the module 3100 . In accordance with prior discussion hereinabove, one or more sensors such as pressure sensors 3204 , 3206 , 3208 , 3210 , 3212 , 3214 , for example, may be operatively associated with the control module 3202 and/or the electronic valves 2822 ″, 2828 ″, 2842 ″, 2848 ″, 2862 ″, 2868 ″, respectively, to provide pressure level information, for example, to the control module 3002 .
It can be seen that the various embodiments of valve assemblies and valve systems described herein purge pre-filter portions, filter portions and/or post-filter portions of the various fluid systems described herein. It can be appreciated that any one or more of the fluid operation method steps described herein, alone or in combination, may be performed in accordance with the present systems and methods. The steps may be employed to perform a variety of fluid operations including, for example and without limitation, refill, evacuation, and/or filter purge operations.
Where applicable and operational in the context of various embodiments of valve assemblies and systems described herein, one or more valves may be in a normally closed or normally open position prior to, during, or after performance of a particular fluid operation. In addition, one or more types of valves may be employed in certain embodiments of the present systems and methods (e.g., all check valves may be used, all electronic valves may be used, or some reasonable combination of both check valves and electronic valves may be employed).
It can be appreciated that, where applicable and operational in the context of various embodiments of valve assemblies and systems described herein, performing a refill fluid operation to a pre-filter portion of a fluid system improves filtration of the refill fluid. In various embodiments, the refill fluid encounters at least one filter, for example, before the refill fluid encounters various other operative components of the fluid system.
Referring again to FIGS. 34 , 35 , 39 and 40 (and in analogous structural, functional and operational accordance with prior discussion hereinabove with reference to FIG. 20 , in particular), one or more of the control modules 2316 , 2502 , 3002 , 3202 may include various components for controlling and monitoring a fluid system, as well as for monitoring, collecting and analyzing data associated with the various fluid system and method embodiments described herein. For example, the various sensors described in FIGS. 34 , 35 , 39 and 40 can include, for example and without limitation, sensors to detect temperature, pressure, voltage, current, contaminants, cycle time, flow sensors (presence or absence of flow), automatic “off” of one or more pumps in a fluid system, and/or other sensors suitable for detecting various conditions experienced by a machine and its components. The control modules 2316 , 2502 , 3002 , 3202 may also include one or more data storage media for storing, retrieving and/or reporting data communicated to the control modules 2316 , 2502 , 3002 , 3202 . Data stored within these data storage media may include a variety of data collected from the condition of a fluid system including, for example and without limitation, oil condition, particle count of contaminants, cycle time data for time to evacuate or time to refill a given reservoir, time stamp data on a reservoir-by-reservoir basis, time stamp data on a system-by-system basis, fluid receptacle or other fluid storage/retention medium. In addition, the control modules 2316 , 2502 , 3002 , 3202 may include controls that actuate (e.g., open or close) their respectively associated electronic valves in accordance with pressure levels, for example, sensed at various inlets or outlets of the electronic valves.
Data can be communicated to the control modules 2316 , 2502 , 3002 , 3202 to and/or from a fluid system through a variety of methods and systems. In various embodiments disclosed herein, data may be communicated, for example, by a wireline connection, communicated by satellite communications, cellular communications, infrared and/or communicated in accordance with a protocol such as IEEE 802.11, for example, or other wireless or radio frequency communication protocol among other similar types of communication methods and systems. One or more data devices can be employed in operative association with the control modules 2316 , 2502 , 3002 , 3202 for the purpose of receiving, processing, inputting and/or storing data and/or for cooperating with the control modules 2316 , 2502 , 3002 , 3202 to control, monitor or otherwise manipulate one or more components included within a fluid system. Examples of data devices include, for example and without limitation, personal computers, laptops, and personal digital assistants (PDA's), and other data devices suitable for executing instructions on one or more computer-readable media.
In certain embodiments, the various sensors described in FIGS. 34 , 35 , 39 and 40 can be configured to detect one or more of the following conditions within a fluid system: engine oil pressure, oil temperature in the engine, amount of current drawn by a pre-lubrication circuit, presence of contaminants (such as oil contaminants, for example) in the engine, amount of time that has elapsed for performance of one or more cycles of various engine operations (i.e., cycle time) such as fluid purge operations, pre-lubrication operations, fluid evacuation operations, fluid refill operations, fluid flow rates, and others. One example of a sensor that may be used in accordance with various embodiments of the present systems and methods is a contamination sensor marketed under the “LUBRIGARD” trade designation (Lubrigard Limited, United Kingdom, North America, Europe). A contamination sensor can provide information regarding oxidation products, water, glycol, metallic wear particles, and/or other contaminants that may be present in the engine oil, hydraulic oil, gearbox oil, transmission oil, compressor oil and/or other fluids used in various machines. In various aspects of the present methods and systems, the contamination sensor may be employed during one or more fluid processes, for example, such as a fluid evacuation operation or a fluid refill operation.
It can be appreciated that the control modules 2316 , 2502 , 3002 , 3202 may receive and store data associated with activation and deactivation of various components of a fluid system and operation of a machine, such as an engine, for example, included within the fluid system. Cycle time, for example, can be calculated from analysis of collected data to provide an indication of elapsed time for completing evacuation and/or refill operations. For a given oil temperature or temperature range (e.g., as can be detected and communicated by a temperature sensor), an average cycle time, for example, can be calculated through analysis of two or more collected cycle times. In various aspects, the present methods and systems can determine whether the most recently elapsed cycle time deviates from a nominal average cycle time, or range of cycle times, for a given oil temperature or temperature range. In addition, factors may be known such as the type and viscosity of fluids (e.g., such as oil) used in connection with operation of the machine. An unacceptable deviation from a nominal cycle time, or range of times, can result in recording a fault in data storage media of the control modules 2316 , 2502 , 3002 , 3202 . It can be appreciated that many other types of fault conditions may be detected, analyzed and recorded in connection with practice of the present systems and methods.
Collected and analyzed data, as well as recorded fault events, can be stored in association with the control modules 2316 , 2502 , 3002 , 3202 , internal data modules associated with the control modules 2316 , 2502 , 3002 , 3202 , and/or at a remote location. In various embodiments, the control modules 2316 , 2502 , 3002 , 3202 may be configured for operation as integral components of a machine or as remote components not installed locally on the machine. The collected and analyzed information can be stored in one or more data storage media of the control modules 2316 , 2502 , 3002 , 3202 . The information can also be stored externally with respect to a machine and its components. Data may be transmitted wirelessly by a radio frequency communication or by a wireline connection from the control modules 2316 , 2502 , 3002 , 3202 to one or more data devices such as a personal digital assistant, for example, configured and employed as a computer system for receiving and processing data collected from the control modules 2316 , 2502 , 3002 , 3202 during fluid evacuation and fluid refill processes.
In one illustrative example, information related to an oil filter purge operation, such as the date and time of the filter purge or the cycle time of the filter purge, for example, and/or other machine conditions can be recorded and processed in connection with operation of the control modules 2316 , 2502 , 3002 , 3202 . In addition, the condition (e.g., open or closed) of various valve inlets and outlets, and the date/time at which they are actuated, may be detected, recorded and/or analyzed for various fluid operations. In accordance with the systems and methods disclosed herein, data may be collected and recorded on a reservoir-by-reservoir basis and/or on a fluid system-by-fluid system basis as service is performed on a machine, for example.
Referring now to FIGS. 41A through 41C , various embodiments of a connection/disconnection detection system 4000 are provided in accordance with the present invention. As shown, a first coupling portion 4002 is fluidically connected to a portion of a first fluid system 4003 (shown partially for convenience of illustration), and a second coupling portion 4004 is fluidically connected to a portion of a second fluid system 4005 (shown partially for convenience of illustration). In various embodiments, the first and second fluid systems may be structured as independently operated fluid systems or may be structured for operation as part of a single fluid system. The first coupling portion 4002 may include one or more electrical contacts 4006 , 4008 and the second coupling portion 4004 may include at least one electrical contact 4010 .
As shown in FIG. 41B , upon connection of the first coupling portion 4002 to the second coupling portion 4004 , an operative association is established among the electrical contacts 4006 , 4008 , 4010 . In the example shown, connection of the coupling portions 4002 , 4004 is established by inserting the second coupling portion 4004 into the first coupling portion 4002 and rotating the second coupling portion 4004 in the direction of the arrow 4011 . It can be appreciated, however, that any suitable method or device for connecting the coupling portions 4002 , 4004 may be employed within the scope of the present invention. In certain embodiments, the electrical contacts 4006 , 4008 , 4010 may be replaced with any suitable device or method for establishing an electrical operative association using the coupling portions 4002 , 4004 . Examples of other devices include, without limitation, sensors, contact switches, magnetic switches, Hall effect sensors, and/or any other operationally and structurally suitable devices.
In various embodiments, the electrical contacts 4006 , 4008 are operatively associated with a signal processor 4012 . The signal processor 4012 may include a sensor/receiver 4014 for receiving an electrical signal from the contacts 4006 , 4008 once the contact 4010 of the first coupling portion 4002 completes an electrical circuit with the contacts 4006 , 4008 of the second coupling portion 4004 upon connection of the coupling portions 4002 , 4004 . A transmitter 4016 may be included within the signal processor 4012 for transmitting the electrical signal representative of the connection and/or data representative of the electrical signal to a control module 4018 . The control module 4018 may be configured to function in accordance with the various embodiments of control modules described previously herein. For example, the control module 4018 may record in a suitable storage medium a date and/or a time when connection or disconnection of the coupling portions 4002 , 4004 has occurred.
Referring now to FIG. 41C , in another mode of operation of the connection/disconnection detection system 4000 , the second coupling portion 4004 may be moved in the direction of the arrow 4026 to initiate disconnection of the second coupling portion 4004 from the first coupling portion 4002 . As shown, the disconnection of the coupling portions 4002 , 4004 results in disassociation of the electrical contact 4010 from the electrical contacts 4006 , 4008 . In various embodiments, the sensor/receiver 4014 of the signal processor 4012 may be configured to detect this disassociation of the electrical contacts 4006 , 4008 , 4010 . An electrical signal representative of the disconnection and/or a data signal representative of the disconnection of the coupling portions 4002 , 4004 may be transmitted through the transmitter 4016 for further processing by the control module 4018 . For example, the control module 4018 may record in a suitable storage medium a date and/or a time when the disconnection of the coupling portions 4002 , 4004 occurred.
The signal processor 4012 further may include a power source 4020 for supplying power to operate the various components of the signal processor 4012 . In certain aspects, the power source 4020 may receive electrical energy, for example, from a battery 4022 of a machine 4024 for which various fluid operations are performed.
Referring now to FIG. 42 , embodiments of a power supply system 4100 provided in accordance with the present invention are shown. For convenience of disclosure, embodiments of the present invention illustrated in FIG. 32 (previously discussed) are shown in operative association with the power supply system 4100 . It can be appreciated that the power supply system 4100 may be applied, where structurally and functionally appropriate, to various embodiments of fluid systems, assemblies and other fluidic components and fluid operations described herein.
The power supply system 4100 may include a power receptacle 4102 structured to receive a power cord, for example, or other electrically operative connection to one or more of the fluid components 2120 . In various embodiments, the power receptacle 4102 is positioned in a location adjacent to or in the vicinity of a fluidic structure, such as the inlet/outlet port 2112 , for example. The power receptacle 4102 may be electrically associated with a machine 4104 for which one or more fluid service operations are performed. In certain embodiments, the power receptacle 4102 may be electrically operatively associated with a battery 4106 , for example, or other power source of the machine 4104 . A converter 4108 may be optionally included within the power supply system 4100 to convert a DC power source of the machine 4104 , for example, to an AC power source at the power receptacle 4102 , for example, which is accessible for electrical connection of the fluid component 2120 to the power receptacle 4102 . In certain embodiments the battery 4106 of the machine 4104 may be replaced or supplemented with an off-board power source, for example, or another power source external to the operation of the machine 4104 . Furthermore, it can be appreciated that the fluid components 2120 , of either the on-board or off-board variety, may have their own independent power sources in lieu of or in addition to external power sources such as the battery 4106 of the machine 4104 , for example.
The benefits of the present systems and methods are readily apparent to those skilled in the art. Systems and methods for selectively and/or sequentially performing fluid evacuation and/or refill processes can be useful in performing service and maintenance operations on machines. Such capabilities can ultimately improve the performance and useful life of machines for which such orchestrated fluid evacuation and/or fluid refill procedures are performed. In addition, the use of controls, monitoring, and data storage and analysis in connection with performing multiple fluid evacuation and/or refill processes can further enhance the overall effectiveness of service and maintenance operations performed on a variety of machines.
It should be appreciated that all the figures are presented for illustrative purposes and not as construction drawings. Omitted details and modifications or alternative embodiments are within the purview of persons of ordinary skill in the art. Furthermore, whereas particular embodiments of the invention have been described herein for the purpose of illustrating the invention and not for the purpose of limiting the same, it will be appreciated by those of ordinary skill in the art that numerous variations of the details, materials and arrangement of parts may be made within the principle and scope of the invention without departing from the invention as described in the appended claims.
The term “computer-readable medium” is defined herein as understood by those skilled in the art. It can be appreciated, for example, that method steps described herein may be performed, in certain embodiments, using instructions stored on a computer-readable medium or media that direct a computer system to perform the method steps. A computer-readable medium can include, for example, memory devices such as diskettes, compact discs of both read-only and writeable varieties, optical disk drives, and hard disk drives. A computer-readable medium can also include memory storage that can be physical, virtual, permanent, temporary, semi-permanent and/or semi-temporary. A computer-readable medium can further include one or more data signals transmitted on one or more carrier waves.
As used herein, a “computer” or “computer system” may be a wireless or wireline variety of a microcomputer, minicomputer, laptop, personal data assistant (PDA), cellular phone, pager, processor, or any other computerized device capable of configuration for transmitting and receiving data over a network. Computer devices disclosed herein can include memory for storing certain software applications used in obtaining, processing and communicating data. It can be appreciated that such memory can be internal or external. The memory can also include any means for storing software, including a hard disk, an optical disk, floppy disk, ROM (read only memory), RAM (random access memory), PROM (programmable ROM), EEPROM (extended erasable PROM), and other like computer-readable media.
It is to be understood that the figures and descriptions of the present invention have been simplified to illustrate elements that are relevant for a clear understanding of the present invention, while eliminating, for purposes of clarity, other elements. Those of ordinary skill in the art will recognize, however, that these and other elements may be desirable. However, because such elements are well known in the art, and because they do not facilitate a better understanding of the present invention, a discussion of such elements is not provided herein.
It can be appreciated that, in some embodiments of the present methods and systems disclosed herein, a single component can be replaced by multiple components, and multiple components replaced by a single component, to perform a given function or functions. Except where such substitution would not be operative to practice the present methods and systems, such substitution is within the scope of the present invention.
Examples presented herein are intended to illustrate potential implementations of the present method and system embodiments. It can be appreciated that such examples are intended primarily for purposes of illustration. No particular aspect or aspects of the example method and system embodiments described herein are intended to limit the scope of the present invention.
While the present methods and systems have been principally described in relation to relatively large-scale diesel engines, it should be recognized that the invention is also useful in a wide variety of other types of internal combustion engines. For example, use of the present methods and systems in automotive applications is contemplated, such as in connection with automotive engines. Thus, whereas particular embodiments of the invention have been described herein for the purpose of illustrating the invention and not for the purpose of limiting the same, it can be appreciated by those of ordinary skill in the art that numerous variations of the details, materials and arrangement of parts may be made within the principle and scope of the invention without departing from the invention as described in the appended claims. | Various fluid system and fluid operation embodiments include a first valve structured to permit fluid flow therethrough in response to application of positive pressure at an inlet of the first valve with an outlet of the first valve in fluid communication with a portion of a fluid system; a second valve has an outlet in fluid communication with the inlet of the first valve, and the second valve is structured to permit fluid flow therethrough in response to application of negative pressure at the outlet of the second valve; and, an inlet/outlet port in fluid communication with the inlet of the first valve and the outlet of the second valve at a common refill/evacuation location. Systems and methods incorporating electronic valves, configurations of multiple check valve assemblies, and modules of valve assemblies are also provided herein. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. | 5 |
TECHNOLOGICAL FIELD
[0001] The invention relates to a conductive cupriferous-alloy material for use in plug or clamp connectors as conceptually specified in claim 1 . It further relates to a contact component according to claim 18 as well as to a subassembly according to claim 19 and a strip or profile element according to claim 20 .
PRIOR ART
[0002] The conductivity of cupriferous materials has been known from prior art, as has the suitability of copper-containing materials for the application of electroplated layers for surface treatment. By contrast, PVD, CVD or PVD/CVD coatings have so far been rarely used on the relatively soft cupriferous materials in view of the fact that, for instance when exposed to substantial sliding friction as may occur in the assembly of plug or clamp connectors, the coating is pushed into the base material or it breaks, while many of the layer systems used in the coating of tools have too high a coefficient of friction (for example, the coefficient of friction of the WC or Cr x C y carbides is about 0.5 and even higher), too high a roughness factor or too little conductivity, thus making them fairly unsuitable for an application of this type.
[0003] DE 1 802 932 describes a high-frequency plasma process for the coating of electrical contacts with carbide-based anti-wear layers. DE 3011694 covers a similar method which also includes the application of an electroplated bonding layer on various hardened or tempered metallic materials with subsequent PVD coating in a high-frequency plasma, which process also includes the deposition of a hard-material i.e. carbide layer. While this provides good electrical conductivity and enhanced wear resistance, the carbide coating results in a relatively high coefficient of friction.
[0004] DE 4421144 describes coated tools whose product life is extended by the deposition of a hard-material layer consisting of a metal carbide, followed by the application of a friction-reducing, free carbon-containing tungsten carbide-based layer.
DESCRIPTION OF THE INVENTION
[0005] It is the objective of this present invention to introduce a cupriferous conductive material that avoids the drawbacks inherent in prior art while offering better electrical properties as well as improved product-life and antifriction performance compared to materials with conventional coatings.
[0006] That objective is achieved with the inventive features specified in the characterizing clause of claim 1 .
[0007] By applying carbon-containing antifriction and hard-material layers, modified according to the invention to have a carbon content greater than or equal to 40% but with an atomic percentage of less than or equal to 70 and deposited on copper metal or copper alloys, it is now possible to enhance the surface hardness and thus the wear and abrasion resistance of the material without significantly changing its excellent electrical properties. The definition of carbon content refers to the concentration of carbidically bound and free carbon which, together with the carbide builder and selected additional elements, adds up to 100%. In the process, by a method described in more detail further below, a hard-material layer is deposited that has defined tribological and electrical properties and results in an extended life of the conductive material concerned. These layers will be slightly less hard than conventional—for instance carbide—layers but significantly harder than the base layer which they protect against abrasive wear. Surprisingly, these layers offer better protection of the base material in the case of plug and clamp connectors than do conventional hard layer systems, although for applications involving high surface pressures a support layer may still be added. In the case of these hard-material coatings this phenomenon may also be attributable to the relatively low coefficient of friction, an advantage for instance for plug connectors since it requires less insertion force, which in turn prevents the scratching of the possibly uncoated matching socket.
[0008] It is these very properties that make such coatings suitable for application in vehicle or aircraft engineering as well, i.e. especially for application on components exposed to continuous vibration, oscillation or the like, perhaps even in combination with concussive impact. Their greater stability compared to conventional copper-based conductive materials prevents operationally compromising or even inhibiting surface fatigue to which such connecting elements are susceptible due to the relatively limited hardness of the copper or the traditionally coated copper materials. Moreover, tribo-oxidative changes that occur at elevated operating temperatures and often cause such plug and clamp connectors to fail can be effectively prevented.
[0009] So far, a very significantly improved load resistance has been exhibited by plug and clamp connectors consisting of the following cupriferous alloys coated in accordance with this invention: copper, bronze, brass or German silver. Similar improvements, however, can be expected with other base materials as well, such as CuBe and other alloys, or in other applications.
[0010] It may also be advantageous to use pre-electroplated conductive materials. Examples thereof include Cr, Ni or CrNi layers that are deposited before the support layer is applied.
[0011] In view of the low precipitation temperatures involved, plasma CVD, PVD or PVD/CVD hybrid techniques lend themselves particularly well to the deposition of Me-DLC layers for the coating for instance of heat-treatable copper metals.
[0012] But then, it was not possible with conventional coatings such as the free-carbon containing layers described in DE 4421144 or the DLC (diamond-like carbon) layers described in U.S. Pat. No. 4,992,153 or DE 10018143 to obtain adequate conductivity and, in the case of conventional carbide layers, to adequately prevent the latter from denting the base material as mentioned above. Surprisingly, it was only by selecting a carbon content greater than or equal to 40% but with an atomic percentage smaller than or equal to 70 that a significant conductivity improvement could be achieved. Particularly good results were obtained with a carbon content greater than or equal to 50 but with an atomic percentage smaller than or equal to 60.
[0013] Applying an additional support backing i.e. layer comprising at least one metal Me from among the subgroups IV, V and VI of the periodic system of elements (i.e. Ti, Zr, Hf; V, Nb, Ta; Cr, Mo, W) or aluminum or Si, prevented any denting even under very high pressure. It was also found to be particularly desirable to use support layers which, in addition to the metal component, also contained a nonmetallic element such as C, N, B or O, or hard-material compounds composed of the metals and nonmetals mentioned. As an example only, such support layer systems may consist of TiN or Ti/TiN (meaning a metallic titanium layer with an adjoining titanium nitride hard layer), or of CrN or Cr/CrN, Cr x C y or Cr/Cr x C y , Cr x (CN) y , TiAl or TiAlN and TiAl/TiAlN.
[0014] Depending on the intended application it is important for the support layer to meet a minimum thickness requirement which is a function primarily of the surface pressure in each particular case. For example, in cases of minor surface pressures a DLC layer 0.5 μm thick provided adequate support, whereas a backing only 0.3 μm thick did not offer sufficient support. In general, however, a layer thickness of at least 1 to about 3 μm is recommended. For applications involving particularly high surface pressures it may be desirable to use layers of a greater thickness, for instance 6 μm.
[0015] In addition, it is possible to interposition between the support layer and the antifriction layer a metallic intermediate layer with or without a gradual transition, or a direct junction in the form of a graded index layer with a carbon content progressively increasing in the direction of the antifriction layer.
[0016] Desirably, therefore, the DLC antifriction layer is constructed as follows: Deposited directly on the support layer is a metallic intermediate layer consisting of at least one metal Me of the elements of the IV, V or VI subgroup, Al or Si. The intermediate layer preferably consists of Cr or Ti, elements that have been found to lend themselves particularly well to this effect. It is equally possible, however, to use nitridic, carbidic, boridic or oxidic intermediate layers, or intermediate layers composed of one or several metals in combination with one or several of the above-mentioned nonmetals which, if necessary, may themselves be built up on a metallic base layer with or without a gradual transition. That intermediate step can be omitted if the carbon antifriction layer is applied directly on the bonding layer and the bonding layer consists of a metal or of a compound suitable for use as a bonding layer.
[0017] Preferably following that, or directly in its place without an intermediate layer, is a transitional layer especially in the form of a graded index layer over the course of which, perpendicular to the surface of the work piece, the metal content decreases and the carbon content increases. The carbon increase may be obtained by the addition of perhaps different carbidic phases or of free carbon or of a mixture of such phases with the metallic phase of the intermediate layer. As those skilled in the art know, the thickness of the graded index layer can be selected by setting appropriate process ramps. The increase in the C-content and decrease in the metallic phase may be continuous or stepwise, and at least in part of the graded-index layer a series of high-metal and high-C layers may be provided to progressively reduce laminar stress. As an example, the initial layer may be an MeC layer deposited for instance by sputtering, with the free-carbon proportion increased either continually or in steps by the injection of a carbon-containing reactive gas. For tungsten carbide-based layers, as an example, a ratio of about 50:1 to 2:1 between the carbidically bound and the free carbon has been found to work very well. Similar relationships have been established for chromium carbide-, tantalum carbide- and molybdenum carbide-based layers.
[0018] In essentially continuous fashion the above-mentioned configuration of the graded-index layer causes the respective characteristics of the material (e.g. E-module, structure etc.) of the support layer and the DLC layer to be mutually adapted, thus helping to minimize the risk of fissuring otherwise encountered along the metal i.e. Si/DLC interface.
[0019] The DLC antifriction layer process can be terminated by turning off the sputter and/or bias upon reaching a defined flow of the carbon-containing process gas or upon reaching a particular pressure level. Alternatively, the coating parameters can be held constant during the final process phase in order to maintain the properties of the outer functional layer constant above a desired minimum layer thickness.
[0020] The hardness of the entire carbon layer is selected at a value greater than 0.8 GPa, preferably greater than or equal to 10 GPa, where even at a layer thickness of >1 μm and preferably >2 μm on a steel test sample with a hardness of about 60 HRC a bonding strength of better than or equal to HF 3 but preferably equal to HF 1 per VDI 3824 page 4 is attained. Measurements of the contact resistance of DLC layers according to the invention have resulted in values of between δ=0.1 mΩ and δ=90 mΩ, the selected values preferably being between 0.5 mΩ and 10 mΩ since, on the one hand, δ-values smaller than 0.5 mΩ are attainable only with the addition of precious metals, substantially increasing the cost of manufacture, while on the other hand a contact resistance of more than 10 mΩ is already too high for certain applications.
[0021] At the same time, the object carbon layer offers the desirable feature of a low coefficient of friction as is typical for Me-carbon, preferably at μ≦0.2 in the pin-on-disk test at a layer roughness level of R a =0.01-0.04; R z DIN<0.8 and preferably <0.5.
[0022] The growth rate is about 1-3 μm/h and depends, apart from the process parameters, on the load and the holding device. Major factors in this case depend on whether the parts to be coated are mounted on single-, double- or triple-rotating holders, on magnetic holders, on clamps or on plug-in retainers. Similarly important is the overall mass and the plasma permeability of the holders. For example, lightweight holders such as spoke or spider plates rather than solid plates produce higher growth rates and in general a better overall layer quality. The laminar stress may be around 0.8 GPa and thus within the usual range for hard DLC layers. Moreover, at a slightly lower hardness (9 to 15 GPa), layers of this type exhibit a distinctly lower coefficient of friction, reducing the insertion force involved.
[0023] These properties can be further improved and/or stabilized against corrosion/oxidation by the addition—through Co sputtering or evaporation, alloying into the target materials, or similar techniques—of small amounts of the elements Ag, Au, Cu, Fe, Ir, Mo, Ni, Pd, Pt, Os, Rh, Ru, W and/or alloys thereof. If particularly high conductivity is needed, it will be desirable to provide the final layer package with a residual metal content at a minimum of 30 and a maximum of 60% but preferably between 40 and 50%.
[0024] In view of the excellent mechanical properties of these metal-containing DLC layers, they also lend themselves well to applications where the coated conductive material is to additionally serve a bearing function. For example, these conductive materials can be advantageously used for bearings that double as conductors of electrical signals.
EXAMPLES AND TESTS PERFORMED
[0025] The following will describe the invention with the aid of various implementation examples. All Me-DLC layers and support layers were precipitated at temperatures below 250° C. and deposited on copper-based materials in a Balzers BAI 830 C production system, a modified version as discussed in DE 100 18 143 under FIG. 1 and related description [0076] to [0085]. All coatings were first pretreated in a heating and etching procedure, utilizing a low voltage arc, as described in process example #1 of that document. The correspondingly identified sections of that preliminary patent disclosure are hereby made an integral part of this present patent application.
Comparative Example #1
[0026] In the terminating i.e. outer layer region a metalliferous DLC antifriction layer was applied on a CuSn8 bronze substrate via a chromium bonding layer but without the addition of a support layer. First, following the above-mentioned pretreatment, the chromium bonding layer was deposited as described in the process example #1 of DE 100 18 143.
[0027] Next, with the Cr targets activated, six WC targets were activated applying power at a rate of 1 kW each and both target types were simultaneously run for 2 minutes. In the process, with the Ar flow kept constant, the power of the WC targets was increased over 2 minutes from 1 kW to 3.5 kW. At the same time the negative substrate voltage on the components was increased, ramp-style over 2 minutes, from 0 V at the end of the Cr bonding layer to 300 V. The 300 V was thus reached when the WC targets were running at maximum power. The Cr targets were then turned off. The WC targets were allowed to run for 6 minutes at a constant Ar flow and a power output of 3.5 kW after which, over 11 minutes, the acetylene gas flow was increased to 200 sccm and held constant for 60 minutes at the parameters described in Table 1). After that the coating process was ended.
[0000]
TABLE 1
Coating parameter #1 - metal-containing DLC layer
Argon flow
115
sccm
Acetylene flow
200
sccm
Bias voltage
−300
V
Coil voltage, upper coil
6
A
Coil voltage, lower coil
0
A
Target power
6 × 3.5
kW
Example #2
[0028] This differed from Example #1 in that during the last process phase the acetylene gas flow was increased over 5 minutes to only 80 sccm where it was held constant for 60 minutes.
Example #3
[0029] This differed from Example #1 in that during the last process phase the acetylene gas flow was increased over 2 minutes to 30 sccm where it was held constant for 60 minutes.
Comparative Example #4
[0030] This differed from Example #1 in that during the last process phase no acetylene was added and, after the Cr targets had been turned off, the WC targets were run for 60 minutes at a constant Ar flow.
Example #5
[0031] For Example #5 the first step was to deposit a CrN support layer whereupon, analogous to Example #3, a conductive Me-DLC layer was applied on the support layer. The CrN support layer was deposited in accordance with the parameters specified in Table 5), with the plasma density additionally augmented by a low voltage arc discharge ignited and operated in the central axis between a hot cathode and an auxiliary anode.
[0000]
TABLE 5
CrN support layer coating parameters
Argon flow
100
sccm
Nitrogen flow
100
sccm
Arc current
75
A
Bias voltage
−100
V
Coil voltage, upper coil
6
A
Coil voltage, lower coil
0
A
Target power
2 × 8
kW
Example #6
[0032] For Example #6, the first step was to apply a chromium bonding layer as in Example #1. The adjoining WC-containing functional layer was doped with Ag.
[0033] With the Cr targets activated, four WC targets were activated with a power of 1 kW each and both target types were allowed to simultaneously run for 2 minutes, while over 2 minutes, with the Ar flow kept constant, the power of the WC targets was increased from 1 kW to 3.5 kW.
[0034] Two silver targets that were also mounted in the coating system were ignited at the same time as the WC targets and during the same time span their power was increased from 0 to 1 kW. Concurrently, the negative substrate voltage on the components was increased, ramp-style over 2 minutes, from 0 V at the end of the Cr bonding layer to 300 V. The Cr targets were then turned off. The WC and Ag targets were jointly run for 6 minutes under a constant Ar flow whereupon, over 2 minutes, the acetylene gas flow was increased to 30 sccm, and during the final coating phase the parameters listed in Table 6) were held constant for 60 minutes.
[0000]
TABLE 6
Metal-containing coating parameters
Argon flow
115
sccm
Acetylene flow
30
sccm
Bias voltage
−300
V
Coil voltage, upper coil
6
A
Coil voltage, lower coil
0
A
WC target power
4 × 3.5
kW
Ag target power
2 × 1
kW
Assessment of the Layers
[0035] As will be evident from Table 7), prior-art coatings as described in Comparative Examples #1 and #4 exhibit relatively high contact resistance. Example #1 is typical of an a-C:H:Me or Me-DLC layer, with a C-component rapidly increasing toward the surface. Example #4 illustrates a carbide layer without noteworthy free-carbon constituents.
[0036] The measured values, representing averages from 5 different measuring points, were in each case acquired 10 seconds after the placement of a 100 g contact weight. The tip of the contact weight consisted of gold with a 3 mm diameter. The individual value determined was verified by a preceding and a subsequent reference measurement on gold.
[0037] The abrasive force of the plug connectors was determined on a macro abrasion test station for
[0000]
Standard connectors
DLC connectors
(tin-plated)
Sample geometry
rider on flat
rider on flat
Rider diameter
4 mm
4 mm
Contact surface
0.3 mm 2
0.3 mm 2
Test atmosphere
dry
dry
Frequency
1 cycle in 2.5 sec
1 cycle in 2.5 sec
Test duration
3000 cycles
25 cycles
Normal force
20 N
5 N
Path length of friction
3 mm
3 mm
[0038] Determining the abrasive force after a defined number of cycles reveals the abrasive wear of the sample. After 25 cycles the tin-plated standard connector showed an abrasive force of 1000 mN. Increasing the number of cycles would lead to complete destruction. The values for DLC-coated connectors are shown in the third column.
[0039] Surprisingly, the tests revealed that coatings with a free-carbon content in an intermediate range (Examples #2 and #3) exhibit markedly lower contact resistance. That low contact resistance remained unaffected even after a CrN support layer was added as indicated in Example #5. Co sputtering of Ag as described in Example #6 reduced the contact resistance even further.
[0000]
TABLE 7
Contact resistance and abrasive force of different DLC coatings.
C2H2
Flow
C-Content
Contact Resistance
Abrasive Force
Example #
[SCCM]
[%]
[mΩ]
[mN]
1
200
75
25
900
2
20
60
25
900
3
30
54
2
1000
4
0
50
20
1500
5
30
54
2
900-1000
6
30
54
1
— | The invention relates to a conductive material consisting of an alloy that contains copper, for use as a plug-in or clip connection. Said material comprises a cover layer that is deposited on at least some sections of the contact surface, said layer consisting at least of a support layer and an adhesive layer. The anti-friction layer has a carbon content greater or less than 40 and less than or equal to 70 atomic percent. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
The present application is an improvement to the co-pending design patent application filed Apr. 23, 1990 having Ser. No. 07/513,158 entitled "Snow Remover".
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an item of hardware used principally for snow removal from sidewalks and driveways.
2. Description of Related Art
U.S. Pat. No. 4,916,837 issued Apr. 17, 1990 to Olmr et al is directed to a "Single Stage Snowthrower" and indicates the present lack of a known, simple snow remover inasmuch as the disclosure of such Patent provides a complex, expensive, and ineffective snow throwing device.
Summary of the Invention
An article of manufacture adapted for use as a snow remover is provided and is characterized by a simple, light-weight, elongated structure having a plurality openings at one end and a metal attachment at the opposite end to create proper friction for scraping most outdoor surfaces and for providing durability when scraped across rough surfaces for a long period of time. An important feature of the invention is a single roller or wheel which is positioned near the end of the snow remover having the metal attachment thereby allowing the snow remover to be pushed with minimal effort by an individual person. Also, openings may be provided on the sides if desired. The length of the snow remover and the positioning of the wheel allow the person pushing the snow remover to grasp such snow remover near the waist to allow maximum, yet comfortable, force to be applied to such snow remover. A plurality of handles are positioned near the end of the snow remover to allow adaptability of the snow remover for use as a dolly to transport various items such as pot plants or dirt around a lawn, for example. Also, the article of manufacture of the present invention may be attached to a vehicle such as a snowmobile and used as a trailer. The bottom of the article of manufacture has a plurality of elongated protrusions to add strength on the ground when the article of manufacture is used as a snow remover and to act as keels when used as a sled.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of an individual using the device of the present invention;
FIG. 2 is a top, plan view of the device of the present invention;
FIG. 3 is a side, elevational, partial sectional view taken along line 3--3 of FIG. 2;
FIG. 4 is an end, elevational, partial sectional view taken along line 4--4 of FIG. 3;
FIG. 5 is a side, elevational view of the device of the present invention showing handles attached; and
FIG. 6 is a bottom, elevational view of part of the device of the present invention taken along line 6--6 of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a perspective view of the device 10 of the present invention in use by an individual 12 having hands 14 and 16 positioned in openings of the device 10 for stabilization and control of the directional movement of the device 10 when being used to remove snow 18 from a sidewalk 20. It will be appreciated that the device of the present invention may be utilized for removal of snow at any location where the snow has accumulated and needs to be removed. The device of the present invention is contoured and shaped so that an individual utilizing such device needs only to apply minimal effort in pushing the device of the present invention because, in most instances, the device is approximately waist-high for the individual using such device.
The device of the present invention uses a scraping and scooping motion which lifts the snow at an angle to allow for accumulation and packing of the snow. The snow is discarded with a lateral motion by lifting either one of the handles and depositing the snow to the side of the device. As will be explained in detail subsequently, the configuration of the device of the present invention is such that the bottom edge reaches the ground and the top edge, as pointed out previously, is approximately waist-high, thereby allowing an average-sized individual to lean into the device to create a forward motion while using the handles of the device to balance and guide or direct such device. The forward motion is generated from the waist and arms thereby putting very little pressure on the lower back of the individual who is utilizing such device. As will be explained in detail subsequently, an optional wheel assembly allows easier forward motion and carries some of the weight of the load on the device. The wheel can be removed for lighter jobs.
FIG. 2 is a top, plan view of the article of manufacture or device 10 of the present invention. Such device may be manufactured from a durable, weather-resistant, rigid, plastic material which will withstand varying climate conditions or from steel and wood. Essentially, such device is designed so that the bottom edge and the wheel are in contact with the ground thereby allowing a rolling and scraping function.
At one end of the device are a plurality of openings such as opening 22 and opening 24. These openings are elongated to accommodate the hands of an individual who is using the device.
At the end opposite from the openings is a metal strip 26 which extends along the entire edge of the device and is attached, for example with a plurality of fasteners such as bolts 28, 30, 32 and 34. It will be appreciated that the device of the present invention may be used for leveling dirt as well as for snow removal.
The metal strip 26 has two main purposes. One purpose is to create the proper friction for scraping most outdoor surfaces such as concrete, wood, asphalt, or gravel. The second purpose is to provide durability when the device is scraped across rough surfaces for long durations of time. A plurality of elongated raised surfaces such as surface 36 and surface 38 extend along the longitudinal axis of the device for approximately three-fourths of the total length of the device.
A plurality of openings such as opening or hole 40, 42, 44, 46, 48 and 50 allow a wheel having a plate 52 to be fastened to the lower portion of the device with a plurality of bolts, for example, and to allow for adjustment for the height of the operator.
A plurality of holes such as hole 54, 56, 58 and 60 are positioned near opening 22 to allow a handle to be attached to the device 10 in a manner to be explained subsequently.
Near opening 24 are a plurality of holes such as hole 62, 64, 66 and 68. These holes also allow a handle to be attached near opening 24 as will be explained subsequently.
FIG. 3 is a side, elevational, partial sectional view of the device 10 of the present invention showing wheel 70 positioned on axle 72 to support member 74 which is attached to the lower portion of the device 10 with a plurality of bolts positioned in the holes mentioned in connection with FIG. 2.
Metal strip 26 is shown positioned at the end of the device 26 opposite from openings 22 and 24. Elongated, raised surface 36 is positioned along the lower portion of the device which has a suitable curvature to allow optimum use of the wheel arrangement at the lower-most portion of the curved bottom surface.
FIG. 4 is an end, elevational, partial sectional view of the device taken along line 4--4 of FIG. 3. The elongated, raised surface 36 and the elongated, raised surface 38 are shown positioned on either side of the wheel 70 positioned on axle 72 in support member 74. Opening 22 and opening 24 are positioned near the uppermost surface of the device to allow the device to achieve optimum results as pointed out previously.
FIG. 5 is a side, elevational view of the device 10 showing handle 76 attached to such device. Handle 76 may be comprised of any suitable material with a bent lower portion 78 attached to device 10 near each of the openings 22 and 24. Upper portion 80 of the handle 76 may have a grip 82 attached to allow hands of an individual to better hold the handle 76.
Lower portion 78 may be attached to the device 10 with a plurality of bolts such as bolt 84 and 86.
When handles such as handle 76 are attached to the device, such device can be used as a light garden dolly or wheelbarrow. Small loads such as firewood, plants, dirt and other objects may be moved around a home or business by utilizing the device of the present invention. The wheel carries the load and because there is only one wheel, the device is highly maneuverable and the device also may be easily stored by hanging the device on a wall having nails, for example, which may fit inside of the openings 22 and 24.
The device of the present invention also can be used as a sled or toboggan since it is large enough for two adults or two children to slide down a hill.
FIG. 6 is a bottom, elevational view taken along line 6--6 of FIG. 5 and shows handle 88 attached to device 10 with a plurality of bolts such as bolts 90, 92, 94 and 96. These bolts extend into plate 98 having handle 88 attached thereto. Grip 100 is positioned on handle 88 as explained previously in connection with FIG. 5. Elongated, raised surface 36 is shown in FIG. 6 extending to the area of plate 98. Opening 22 is shown in FIG. 6 and handle 88 is positioned substantially in the middle of opening 22 to allow optimum handling of the device.
Thus, it will be appreciated that the present invention provides a device capable of removing snow in an efficient, economical, simple, and safe manner not known and used prior to the present invention. The device may be fitted with a wheel assembly and with optional handles to allow versatility of use of the device as a dolly or wheelbarrow. The device of the present invention also may be attached to a vehicle for use as a trailer. The device of the present invention is relatively easy to manufacture and maintain and, when used properly, may be utilized for a long period of time.
Although preferred embodiments of the invention have been shown and described, it will be appreciated by those skilled in the art to which the present invention pertains that modifications and improvements may be made without departing from the spirit of the invention defined by the claims. | An article of manufacture is provided for use primarily in removal of snow from driveways, sidewalks, decks and other locations where snow accumulates and needs to be removed. Such article of manufacture also may be used as a dolly, sled, or a trailer-like device for pulling by a vehicle or snowmobile. | 4 |
The invention relates to a method for operating an electromagnetic actuator having a housing with a magnetic coil, an actuating pin, and a magnetic armature that moves, due to the impingement of magnetic force of the energized magnetic coil, the pin out of the housing in the extension direction, as well as a holding element that is arranged between the magnetic armature and the housing and blocks the movement of the magnetic armature below a magnetic force threshold.
BACKGROUND
Such an actuator is known from the unpublished DE 10 2011 078 525 A1, wherein the holding element is a permanent magnet that is arranged between the housing and the magnetic armature and holds the magnetic armature and the pin at rest until the magnetic force threshold is exceeded. The actuator is part of a valve train of an internal combustion engine with variable-lift gas-exchange valve actuation. The variable lift is generated by the camshaft that comprises a carrier shaft and a cam piece locked in rotation on this carrier shaft and arranged so that it can move between axial positions. The cam piece has at least one cam group of directly adjacent cams with different lifts and an axial slotted piece in which the pin of the actuator is coupled, in order to shift the cam piece on the carrier shaft between the axial positions and thus to switch the instantaneous cam lift pick-off from one cam to another cam.
The switching procedure should be precise and reproducible at the highest possible switching rotational speed and accordingly within the shortest amount of time and should be completed for all cylinders of the internal combustion engine within one work cycle. Ideally, all of the actuators are sufficiently quick and have no time variance with respect to the movement behavior of the pin moving out from the housing. In reality, however, the precise timing of the switching process is negatively affected by the varying extension movement of the pin due to production tolerances and the wear of the actuator components, as well as the large operating temperature range that causes not only varying friction relationships on the oiled actuator components, but also varying electrical resistance in the magnetic coils.
In the case of the variable lift valve train, the insufficiently precise timing of the actuator can lead to unacceptable incorrect switching of the cam pieces on the carrier shaft.
SUMMARY
The present invention is based on the objective of disclosing a method for operating an actuator of the type named above that allows, despite the disrupting effects negatively affecting the timing of the actuator, a movement profile that is as precise as possible in time for the pin extending out from the housing.
The solution to this objective is given through one or more features of the invention, while advantageous refinements and constructions of the invention can be taken from the description and claims. Accordingly, the method should comprise the following steps:
when a pin is actuated, determine an actual dead time during which the magnetic armature is essentially stationary when the magnetic coil is energized, wherein the actual dead time ends with the current in-rush to the magnetic coil due to counter induction of the magnetic armature overcoming the magnetic force threshold;
before a subsequent pin actuation, determine the beginning time point for energizing the magnetic coil, wherein the current beginning time point is advanced by the determined actual dead time relative to the desired movement beginning of the pin traveling out from the housing.
In the method according to the invention, the actual dead time of the actuator is monitored continuously and input as a current value into a downstream controller of the actuator. Thus, one of the significant disrupting influences on the timing of the actuator is minimized, namely the time variance of the actual beginning of movement of the pin. For an earlier pin actuation, this is realized by determining the actual dead time and for a subsequent later pin actuation, by holding the actual dead time, individually for each actuator. The behavior becomes more exact the more often the actual dead time is monitored and updated. Ideally, it is determined for each pin actuation and stored as the current control parameter in the control unit of the actuator. The actual dead time begins when the magnetic coil is energized and ends with the beginning of movement of the pin. The beginning of movement of the pin is defined as the time at which the current or voltage profile on the energized magnetic coil experiences a pronounced drop due to the counter induction of the magnetic armature that had been stationary up to then and is now moving outward. At this point, the dropping current of the voltage profile shows a maximum that can be evaluated precisely and results from the sudden acceleration of the magnetic armature overcoming the magnetic force threshold. The metrological determination of this characteristic current or voltage maximum can be found as such in the prior art, wherein a suitable measurement and evaluation circuit for the control unit can be found, in particular, in DE 101 50 199 A1.
BRIEF DESCRIPTION OF THE DRAWINGS
Additional features of the invention result from the following description and from the drawings in which the method according to the invention is explained as preferred but nevertheless as an example application for a variable lift valve train of the type named above. If not mentioned otherwise, features or components that are identical or that have identical functions are provided with identical reference symbols. Shown are:
FIG. 1 a known valve train in side view,
FIG. 2 a cross-sectional view through the axial slotted piece according to FIG. 1 with a schematic sequence of the coupling actuator pin,
FIG. 3 the actuator timing with respect to the cam angle without using the method according to the invention,
FIG. 4 the actuator timing with respect to the cam angle using the method according to the invention,
FIG. 5 an actuator of the valve train in a simplified longitudinal section view,
FIG. 6 the typical current/voltage profile on the magnetic coil for controlling the actuator according to FIG. 5 ,
FIG. 7 the typical path profile of the magnetic armature for controlling the actuator according to FIG. 5 , and
FIG. 8 a characteristic map for testing the plausibility of the determined actual dead times of the actuator.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a variable lift valve train 1 of an internal combustion engine whose basic functioning principle can be summarized in that a conventional, rigidly formed camshaft is replaced by a carrier shaft 2 with external teeth and cam pieces 3 that are arranged on this carrier shaft and are locked in rotation by means of internal teeth and movable in the longitudinal direction. Each cam piece 3 has two groups of axially adjacent cams 4 and 5 whose different lift profiles are transferred via cam followers 6 to gas exchange valves 7 . The displacement of the cam piece 3 on the carrier shaft 2 required for the operating point-dependent activation of each cam 4 or 5 is realized by spiral-shaped axial slotted pieces 8 on the cam piece 3 that differ in their orientation according to the direction of displacement and in which a cylindrical pin 9 of an electromagnetic actuator 10 (see FIG. 5 ) is coupled according to the instantaneous position of the cam piece 3 .
FIG. 2 shows a sequence of the pin 9 coupling in the groove-shaped axial slotted piece 8 . The pin is located at a distance to the high circle 11 and at rest up to the angle position a. At this point in time, the actual dead time designated with t 11 ends for the already energized actuator 10 and the pin 9 begins with its extension movement in the direction of the axial slotted piece 8 . At the angle position b, the pin 9 is set on the high circle 11 and then follows the axial slotted piece 8 that dips relative to the high circle 11 , as shown with the angle positions c, d, and e. The groove depth of the axial slotted piece 8 remains constant starting from the position d, so that, at this position, the extension movement of the pin 9 stops. The time between the end of the actual dead time t 11 and reaching the position d is designated as the coupling time t 12 .
An essential element for the success of the switching process of all cam pieces 3 within the same camshaft revolution is now the precise control timing of the actuators 10 , so that all pins 9 couple in their axial slotted pieces 9 at the correct time. This is illustrated with reference to FIGS. 3 and 4 that show the influence of the varying actual dead time t 11 on the success of the switching process. Shown in each are the time events of the actuator 10 relevant for the switching process of the cam piece 3 versus the cam angle.
FIG. 3 shows the previously typical activation of the actuator 10 , i.e., without using the control method according to the invention.
The control of the actuator 10 is here realized without the exact knowledge of the actual dead time t 11 . Typically, minimum and maximum dead time values t 11 obtained by means of statistical methods are used for control. The necessity to design the control for extreme parts (very slow and very fast) limits the functional range of the average system. Thus, the rotational speed band in which a switching process of the cam piece 3 is permissible can be selected only very conservatively. In addition, for reasons of exorbitant increase in the variance, the switching at low temperatures must be limited to an initial actuation for ensuring the reference lift curve/cylinder number.
The control of the actuators 10 is typically realized by transistors that are switched by the control unit (not shown). Here, the magnetic coil 12 of each actuator 10 (see FIG. 5 ) is controlled in time with the available electric system voltage. The control of the actuator 10 and its actual dead time t 11 begins at the time “trigger point.” For a successful switching process (“proper event”) of the cam piece 3 it is decisive that the beginning of movement of the pin 9 takes place at the earliest at the time “earliest switching point” at the angle position a (see FIG. 2 ) and at the latest at the time “latest switching point.” The variance band designated in the diagrams with “scatter band” for the variance caused during operation of the actual dead time t 11 , especially due to wear and temperature influences, is now greater than that at the available time of the “proper event.” This leads to emission-related incorrect switching of the cam piece 3 (“erroneous event”), wherein, on one hand, the actual dead time t 11 of the fastest actuator 10 (“t 11 fastest actuator”) is too short and its pin 9 already moves out before the angle position a and, on the other hand, the actual dead time t 11 of the slowest actuator 10 (“t 11 slowest actuator”) is too long and its pin 9 moves out only after the angle position a.
FIG. 4 shows a control of the actuator 10 accordingly using the method according to the invention.
In this case, the control of the actuator 10 takes place with knowledge of the individual actual dead time t 11 of the actuator 10 that was determined in an earlier switching process of the associated cam piece 3 —the determination itself will be explained further below with reference to FIGS. 5 and 8 . The determined actual dead time t 11 (“t 11 rated actuator”) is now subtracted from a time lying within the “proper event” for the desired beginning of movement of the pin 9 at the angle position a, so that the beginning time point calculated in this way for later energizing of the actuator (“calculated trigger point”) is moved ahead by the previously determined actual dead time t 11 . The beginning of this current is also determined individually for each actuator 10 . It can be clearly seen that the variance band of the actual dead time t 11 actually occurring during the now following switching process of the cam piece 3 (“reduced scatter band”) is considerably smaller and within the time interval required for the “proper event.”
FIG. 5 shows the principle setup of an actuator 10 that is suitable for the method according to the invention. This comprises a housing 13 with the magnetic coil 12 and contacting 14 of the coil 12 , the actuating pin 9 , and the magnetic armature 15 that moves the pin 9 in the extension direction out from the housing 13 with the impingement of magnetic force through the energized magnetic coil 12 . A retaining element 16 arranged between the magnetic armature 15 and the housing 13 blocks the movement of the magnetic armature 15 and the pin 9 until the magnetic force of the magnetic coil 12 exceeds the magnetic force threshold of the retaining element 16 . The retaining element 16 is a permanent magnet in the shown embodiment.
FIG. 6 shows the current/voltage profile U/I of the energized magnetic coil 12 versus the time t and FIG. 7 shows the associated path profile s(t) of the pin 9 moving out from the housing 13 . During the dead time t 11 , the current I and voltage U of the magnetic coil 12 increase, wherein its magnetic force is not yet sufficiently large to overcome the retaining force of the permanent magnet 16 acting against it. The magnetic armature 15 and the pin 9 remain at rest at x 0 accordingly. At the end of the dead time t 11 and at the beginning of the coupling time t 12 , the magnetic field of the magnetic coil 12 overcomes the blocking magnetic force threshold of the permanent magnet 16 , so that the magnetic armature 15 drives the pin 9 out of the housing 13 and the armature movement generates a counter induction in the magnetic field of the magnetic coil 12 . For the duration of the magnetic armature movement, the counter induction induces a current that acts against the current driven by the electric system and depends, among other things, on the velocity of the magnetic armature 15 . During the coupling time t 12 of the magnetic armature 15 and the pin 9 , the sum characteristic curve of both currents shows a characteristic drop that begins with a change in slope in the characteristic curve that can be evaluated precisely. The time of the change in slope is determined with the help of a known measurement and evaluation circuit (see above) and defines the end of the actual dead time t 11 and the beginning of the coupling time t 12 .
The coupling time t 12 ends at the time when the pin 9 reaches the angle position d and remains in the extended rest position x 1 in the further movement of the axial slotted piece 8 . From this time point on, the magnetic armature 15 also remains at rest, so that the counter induction goes to zero and the current/voltage profile increases again.
The actual dead time t 11 determined for each actuator 10 is stored updated for a subsequent pin actuation in the control unit of the actuator 10 . The determined value can be checked for plausibility in advance, for which the characteristic map shown in FIG. 8 for the dead time values t 11 designated with “plausible values” is used for reference. As input parameters for the characteristic map, the coil temperature T and the current electric system voltage U are used. With the help of the continuously determined actual dead times t 11 and the information on temperature and voltage, the present characteristic map can be continuously updated. It is further possible to divide the characteristic map into the cases of first switching and continued switching, in order to take into account setting phenomena after the valve train 1 has been stopped for long periods of time.
LIST OF REFERENCE NUMBERS
1 Valve train
2 Carrier shaft
3 Cam piece
4 Cam
5 Cam
6 Cam follower
7 Gas exchange valve
8 Axial slotted piece
9 Actuator pin
10 Actuator
11 High circle
12 Magnetic coil
13 Actuator housing
14 Contacting
15 Magnetic armature
16 Holding element/permanent magnet | A method for operating an electromagnetic actuator ( 10 ) with an actuating pin ( 9 ) is proposed which comprises the following steps: —determining a pin actuation actual dead time (t 11 ), during which the magnetic armature ( 15 ) is substantially immobile while a magnetic coil ( 12 ) is supplied with current, wherein the actual dead time ends with the current break-in at the magnetic coil, as a result of counter induction of the magnetic armature overcoming the magnetic force threshold; —determining, before a subsequent pin actuation, the starting time of the magnetic coil current supply, wherein the starting point of the current is advanced compared with that of the target movement start of the pin out of the actuator housing ( 13 ) and the determined actual dead time. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to a control apparatus for an electric power steering system in which a steering system of an automobile or a vehicle is provided with a steering assist force generated by a motor. More particularly, the invention relates to a control apparatus for an electric power steering system in which convergence of a yaw rate of a vehicle is ensured.
2. Description of the Related Art
An electric power steering system for assisting a steering system of an automobile or a vehicle by a motor torque operates in such a manner that a steering shaft or a rack shaft is assisted by a driving force of the motor through a speed reducer using a transfer mechanism, such as a gear or a belt. The known electric power steering system performs feedback control of motor current to accurately generate an assist torque (steering assist torque). The feedback control is used for adjusting voltage impressed on the motor so that the difference between a current control value and a motor current detected value decreases. In general, the adjustment of the voltage impressed on the motor is performed by adjusting a duty ratio of pulse width modulation (“PWM”) control. Referring now to FIG. 1, a general structure of an electric power steering system is shown. A shaft 2 of a steering wheel 1 is connected to a tie rod 6 of a vehicle wheel through a speed reduction gear 3 , universal joints 4 a and 4 b, and a pinion rack mechanism 5 . A torque sensor 10 for detecting a steering torque of the steering wheel 1 is provided on the shaft 2 . A motor 20 for assisting a steering effort of the steering wheel 1 is connected through a clutch 21 and the speed reduction gear 3 to the shaft 2 . A battery 14 supplies electric power through an ignition key 11 and a relay 13 to a control unit 30 that controls the power steering system. The control unit 30 computes a steering assist command value I of an assist command based on a steering torque T detected by the torque sensor 10 and a vehicle velocity V detected by a velocity sensor 12 , and controls the current to be supplied to the motor 20 based on the computed steering assist command value I. The control unit 30 performs ON/OFF control of the clutch 21 . The clutch 21 is normally in an ON condition (engaged). However, the clutch 21 is in an OFF condition (disengaged) when the control unit 30 determines that the power steering system is at fault, or the power supply from the battery (voltage Vb) is cut-off by the ignition key 11 or the relay 13 .
The control unit 30 consists mainly of a CPU. FIG. 2 illustrates general functions executed in the CPU by a program. For example, a phase compensator 31 does not represent a phase compensator as an independent hardware component; rather, it represents a phase compensating function executed in the CPU. The function and the operation of the control unit 30 are described below. The torque sensor 10 detects a steering torque T and inputs it to the phase compensator 31 . The inputted steering torque T is phase-compensated for by the phase compensator 31 to enhance the stability of the steering system. Then the phase-compensated steering torque TA is inputted to a steering assist command value computing unit 32 . The vehicle velocity V detected by the velocity sensor 12 is further inputted to the steering assist command value computing unit 32 . The steering assist command value computing unit 32 determines the steering assist command value I, which is equivalent to a control target value of the current to be supplied to the motor 20 , based on the inputted steering torque TA and the velocity V. Then the steering assist command value I is inputted to a subtractor 30 A as well as to a differential compensator 34 of a feed-forward system for increasing a response speed. A deviation (I-i) determined by the subtractor 30 A is inputted to a proportional computing unit 35 and to an integral computing unit 36 . The proportional output and the integral output are both inputted to an adder 30 B. The integral computing unit 36 is used for improving characteristics of a feedback system. The outputs of the differential compensator 34 and the integral computing unit 36 also are inputted to the adder 30 B. As a result, all the inputs to the adder 30 B add up to a current control value E. The current control value E is inputted as a motor drive signal to a motor drive circuit 37 . Finally, a motor current value i of the motor 20 is detected by a motor current detecting circuit 38 , which in turn is fed back through the subtractor 30 A.
Now referring to FIG. 3, an example of the structure of the motor drive circuit 37 is shown. The motor drive circuit 37 includes a field-effect transistor (“FET”) gate drive circuit 371 for driving each gate of FET 1 to FET 4 based on the current control value E from the adder 30 B, an H-bridge circuit including FET 1 to FET 4 , and a booster power supply 372 for driving a high side of FET 1 and FET 2 . The FET 1 and FET 2 are switched between an ON condition and an OFF condition by a PWM signal of a duty ratio D 1 , which is determined based on the current control value E, thereby controlling the current Ir actually supplied to the motor 20 . The FET 3 and FET 4 are driven by a PWM signal of a duty ratio D 2 , which is defined by a predetermined linear function formula (given constants a and b, D 2 =a·D 1 +b) in a region where the duty ratio D 1 is of a small value. After the duty ratio D 2 has reached 100%, FET 3 and FET 4 are switched between an ON condition and an OFF condition in accordance with a rotation direction of the motor 20 , which is determined based on the sign of the PWM signal.
There are known electric power steering systems that generate a moderate response in quick steerage of a vehicle. An example of such electric power steering systems is shown in Japanese Patent Publication No.45-41246. The Japanese Patent Publication No.45-41246 describes an apparatus which includes a torsion torque sensor for detecting a torsion torque of a steering shaft when turning a vehicle. In response to the output signal of the torsion torque sensor, the apparatus controls a rotation direction and a rotation torque of an electric motor. However, the above known control apparatus for the electric motor has problems as below. When the output of the control apparatus is set at a high level, convergence of a steering wheel in hand-off steerage of the vehicle deteriorates due to inertia of the control system. In addition, when quickly steering the vehicle around a sharp curve, a driver generally feels more comfortable if there is a moderate response to the steering wheel. Nevertheless, the above known electric power steering system does not include a unit for compensating for an assist steering force (power assist) in accordance with the steering speed. Hence, when making a sharp turn around a curve having a small radius, the driver feels insecure because the steering wheel feels too light.
To solve the above problems, a motor control apparatus, such as disclosed in Japanese Patent No.2568817, is provided wherein brake is applied based on the steering angle of a steering wheel. Specifically, the motor control apparatus for an electric power steering system controls rotation direction and rotation torque of an electric motor that provides a steering mechanism with an assist steering force in accordance with a command signal based on the output signal of a torsion torque sensor for detecting a torsion torque of the steering system. The motor control apparatus includes a detector for detecting a steering angular velocity in the steering system, a steering angle phase-compensating command unit for generating a damping signal, which defines rotation torques in both the steering forward direction and the backward direction, in accordance with the steering angular velocity, and a drive control unit for controlling the rotation direction and the rotation torque of the electric motor in accordance with a command signal which is the sum of the damping signal and the command signal determined based on the torsion torque signal of the steering system.
However, the above known apparatus generates a rotation torque, in response to the steering angular velocity, in the direction opposite to the steering forward direction, and brakes a change in the steering angle, thereby leading to the following problems. Specifically, because the apparatus directly brakes change in the steering angle, there is a risk that yawing of the vehicle diverges. In addition, the yawing of the vehicle is asynchronous with the steering angle, which causes an unnatural steerage feeling for a driver. Further, because the brake is directly applied to resist the change in the steering angle, the rate of convergence responding to the effort on the steering wheel is slow, during which the vehicle moves laterally, thus resulting in a dangerous situation.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a control apparatus for an electric power steering system for applying brake on a yaw rate of a vehicle to ensure convergence of the yaw rate, by generating a convergence signal for converging the yaw rate based on a relation between a steering angle of the electric power steering system and the yaw rate of the vehicle, thus ensuring convergence of the yaw rate without discomforting the driver.
To this end, according to the present invention, there is provided a control apparatus for an electric power steering system for controlling a motor that provides a steering mechanism of a vehicle with a steering assist force. The control apparatus includes a first computing unit for computing a steering assist command value based on a steering torque generated on a steering shaft, a second computing unit for computing a current control value from the steering assist command value and a motor current value, a control unit for controlling the motor based on the current control value, a detecting unit for detecting a rate of change in a yaw rate of the vehicle, and a damping unit for applying damping on the yaw rate based on the rate of change.
The detecting unit may include a steering angular velocity computing unit and a yaw rate differential estimating unit.
The present invention will be more fully understood from the following description of the preferred embodiment with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is a block diagram of an example of an electric power steering system;
FIG. 2 is a block diagram of a general internal structure of a control unit;
FIG. 3 is a connecting diagram of an example of a motor drive circuit;
FIG. 4 is a block diagram of an example of the structure of the present invention;
FIG. 5 is an illustration of a modeled automobile;
FIG. 6 is a block diagram of the model shown in FIG. 5 in a transfer function;
FIG. 7 is a block diagram of a feedback system of a motor torque and a yaw rate γ;
FIG. 8 is an illustration of frequency characteristics of a transfer function G(s);
FIG. 9 is a block diagram of the structure of a convergence system according to the present invention;
FIG. 10 is an illustration of an equivalent circuit of the structure shown in FIG. 9; and
FIG. 11 is an illustration of effects of a yaw rate convergence control.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Generally, dynamic characteristics of an automobile can be expressed by the following expression 1 using a two-wheel model, given β as a slip angle, γ as a yaw rate (yaw speed), δ as an actual steering angle, and A 11 to A 22 , B 1 and B 2 as constants where speed is assigned as a parameter: β t γ t = A 11 A 12 A 21 A 22 β γ + B 1 B 2 δ ( 1 )
The above expression (1) is simplified using matrices A and B to expression (2): β t γ t = A β γ + B δ ( 2 )
A self-aligning torque (Ts) which operates in a movement of a vehicle is expressed as expression (3): Ts = C β γ + D δ ( 3 )
Using the above expressions (1) to (3), transfer characteristics in which the actual steering angle δ is the input and the self-aligning torque Ts is the output can be obtained from the following expressions 4 and 5, given I as a 2×2 unit matrix, s as a Laplace operator, and a 1 , a 2 , c 0 , b 0 , b 1 , c 1 , and c 2 as constants where speed is assigned as a parameter: Ts ( s ) = { C ( s · I - A ) - 1 · B + D } · δ ( s ) = { ( c 0 · s 2 + c 1 · s + c 2 ) / ( s 2 + a 1 · s + a 2 ) } · δ ( s ) ( 4 ) γ ( s ) = { [ 0 1 ] ( s · I - A ) - 1 · B } · δ ( s ) = { ( b 0 · s + b 1 ) / ( s 2 + a 1 · s + a 2 ) } · δ ( s ) ( 5 )
Referring now to FIG. 5, a vehicle model is shown. A steering effort of a driver is represented by Th and a column-shaft-reduced value of a torque generated by a motor, i.e., the motor torque i terms of the torque acting on the column shaft, by Tm. A resonance system including a torsion bar spring of the electric power steering has the natural frequency more than ten times as high as the natural frequency of γ and, hence, may simply be taken as a rigid body. Given g as a speed increasing ratio of a pinion rack, and J as a constant including handle inertia, motor inertia, and a speed reduction ratio, the model shown in FIG. 5 can be understood to have the transfer characteristics represented by blocks shown in FIG. 6 . Referring now to the block diagram shown in FIG. 6, the transfer characteristics from the column-shaft-reduced value Tm to the output δ are obtained as: δ ( s ) Tm ( s ) = 1 J 1 + g J · c 0 · s 2 + c 1 · s + c 2 s 2 + a 1 · s + a 2 = s 2 + a 1 · s + a 2 ( g · c 0 + J ) s 2 + ( g · c 1 + J · a 1 ) s + ( g · c 2 + J · a 2 ) ( 6 )
Using the above expression (6), the transfer characteristics from the column-shaft-reduced value Tm to the yaw rate γ are simplified to: γ ( s ) Tm ( s ) = s 2 + a 1 · s + a 2 ( g · c 0 + J ) s 2 + ( g · c 1 + J · a 1 ) s + ( g · c 2 + J · a 2 ) · b 0 · s + b 1 s 2 + a 1 · s + a 2 = b 0 · s + b 1 ( g · c 0 + J ) s 2 + ( g · c 1 + J · a 1 ) s + ( g · c 2 + J · a 2 ) ( 7 )
Expression (7) demonstrates that feeding back *γ (a differential of γ) produces a damping effect on the yaw rate γ, i.e., an improved convergence of the yaw rate. Let us consider a system, such as shown in FIG. 7, which performs a predetermined feedback of the column-shaft-reduced value Tm of the motor output torque by means of a signal incorporating the yaw rate γ.
The block diagram shown in FIG. 7 leads to the following: γ ( s ) Th ( s ) = b 0 · s + b 1 ( g · c 0 + J ) s 2 + ( g · c 1 + J · a 1 ) s + ( g · c 2 + J · a 2 ) 1 + b 0 · s + b 1 ( g · c 0 + J ) s 2 + ( g · c 1 + J · a 1 ) s + ( g · c 2 + J · a 2 ) · P ( s ) ( 8 )
Letting Kd be a feedback gain of the yaw rate γ and putting it as P(s)=Kd·s/(b 0 ·s+B 1 ), expression (8) can be expressed as: γ ( s ) Th ( s ) = b 0 · s + b 1 ( g · c 0 + J ) s 2 + ( g · c 1 + J · a 1 + Kd ) s + ( g · c 2 + J · a 2 ) ( 9 )
The difference between expression (7), which is before feeding back the yaw rate γ, and expression (9) is an addition of the gain Kd to the second term (linear term of s) of a denominator in expression (9). Hence, damping in accordance with the feedback gain Kd of the yaw rate γ is applied on the transfer characteristics from the steering torque Th to the yaw rate γ, thereby improving the convergence of the vehicle behavior in hand-off steerage of the vehicle.
It will next be described that an increase in a positive constant of the linear term of s will cause an increase in damping. The characteristics of a transfer function G(s)=ω 2 /(c·s 2 +2ζ·ω·s+ω 2 ) are gain 1 , the natural frequency ω, and damping ζ, showing the frequency characteristics as in FIG. 8 . In the transfer function, the damping ζ appears only in the linear term of s. Comparing expressions (7) and (9), the natural frequency ω is the same in the defined constant terms in denominators; the only difference is an increase in the linear term of s of the denominator in expression (9). Hence, it can be concluded that there is an increase in damping from expression (7) to expression (9). Thus, a feedback value to the motor torque is expressed as expression (10): Tm ( s ) = { Kd · s / ( b 0 · s + b 1 ) } · γ ( s ) = { Kd / ( b 0 · s + b 1 ) } · * γ ( s ) ( 10 )
In other words, it is understood that feeding back the differential *γ(s) of the yaw rate to the column-shaft-reduced value Tm of the motor torque allows application of damping on the yaw rate γ.
Heretofore, a method for measuring the yaw rate γ to compute the differential *γ of the yaw rate and feeding it back to the column-shaft-reduced value Tm of the motor torque has been described. Now, a method for estimating *γ and feeding it back to the column-shaft-reduced value Tm of the motor torque is described below. Generally the electric power steering system either measures or estimates a motor angular velocity *θ to perform a control to compensate for the influences of motor inertia and friction. A system which outputs the yaw rate γ in response to the input of the actual steering angle δ has the transfer characteristics expressed as expression (11):
γ(s)/δ(s)=(b 0 ·s+b 1 )/(s 2 +a 1 ·s+a 2 ) (11)
Assuming h is a speed reduction ratio and thus δ=h·θ(s), the following can be concluded:
γ(s)={(b 0 ·s+b 1 )/(s 2 +a 1 ·s+a 2 )}·δ(s)
γ(s)={(b 0 ·s+b 1 )/(s 2 +a 1 ·s+a 2 )}·h·θ(s) (12)
Hence, the following can be derived by differentiating the expression (12):
*γ(s)={(b 0 ·s+b 1 )/(s 2 +a 1 ·s+a 2 )}·h·*θ (13)
Substituting an estimated value #θ(s) for the motor angular velocity *θ(s), it is possible to estimate *γ(s) using the following expression (14):
#γ(s)={(b 0 ·s+b 1 )/(s 2 +a 1 ·s+a 2 )}·h·#θ(s) (14)
Here, #γ(s) is estimation of *γ(s). Hence, it is expressed as expression (15): Tm ( s ) = { Kd / ( b 0 · s + b 1 ) } · * γ ( s ) = { Kd / ( b 0 · s + b 1 ) } · # γ ( s ) = { ( b 0 · s + b 1 ) / ( s 2 + a 1 · s + a 2 ) } · h · { Kd / ( b 0 · s + b 1 ) } · # θ ( s ) = { h · Kd / ( s 2 + a 1 · s + a 2 ) } · # θ ( s ) ( 15 )
Using the motor angular velocity estimated value #θ to compute expression (15), the column-shaft-reduced value Tm of the motor torque is defined. It is therefore possible to achieve the same effect as that obtained through the determination of the differential *γ(s).
Referring now to FIG. 4 corresponding to FIG. 2, an example of the structure of the present invention is illustrated. A motor angular velocity estimating unit 301 in a control unit 30 A estimates a motor angular velocity ω from a current control value E (corresponding to a voltage across motor terminals) and a motor current value i. The estimated motor angular velocity ω is inputted to a loss torque compensator 303 and to a convergence controller 340 . The output of the loss torque compensator 303 is inputted to an adder-subtractor 30 A. The loss torque compensator 303 performs an assist to make up for a loss torque of a motor 20 in the direction where the loss torque of the motor 20 is generated, i.e. a rotation direction of the motor 20 . The convergence controller 340 includes a steering angular velocity computing unit 341 , which computes a steering angle θ from the motor angular velocity ω, and a yaw rate differential estimating unit 342 , which outputs a convergence signal CN for converging the yaw rate based on the steering angular velocity *θ. The convergence signal CN is inputted to the adder-subtractor 30 A as a feedback. In addition, the motor angular velocity ω is inputted to a motor angular acceleration estimating unit (differentiator) 302 to estimate a motor angular acceleration, which in turn is inputted to an inertia compensator 305 . The inertia compensator 305 outputs a compensation signal, which is then inputted to the adder-subtractor 30 A. The inertia compensator 305 is used for assisting the equivalent of a force generated by inertia of the motor 20 , thereby preventing any inertia feeling or deterioration in the control response.
Firstly in the present invention, the steering angular velocity computing unit 341 computes the steering angular velocity *θ from the motor angular velocity ω. Since the motor angular velocity ω is approximately proportional to the steering angular velocity *θ, the steering angular velocity *θ is easily computed from the motor angular velocity ω. The yaw rate differential estimating unit 342 obtains a rate of change in the yaw rate γ of the vehicle from the steering angular velocity *θ. In general, a relation between the steering angle θ and the yaw rate γ is expressed as expression (16)
γ(s)={(b 0 ·s 2 ·s+b 1 ·s+b 2 )/(s 2 +a 1 ·s+a 2 )}·θ(s)·b 0 /(s 2 +a 1 ·s+a 2 )·θ(s) (16)
Both members of expression (16) are differentiated, and the following is obtained:
*γ(s)=b 0 /(s 2 +a 1 ·s+a 2 )·*θ(s) (17)
In other words, the rate of change *γ is obtained from the steering angular velocity *θ(s) using expression (17). Here, the natural frequency of the transfer characteristics of the torque to the steering angle in a mechanical system of the steering system is about ten times as high as the natural frequency of the transfer characteristics of the steering angle to the yaw rate. Hence, the torque T is approximately proportional to the steering angle θ. Consequently, feeding back a torque signal, which is proportional to *γ(s) in expression 17, allows the generation of a steering angle signal, which is in synchronism with the rate of change in the yaw rate. As a result, damping is applied on the yaw rate. The reason for this has been described hereinabove.
γ(s)=b 0 /(s 2 +a 1 ·s+a 2 )·θ(s)T(s)=θ(s) (18)
FIG. 9 illustrates a block diagram for obtaining a transfer function shown in FIG. 10, which is obtained when the constant K is greater than constants m and c, the block diagram shown in FIG. 10 is taken. Referring now to FIG. 9, block 350 shows a transfer function of the steering system, and block 351 indicates a transfer function of the vehicle. The block diagram shown in FIG. 10 is expressed as expression (19):
γ(s)/T(s)=(1/K)·b 0 /(s 2 +(a 1 +Kd)·s+a 2 ) (19)
Hence, damping is applied on the yaw rate. As indicated in expression (19), since damping (a 1 +Kd) which affects the natural frequency a 2 of the vehicle is increased, the convergence speed will not be impaired. Because variables a 1 , a 2 , b 0 , and b 1 have speed as a parameter, it is preferable to change their values in accordance with the velocity of the vehicle.
A control apparatus according to the present invention generates a convergence signal for converging a yaw rate based on a relation between a steering angle of an electric power steering system and the yaw rate of a vehicle, so that the convergence of the yaw rate is ensured. In addition, the apparatus prevents the yaw rate under the control from becoming slower than the convergence speed of the yaw rate that is peculiar to the vehicle.
FIG. 11 illustrates an example of experimental characteristics in two cases, i.e., one case where a yaw rate convergence control has been performed and the other case where no such a control has been performed. From the experimental result, it may be understood that the present invention is highly advantageous. | A control apparatus for an electric power steering system ensures convergence of a yaw rate of a vehicle without discomforting a driver, thus improving steerage of the vehicle. The control apparatus controls a motor that provides a steering mechanism with a steering assist force based on a current control value. The current control value is computed from a steering assist command value, which is computed based on a steering torque generated on a steering shaft, and from a motor current value. In the control apparatus, a rate of change in the yaw rate of the vehicle is detected, based on which damping is applied on the yaw rate. | 1 |
TECHNICAL FIELD
The present invention relates to a pressure adjustment device, more particularly to a pressure adjustment device, which can adjust the negative pressure inside the ink cartridge timely so as to prevent ink from leaking and prevent inkjet print from not working owing to excess negative pressure.
BACKGROUND OF THE PRESENT INVENTION
Drop-on-demand is a generally used method to control ink to output from an ink storage tank to a recording media (such as printing paper) in a conventional inkjet printing. The traditional inkjet pen, which uses drop-on-demand, is generally furnished with hot bubble type or piezoelectric force wave type printing head. The main element of hot bubble type printing head is a thin film resistance, when is heated, a trace of ink drops can be evaporated instantly, fast expansion after evaporation of ink drops cause little ink to pass the injection exit of the printing head again to spray and print onto a printed paper. Although the printing head of drop-on-demand can get ink from the ink storage tank in the inkjet pen effectively to spray ink drops, but drop-on-demand needs a control function to make sure that ink does not leak out of the printing head when the printing head is not working. That such kind of control function stops ink to leak from the printing head is attained by generating a slight negative pressure in the ink storage tank. What is called negative pressure indicates that a part of vacuum is formed in the ink storage tank, it is shown as a positive value as measuring negative pressure, so the increase in negative pressure means the increase of vacuum degree. Ink can be stopped to leak out of the printing head by increasing negative pressure.
Although ink can be stopped to leak out of the printing head by increasing negative pressure, but negative pressure cannot be too large, otherwise it will cause the printing head to be unable to overcome negative pressure and make ink drops to be unable to spray out. Another, the negative pressure in the ink storage tank of the inkjet pen must be able to be adjusted as surrounding pressure changes so as to be kept in an appropriate range. Such as, when the surrounding pressure lowers, the negative pressure for stopping ink to leak out of the printing head is increased relatively. Besides, the “operation effect” of the ink storage tank may also affect the negative pressure in the ink storage tank, such as, when the ink in the ink storage tank is consumed continuously; it will cause the negative pressure in the ink storage tank to increase. If the negative pressure is not adjusted appropriately, the printing head is affected gradually by too large negative pressure to change the dimension of the sprayed-out ink drop. It not only influences the printing quality, but also even cannot spray out ink completely at last.
The known pressure adjustment technology, such as the U.S. Pat. Nos. 5,409,134 and 5,505,339 have already revealed an adjuster for adjusting the negative pressure in the ink storage tank. Such kind of adjuster generally is a elastic gasbag the principle it uses is to let the volume of the ink storage tank and the change of the negative pressure be adjusted by the variation of the occupied volume of the elastic gasbag in the ink storage tank. For an example, when surrounding pressure lowers, the negative pressure in the inkjet pen relative to surrounding environment is also lowered. At that time, the adjuster begins to work (the elastic gasbag shrinks) to increase the volume of the ink storage tank so as to increase the negative pressure to prevent ink from leaking. On the contrary, when surrounding pressure arises or the negative pressure in the ink storage tank increases owing to the consumption of ink, this elastic gasbag will expand to lower the negative pressure slightly to prevent ink from leaking. Therefore, such kind of adjuster has an ability of two-ways adjustment of the pressure change.
Although these elastic-gasbag-type adjuster can adjust the negative pressure in the ink storage tank successfully, but in general, the maximum expansion of the elastic gasbag has its own limit, therefore when ink is consumed to a certain extent, the volume of the ink storage tank cannot be changed any more for the reason that the elastic gasbag has already reach the maximum expansion, the result that ink reduces continuously will cause the negative pressure to be too large and to exceed the proper range, therefore, the printing head cannot overcome the negative pressure so that it will cause ink drops to be unable to spray out, and so, ink in the ink storage tank cannot be consumed completely.
Another known pressure adjuster of the inkjet pen is called “bubble generator”, such as the U.S. Pat. Nos. 5,526,030 and 5,600,358. The bubble generator has a nozzle, the ink storage tank communicates with atmosphere via the nozzle. After the dimension of the nozzle is decided appropriately, ink can gather around in the nozzle and constructs a fluid-type seal through capillary force. When the negative pressure is too large, surrounding air will enter into ink storage tank as bubble type, this will cause the negative pressure in the ink storage tank to be lowered. When the negative pressure lowers to a certain extent, the force entering bubble will be smaller than the capillary force so as to rebuild the fluid-type seal to stop bubble to enter no more. However, such kind of pressure adjuster only can adjust pressure variation one way, this is to say, when surrounding pressure lowers, the pressure adjuster will not work, this will cause ink to leak from the nozzle. Besides, the bubble generator control the negative pressure of the ink storage tank through capillary effect between gaps, this will cause that gaps must be controlled precisely, and such kind of the requirement will increase the difficulty of manufacturing and installment. If ink dries at the nozzle, it will cause the pressure adjuster to lose efficacy.
SUMMARY OF THE INVENTION
The main object of the present invention is to provide an ink pressure adjustment device for inkjet pen, preventing the negative pressure inside an ink cartridge of an inkjet pen from being too large.
Another object of the present invention is to provide an ink pressure adjustment device for inkjet pen, which doesn't occupy space, the manufacturing cost thereof is low, the installment thereof is easy and the negative pressure of an ink cartridge can be two-ways adjusted.
The pressure adjustment device reveal a tension valve attached to the surface of the gasbag, this tension valve can operate in coordination with the expansion and shrinkage movements of the gasbag, opens or closes timely an air hole disposed at the surface of the gasbag for communicating atmosphere and the inner part of the ink cartridge by way of the gasbag, particularly before the negative pressure value increase to an extent that the printing head cannot spray out ink, the tension has already open the air hole, part of atmosphere (air) will enter the ink cartridge form the tension valve at that time (probably as a type of bubble), so as to prevent the negative pressure in the ink cartridge from increasing too high to lead to a result that inkjet printing doesn't work.
In a preferred embodiment of the present invention, the tension valve is made of rubber or other similar materials and is a thin plate element with a slit therein. It is attached on the surface of the gasbag, the curving extent of surface deformation at the gasbag expansion may decide to open or close the tension valve. That the negative pressure in the ink cartridge is higher means the expansion degree of the gasbag increases (it also means that the occupied volume of the gasbag in this ink cartridge increases), the expanding gasbag will open the slit that is attached on the surface of the tension valve owing to the deformation of the surface thereof so as to cause part of atmosphere (air) enter the ink cartridge through this slit to adjust the negative pressure in the ink cartridge.
In another preferred embodiment of the present invention, a tension valve even can replace the spring used in the traditional elastic gasbag, a thin plate type tension valve made of rubber and other similar material is attached on the most parts of the surface of the gasbag, it can provide a proper shrinking force to restrain the expansion of the gasbag through the elasticity of rubber itself and plasticity thereof so as to reduce the occupied volume of the gasbag in the ink cartridge, this is just like the traditional technology to press the gasbag by spring to provide the needed negative pressure.
The detailed description of the present invention and embodiments accompanying the drawings will be described as following.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 A˜ 1 B is a cross sectional view of a preferred embodiment of the present invention, showing a structure of a pressure adjustment device in an ink cartridge of an inkjet pen when a tension valve isn't opened.
FIGS. 2 A˜ 2 B is a cross sectional view of a preferred embodiment of the present invention, showing a structure of a pressure adjustment device in an ink cartridge of an inkjet pen when a tension valve is opened.
FIGS. 3B and 3C are diagrams of a preferred embodiment of the present invention, showing three shapes of slits of different tension valves.
FIGS. 4 A˜ 4 B is a cross sectional view of another preferred embodiment of to the present invention, showing a structure of a pressure adjustment device in an ink cartridge of an inkjet pen when a tension valve isn't opened.
FIGS. 5 A˜ 5 B is a cross sectional view of a preferred embodiment of the present invention, showing a structure of a pressure adjustment device in an ink cartridge of an inkjet pen when a tension valve is opened.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
First, please referring to FIGS. 1 A˜ 1 B, needed ink of an inkjet pen or inkjet printing facilities is received in an ink cartridge 10 , an inkjet printing head 11 is installed to the bottom of the ink cartridge 10 , which is a hot bubble type or piezoelectric type, and is utilized to spray the ink stored in the ink cartridge 10 onto record media such as normal paper or other similar stuff.
A pressure adjuster of the present invention comprises a gasbag 20 , a tension valve 30 and an elastic element 40 . The gasbag 20 is installed in the ink cartridge 10 , the inner part of the gasbag 20 communicates with atmosphere via an air hole 12 disposed at the wall of the ink cartridge 10 , and at least one another air hole 21 is further disposed at a surface of the gasbag 20 to communicate the gasbag 20 with the inner part of the cartridge 10 . The tension valve 30 is attached to the surface of the gasbag 20 and is utilized to control the opening and closing of the above-mentioned air hole 21 . The elastic element, such as spring or other similar elements, is utilized to provide a resistance force to the gasbag 20 when it is expanding, and generates needed negative pressure in the ink cartridge 10 by lowering the volume occupied by the gasbag 20 in the ink cartridge 10 . In a preferred embodiment of the present invention, the elastic element 40 is a spring, one end thereof presses against the ink cartridge 10 , another end thereof is fixed to a plate 41 , it generates needed negative pressure (vacuum degree) in the ink cartridge 10 by pressing the gasbag 20 via the plate 41 through the elastic force of the elastic element 40 and by lowering the volume occupied by the gasbag 20 in the ink cartridge 10 .
The structure of the gasbag 20 must be guaranteed to have a curved surface after it is expanded. Therefore, folding the two pieces of waterproof thin films together, and then sealing or melting circumferential edge together can make the gasbag 20 . And the tension valve 30 is then tightly attached on the surface of the gasbag 20 , it can be opened by the curved surface formed after the gasbag 20 is expanded to deform.
The tension valve 30 is a thin film shape element and can be made of such as rubber or other similar materials. The tension valve 30 is kept flat in a normal condition. The tension valve 30 has a slit 31 , which is pierced through it completely. This slit 31 is kept completely closed when the tension valve 30 is kept flat in a normal condition, as shown in FIG. 1 B. On the other hand, this slit 31 will be opened when the surface of the gasbag 20 is deformed to curve, the both front and rear sides of the tension valve 30 can communicate each other via this slit 31 at that time, as shown in FIGS. 2 A˜ 2 B, the inner part of the ink cartridge 10 will communicate with the inner part of the gasbag 20 via the air hole 21 , so that a part of atmosphere will pass the inner part of the gasbag 20 and then enter the inner part of the ink cartridge 10 via the air hole 21 so as to lower the negative pressure (vacuum degree) in the inner part of the ink cartridge 10 , and to prevent the negative pressure in the inner part of the cartridge from being too high to fail the inkjet printing.
The slit 31 of the tension valve can be a single straight-line type slit, as shown in FIGS. 3A and 3B, and can also be several slits 31 a and 31 b that cross each other, as shown in FIG. 3 C. Furthermore, for the reason that the slit 31 of the tension valve 30 can be opened accurately when the surface of the gasbag 20 deforms, a chamfer angle 310 can be disposed at one side of the slit 31 that faces to the gasbag 20 , as shown in FIG. 1 . On the other hand, the dimension of the chamfer angle 310 can determine what extent the surface of the gasbag 20 must be deformed to let the slit 31 to be opened.
As FIGS. 1 A˜ 1 B shown, atmosphere will not pass through the air hole 21 and slit 31 to enter the ink cartridge 10 , if the curving degree of the surface of the gasbag is not enough to open the slit 31 of the tension valve, at that time, the gasbag 20 will start to expand as the ink is consumed or atmosphere pressure arises, in the meanwhile, the elastic element 40 will also thrust the gasbag 20 to provide a resistance force for stopping the expansion of the gasbag 20 , and to generate a little negative pressure in the ink cartridge 10 at the right moment, to keep the ink in the ink cartridge 10 and not to leak form the inkjet printing head 11 . When the ink is consumed continuously, the gasbag 20 will expand and deform, the silt 31 of the tension valve 30 will be opened owing to a certain degree of curvature reached by the deformation of the surface of the gasbag 20 , and a little atmosphere will be released into the ink cartridge to cause the negative pressure in the ink cartridge 10 to be lowered, the gasbag shrinks again and recover to a little earlier state so as to let the slit 31 of the tension valve to be closed again. To go round and begin again, it can prevent the negative pressure in the ink cartridge 10 from being too large and failing to spray ink. On the contrary, when atmosphere lowers (such as the course of airplane conveyance), the elastic element 40 will also press the gasbag 20 to shrink so as to arise the negative pressure in the ink cartridge 10 to prevent the ink to leak from the inkjet printing head 11 . So, the pressure adjuster of the present invention can adjust the negative pressure in the ink cartridge 10 two ways according to the change of the outside pressure.
Furthermore, please refer to FIGS. 4 A˜ 4 B, it shows another preferred embodiment of the present invention. In this embodiment, the elastic element 40 will not installed in a pressure adjuster, but the dimension will be increased to attach on the most part of the surface of one side of the gasbag 20 , the tension valve 30 provides a proper shrinkage force to suppress the expansion of the gasbag 20 by the elasticity and plasticity of the tension valve 30 itself so as to be able to replace the elastic element 40 to compress the gasbag properly, and lower the volume occupied by the gasbag 20 in the ink cartridge 10 to provide the need negative pressure. On the contrary, when the gasbag 20 expands and deforms, the slit 31 of the tension valve 30 will be opened owing to a certain degree of curvature reached by the deformation of the surface of the gasbag 20 , as shown in FIGS. 5 A˜ 5 B. A little atmosphere will be released into the ink cartridge 10 to cause the negative pressure in the ink cartridge 10 to be lowered, then the gasbag 20 shrink again to recover to a little earlier state so as to let the slit 31 of the tension valve to be closed again, as shown in FIG. 4 B. To go round and begin again, it can prevent the negative pressure in the ink cartridge 10 from being too large and failing to spray ink.
The present invention can solve the deficit that ink cannot be used up or the pressure can only be adjusted in one way. The design of the tension not only is rather not limited by the space, but also can lower manufacturing and assemblage expense substantially. | The present invention is an ink pressure adjustment device of inkjet pen; the device is utilized to adjust negative pressure in an ink cartridge mainly through an expandable and shrinkable gasbag installed in the ink cartridge, and a tension valve attached on the surface of the gasbag. The tension valve can open or close automatically an air hole that communicates atmosphere and the inner part of ink cartridge via the gasbag according to the expansion and shrinkage of the gasbag, causing a part of atmosphere to enter the ink cartridge so as to adjust the negative pressure of the ink cartridge and not only can prevent ink from leaking but also prevent the negative pressure from being too large to fail the inkjet printing. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to locks, and more particularly to an extendable cable lock providing a theft deterrent device for locking garments, bikes, skis, luggage and many other items.
Various arrangements are known for locking garments, skis, luggage and the like to provide a theft deterrent. Some of these devices are shown in U.S. Pat. Nos. 4,069,691, 3,885,674 and 51,524. These devices, however, are not portable and are designed solely for use in locking garments. Although U.S. Pat. No. 1,326,584 shows a portable locking device, it's extendable cable is not automatically retractable. Thus, there remains a need for a multi-purpose lock that is lightweight and compact so that it can be carried in the pocket of a coat, jacket, pants or purse.
SUMMARY OF THE INVENTION
A portable, hand-holdable, retractable cable lock providing a multi-purpose theft deterrent device which is lightweight, compact and inexpensive to manufacture.
The retractable cable lock includes a casing and a spool rotatably mounted within the casing. The casing includes a pair of annular cup-shaped cap members each having a circumferential rim adapted to be in interfitting engagement with one another when the cap members are assembled. The spool includes a cylindrical core and a pair of opposing spaced apart annular retaining plates defining an area therebetween upon which a cable may be wound. The spool is mounted for free rotational movement relative to the casing.
Locking means is provided for locking the free end of the cable to the casing. The locking means includes an elongate member at the cable's free end adapted to cooperate with tumbler means within the casing.
A coil spring located within the casing has one end attached to the spool and its other end attached to the casing. When the cable is unlocked and extended, the coil spring applies a retracting force on the spool to rotate the spool and automatically rewind the cable thereon.
The cable lock further includes latch means for permitting free rotation of the spool in one direction to extend the cable, but preventing free rotation of the spool in its other direction to rewind the cable unless disengaged. The latch means includes a ratchet wheel disposed within the casing, a pawl member pivotally mounted on the side of the casing for engagement with the ratchet wheel, and a ratchet spring for normally biasing one end of the pawl into engagement with the ratchet wheel.
The cable lock also includes first and second annular thin discs disposed within the casing coaxially with the spool. The discs are disposed on either side of the spool to provide a means for reducing friction when the spool is rotated within the casing.
The present invention thus provides a portable, hand-holdable, retractable cable lock which provides a multi-purpose theft deterrent device.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings illustrate the best mode presently contemplated of carrying out the invention.
In the drawings
FIG. 1 is a perspective view of a retractable cable lock constructed in accordance with the principles of the present invention;
FIG. 2 is an exploded view showing the arrangement of the components for the retractable cable lock of FIG. 1;
FIG. 3 is a plan view with parts broken away and in section of the retractable cable lock of FIG. 1;
FIG. 4 is a fragmentary sectional view in elevation taken along the plane of the line 4--4 in FIG. 3 illustrating a tumbler in its locking position; and
FIG. 5 is a fragmentary view similar to FIG. 4 illustrating the tumbler rotated to its unlocking position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, FIG. 1 illustrates a retractable cable lock generally designated by the numeral 1 constructed in accordance with the principles of the present invention. Cable lock 1 may be utilized as a multi-purpose lock for bikes, skis, luggage, garments such as coats and jackets, and many other items for quick and easy anti-theft security. Cable lock 1 is portable, hand-holdable, lightweight and compact so that it can be easily carried in the pocket of a coat, jacket, pants or purse.
Referring now to FIG. 2, cable lock 1 includes an outer casing having a pair of annular, cup-shaped cap members 2 and 3 for housing the remaining components of lock 1. Bottom cap member 2 includes an annular, flat base plate 4 and a circumferential outer rim 5 projecting from the inner side of base 4 to be concentric with a central axis designated in FIG. 2 by the numeral 6. A circular boss 7 projects inwardly from the inner side of base 4 and includes a threaded stud 8 of lesser diameter both of which are located coaxially with respect to axis 6. As shown best in FIG. 3, rim 5 includes a bore 9 formed therethrough the purpose of which will hereinafter be described. Cap member 2 also includes an enlargement having a rectangular shaped recess 11 formed therein and a semicircular bore 50 communicating between recess 11 and the outer surface of enlargement 10. Bore 50 also includes a radially extending notch 51 which extends from the outer surface of enlargement 10 to recess 11.
To cap member 3 also includes an annular, flat base plate 12 having a central opening 13 formed therethrough for receiving stud 8, and a circumferential outer rim 14 extending inwardly from the inner side of base 12 to be concentric with central opening 13 and axis 6. Cap member 3 further includes an enlargement 15 having four elongated slots 16 formed therethrough and a semicircular bore 17 communicating between the outer surface of member 3 and its adjacent slot 16. As seen best in FIG. 2, rim 5 of cap member 2 includes an annular shoulder 18 formed therein. The surface of shoulder 18 is coplanar with the inner surface of enlargement 10 so as to permit interfitting engagement with rim 14 and enlargement 15. Thus, when assembled rim 5 embraces rim 14 and shoulder 18 engages the end of rim 14 to provide a smooth mating relationship between cap members 2 and 3. It should also be noted that when assembled semicircular bores 17 and 50 form a circular bore the purpose of which will hereinafter be described.
As shown in FIG. 2, cable lock 1 includes a spool 20 on which is stored a length of cable 21. Spool 20 inbludes a cylindrical core 22 and a pair of opposing, parallel, spaced apart annular retaining plates 23 and 24 thereon defining an area therebetween for storing the length of cable 21 about core 22. The outer circumference of plates 23 and 24 lie substantially adjacent to the inner circumference of rim 5 so that the diameter of plates 23 and 24 is substantially identical to the diameter of the annular chamber defined by cap members 2 and 3. The inner diameter of the central opening in core 22 is substantially equal to the outer diameter of boss 7 so that core 22 receives boss 7 therein to provide free rotational movement of spool 20 relative to cap members 2 and 3. As shown best in FIG. 2, retaining plate 24 is spaced from the end of core 22 so that core 22 projects from the righthand side of spool 20 the purpose of which will hereinafter be described. Core 22 also includes an axially extending slot 25 projecting radially through its wall the purpose of which will also hereinafter be described.
Cable 21 is wound on spool 20, and as shown best in FIG. 3 has one end attached to core 22 and its other end or free end extending through bore 9 in rim 5 of cap member 2. Cable 21 is approximately 1/8 inch thick and about 82 inches long which is sufficient to enable it to lock various items such as skis, bikes, luggage, garments, and the like together. In order to accommodate these dimensions for cable 21, the casing is approximately 1/2 inch thick by about 3 inches in diameter. Thus, the device is small, portable, and hand-holdable and may be carried in a pocket, purse or other convenient place. Cable 21 may be composed of any lightweight and relatively strong material and preferably is composed of a braided metal having a nylon jacket.
As shown best in FIGS. 2 and 3, cable lock 1 also includes latch means for permitting free rotation of spool 20 in one direction to extend cable 21 and for preventing free rotation of spool 20 in its other direction to rewind cable 21. The latch means includes an annular ratchet wheel 26 disposed within cap members 2 and 3 coaxially with spool 20 and central axis 6. The outer diameter of wheel 26 is substantially identical to the outer diameter of plates 23 and 24 of spool 20. The inner diameter of wheel 26 is substantially identical to the outer diameter of core 22 so that wheel 26 is received on core 22 for rotation therewith in a press fit arrangement. Wheel 26 includes four teeth located equal distances apart along its circumference. Each tooth is defined by a radially extending shoulder 27 and a surface 28 extending transversely to shoulder 27.
The latch means for cable lock 1 also includes a pawl member 29 pivotally mounted on cap member 2. Pawl 29 is located within a cutout 30 formed in enlargement 10 of cap member 2, and the pivotal connection of pawl 29 is provided by a pin 31. As shown best in FIG. 3, one end of pawl 29 may extend into the interior of the chamber formed by cap members 2 and 3 to engage shoulders 27 of ratchet wheel 26. The other end of pawl 29 extends outside of cap members 2 and 3 and is actuatable by a user's finger to pivot pawl 29 into or out of engagement with shoulders 27 of ratchet wheel 26. A ratchet spring 32 normally biases pawl 29 into engagement with shoulders 27 of ratchet wheel 26. Spring 32 is a preformed wire member wrapped about pin 31 having one end engaging the side of cutout 30 and its other end engaging the inner end of pawl 29. Thus, as wheel 26 and spool 20 are rotated in a clockwise direction as shown in FIG. 2 the inner end of pawl 29 will travel along the outer circumference of wheel 26 until it meets surface 28. Pawl 29 will then follow surface 28 until it meets shoulder 27 to prevent any further rotation of spool 20 and wheel 26. Thus, in order to rewind cable 21 a user must hold pawl 29 in the position shown in solid lines in FIG. 3. When extending cable 21 the inner end of pawl 29 travels along the outer circumference of wheel 26 so that when wheel 26 and spool 20 are rotated in a counterclockwise direction there is no need for a user to manipulate pawl 29.
A coil spring 33 is located in the chamber formed by cap members 2 and 3 and is located between ratchet wheel 26 and cap member 3. As shown best in FIG. 3, the inner end of spring 33 includes a tab which is received within slot 25 in core 22 of spool 20 so that spring 33 is firmly attached to spool 20. The outer end of spring 33 also includes a tab which is received within a slot 34 formed in rim 5 of cap member 2 so that spring 33 is also firmly attached to cap member 2. Thus, as spool 20 is rotated in a counterclockwise direction as shown in FIG. 3 to extend cable 21 spring 33 is tightened so that upon disengagement of pawl 29 from wheel 26 spring 33 automatically drives spool 20 in a clockwise direction to rewind cable 21 thereon.
As shown in FIG. 2, an annular separator plate 35 is interposed between spring 33 and ratchet wheel 26. The outer diameter of plate 35 is substantially identical to the outer diameter of wheel 26 and plates 23 and 24 of spool 20, and its inner diameter is substantially identical to the outer diameter of core 22. Thus, plate 35 is disposed coaxially with spool 20, wheel 26, spring 33 and central axis 6.
Cable lock 1 also includes means for reducing friction between the various components described above as spool 20 rotates within cap members 2 and 3. In order to accomplish this, cable lock 1 includes a pair of thin, annular discs 36 and 37 disposed on either side of spool 20. Disc 36 is located between plate 23 of spool 20 and base plate 4 of cap member 2 while disc 37 is located between ratchet wheel 26 and separator plate 35. Both discs 36 and 37 are positioned coaxially with central axis 6 and have a diameter substantially equal to that of plates 23 and 24, wheel 26 and separator plate 35. Disc 36, however, has an inner diameter substantially equal to the outer diameter of boss 7 so that it is received thereon for free rotation thereabout. Disc 37 on the other hand has an inner diameter substantially equal to the outer diameter of core 22 and is received thereon for free rotation thereabout.
A case nut 38 is employed in order to assemble the various components described above as shown in FIG. 2. Nut 38 is an annular washer-like device having internal threads which engage the threads of stud 8 so that when turned down it forces rim 14 to bear against shoulder 18 of rim 5 so that cap members 2 and 3 are securely held together.
Lock means is employed to lock the free end of cable 21 to the casing of cable lock 1. The lock means includes tumbler means disposed within rectangular recess 11 in enlargement 10 of cap member 2, and an elongate member 39 attached to and extending coaxially from the free end of cable 21. As shown, member 39 includes a flange 40 and a plurality of aligned spaced apart lugs 41 thereon projecting transversely to the longitudinal axis of cable 21. Lugs 41 are adapted to cooperate with the tumbler means for locking the elongate member 39 and consequently cable 21 in the casing of cable lock 1. In order to accomplish this, the tumbler means includes a plurality of tumbler bearings 42 and tumblers 43. Each bearing 42 includes a central opening 44 and a rectangular portion 45. Portion 45 engages the bottom of recess 11 and the underside of enlargment 15 of cap member 3 in order to hold the bearing 42 in position. Each pair of adjacent bearings 42 supports a tumbler 43 therebetween as shown best in FIG. 3.
Each tumbler includes a cylindrical core 47 and a flange-like body 48 centrally located between the end of core 47 projecting through a corresponding slot 16 formed in enlargement 15 of cap member 3. As shown best in FIG. 3, each body 48 includes a plurality of indicia thereon and has a pair of knurled outer rims to aid the user in rotating tumblers 43. As shown in FIGS. 4 and 5, each core 47 includes a radially extending bore 49 formed therein having a diameter slightly greater than the diameter of lugs 41 on elongate member 39. As shown in FIG. 3, the central longitudinal openings in cores 47 are coaxially aligned with the opening formed by bores 17 and 50 extending through the side of enlargements 10 and 15. The diameters of cores 47 are substantially equal to the outer diameter of elongate member 39 so that they may receive elongate member 39. Additionally, tumblers 43 are spaced apart so that the spacing between bores 29 is identical to the spacing between lugs 41 on elongate member 39. Thus, when all of the bores 49 in tumblers 43 are aligned in a downward direction elongate member 39 may be slid through the opening in the side of the casing into tumblers 43. Then, upon rotation of one or all tumblers so that bores 49 no longer align with lugs 41 elongate member 39 is locked within the casing of cable lock 1. To remove elongate member 39 or unlock cable 21 all of the tumblers 43 must be rotated to a position wherein their bores 49 are extending downwardly to align with lugs 41 whereupon elongate member 39 may be removed therefrom.
In operation, one need merely pull on cable 21 and extend cable 21 to the desired position whereupon pawl 29 engages a shoulder 27 to automatically hold cable 21 in this position. Then, the user merely extends the free end of cable 21 through a sleeve of a garment, around a bar of a coat rack, and then insert elongate member 39 within tumblers 43 and rotate one or more of tumblers 43. To unlock the device and remove the garment, the user merely rotates tumblers 43 to the predetermined combination wherein bores 49 are aligned with lugs 41 on elongate member 39 so that elongate member 39 may be removed. Then, the user pivots pawl 29 out of engagement with shoulders 27 of ratchet wheel 26 and spring 33 automatically rewinds cable 21 on spool 20.
A retractable cable lock has been illustrated and described for use as a multi-purpose lock for bikes, skis, luggage, garments and many other items for quick and easy theft resistant locking. The lock is lightweight, compact, portable, hand-holdable and inexpensive to manufacture.
Various modes of carrying out the invention are contemplated as being within the scope of the following claims particularly pointing out and distinctly claiming the subject matter which is regarded as the invention. | A portable, hand-holdable, retractable cable lock includes a cable-carrying spool rotatably mounted within a casing. The cable extends through the casing and its free end may be locked to the casing to provide a theft deterrent. A coil spring within the casing applies a retracting force on the spool so that when the cable is unlocked and in an extended position the spring automatically rotates the spool to rewind the cable thereon. A ratchet mechanism permits free rotation of the spool in one direction to extend the cable, but prevents rotation of the spool in its other direction to rewind the cable unless disengaged. | 8 |
FIELD OF THE INVENTION
This invention relates to cyclic processes and apparatus for hydrocarbon conversion especially in the manufacture of gasoline and/or distillate range hydrocarbon fuels. In particular it provides a catalyst regeneration technique for operating an integrated multi-stage plant wherein a crystalline zeolite oligomerization catalyst is employed for converting olefinic feedstocks containing C 2 -C 6 alkenes at elevated temperature and pressure.
BACKGROUND OF THE INVENTION
In the process for catalytic conversion of olefins to heavier hydrocarbons by catalytic oligomerization using an acid crystalline zeolite, such as ZSM-5 type catalyst, process conditions can be varied to favor the formation of either gasoline or distillate range products. At moderate temperature and relatively high pressure, the conversion conditions favor distillate range product having a normal boiling point of at least 165° C. (330° F.). Lower olefinic feedstocks containing C 2 -C 6 alkenes may be converted selectively; however, the distillate mode conditions do not convert a major fraction of ethylene. While propene, butene-l and others may be converted to the extent of 50 to 95% in the distillate mode, only about 10 to 20% of the ethylene component will be consumed.
In the gasoline mode, ethylene and the other lower olefins are catalytically oligomerized at higher temperature and moderate pressure. However, coking of the catalyst is accelerated by the higher temperature. Under these conditions ethylene conversion rate is greatly increased and lower olefin oligomerization is nearly complete to produce an olefinic gasoline comprising hexen, heptene, octene and other C 6 + hydrocarbons in good yield. To avoid excessive temperatures in the exothermic reactors, the lower olefinic feed may be diluted. In the distillate mode operation, olefinic gasoline may be recycled and further oligomerized, as disclosed in U.S. Pat. No. 4,211,640 (Garwood and Lee). In either mode, the diluent may contain light hydrocarbons, such as C 3 -C 4 alkanes, present in the feedstock and/or recycled from the debutanized product.
In U.S. patent application Ser. No. 481,705, filed Apr. 4, 1983 and incorporated herein by reference, a two stage catalytic process is disclosed for converting lower olefins at elevated temperature and pressure, with unconverted reactant, mainly ethylene, from a first stage being completely converted at higher temperature in a second stage. Although, the same type catalyst (H-ZSM-5) is employed in each stage, significant differences in the operating temperatures and catalyst use contribute to different rates of inactivation, largely due to coking.
The present invention takes advantage of the accelerated aging rate for hydrocarbon conversion catalysts operating under process conditions which produce coke deposits. Increased coking will decrease conversion at a given temperature, and it is conventional practice to increase process temperature to maintain the desired level of conversion. In the two stage olefin oligomerization process contemplated in the preferred embodiment herein, the primary stage feedstock is selectively converted over highly active ZSM-5 type catalyst at moderate temperature and high pressure. Under these conditions C 3 + olefin primary reactants are converted efficiently in major amount to a highly desirable distillate product; however, only a minor amount of ethylene is converted at primary stage temperature.
By recovering unreacted ethylene and other light olefins from the primary stage, a second reactant stream for high temperature conversion can utilize coked catalyst that would no longer be suitable for lower temperature use due to loss of activity.
In order to maintain the MOGD plant in continuous operation, it is necessary to either replace or regenerate spent catalyst periodically. Advantageously, a single reactor can serve the entire multi-stage complex by appropriate sequencing of a plurality of fixed bed reactors. By employing the same type of catalyst bed in similar amount and configuration for each reactor, the same reactor shell can be switched to serve in any of the process positions according to need.
SUMMARY
A technique has been found for multi-stage organic hydrocarbon conversion employing a first moderate lower temperature stage and a second severe high temperature stage in a reactor bank operatively connectable for service in more than one stage as well as in a regeneration loop.
Accordingly, it is an object of this invention to provide a continuous process and apparatus for converting an olefinic feedstock containing ethylene and C 3 + olefins by catalytic oligomerization to produce heavier hydrocarbons in the gasoline or distillate boiling range. This technique provides methods and means for (a) contacting the olefinic feedstock in a first catalytic stage comprising a plurality of serially connected fixed bed reactors with crystalline zeolite oligomerization catalyst at moderate temperature under conditions favorable for conversion of C 3 + olefins to a first reactor effluent stream rich in distillate range hydrocarbons; (b) separating the first reactor effluent stream into a first stream rich in distillate and a second stream rich in ethylene; (c) contacting the ethylene-rich stream from step (b) in a second catalytic stage comprising at least one fixed bed reactor with said crystalline zeolite oligomerization catalyst at substantially higher temperature under conditions favorable for conversion of ethylene and other lower olefins to a second reactor effluent stream rich in olefinic gasoline range hydrocarbons. An improved reactor sequence comprises a cyclic fluid handing technique to connect the first stage serial reactors in operative fluid flow relationship whereby fresh or regenerated catalyst in a terminal reactor stage position receives effluent from a least one preceding first stage reactor operating at moderate temperature, said preceding first stage reactor containing catalyst of less activity than said catalyst in the terminal reactor stage position; sequencing process flow to connect said preceding first stage reactor in said second stage to receive said ethylene-rich stream, increasing temperature in said previously preceding first stage reactor to second stage temperature conditions; removing a second stage reactor containing inactivated catalyst from conversion service, connecting said inactivated catalyst in fluid flow relationship with a catalyst regeneration loop, and regenerating said catalyst in situ; advancing the terminal reactor of the first stage to a preceding serial position in the first stage; and adding a fresh or regenerated catalyst reactor in the first stage terminal position.
THE DRAWINGS
FIG. 1 is a schematic representation of a preferred two stage reactor system and a multi-tower fractionation system;
FIG. 2 is a typical olefin conversion reactor system for first stage distillate mode operation;
FIG. 3 is a typical second stage reactor system for gasoline mode operation;
FIG. 4 is a reactor bank layout and simplified piping diagram;
FIG. 5 is a reactor piping diagram;
FIG. 6 is a plot of stream temperature vs reactor sequence position; and
FIG. 7 is a process flow sheet for a typical regeneration loop.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Conversion of olefins to gasoline and/or distillate products is disclosed, for example, in U.S. Pat. Nos. 3,960,978 and 4,021,502 (Givens, Plank and Rosinski) wherein gaseous olefins in the range of ethylene to pentene, either alone or in admixture with paraffins are converted into an olefinic gasoline blending stock by contacting the olefins with a catalyst bed made up of a ZSM-5 type zeolite. In U.S. Pat. No. 4,227,992 Garwood and Lee disclose the operating conditions for the Mobil Olefin to Gasoline Distillate (MOGD) process for selective conversion of C 3 + olefins and only 20% maximum ethene (C 2 = ) conversion. In a related manner, U.S. Pat. No. 4,150,062 (Garwood et al) discloses a process for converting olefins to gasoline components. Typically, the process recycles cooled gas or liquid C 3 -C 4 alkanes from a high-temperature, high-pressure separator downstream of the catalyst bed back into the reaction zone where additional olefins are converted to gasoline and distillate products. If the reaction of the olefins in converting them to distillate and gasoline is allowed to progress in the catalyst stream without any measures taken to prevent the accumulation of heat, the reaction becomes so exothermically accelerated as to result in high temperatures and the production of undesired products.
The oligomerization catalysts preferred for use herein include the shape selective crystalline aluminosilicate zeolites having a silica to alumina ratio of at least 12, a constraint index of about 1 to 12 and acid cracking activity of about 160-200. Representative of the ZSM-5 type zeolites are ZSM-5, ZSM-11, ZSM-12, ZSM-23, ZSM-35 and ZSM-38. ZSM-5 is disclosed and claimed in U.S. Pat. No. 3,702,886 and U.S. Pat. No. Re. 29,948; ZSM-11 is disclosed and claimed in U.S. Pat. No. 3,709,979. Also, see U.S. Pat. No. 3,832,449 for ZSM-12; U.S. Pat. No. 4,076,842 for ZSM-23; U.S. Pat. No. 4,016,245 for ZSM-35 and U.S. Pat. No. 4,046,839 for ZSM-38. The disclosures of these patents are incorporated herein by reference. A suitable catalyst for fixed bed is an HZSM-5 zeolite with alumina binder in the form of cylindrical extrudates of about 1-5 mm.
In order to take advantage of the inventive concept, the preferred feedstock to be changed to the first stage of the integrated system should contain at least 5 mole % ethylene, preferable 10 to 50%, and substantially no hydrogen. A typical olefinic feedstock contains a major fraction (50 + mole %) of combined C 2 -C 4 alkenes with minor amounts of C 5 + alkenes. Other volatile hydrocarbons such as low molecular weight paraffins are often found in pertroleum refinery streams, such as catalytic cracker by-product depropanizer off-gas. It is an object of the present invention to upgrade lower olefinic hydrocarbons to more valuable liquid fuel products or the like.
OLEFIN CONVERSION PROCESS
Referring to the drawing of FIG. 1, the flow sheet shows a preferred process wherein the total olefinic feedstock 10 is charged to a maximum distillate mode first stage unit 20. Here the C 3 + olefins are converted to primarily distillate, while C 2 = reaction is low, on the order of 10 to 20%. The reactor effluent is then fractionated or flashed in separator 30 to give a pressurized vapor phase (primarily C 5 and lower), which is cascaded at a lower pressure to a gasoline mode second stage unit 40. High temperature olefin conversion approaches 100% on reaction to olefinic gasoline with some distillate in the absence of added hydrogen. Both reactor effluents are combined and sent to a common fractionation system 50.
A series of distillation towers include deethanizer column 52, from which C 1 -C 2 off-gas is withdrawn as overhead vapor stream 53. Heavier components in bottoms stream 54 are further fractionated in debutanizer column 55 to provide C 3 -C 4 overhead stream 56. This stream may be recovered at LPG product and/or recycled to the gasoline mode 40 reactor to help control heat of reaction. Debutanizer bottoms stream 57 is further fractionated in splitter column 58 to provide C 5 + overhead vapor sream 59 rich in hexenes, octenes or the like. This olefinic gasoline product is recycled to the distillate reactor to help control heat of reaction and further react to distillate, or recovered as usuable product. Fractionator bottoms stream 60 consisting essentially of distillate range hydrocarbons boiling above about 165° C. may be used as fuel oil or hydrotreated in known manner to improve its cetane number. Using the combined effluent fractionation system any light distillate produced in the gasoline reactor is recovered as distillate.
A typical distillate mode first stage reactor system 20 is shown in FIG. 2. A multi-reactor system is employed with inter-zone cooling, whereby the reaction exotherm can be carefully controlled to prevent excessive temperature above the normal moderate range of about 190° to 315° C. (375°-600° F.). C 2 -C 6 olefinic feedstock is introduced through conduit 10 and carried by a series of conduits through heat exchangers 12A, B, C and furnace 14 where the feedstock is heated to reaction temperature. The olefinic feedstock is then carried sequentially through a series of zeolite beds 20A, B, C wherein at least a portion of the olefin content is converted to heavier distillate constituents. Advantageously, the maximum temperature differential across only one reactor is about 30° C. (ΔT˜50° F.) and the space velocity (LHSV based on olefin feed) is about 0.5 to 2.5. The heat exchangers 12A and 12B provide inter-reactor cooling and 12C reduces the effluent to flashing temperature. An optional heat exchanger 12D may further recover heat from the effluent stream 21 prior to phase separation. Gasoline from recycle conduit 59A is pressurized by pump means 59B and combined with feedstock, preferably at a ratio of about 1-3 parts by weight per part of olefin in the feedstock.
Between stages it is preferred to take advantage of a significant pressure drop by flashing the effluent with a pressure differential of at least 1400 kPa (200 psi) between the first stage and phase separator vessel 30. The first stage is operated at elevated pressure of about 4200 to 7000 kPa (600-1000 psig); however, the partial pressure reaction requirements of propene and butene may dictate higher total pressure where the feed stock contains large amounts of ethene or other gases. Any suitable enclosed pressure vessel can be used as the separator unit, which is operatively connected by conduits 21, 31, 32 in fluid flow relationship to the two stages and fractionation system.
The gasoline mode reactor 40 shown in FIG. 3, is relatively simple, since the higher temperature conversion does not require maximum differential temperature control closer than about 65° C. (ΔT˜120° F.) in the approximate elevated range of about 285° C. to 425° C. (550°-800° F.). The reactor bed 20D is maintained at a moderate super atmospheric pressure of about 400 to 3000 kPa (50-400 psig) and the space velocity for ZSM-5 catalyst to optimize gasoline production should be about 0.2 to 3 (LHSV). Preferably, all of the catalyst reactor zones in the system comprise a fixed bed down flow pressurized reactor having a porous bed of ZSM-5 type catalyst particles with an acid activity of about 160 to 200.
The overall pressure drop across the system is at least 1500 kPa and it is advantageous to take most of this pressure drop prior to entering the flashing vessel 30, such that the flashing vessel is maintained at a pressure only high enough to allow overhead vapor to cascade into the gasoline mode reactor 40.
Unconverted ethylene and other light gases are passed from the separator through conduit 31, heat exchanger 12F, and furnace 14A to gasoline mode reactor bed 20D. Sine this reactor operates at a high differential (ΔT˜120° F.) the furnace need not be used in normal operation and can be bypassed, with all feed preheat coming from exchanger 12F. The second stage effluent is cooled partially in exchanger 12F and passed through conduit 42 to the fractionation system 50. Optionally, a portion of the hot effluent may be diverted by valve 44 through heat recovery exchanger 46. C 3 -C 4 alkanes of other diluents may be introduced through recycle conduit 56A and pump 56B.
REACTOR SEQUENCING
For sequencing catalyst beds, the most aged catalyst can be used in the high temperature reactor of stage II prior to regeneration. The advantage of rotating reactors through both Stage I and Stage II loops over a conventional design is the need for only one spare reactor and only one regeneration loop. The multiple reactor configuration shown in FIG. 4 is operatively interconnected via fluid handling means to permit any of the five fixed substantially identical reactors to be placed in service for primary or secondary stage operation or regeneration according to the degree of catalyst coking. A number of reactors 101, 102, 103, 104, 105 are each connectable through suitable valving to feedstock manifold 116, primary stage effluent manifold 121, secondary feed stream 131, secondary stage effluent outlet 142, and regeneration manifold 200. These connections are shown in detail in FIG. 5, which depicts piping arrangements for a typical single reactor in the complex, which shows the flow lines described above and also the intra-stage piping 134,135 to receive partially reacted feedstock from a preceding reactor and passing partially reacted effluent to a succeeding stage. FIG. 4 depicts a preferred two-stage plant to show a possible flow configuration for this system. Because of the large number of valves required, these have not been included in the drawings. However, it is understood that all lines require conventional multiple block valves for safety in handling both hydrocarbons and air.
In the initial cycle described, the feedstock is transported in sequence through reactors A, B, C, (Stage I) and reactor D (Stage II), while reactor E is out of service. The reactors are shifted in sequence as tabulated below.
______________________________________Stage ICycle # First Intermediate Last Stage II Regen.______________________________________1 A B C D E2 B C E A D3 C E D B A4 E D A C B5 D A B E CRepeat A B C D E______________________________________
FIG. 6 is a graphic plot of temperature profile along the vertical axis of a series of fixed bed oligomerization reactors. Olefinic feedstock passed through the first reactor A of Stage I, with temperature increasing adiabatically until cooled to favor distillate-forming. In a similar manner the temperature profile of intermediate reactor B and Stage I last reactor C is depicted. Following interstage separation, the olefinic vapor phase is preheated about 50° C. or more above the first stage maximum temperature to effect complete conversion over the less active Stage II catalyst.
REGENERATION OPERATION
Preferably the ZSM-5 catalyst is kept on stream until the coke content increases from 0% at the start of cycle (SOC) until it reaches a maximum of 30 weight % at end of cycle (EOC) at which time it is regenerated by oxidation of the coke deposits. Typically a greater than 30-day total cycle can be expected between regenerations. The reaction operating temperature depends upon its serial position. The system is operated advantageously (as shown in FIGS. 1-7) by increasing the operating temperature of the first reactor (Position A) from about 250° C.-290° C. (SOC) to about 270° C.-310° C. (EOC) at a catalyst aging rate of 1°-6° C./day. Primary stage reactors in the second and subsequent positions (B, C, etc.), containing catalyst with less time in stream (i.e. higher catalytic activity, are operated at lower SOC temperature. Operating in such a manner the average reactor temperature for the reactor in position C will generally be less than the average reactor temperature in position B, which will generally be less than the average reactor temperature in position A. Thermodynamically it is advantageous to maintain the primary stage terminal reactor (position C) with fresh catalyst, since this allows a lower average reactor temperature, which will form the product of higher molecular weight oligomer. The aging rate for reactors in positions B and C is about 1°-6° C./day. Aging rates for reactors in all primary stage positions (A, B and C) are adjusted to maintain approximately equal conversion rates. The Stage I end of cycle is signalled when the outlet temperature of the reactor in position A reaches its allowable maximum. At this time the inlet temperature is reduced to start of cycle levels in order to avoid excessive coking over the freshly regenerated catalyst when the regenerated reactor 31E is brought on-line, after having been brought up to reaction pressure with an effluent slip stream. Regeneration of coked catalyst may be effected by any of several procedures. The catalyst may be removed from the reactor of the regeneration treatment to remove carbonaceous deposits or the catalyst may be regenerated in-situ in the reactor. In FIG. 7, a typical regeneration subsystem is shown, wherein the off-stream fixed catalyst bed unit 31D is operatively connected with a source of oxidizing gas at elevated temperature. A programmable logic controller may be employed to control the sequencing of valve operations during all stages of reactor system operation.
The regeneration circuit includes a recycle gas compressor 201 which circulates the regeneration gas. This compressor takes suction from phase separator 203. The gas then passes through the feed/effluent heat exchanger 204 to the regeneration heater 205 and into reactor 220E. Here the catalyst is regenerated by burning off coke, producing CO 2 and H 2 O. Reactor effluent is cooled in the feed/effluent exchanger 204 then in an air cooler 206 and is finally cooled in the trim cooler 207 before entering the separator 203. Gas is released from the separator to maintain system pressure through pressure-response venting means 208. By the time it reaches the separator, water vapor formed during the burn has condensed and is separated from the recycle gas. Because water vapor at high temperatures may damage the catalyst, separator temperature is maintained low (40°-50° C. at 800 kPa) in order to minimize the H 2 O partial pressure in the recycle gas returning to the reactor.
At the beginning of the regeneration the system is brought up to pressure with nitrogen from inert gas source 209, the reactor inlet temperature adjusted to about 370° C. and air is injected at the compressor suction by air make-up compressor 210 at a rate controlled to give a maximum oxygen concentration of 0.7% at the reactor inlet. As burning begins, a temperature rise of about 85° C. will be observed. As the burn dies off the inlet temperature is raised to maintain about 455° C. outlet temperature. When the main burn is completed, as evidenced by no temperature rise across the catalyst bed, the temperature is raised over 500° C. and the O 2 content to 7.0%. This condition is held at least one hour (or until all evidence of burning has ceased). When the regeneration is complete, the temperature is reduced and the system purged free of O 2 with nitrogen. The reactor is then blocked off from the regeneration loop and brought up to reaction pressure with a slip stream from the process reactor effluent line. To reconnect the regenerated reactor in the proper serial position, reactor 220E is then paralleled with the Stage I last reactor. When full flow is established in the regenerated reactor in this position, the last reactor is paralleled with the intermediate Stage I reactor, etc., proceeding sequentially through both stages. Finally the fully coked catalyst bed in Stage II is blocked in, depressured, and repressured with nitrogen, then opened to the regeneration circuit, as unit 220E in FIG. 7. Thus each reactor will move from position C to position B to position A before being taken off-line for catalyst regeneration.
It is preferred to have at least three Stage I adiabatic reactors in continuous service; however, the ΔT becomes smaller with increased numbers of serial reactors and difficulties may be encountered in exploiting the reaction exotherm for preheating reactor feed. A smaller number of serial reactors in the system would require much greater recycle to control the reaction exotherms from catalytic oligomerization.
The concept of moving reactors through a programmed sequence may have value for processes where different stages operate at significantly different temperatures, or where equilibrium would be favored by operating with different temperatures through a set of reactors.
Various modifications can be made to the system, especially in the choice of equipment and non-critical processing steps. While the invention has been described by specific examples, there is no intent to limit the inventive concept as set forth in the following claims. | A reactor sequencing technique is useful for multi-stage hydrocarbon conversion systems employing a number of fixed bed catalytic reactors at various process temperatures and catalytic activity levels. A process for oligomerizing lower olefins (e.g., C 2 -C 6 ) is disclosed wherein catalyst partially inactivated in a primary stage is employed to effect conversion at higher temperature in a secondary stage prior to catalyst regeneration. | 2 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to the protection of vehicular occupants against harmful radiation, and more particularly, to the protection of automobile occupants against harmful ultraviolet radiation.
[0002] Ultraviolet radiation, especially in the A, B and C bands, can be harmful to animals, including humans. In order to protect against this kind of radiation, it is necessary to limit the amount of glass surface commonly found in automotive vehicles. At the same time, it is desirable to expand the glass surface in order to promote visibility.
[0003] Accordingly, it is an object of the invention to provide protection against the exposure of automotive occupants to harmful radiation while simultaneously not interfering with the desire to increase the amount of light transmittive surface in order to promote automotive visibility.
[0004] There have been numerous attempts to provide ultraviolet protection. An illustrative example is provided by U.S. Pat. No. 6,235,271, which issued to Luther et al., on May 22, 2001. Luther et al. disclose a sunprotection agent, which is especially suitable for use in pharmaceutical or cosmetic applications, containing a micronized organic UV absorber, and a non-micronized UV absorber and/or an inorganic-micropigment, together with a polymeric hollow sphere additive and/or xanthan and/or polyvinylpyrrolidone.
[0005] Another preparation for ultraviolet protection is set forth in U.S. Pat. No. 4,804,531 which issued to Grollier on Feb. 14, 1989. Grollier discloses a cosmetic screening composition containing a UV screen in combination with a polymer obtained by block polymerization in emulsion and its use for the protection of the human epidermis against ultraviolet radiations.
[0006] Still another composition for UV protection is provided by U.S. Pat. No. 4,524,061, which issued to Cho et al. on Jun. 18, 1985. This patent is directed to a polymeric sunscreen agent of interpolymers including an olefinic p-aminobenzoate devoid of hydroxy substitution, N-vinylpyrrolidone, and at least a vinyl lactam monomer.
[0007] There also have been numerous attempts to provide ultraviolet protection for glass, but none of these achieve the advantages and simplicity of the invention. The prior art includes the following patents: U.S. Pat. No. 6,220,059, “Method of Coating a UV-fiber With Blocking Layers and Charging the Fiber With Hydrogen Or Deuterium”; U.S. No. 6,159,608,
[0008] “Thermoplastic Interlayer Film”; U.S. Pat. No. 6,143,417, “Contamination-Resistant Float Glass”; U.S. Pat. No. 6,138,663, “Cooking Apparatus Containing A Window That Is A Contamination-Resistant Float Glass”; U.S. Pat. No. 6,122,093, “Reduced Ultraviolet Radiation Transmitting, Safety Protected Electrochromic Glazing Assembly”; U.S. Pat. No. 6,121,354, “High Performance Single-Component Sealant”; U.S. Pat. No. 6,117,497, “Solid Surface Modification Method and Apparatus”, U.S. Pat. No. 6,022,624, “Partially Crystallizing Lead-Free Enamel Composition for Automobile Glass”; U.S. No. 5,986,797, “Reduced Ultraviolet Radiation Transmitting, Safety Protected Electrochromic Glazing Assembly”; U.S. Pat. No. 5,972,565, “Flexographic Printing Forms Having Resistance to UV-Hardenable Printing Inks”; U.S. Pat. No. 5,948,594, “Flexographic Printing Forms for UV-Hardenable Printing Inks”; U.S. Pat. No. 5,925,160, “Partially Crystallizing Lead-Free Enamel Composition For Automobile Glass”; U.S. Pat. No. 5,908,585, “Electrically Conductive Transparent Film And Coating Composition For Forming Such Film”; U.S. Pat. No. 5,864,419, “Near-Infrared Reflecting, Ultraviolet Protected, Safety Protected, Electrochromic Vehicular Glazing”, U.S. Pat. No. 5,846,279, “Process for Producing A Contamination-Resistant Float Glass”; U.S. Pat. No. 5,792,560, “Thermoplastic Interlayer Film”; U.S. Pat. No. 5,783,507, “Partially Crystallizing Lead-Free Enamel Composition For Automobile Glass”; U.S. Pat. No. 5,680,245, “Reduced Ultraviolet Radiation Transmitting, Electrochromic Assembly”; U.S. Pat. No. 5,641,716, “Glass Production Method Using Ilmenite”; U.S. No. 5,629,365, “UV-Absorbing Polymer Latex”; U.S. Pat. No. 5,610,108, “Reducing Melt Borosilicate Glass Having Improved UV Transmission Properties And Water Resistance And Method of Use”; U.S. Pat. No. 5,578,378, “Anti-Fogging Coating Composition, Product Coated With Said Composition And Method for Preparation of Said Product”; U.S. Pat. No. 5,547,904, “Borosilicate Glass Having Improved UV Transmission, Thermal and Chemical Properties and Method of Making and Using Same”; U.S. Pat. No. 5,523,877, “Reduced Near-Infrared Radiation Transmitting Ultraviolet Protected, Safety Protected Electrochromic Vehicular Glazing”; U.S. Pat. No. 5,523,263, “Glass Production Method Using Ilmenite”; U.S. Pat. No. 5,480,722, “Ultraviolet Ray Absorbent Glass and Method For Preparing the Same”; U.S. Pat. No. 5,385,872, “Ultraviolet Absorbing Green Tinted Glass”; U.S. Pat. No. 5,364,433, “Optical Member of Synthetic Quartz Glass For Excimer Lasers and Methods For Producing Same”; U.S. Pat. No. 5,355,245, “Ultraviolet Protected Electrochemichromic Rearview Mirror”; U.S. Pat. No. 5,249,076, “Optical Filter Structure”; U.S. No. 5,240,886, “Ultraviolet Absorbing, Green Tinted Glass”; U.S. Pat. No. 5,239,406, “Near-Infrared Reflecting, Ultraviolet Protected, Safety Protected, Electrochromic Vehicular Glazing”; U.S. Pat. No. 5,214,008, “High visible, Low UV and Low IR Transmittance Green Glass Composition”; U.S. Pat. No. 3,115,346, “anti-Scatter, Ultraviolet Protected, Anti-Misting, Electro-Optical Rearview Mirror; U.S. Pat. No. 5,098,948, “Water-Based Protective Compositions for Coating Films and Preparation Processes Thereof”; U.S. Pat. No. 5,077,133, “Infrared And Ultraviolet Radiation Absorbing Green Glass Composition”; U.S. Pat. No. 5,045,509, “UV-Transparent Glass”; U.S. Pat. No. 4,792,536, “Transparent Infrared Absorbing Glass And Method of Making”; U.S. Pat. No. 4,649,062, “Ultraviolet Radiation Curable Vehicle For Ceramic Colors, Composition and Method”; U.S. Pat. No. 4,326,214, “Thermal Shock Resistant Package Having an Ultraviolet Light Transmitting Window For a Semiconductor Chip”.
SUMMARY OF THE INVENTION
[0009] In accomplishing the foregoing and related objects, the invention provides a light-transmissive surface which permits unimpeded visual radiation, but simultaneously serves as a protective shield against ultraviolet (UV) radiation, particularly in the UV-A, UV-B and UV-C bands.
[0010] The invention functions by absorbing the UV portion of radiation below 315 nanometers (“nm”) of the A, B and C bands, and provides a method for the manufacture of such a light transmissive surface, as well as for the use of such surface as automotive glass.
[0011] The light-transmissive medium of the invention includes means for permitting unimpeded visual radiation, and means included for simultaneously serving as a protective shield against ultraviolet radiation.
[0012] The light-transmissive medium can include a conjugated double-bond polymer, selected from the class consisting of alkenes and arenes.
[0013] The light-transmissive medium can include the conjugated double-bond polymer in another polymeric material comprising an interlayer for glass, such as polyvinyl butyral.
[0014] In a method of the invention for providing a light-transmissive surface, the steps include (a) providing a medium that shields ultraviolet radiation; (b) combining the medium with a substance that provides general radiation transmission. The medium can be mixed with the substance and be selected from the class of conjugated multiple-bond polymers.
[0015] In the method, the medium can be a salt that absorbs UV radiation, such as cerium aluminate.
[0016] In a method of the invention for providing a light-transmissive material, the steps include (a) providing a substance that shields ultraviolet radiation; (b) providing a substance that is generally radiation transmissive; and (c) combining the substances of steps (a) and (b).
[0017] The method further includes the step of casting the combined substances into a specified shape, such as automotive glass.
[0018] In the method, the substance that shields ultraviolet radiation can have conjugate, multiple bonds selected from the class consisting of alkenes and arenes.
[0019] In an apparatus for protecting against harmful radiation, the apparatus can have an interior which is subject to radiation exposure and include a material for limiting the extent to which harmful components of radiation can penetrate the interior.
[0020] The apparatus can be an automobile with glass paneling which has been modified to curtail the transmission of ultraviolet radiation.
[0021] In accordance with one aspect of the invention, the light transmissive medium, such as glass is mixed, for example, by combination with a material that inhibits UV transmission while simultaneously permitting unimpeded transmission of the ordinary visual components.
DETAILED DESCRIPTION
[0022] The combination of substances in accordance with invention is achieved in a variety of ways. In one technique of the invention, the combination is by mixing with a compound containing cerium. Advantageously, the cerium is present between about 0.065% and 3.25%, by weight, and preferably between about 0.065% and 1.3%, by weight, in relation to the overall weight of the light transmissive medium, such as glass.
[0023] Since glass is a super-cooled fluid, the desired combination may be achieved by dissolving cerium aluminate into the molten glass. When a multivalent alkene, desirably containing between 2 and 5 alternate double-bonds, is used for UV absorbtion, it is necessary to include the absorbant in a plastic material which is adherable to glass.
[0024] Illustratively, the plastic material is polyvinyl acetal. These are vinyl resins resulting from the condensation of polyvinyl alcohol with an aldeyhde; acetal dehyde, formaldehyde and butyral dehyde. Other vinyl resins include: polyvinyl formal and polyvinyl butyral. These are thermoplastic materials produced by extrusion, molding and casting.
[0025] In accordance with a feature of the invention, when a salt is used as the UV absorbant, only a single melting step need be employed by melting together sand, or other suitable material for the production of glass, and the mixing or doping substance, such as cerium aluminate.
[0026] Preferably the cerium aluminate is in powder form, and is homogeneously mixed with the sand. The grain size of the cerium-aluminate powder advantageously is on the order of 20 millimicrons (“.mu.m”), or less.
[0027] The cerium-aluminate powder can be produced from an initial mixture of cerium oxide (“CeO 2 ”) and aluminum oxide (“Al 2 O 3 ”), heated to glowing temperature when solid. The mole-relationship of the aluminum oxide and cerium oxide in initial mixture, preferably is 0.5:1.
[0028] By weight, the quantity of cerium aluminate, with respect to the sand is on the order of about 5%, preferably between 0.1% and 2%. Titanium oxide (“TiO 2 ”), can be added as a further doping compound and homogeneously mixed into the sand.
[0029] In general the dopant is a lanthanide-metallic salt, in which the lantahnide metal cerium can be replaced by Praesodymium (Pr), Neodymium (Nd), Promethium (Pm), Samarium (SM), Europium (Eu), Gadolinium (Gd), Terbium (Tb), Dyusprosium (DY), Holminium (HO), Erbium (Er), Thulium (Tm), Ytterbium (Yb), or Lutetium (Lu). The metal aluminum can be replaced by Gallium (Ga), Indium (In), or Thalium (TH).
[0030] In accordance with another aspect of the invention, a polyunsaturated polymer with conjugate multiple bonds is employed. Illustratively, there can be three double bonds. The electrons in the lower band jump to a higher level as a result of the absorption of ultraviolet light.
[0031] The absorption of UV is in accordance with the chain length of the polymer when it is an alkene with conjugate double bonds (alkene-cdb), or alkadiene. Thus, butene-cdb, or butadiene, as illustrated by equation (1), below, has a four-carbon chain and is particularly useful for the absorption of UV-A.
[0032] in which X is hydrogen (H) or a radical, such a methyl (—CH3).
[0033] The term “conjugate double bond” refers to the alternating presence of double bonds in the chain structure.
[0034] For the absorption of UV-B, a suitable alkene-cdb, or alkadiene, is pentene-cdb, or pentadiene, which is illustrated by equation (2a) below.
[0035] in which X is hydrogen (H) or a radical, such a methyl (—CH3).
[0036] Alternatively, the pentadiene can take the form illustrated by (2b) below.
[0037] in which X is hydrogen (H) or a radical, such a methyl (—CH3), and Y is a radical, different than X.
[0038] The pentadienes of equations (2a) and (2b) can have different properties depending upon the radical attached to the first carbon. When the radicals are different, the resulting polymers are isomers.
[0039] Similarly, for the absorption of UV-C, a suitable alkadiene is hexadiene, which is illustrated by equation (3) below in which the attached hydrogens are similar to those shown above for equations (1), (2a) and (2b).
[0040] In accordance with a further aspect of the invention, the polymer can be an alkyne, which is one of a class of unsaturated hydrocarbons of the homologous series having the generic formula C(n)H(2n-2). As with the alkadienes, the shorter chains are used for the absorption of longer wave length UV and the longer chains are for the higher wave length UV.
[0041] Conjugate double bonds of use in the practice of the invention are also to be found in the arenes which are unsaturated cyclic hydrocarbons containing one or more rings. A typical arene is benzene which has a six-carbon ring with three conjugate double bonds.
[0042] The invention employs conjugate bonds to absorb ultraviolet radiation, and for low molecular weights is colorless.
[0043] The foregoing examples are merely illustrative and other materials and methods will occur to those of ordinary skill in the art. | Light-transmittive medium permitting unimpeded visual radiation while simultaneously serving as a protective shield against ultraviolet radiation by employing a conjugated double-bond polymer as an interlayer for glass or mixing in glass a salt that absorbs ultraviolet radiation. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to solid diffusion dopants for semiconductors and methods of making the same. More particularly, the invention pertains to solid diffusion sources for the phosphorus doping of semiconductors and methods of making the same.
2. Description of the Prior Art
At present, the so-called open tube method is mainly employed for the diffusion of phosphorus into silicon semiconductors and phosphorus containing substances such as red phosphorus, P 2 O 5 , POCl 3 , PH 3 etc. are used as phosphorus diffusion sources. Particularly, POCl 3 , and PH 3 are employed in many cases.
In the diffusion employing such impurity sources, an accurate control of the pressure of vapor from the diffusion source, or the flow rate of a gas when it is used as the diffusion source, is required for controlling the concentration of phosphorus diffusing into the silicon. And this necessitates a precise control of the temperature of the diffusion source, the flow rate of the carrier gas, etc.
Conventional doping methods employing liquid diffusion sources are briefly, as follows. Only vapor emanating from the diffusion source, heated at a temperature, below 600° C, or a mixed gas of the vapor and a very small amount of oxygen or a large amount of inert gas, is introduced into a doping chamber kept at a temperature ranging from 750° to 1200° C to effect therein the diffusion of phosphorus into silicon semiconductors.
In this case, many silicon slices or wafers are usually arranged in the doping chamber for the purpose of enhancement of the doping efficiency. In such a doping procedure, however, the concentration of phosphorus diffusing into the silicon wafers may greatly differ on the sides of gas inlet and outlet in some cases. This is caused by a non-uniform flow of gas in the doping chamber, so that a uniform flow of gas is necessary for uniform diffusion of phosphosphorus. However, it is very difficult to establish such a uniform flow of gas. Even under the same doping conditions, dispersion is noted in the phosphorus concentration among doping lots or silicon wafers of the same lot or in each silicon wafer.
Further, the gas diffusion sources such as PH 3 , PBr 3 , etc. have not only the same disadvantages as the liquid diffusion sources mentioned above but also a disadvantage of high toxicity. Moreover, solid red phosphorus has a defect of fluctuation in composition due to a thermal history of diffusion and P 2 O 5 has high hygroscopicity which is likely to carse a fluctuation in the vapor pressure. In any case, the phosphorus concentration in the silicon varies widely.
To overcome such shortcomings described above, wafer-shaped, solid dopants, which are equal in size to or a little larger than the silicon wafers, are used in the diffusion of boron in silicon semiconductor. With this method, the dopants and the silicon wafers are alternately disposed in parallel but closely spaced relationship to each other and then simultaneously placed in a doping chamber precisely controlled in temperature. In the doping chamber, a gas containing boron, generated from the dopants reacts with the silicon and the boron diffuses into the silicon wafers. With this method, all the silicon wafers make contact with the gas containing boron, generated from the dopants disposed adjacent thereto, and this eliminates the possibilities of dispersion in the diffused boron concentration resulting from the difference in position among the silicon wafers. Thus, uniform diffusion is easily achieved
Also in the case of phosphorus, if such a substance is available which remains solid at such a diffusion temperature as mentioned above and can be disposed adjacent to the silicon wafers and which generates a gas containing phosphorus at the diffusion temperature, phosphorus will also make useful diffusion dopants. Recently, inventions of solid diffusion dopants, made for the abovesaid purpose, have been patented.
One of such solid dopant sources is indicated in U.S. Pat. No. 3,849,344, in which the dopant contains a compound SiO 2 .P 2 O 5 or 2SiO 2 .p.sub. 2 O 5 and the others are proposed in U.S. Pat. Nos. 3,841,927 and Published Application No. B 351,348, in which the dopants contain Al(PO 3 ) 3 . However, these solid dopants are all those which are suitable for the diffusion of the so-called high phosphorus concentration region that the surface phosphorus concentration in silicon wafers after predeposition is 10 20 to 10 21 atoms/cm 3 , and, at a temperature suitable for the diffusion of a region having a surface phosphorus concentration of less than about 10 20 atoms/cm 3 , a sufficient amount of phosphorus-containing gas is not generated from the dopants and the surface phosphorus concentration in the silicon wafers greatly varies with the place.
SUMMARY OF THE INVENTION
This invention is to provide a solid diffusion source for the phosphorus doping of silicon semiconductors, with exhibits excellent characteristics in the diffusion of a low phosphorus concentration region having a surface phosphorus concentration of lower than 10 19 atoms/cm 3 or so after diffusion.
The solid diffusion dopant of this invention comprises a substance which is composed of at least one compound (R 2 O 3 ) selected from the group consisting of Y 2 O 3 , La 2 O 3 and Ce 2 O 3 and phosphorus pentoxide P 2 O 5 and contains mainly a compound with a chemical formula R 2 O 3 .5 P 2 O 5 . With the use of this diffusion dopant, it is possible to effect doping in which dispersion in the surface phosphorus concentration in silicon semiconductors is small in the diffusion within a temperature range of from 700° to 950° C.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The compound R 2 O 3 employed in this invention may be Y 2 O 3 , La 2 O 3 or Ce 2 O 3 alone or may be a solid solution. The compound R 2 O 3 .5 P 2 O 5 means a crystalline or amorphous substance that the molar ratio of P 2 O 5 to R 2 O 3 is about 5 and this compound may contain a small amount of by-product which is formed in the formation of this compound, such, for example, as R 2 O 3 .3P 2 O 5 . The abovesaid substance mainly containing the compound R 2 O 3 .5 P 2 O 5 comprises the compound alone or a mixture of the compound and another inorganic compound which is added for the purpose of accelerating sintering or improving the mechanical strength of the resulting molding in such an amount as not to cause a remarked change in the pressure of phosphorus containing vapor evaporated from the compound R 2 O 3 .5 P 2 O 5 during diffusion.
Other preferred inorganic compounds are metal oxides such, for example, as SiO 2 , Al 2 O 3 , ZrO 2 , ThO 2 , etc. and nitrides and carbides of Si, Zr, Ti, Al, etc. which do not substantially contain elements or oxides such as alkaline metals, lead, iron, etc. which are liable to diffuse as impurities other than phosphorus into silicon semiconductors to exert bad influence on the electrical properties of the semiconductors obtained in the diffusion of phosphorus.
The additive may be either granular or fibrous in shape but the fibrous additive provides for enhanced mechanical strength of the solid dopant. In the case where the solid dopant is in the form of a wafer, the thermal shock resistance of the wafer presents a problem when it is put in and out of the doping chamber of high temperature. To improve the thermal shock resistance of the wafer, the abovesaid fibrous additive is especially preferred. Example of such fibrous materials are silica fiber and silica-alumina fiber and the shape of fiber is particularly preferred to have a diameter of less than 50μ and a fiber length of less than 1 cm.
The amount of such inorganic compound added is smaller than 20 wt% with respect to the compound R 2 O 3 .5 P 2 O 5 . And when the amount of the inorganic compound exceeds the abovesaid value, the pressure of the phosphorus containing vapor generated during doping remarkedly changes to make the doping unstable.
The solid dopant retains its solid form when heated at the same temperature as the silicon wafer. The shape of the solid dopant is usually preferred to be substantially the same as the silicon wafer but may be any convenient one as long as it does not exert bad influence on the dispersion of the phosphorus concentration in the silicon wafer.
The compound R 2 O 3 .5 P 2 O 5 of this invention can be easily produced by mixing an oxide Y 2 O 3 , La 2 O 3 , Ce 2 O 3 or CeO 2 with orthophosphoric acid and by firing the mixture at 500° to 700° C. for about 10 hours. Further, this compound can also be produced by firing a mixture of orthophosphoric acid and a compound which forms the abovesaid oxide when heated, such as oxalate of, for example, Y, La or Ce, and an inorganic salt of nitric acid or the like.
It is also possible to employ, as the P 2 O 5 source, hydroxyacid of phosphorus such as pyrophosphoric acid, metaphosphoric acid or the like, or an ammonium salt of such acid.
It is preferred that the solid dopant is in the form of wafers, which can be easily obtained by an ordinary sintering, hot-pressing or like molding process and a process of cutting the molding by a diamond cutter or the like into individual wafers.
EXAMPLE 1
362 grams of lanthanum oxide, 1155 grams of 85% phosphoric acid aqueous solution and a small amount of water were carefully mixed together to obtain a slurry mixture, which was dried by heating in a platinum vessel at 110° C. for 24 hours. Further, the mixture was fired in an electric furnace at 750° C. for 10 hours to obtain 1012 grams of a white solid powder containing mainly a crystalline compound that the molar ratio P 2 O 5 /La 2 O 3 was about 5/1.
The solid powder was molded by hot pressing. That is, the solid powder was compacted in a graphite die having an inner diameter of 50 mm and heated at 900° C. in a nitrogen atmosphere for 30 minutes under a pressure of 100 kg/cm 2 , thereafter being cooled to room temperature to obtain a molding having a porosity of 18%. The molding was sliced by diamond sawing into wafer-shaped dopants 1 mm thick.
The dopants thus obtained and P-type silicon wafers (each having a resistivity in the range of from 4 to 10 Ω.sup.. cm, a thickness in the range of from 0.28 to 0.29mm and a diameter of 50 mm) were alternately arranged on a quartz boat at intervals of 6 mm. The alternating silicon and dopant wafers were placed in a furnace having a uniform temperature zone controlled to ±0.5° C. and a stream of nitrogen (1 l/min.) was passed over the silicon and dopant wafers to effect predeposition. After etching of the silicon wafers by a 10% HF aqueous solution for 30 seconds, their sheet resistances were measured.
The results of the measurement are shown in the Table. As is apparent from the table, stable predeposition could be achieved for many hours in low phosphorus concentration regions in which the sheet resistance of the silicon wafer was in the range of from about 20 to 630 Ω/□.
EXAMPLE 2
688 grams of cerium oxide (IV), 2306 grams of 85% phosphoric acid aqueous solution and a small amount of water were carefully mixed together to obtain a slurry mixture, which was dried by heating in a platinum vessel at 110° C. for 24 hours. Further, the mixture was fired in an electric furnace at 750° C. for 10 hours to obtain 2005 grams of a white solid powder containing mainly a crystalline compound that the molar ratio P 2 O 5 /Ce 2 O 3 was about 5/1.
The solid powder was molded by hot pressing. That is, the solid powder was compacted in a graphite die having an inner diameter of 50 mm and heated at 950° C. in a nitrogen atmosphere for 15 minutes under a pressure of 100 kg/cm 2 , thereafter being cooled to room temperature to obtain a molding having a porosity of 25%. The molding was sliced by diamond sawing into wafer-shaped dopants 1 mm thick.
The dopants thus obtained and P-type silicon wafers (each having a resistivity in the range of from 4 to 10 Ω.sup.. cm, a thickness in the range of from 0.28 to 0.29 mm and a diameter of 50 mm) were alternately arranged on a quartz boat at intervals of 6 mm. The alternating silicon and dopant wafers were placed in a furnace having a uniform temperature zone controlled to ±0.5° C. and a stream of nitrogen (1 l/min.) was passed over the silicon and dopant wafers to effect predeposition. After etching of the silicon wafers by a 10% HF aqueous solution for 30 seconds, their sheet resistances were measured.
The results of the measurement are shown in the Table. As is apparent from the table, stable predeposition could be achieved for many hours in low phosphorus concentration regions in which the sheet resistance of the silicon wafer was in the range of from about 73 to 1900 Ω/□.
EXAMPLE 3
226 grams of yttrium oxide, 1153 grams of 85% phosphoric acid aqueous solution and a small amount of water were carefully mixed together to obtain a slurry mixture, which was dried by heating in a platinum vessel at 110° C. for 24 hours. Further, the mixture was fired in an electric furnace at 600° C. for 10 hours to obtain 930 grams of a white solid powder containing mainly a crystalline compound that the molar ratio P 2 O 5 /Y 2 O 3 was about 5/1.
The solid powder was molded by hot pressing. That is, the solid powder was compacted in a graphite die having an inner diameter of 50 mm and heated at 700° C. in a nitrogen atmosphere for 15 minutes under a pressure of 100 kg/cm 2 , thereafter being cooled to room temperature to obtain a molding having a porosity of 18%. The molding was sliced by diamond sawing into wafer-shaped dopants 1 mm thick.
The dopants thus obtained and P-type silicon wafers (each having a resistivity in the range of from 4 to 10 Ω.sup.. cm, a thickness in the range of from 0.28 to 0.29 mm and a diameter of 50 mm) were alternately arranged on a quartz boat at intervals of 6 mm. The alternating silicon and dopant wafers were placed in a furnace having a uniform temperature zone controlled to ±0.5° C. and a stream of nitrogen (1 l/min.) was passed over the silicon and dopant wafers to effect predeposition. After etching of the silicon wafers by a 10% HF aqueous solution for 30 seconds, their sheet resistances were measured.
The results of the measurement are shown in the Table. As is apparent from the table, stable predeposition could be achieved for many hours in low phosphorus concentration regions in which the sheet resistance of the silicon wafer was in the range of from about 152 to 4800 Ω/□.
EXAMPLE 4
163 grams of lanthanum oxide, 113 grams of yttrium oxide, 1160 grams of 85% phosphoric acid aqueous solution and a small amount of water were carefully mixed together to obtain a slurry mixture, which was dried by heating in a platinum vessel at 110° C. for 24 hours. Further, the mixture was fired in an electric furnace at 600° C. for 20 hours to obtain 940 grams of a white solid powder containing mainly a crystalline compound that the molar ratio P 2 O 5 /(La 2 O 3 +Y 2 O 3 ) was about 5/1.
The solid powder was molded by hot pressing. That is, the solid powder was compacted in a graphite die having an inner diameter of 50 mm and heated at 700° C. in a nitrogen atmosphere for 30 minutes under a pressure of 100 kg/cm 2 , thereafter being cooled to room temperature to obtain a molding having a porosity of 18%. The molding was sliced by diamond sawing into wafer-shaped dopants 1 mm thick.
The dopants thus obtained and P-type silicon wafers (each having a resistivity in the range of from 4 to 10 Ω.sup.. cm, a thickness in the range of from 0.28 to 0.29 mm and a diameter of 50 mm) were alternately arranged on a quartz boat at intervals of 6 mm. The alternating silicon and dopant wafers were placed in a furnace having a uniform temperature zone controlled to ±0.5° C. and a stream of nitrogen (1 l/min.) was passed over the silicon and dopant wafers to effect predeposition. After etching of the silicon wafers by a 10% HF aqueous solution for 30 seconds, their sheet resistances were measured.
The results of the measurement are shown in Table 1. As is apparent from the table, stable predeposition regions were formed in which the sheet resistance of the silicon wafer was in the range of from about 220 to 224 Ω/□.
EXAMPLE 5
12 grams of silica fiber having a mean diameter of 9μ and a mean fiber length of 5 mm was added to 300 grams of solid powder of the crystaline compound having the molar ratio P 2 O 5 /Ce 2 O 3 of about 5/1, made from cerium oxide (IV) and phosphoric acid in Example 2. The mixture was molded using the same conditions and method as those employed in Example 2, by which was obtained a molding having a porosity of 30%. The molding was sliced by diamond sawing into wafers 1 mm thick and 50 mm in diameter. Predeposition was achieved by using the same conditions and methods as those of Example 2 and then the sheet resistances of silicon wafers were measured. The results of measurements are shown in Table 1. The dopant of this Example exhibited an excellent doping ability as in Example 2. And the dopant wafer did not crack when heated rapidly to 800° C. and cooled rapidly to room temperature.
EXAMPLE 6
In Example 5, silica-alumina fiber (50% silica, 45% alumina and 5% zirconia) having a mean diameter of 15μ was used instead of the silica fiber. The diffusion ability of the dopant of this Example is shown in the Table. The thermal shock resistance of the dopant was also excellent as in the case of employing the silica fiber.
EXAMPLE 7
122 grams of solid powder of the crystalline compound having the molar ratio P 2 O 5 /Ce 2 O 3 of about 5/1, prepared in Example 2, and 12 grams of silica powder were mixed together. The mixture was hot-pressed by the same method as in Example 1 at 800° C. under a pressure of 50 kg/cm 2 for 15 minutes, by which a molding having a porosity of 17.5% was obtained. The molding was sliced into wafers 1 mm thick and 50 mm in diameter. The diffusion ability of the wafer, measured by using the same conditions and method as those employed in Example 2, is shown in the Table. With the wafer of this Example, even after 300 times of predeposition effected at 800° C. for 30 minutes, the value of the sheet resistance was substantially the same as early ones.
For reference, the diffusion ability of a wafer cut out of a molding composed of 122 grams of the compound having the molar ratio P 2 O 5 /Ce 2 O 3 of about 5/1 and 40 grams of silica powder is also shown in the Table. In this case, the diffusion ability is remarkedly lowered. That is, the sheet resistance of a silicon wafer changes with the lapse of time and the phosphorus concentration in the wafer varies widely.
Table__________________________________________________________________________ Number of times of diffusion__________________________________________________________________________ 1st 20th 50th__________________________________________________________________________Predeposition Sheet Status Sheet Status Sheet Statustemperature resistance of resistance of resistance of(° C.) ##STR1## wafer ##STR2## wafer ##STR3## wafer__________________________________________________________________________Example800 620± 30 No change 625± 35 No change 627± 42 No change1 observed observed observed825 240± 10 " 238± 8 " 244± 8 "850 82± 5 " 82± 3 " 83± 3 "900 19± 1 " 19± 1 " 19± 1 "Example750 1820±100 No change 1800± 80 No change 1910± 80 No change2 observed observed observed800 185± 8 " 190± 4 " 190± 7 "850 73± 4 " 75± 3 " 75± 4 "Example700 4500±500 No change 4300±200 No change 4700±500 No change3 observed observed observed750 1720± 20 " 1750± 20 " 1750± 50 "800 152± 3 " 160± 5 " 161± 5 "Example825 220± 8 No change 220± 6 No change 224± 6 No change4 observed observed observedExample800 188± 6 No change 190± 5 No change 190± 6 No change5 observed observed observedExample800 182± 4 No change 180± 5 No change 183± 5 No change6 observed observed observedExample800 190± 2 No change 190± 5 No change 191± 5 No change7 observed observed observed800 230± 3 " 280± 20 " 340±100 "__________________________________________________________________________
EXAMPLE 8
10 grams of silica powder and 10 grams of silica fiber (having a mean diameter of 9μ and a mean fiber length of 5 mm) were added to 295 grams of solid powder of the crystaline compound having the molar ratio P 2 O 5 /Ce 2 O 3 of about 5/1, prepared in Example 1 and they are mixed together. The mixture was hot-pressed by the same method as in Example 1 at 800° C. under a pressure of 50 kg/cm 2 for 10 minutes, by which a molding having a porosity of 23% was obtained. The molding was sliced into wafers 1 mm thick and 50 mm in diameter. The diffusion ability of the wafer was tested using the same conditions and method as those employed in Example 2. The sheet resistance was excellent which was substantially equal to that obtained in Example 2. Further, the wafer was not broken when heated rapidly to 800° C. and cooled rapidly to room temperature, so that the wafer was excellent in thermal shock resistance, too. Moreover, even after predeposition at 800° C. for 30 minutes was repeated 300 times, the sheet resistance exhibited substantially the same value as early ones.
While the invention has been described herein with reference to certain preferred embodiments, it is to be understood that various changes and modifications may be made by those skilled in the art without departing from the concept of the invention, the scope of which is to be determined by reference to the appended claims. | Disclosed is a solid diffusion source for the phosphorus doping of semiconductors, which comprises a substance composed of at least one kind of compound R 2 O 3 selected from the group consisting of Y 2 O 3 , La 2 O 3 and Ce 2 O 3 and P 2 O 5 and containing mainly a compound with a chemical formula R 2 O 3 .5P 2 O 5 . | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for chemical vapor deposition (CVD) of a superconductive oxide, more specifically a process for CVD of a superconductive oxide of (a rare earth metal or a metal of the VA group of the periodic table)-(alkali earth metal)-(copper)-(oxide) system on a substrate.
2. Description of the Related Art
The speed of computers has been remarkably increased, and a multiplication of processors, increase of the switching speed of devices, and a high density packaging of such devices for shortening the length of wiring are carried out to cope with this increase of the speed of computers. A high density wiring or interconnection necessitates fine wiring or interconnection patterns, which decreases the sectional areas of conductors used for the wiring or interconnection but increases the electrical resistance of the wiring or interconnection. This lowers the speed of an electrical signal transmission and distorts the wave-shape thereof.
If a superconductive material can be used as a material for wiring instead of a normal conductor such as copper, the above-mentioned problems will be quickly solved, and if a Josephson element and the like are formed with a superconductive material and integrated, the high speed and low electric power consumption thereof, in combination with a fine packaging art, will allow the realization of a super high speed computer system.
Conventional superconductive materials need a low temperature for transition to a superconductive state and, therefore, must be cooled by liquid helium or liquid hydrogen. Since these cooling mediums are difficult to handle and are expensive, it is practically difficult to use these superconductive materials.
Nevertheless, high temperature superconductive materials, represented by Y-Ba-Cu-O system oxide or ceramics, have been recently developed, and this has opened up new possibilities in the utilization of superconductive materials.
Since oxide superconductors exhibit a superconducting behavior at a relatively high temperature, i.e., higher than the boiling point of liquid nitrogen (77K), oxide superconductors can be widely utilized in, for example, semiconductor devices such as IC's, as parts of various devices, and as wiring in devices a strong demand has arisen for such superconductors. To satisfy this demand, it is necessary to efficiently form a high quality thin film. For example, a semiconductor integrated circuit is composed completely of thin film elements, including a Josephson element, and as a result, the characteristics of a thin film, which depend on the crystallinity thereof, such as crystal size and crystal orientation of the thin film, and the uniformity and reproducibility of the thin film, are important factors determining the yield and reliability of elements and an integrated circuit.
Conventional methods of forming a thin film of a semiconductor material include sputtering and evaporation. In the sputtering process, a target having a composition similar to that of a material to be deposited is used and is vaporized by ion sputtering to be deposited on a substrate. In the evaporation process, a material (source) for forming a thin film is heated until evaporation occurs and is deposited on a substrate.
These conventional thin film forming methods may be applied to a high temperature superconductive material but it is difficult to provide a good crystallinity thin film, particularly a single crystalline thin film, thereby. The sputtering method is suitable for forming a thin film of a single element (Si or a metal) or a simple compound which is not easily decomposed (SiO 2 , Al 2 O 3 , etc.), but is difficult to form a thin film of a complex compound by sputtering, since such a compound is decomposed by the sputtering, and thus control of a composition is very difficult. In the evaporation process, if a compound composed of multi-elements is used, it is difficult to form a film having a uniform composition, since an element which is easily evaporated is first evaporated and a material which is not easily evaporated remains. Particularly, it is difficult to evaporate a compound such as an oxide and deposit it in a uniform manner. In this regard, a method has been proposed of depositing a film of metals having a ratio between the metals required for a desired metal oxide, followed by oxidizing the metal film. In this method, however, the volume of the film is changed by oxidation, which causes roughness of the surface of the film, peeling of the film, or a nonuniform film quality, and it is difficult to obtain a dense film thereby.
In either the sputtering or the evaporation process, it is difficult to form a single crystalline film having a complex composition, since a deposition of discrete metals, alloy and metal oxides or compounds on a substrate occurs. For example, as seen in FIG. 1, when a superconductive oxide of the Y-Ba-Cu-O system mentioned above is formed, discrete metals such as Y, Ba and Cu, various discrete oxides or compounds such as Y 2 O 3 , BaO 2 , Y-Ba-O, CuO, Cu 2 O, Y-Cu-O, Y-O, Ba-Cu-O and Ba-O, or alloys, are deposited on a substrate, and as a result, it is difficult to obtain a film of a compound having a desired composition or a good crystallinity, and such a film has a disadvantageously decreased current density and reduced boundary characteristics when made into a fine pattern, and the like, and thus it is not practical for application to a semiconductor integrated circuit.
SUMMARY OF THE INVENTION
The object of the invention is to provide a method of forming a thin film of a high temperature superconductive oxide having an excellent crystallinity, which is applicable to thin film devices such as a semiconductor integrated circuit, etc.
This and other objects, features, and advantages of the present invention are attained by providing a process for chemical vapor deposition of an oxide superconductive film on a substrate. In this process, the substrate is held in a reaction chamber and heated to a first temperature; a first flow of vapors of a rare earth metal, an alkali earth metal or a halide of an alkali earth metal and a halide of copper having a second temperature equal to or lower than the first temperature is introduced at a position over the substrate in the reaction chamber; a second flow of an oxygen source gas is introduced into the reaction chamber at a position over the substrate; the first and second flows being separated from each other until approaching the substrate, at which point the flows come into contact with each other, and are heated to the first temperature, and react with each other to deposit a superconductive oxide of rare earth metal-alkali earth metal-copper-oxygen system on the substrate. The typical superconductive oxide formed in the above process is represented by the formula X 1 Z 2 CuO x where X stands for at least one rare earth metal, Z stands for at least one alkali earth metal, and x has a value different to the stoichiometric value.
In accordance with the present invention, there is also provided a process for chemical vapor deposition of an oxide superconductive film on a substrate, wherein the substrate is kept in a reaction chamber and heated to a first temperature; a first flow of vapors of a halide of a group metal VA of the elemental periodic table, halides of two alkali earth metals, and a halide of copper having a second temperature lower than the first temperature is introduced to a position over to the substrate in the reaction chamber; a second flow of an oxygen source gas is introduced to a position over the substrate in the reaction chamber; the first and second flows being separated from each other until approaching the substrate, at which point the flows come in contact with each other, are heated to the first temperature, and react with each other to deposit a superconductive oxide of a group VA metal of the periodic table - an alkali earth metal - an alkali earth metal-copper-oxide system on the substrate. The typical superconductive oxide formed in this latter process is represented by the formula QZ 1 Z 2 Cu y O x , where Q stands for a metal of the V group of the periodic table, Z 1 and Z 2 stand for an alkali earth metal, y has a value of about 2 or about 1.5, x has a value different from the stoichiometric value.
In the above two chemical formulae, the ratios of metals may be deviated from that in the formulae; typically, within 10% from the formulae.
The first flow is usually produced by flowing a carrier gas such as helium or argon.
The oxygen source gas may be oxygen, air (oxygen-containing gas), water vapor, etc.
Preferably hydrogen is used, as it has an effect of accelerating the reaction for the deposition a superconductive oxide film.
The main feature of the process of the present invention is that (1) source gases or vapors of metals or metal halides and (2) an oxygen source gas are separated until approaching near to a substrate, and that a temperature of the source gases or vapors of metals or metal halides before approaching the substrate is lower than a temperature of the substrate at the point at which the source gases or vapors react with an oxygen source gas.
If the source gases or vapors of metals or metal halides and an oxygen source gas are not separated until nearing a substrate, i.e., come into contact with each other before nearing the substrate, they react with each other to form an oxide there and control of the composition of the source gases or vapors near the substrate, i.e., where a desired reaction should occur becomes impossible.
If a temperature of the source gases or vapors of metals or metal halides is higher than a temperature of the substrate, there must be a portion having a temperature lower than the temperature of the source gases or vapors before the substrate where the source gases or vapors are deposited, making it impossible to control the composition of the source gases or vapors to a desired one near the substrate.
For the same reasons as above, the source gas or vapor should not be cooled before reaching the substrate after it is evaporated from a source thereof at a required temperature, to provide a desired concentration. This is the second important feature of the process of the present invention.
The third important feature of the process of the present invention is that the appropriate temperature ranges of the various source gases or vapors of metals or metal halides, are as follows:
______________________________________Source General range Preferred range______________________________________BiCl.sub.3 150-250° C. 170-200° C.CuCl 300-500° C. 350-400° C.CuBr.sub.2 350-500° C. 400-450° C.CuI 400-600° C. 450-550° C.YCl.sub.3 650-750° C. 675-725° C.CaI.sub.2 700-900° C. 750-850° C.SrI.sub.2 750-950° C. 775-850° C.BaI.sub.2 850-1050° C. 900-1000° C.BaCl.sub.2 950-1100° C. 1000-1050° C.MgCl.sub.2 700-850° C. 750-800° C.Ba 600-800° C. 650-750° C.______________________________________
According to the process of the present invention, a film of a single crystalline high Tc (transition temperature) superconductive oxide can be obtained, whereby a film of a high Tc superconductive oxide having an excellent film quality, film uniformity and reproducibility, due to a high crystallinity such as crystal size and crystal orientation, can be deposited, and a result, by applying such a high quality superconductive oxide film to IC's, to various parts of devices, and to wiring, the yield and reliability thereof can be increased.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically illustrates the deposition of a Y-Ba-Cu-O system film by sputtering;
FIG. 2 is a sectional view of an apparatus for CVD;
FIG. 3 is an X-ray diffraction pattern of a YBa 2 Cu 3 O 7-x film formed in Example 1;
FIG. 4 is a photograph of the electron diffraction pattern of film shown in FIG. 3;
FIG. 4 schematically illustrates the determination of an electrical resistance of a film;
FIG. 5 is a an graph of an electrical resistance of the film formed in Example 1, with respect to temperature;
FIG. 6 schematically illustrates the deposition of a Y-Ba-Cu-O system film deposited by CVD;
FIG. 7 is a sectional view of another CVD apparatus;
FIG. 8 is a photograph of the electron diffraction pattern of the film shown in FIG. 6;
FIG. 9 is an X-ray diffraction pattern of the BiSrCaCuO x film formed in Example 6;
FIG. 10 is a graph of an electrical resistance of the film shown in FIG. 9, with respect to temperature; and,
FIGS. 11 and 12 are CVD apparatuses which may be used in the process of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is described below with reference to the drawings.
EXAMPLE 1
FIG. 2 illustrates an apparatus for CVD used to obtain this example. In FIG. 2, a cylindrical reaction tube 1 is made of quartz and is heat resistant. The reaction tube 1 is surrounded by four resistance heaters 2a-2d, which generate heat by passing an electrical current therethrough to heat respective portions of the reaction tube 1. In the reaction tube 1, a source chamber 3 is arranged in which three source boats 4a-4c are placed. The source boats 4a-4c contain BaCl 2 , YCl 3 , and CuCl, respectively, and release BaCl 2 gas, YCl 3 gas, and CuCl gas, respectively, when heated by the heaters 2b-2d.
The source chamber 3 has a small-diameter gas inlet port 3a at one end of the chamber 3, through which helium gas as a carrier gas is introduced. The other end of the source chamber 3 is open, and a substrate supporter 5 is placed near that other end at a predetermined distance therefrom. The substrate supporter 5 is made of quartz or ceramics, and substrates 6 on which a superconductive oxide is to be deposited are mounted on the substrate supporter 5. The reaction tube 1 also has a small diameter gas inlet port 1a at one end of the reaction tube 1, through which helium gas as a carrier gas, as well as carbon dioxide gas and hydrogen gas serving as a reducing agent, are introduced into the reaction chamber 1. The reaction chamber 1 has an outlet port 1b at the other end thereof for evacuating the gas in the reaction tube 1.
In the operation to obtain this example, first, substrates 6 are mounted on the supporter 5 and BaCl 2 , YCl 3 , and CuCl are placed in the source boats 4a to 4c, respectively. Then, the reaction tube 1 is heated by the resistance heaters 2a to 2d to release BaCl 2 gas, YCl 3 gas, and CuCl gas while a carrier gas (He) is introduced through the gas inlet port 3a into the source chamber 3 to carry the released gases over the substrates 6. Also, a carrier gas (He) as well as CO 2 and H 2 gases are introduced through the gas inlet port 1a into the reaction tube 1 outside the source chamber 3 and passed over the substrates 6 while the substrates 6 are heated by the resistance heater 2a, and as a result, oxidation and reduction reactions occur over or near the substrates and a high temperature superconductive oxide film of YBa 2 Cu 3 O 7-x is deposited on the substrates 6 by the following chemical reaction.
YCl.sub.3 +2BaCl.sub.2 +3CuCl+7CO.sub.2 +5H.sub.2 →YBa.sub.2 Cu.sub.3 O.sub.7-x +7CO+10HCl
The particular conditions for deposition are as follows.
Temperature of substrates (T sub ): 950°-1200° C.
Temperature of BaCl 2 (T Ba ): 950°-1100° C.
Temperature of YCl 3 (T y ): 650°-750° C.
Temperature of CuCl (T Cu ): 300°-500° C.
CO 2 concentration: 0.01-10% of He concentration
H 2 concentration: 0.01-10% of He concentration
Flow rate of He carrying CO 2 and H 2 : 5-20 l/min
Flow rate of He carrying BaCl 2 , etc.: 5-20 l/min
Pressure: 760 mmHg
Substrate: (1102) sapphire, (100)MgO, (100)SrTiO 3 , (100)MgO.Al 2 O 3 , and MgO on MgO.Al 2 O 3 on Si
Thickness of deposited film: 0.2-5 μm
In this operation, the heating temperatures of the CuCl, YCl 3 , BaCl 2 and the substrates are selected such that these temperatures increase from T Cu to T y to T Ba to T sub . Namely, the arrangement of CuCl, YCl 3 , and BaCl 2 in the source boats 4c to 4a should be such that the heating temperatures of the heaters 4a to 4c are increased from 4c to 4b to 4a, in that order.
The obtained YBa 2 Cu 3 O 7-x film is annealed in an oxygen atmosphere in the reaction tube 1 with the heater 2a maintained at 850° C. for 8 hours, and then gradually cooled. FIG. 3 shows an X-ray diffraction pattern of the thus-obtained film on a (100)MgO substrate with Cu, Kα ray. This pattern clearly demonstrates a formation of (001)YBa 2 Cu 3 O 7-x on (100)MgO.
Next, as shown in FIG. 4, the substrate 6 on which the YBa 2 Cu 3 O 7-x film 7 is formed is cut into pieces measuring 5 mm×10 mm, after annealing.
Four probes 8 are formed by silver paste on this film 7, and wirings 9a to 9d with a constant electric current source 10 and a voltage meter 11 are connected to the probes 8.
The electrical resistance of the film 7 is then determined with respect to the temperature, and as shown in FIG. 5 the electrical resistance rapidly decreases at about 90K and reaches a zero electrical resistance at about 87K, demonstrating the existence of a superconductive state. The conditions of forming this film are T sub =1000° C., T Ba =1000° C., T y =670° C., and T Cu =350° C. The superconductive behavior was also confirmed for other films formed under other conditions.
Accordingly, an excellent single crystalline high temperature superconductive oxide film can be easily formed in accordance with the present invention.
FIG. 6 schematically illustrates the process of this deposition, wherein gases of YCl 3 , CuCl, HCl, BaCl 2 , H 2 , CO, CO 2 , etc., chemically react with each often over the substrate to uniformly deposit a film of a compound of a Y-Ba-Cu-O system on the substrate.
EXAMPLE 2
In this example, O 2 and H 2 are used as the oxidizing and reducing agents instead of the CO 2 and H 2 used in Example 1. The operation of forming a superconductive oxide film is carried out in the same way as in Example 1, except that the following conditions prevail.
T sub : 900° C.
T Ba : 900° C.
T y : 630° C.
T Cu : 320° C.
O 2 concentration: 0-30% of He
Bubbling temperature: 20° C.
Substrate: (1102)sapphire, (100)MgO, (100)SrTiO 3 , (100)MgO.Al 2 O 3 , and MgO on MgO.Al 2 O 3 on Si
Flow rate of He carrying O 2 and H 2 O: 15 l/min
Flow rate of He carrying BaCl 2 etc.: 15 l/min
Thickness of deposited film: 0.2-5 μm
After the deposition of a Y-Ba-Cu-O system film, the film is annealed in an oxygen atmosphere as in Example 1, and as a result, a single crystalline film of YBa 2 Cu 3 O 7-x exhibiting superconductive behavior was obtained.
Note that the CO 2 and H 2 used as oxdizing and reducing agents in Example 1 must be selected with great care and the conditions of the operation must be strictly controlled, since O 2 has a weak oxidizing effect and H 2 has a strong reducing effect, and thus the deposited film can be reduced from an oxide to a metal. In comparison with this, the use of O 2 and H 2 permits a less careful selection and easier control of the conditions of operation.
EXAMPLE 3
The deposition of a YBa 2 Cu 3 O 7-x film was carried out as in Examples 1 and 2, but BaBr 2 or BaI 2 was used instead of BaCl 2 , YF 3 or YBr 3 instead of YCl 3 , and CuF, CuF 2 , CuCl 2 , CuBr, CuBr 2 or CuI instead of CuCl.
The resultant films also proved to be excellent single crystalline superconductive oxide films.
EXAMPLE 4
The deposition of a YBa 2 Cu 3 O 7-x film was carried out as in Example 2, but Ba was used instead of BaCl 2 . The conditions of operation were as follows:
T sub : 900° C.
Temperature of Ba (T Ba ): 700° C.
T y : 630° C.
T Cu : 320° C.
Flow rate of He carrying Ba etc.: 15 l/min
O 2 concentration: 0-30% of He
Bubbling temperature: 0°-100° C.
Flow rate of He carrying O 2 and H 2 : 15 l/min
Substrate: (1102)sapphire, (100)MgO, (100)SrTiO 3 , (100)MgO.Al 2 O 3 , and MgO on MgO.Al 2 O 3 on Si
Thickness of deposited film: 0.2-5 μm
After the deposited film was annealed in an oxygen atmosphere, a single crystalline YBa 2 Cu 3 O 7-x film exhibiting superconductive behavior was obtained.
EXAMPLE 5
Using the same procedures as in the above Examples, a film of a compound having a composition of LnBa 2 Cu 3 O 7-x where Ln is a lanthanide element was deposited on a substrate by using a halide of a lanthanide element instead of a halide of yttrium. The lanthanide element included Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, and Yb. Two or more lanthanide elements could be used in combination. The halide of the lanthanide element includes the chloride, bromide, and iodide of the element.
The thus obtained LnBa 2 Cu 3 O 7-x film was also a single crystalline superconductive oxide film exhibiting superconductive behavior at about 90K.
EXAMPLE 6
FIG. 7 illustrates the apparatus for CVD used in this Example for forming a film of Bi-Sr-Ca-Cu-O system superconductive oxide.
The structure of this apparatus is very similar to that of the apparatus in FIG. 2 except that, in this Example, four source boats and five resistance heaters are used.
In FIG. 7, reference numeral 21 denotes a reaction tube, 21a a gas inlet port, 21b a gas outlet port, 22a to 22e resistance heaters, 23 a source chamber, 23a a gas inlet port, 24a to 24d source boats, 25 a substrate supporter, and 26 substrates.
SrI 2 , CaI 2 , CuI and BiCl 3 were placed in the source boats 24a to 24d, respectively, and a carrier gas of He was introduced through the gas inlet port 23a into the source chamber 23. The substrates 26 were of (100)MgO. Through the gas inlet port 21a, another carrier gas of He in combination with O 2 and H 2 as the oxidizing and reducing agents was introduced into the reaction tube 21 outside the source chamber 23. The reaction gas was evacuated from the outlet port 21b.
The conditions of operation used for depositing a BiSrCaCuO x on a substrate were as follows:
Temperature of substrates (T sub ): 750°-950° C.
Temperature of SrI 2 source (T Sr ): 750°-950° C.
Temperature of CaI 2 source (T Ca ): 700°-900° C.
Temperature of CuI source (T Cu ): 400°-600° C.
Temperature of BiCl 3 source (T Bi ): 150°-250° C.
Flow rate of He carrying BiCl 3 etc: 10-20 l/min
Flow rate of He carrying O 2 and H 2 : 10-20 l/min
Flow rate of O 2 gas: 10-5000 cc/min
Bubbling temperature of H 2 O: 23° C.
Flow rate of He bubbling gas: 10-1000 cc/min
Deposition rate: 3-30 nm/min
Thickness of deposited film: 0.1-10 μm
Oxygen annealing temperature: 400°-850° C.
Oxygen annealing time: 30-60 minutes
Substrate: (1102)sapphire, (100)MgO, (100)SrTiO 3 , (100)MgO.Al 2 O 3 , and MgO on MgO.Al 2 O 3 on Si
FIG. 8 is a photograph of the transmission electron diffraction pattern of (100)BiSrCaCuOx on (100)MgO, which clearly demonstrates that the BiSrCaCuOx film definitely has a single crystalline form. This film was obtained under the conditions of T sub =825° C., T Bi =170° C., T Sr =825° C., T Cu =450° C., and T ca =800° C.
FIG. 9 shows an X ray diffraction pattern obtained from a film deposited according to the above operation, with CuKα ray. In FIG. 9, in addition to the diffraction peaks of (100)MgO, diffraction peaks (008), (0010) and (0012), which stem from particular diffraction planes oriented to (100) of MgO were observed, and thus the formation of a single crystal of BiSrCaCuO x was confirmed. The particular conditions of operation for this film of FIG. 8 were;
T sub =825° C., T Bi =170° C., T sr =825° C., T Ca =800° C., T Cu =450° C.
The electrical resistance of the film obtained above was determined with respect to the temperature, in the same manner as described before with reference to FIG. 4. The result is shown in FIG. 10, in which the electrical resistance rapidly decreases at about 90K and reaches a zero electrical resistance at about 77K, thus exhibiting a superconductive state.
EXAMPLE 7
In the same way as in Example 6, other QZ 1 Z 2 CuO x films were deposited, where Q stands for a group VA metal of the periodic table, and Z 1 and Z 2 stand for a alkali earth metal. The group VA metal may be Sb or Bi and the alkali earth metal may be Ba, Mg, Be, etc. The obtained QZ 1 Z 2 CuO x films were single crystalline and exhibited superconductive behavior.
Note that a high temperature superconductive film of BiSrCaCuO x can be deposited at about 800° C., which is about 100°-200° C. lower than that for a film of YBa 2 Cu 3 O 7-x , and as a result, during the deposition of a BiSrCaCuO x film, a mutual reaction between the substrate and the deposited film is prevented, giving a superconductive film having an abrupt interface. This advantageously enhances the performance of elements for which the interface characteristics thereof are important, such as a Josephson element and a superconductive transistor, etc.
Although only one source chamber 3 or 23 was used in the apparatus for CVD in FIG. 2 and 7, a plurality of source chambers may be used for each source, for example, as shown in FIG. 11.
The CVD apparatus shown in FIG. 11 is the same as that in FIG. 2 except that three source chambers 3--1 to 3--3 are provided in which sources 4a to 4c are arranged, respectively. In this apparatus in FIG. 11, the temperature control of the three sources 4a to 4c is similar to that for the apparatus of FIG. 2, but the flow rates of the respective source gases can be separately controlled, which allows a more precise control of the amount or flow rate of sources gases.
FIG. 12 schematically illustrates another CVD apparatus which may be used for the process of the present invention. In this apparatus, source gases are separately formed and fed to a reactor 31. The source feeding lines 34a to 34c are separated and separately heated, so that each source gas can be fed to the reactor 31 at a desired temperature and a desired flow rate. In this configuration, the temperature of a source gas can be selected regardless of the temperatures of the other source gases. | A thin film of a high temperature superconductive oxide of rare earth metal-alkali earth metal-copper-oxygen system or group VA metal-alkali earth metal-copper-oxygen system, which has an excellent crystallinity, particularly a single crystalline structure, is formed on a substrate by a CVD method, in which halides of the metals and an oxygen source gas are separately flowed over a substrate and caused to react with each other over the substrate, to deposit a desired superconducting oxide film. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of U.S. patent application Ser. No. 14/091,398, filed on Nov. 27, 2013.
FIELD OF THE INVENTION
[0002] The invention relates generally to mixing valves, and more particularly to a venturi mixing valve assembly that precisely and adjustably mixes two fluids.
BACKGROUND OF THE INVENTION
[0003] Diesel engines configured for bi-fuel operation utilize an air and natural gas mixture along with diesel fuel. The advantages associated with bi-fuel operation include reduced diesel fuel consumption and reduced noxious emissions.
[0004] Conversion of a conventional diesel engine for bi-fuel operation is readily and typically accomplished by coupling a natural gas supply line to diesel engine's air intake line. To control the amount of natural gas introduced into the air intake, some type of conventional valve is disposed in the gas supply line. While a simple valve is preferred for robustness and cost, these valves do not typically offer the kind of precise adjustability required for efficient bi-fuel operation at a variety of diesel engine speeds.
SUMMARY OF THE INVENTION
[0005] Accordingly, it is an object of the present invention to provide a mixing valve for use in controlling an air and natural gas mixture provided to a bi-fuel diesel engine.
[0006] Another object of the present invention is to provide a mixing valve that allows for precise adjustment of the amount of natural gas introduced into an air and natural gas mixture being provided to a bi-fuel diesel engine.
[0007] Other objects and advantages of the present invention will become more obvious hereinafter in the specification and drawings.
[0008] In accordance with the present invention, a method of mixing two fluids uses an open-ended first tubular section having a sleeve defined therein wherein a flow path is defined through the sleeve and an annular channel open on one end thereof is defined between the sleeve and an inner surface of the first tubular section. Also included is an open-ended second tubular section defining an annular region with a plurality of holes and a venturi region coupled to the annular region. The annular region circumscribes at least a portion of the sleeve of the first tubular section and is sealed to the sleeve. An open-ended third tubular section is sealed to an outer surface of the first tubular section and to an outer surface of the second tubular section such that (i) the annular channel is enclosed, (ii) an axial relationship between the first tubular section and second tubular section is defined by the third tubular section, and (iii) at least a portion of the holes define a fluid path between the annular channel and the flow path through the first tubular section. A first fluid is introduced into the annular channel, and a flow of a second fluid is introduced along the flow path through the first tubular section. As a result, the first fluid is drawn into the flow of the second fluid via the portion of the holes defining the fluid path.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Other objects, features and advantages of the present invention will become apparent upon reference to the following description of the preferred embodiments and to the drawings, wherein corresponding reference characters indicate corresponding parts throughout the several views of the drawings and wherein:
[0010] FIG. 1 is an exploded side view of an adjustable venturi mixing valve assembly in accordance with an embodiment of the present invention;
[0011] FIG. 2 is an isolated cross-sectional view of the air and natural gas intake portion of the valve assembly taken along line 2 - 2 in FIG. 1 ;
[0012] FIG. 3 is an isolated perspective view of the valve assembly's adjustment ring;
[0013] FIG. 4 is an isolated perspective view of the venturi portion of the valve assembly;
[0014] FIG. 5 is an isolated cross-sectional view of the venturi portion of the valve assembly;
[0015] FIG. 6 is a cross-sectional view of the valve assembly in its assembled configuration with the adjustment ring thereof positioned for the introduction of a gas at the venturi portion of the valve assembly;
[0016] FIG. 7 is perspective view of a locking bar that can be used to fix the position of the adjustment ring in accordance with another embodiment of the present invention; and
[0017] FIG. 8 is a plan view of the valve assembly with the locking bar coupled thereto.
DETAILED DESCRIPTION OF THE INVENTION
[0018] Referring now to the drawings, simultaneous reference will be made to FIGS. 1-6 in order to explain the structure and advantages of the adjustable venturi mixing valve assembly in accordance with an embodiment of the present invention. By way of example, the valve assembly will be explained for its use in a diesel engine configured for bi-fuel operation. However, it is to be understood that the valve assembly could be used in any fluid mixing situation where two diverse fluids/gases need to be mixed together precisely and in adjustable concentrations.
[0019] The entirety of the valve assembly of the present invention will be referenced generally by the numeral 100 . Valve assembly 100 is an open-ended, flow through valve that includes three open-ended tubular sections, i.e., an intake portion 10 , an adjustment ring 30 , and a venturi portion 50 . For purposes of this description, intake portion 10 serves as an air and natural gas intake when valve assembly 100 is incorporated into a bi-fuel diesel engine as will be explained later below with reference to FIG. 6 .
[0020] Intake portion 10 has an open outboard end 12 that receives a flow of air indicated by arrow 200 in FIG. 1 , and has an open inboard end 14 that will be threadably coupled to one side of adjustment ring 30 . A natural gas supply line (not shown) is coupled to a natural gas inlet 16 formed in an outer wall 18 of intake portion 10 . The shape, size and/or configuration of inlet 16 is not a limitation of the present invention. Inlet 16 is in fluid communication with an open-end annular channel 20 ( FIG. 2 ) defined within intake portion 10 . More specifically, annular channel 20 is defined between an inner surface 18 A of outer wall 18 and an inner cylindrical sleeve 22 concentrically defined within outer wall 18 . Opposite its open end, sleeve 22 terminates in an annular flange 22 A sealed to or integrated with inside surface 18 A of outer wall 18 . An annular slot 23 can be provided in the outer surface of sleeve 22 to receive an o-ring seal (not shown) for reasons that will be explained later herein.
[0021] Outer wall 18 is threaded on its outside surface (as indicated by reference numeral 24 ) at inboard end 14 . An o-ring seal 26 is provided at the outside surface of outer wall 18 for sealing engagement with an inside surface of adjustment ring 30 as will be explained later below. O-ring seal 26 can rest in an annular slot 28 (shown in FIG. 2 ) defined in outer wall 18 .
[0022] Adjustment ring 30 is an open-ended tubular ring having an outer surface 32 that can be partially (as shown) or completely knurled to facilitate the gripping thereof. Other surface finishes or devices could be coupled to outer surface 32 to facilitate the gripping thereof without departing from the scope of the present invention. Outer surface 32 can also include indicia and/or indexing mark(s) 34 for alignment with indexing mark(s) and/or indicia (not shown) on one or both of the outer surfaces of intake portion 10 and venturi portion 50 . Such indicia and/or indexing mark(s) can be calibrated to indicate the concentration of natural gas being supplied into air flow 200 based on the relative position of adjustment ring 30 .
[0023] The inner surface 36 of adjustment ring 30 ( FIG. 3 ) defines two spaced-apart and independent threaded regions 38 and 40 sandwiched by two smooth annular regions 42 and 44 . Threaded regions 38 and 40 define threads that oppose one another, i.e., one is right hand threaded and the other is left hand threaded. Threaded region 38 is designed to threadably cooperate with threads 24 on intake portion 10 . Threaded region 40 is designed to threadably cooperate with threads 66 on venturi portion 50 . Smooth annular regions 42 and 44 are designed to form a sliding seal fit with o-ring seals 26 and 68 , respectively, when valve assembly 100 is fully assembled.
[0024] For reasons that will be explained further below, one end (or both ends) of adjustment ring 30 can be provided with through holes 46 . Each hole 46 extends from an end of adjustment ring 30 to outer surface 32 . A line (not shown) such as a wire, a wire tie, a strap, etc., can be fed through hole(s) 46 and “tied” to a nearby stationary fixture to lock adjustment ring 30 in a desired position. However and as will be explained later below, the locking of adjustment ring 30 can be accomplished in other ways without departing from the scope of the present invention.
[0025] For the illustrated example, venturi portion 50 serves as an air and natural gas mixer. Venturi portion 50 includes an open outboard end 52 and an open inboard end 54 that serves as both the inlet for air flow 200 and the inlet for a flow 202 ( FIG. 6 ) of natural gas. More specifically, inboard end 54 is the end of an annular sleeve region 56 that defines a plurality of through holes 58 (e.g., circular holes as shown, slots, etc.) distributed around region 56 . The size, shape, and number of holes 58 are not limitations of the present invention. The interior of region 56 is sized to circumscribe cylindrical sleeve 22 and form a sliding but sealed fit therewith, e.g., via an o-ring 25 fitted in annular slot 23 ( FIG. 2 ) when valve assembly 100 is assembled as shown in FIG. 6 . The interior of region 56 terminates in an annular ledge 60 sized in correspondence with the open end of sleeve 22 such that ledge 60 serves as a travel stop. At least a portion of the interior portion of venturi region 50 between ledge 60 and outboard end 52 is shaped to define a venturi 62 that is readily seen in FIGS. 5 and 6 . The particular features of venturi 62 (e.g., its length, diameter, angular taper, etc.) are not limitations of the present invention.
[0026] In the illustrated embodiment, venturi 62 terminates in and is integrated with an inside surface 63 of the outer wall 64 of venturi portion 50 . Outer wall 64 is threaded on its outside surface as indicated by reference numeral 66 . An o-ring seal 68 is provided at the outside surface of outer wall 64 for sealing engagement with smooth annular region 44 of adjustment ring 30 ( FIG. 6 ). O-ring seal 68 can rest in an annular slot 69 (visible in FIG. 5 ) defined in outer wall 64 .
[0027] In use, valve assembly 100 is assembled as shown in FIG. 6 . For the illustrated embodiment, an air supply 300 is coupled/sealed to outboard end 12 , a natural gas supply 302 is coupled/sealed to inlet 16 , and outboard end 52 is coupled/sealed to an engine manifold 304 of a bi-fuel diesel engine. Each such coupling/sealing can be accomplished in a variety of ways without departing from the scope of the present invention. Valve assembly 100 allows the natural gas in supply 302 to be maintained at zero pressure as air flow 200 pulls natural gas from annular channel 20 (through any of exposed holes 58 ) into venturi 62 .
[0028] With valve assembly 100 so installed and assembled, adjustment ring 30 can be rotated to adjust the amount of natural gas drawn into the air and natural gas mixture. More specifically, intake portion 10 and venturi portion 50 are fixed in terms of any rotational movement about their longitudinal axes, while an opposing thread operation is defined between threads 24 /threaded region 38 and threads 66 /threaded region 40 (i.e., one is threaded for left handed operation and the other is threaded for right hand operation). Accordingly, rotation of ring 30 in one direction draws intake portion 10 and venturi portion 50 axially towards one another, while rotation of ring 30 in the opposite direction causes intake portion 10 and venturi portion 50 to move axially away from one another. Note that the amount of axial movement is relatively small and can generally be supported by the mechanical arrangement of air supply 300 and gas supply 302 . Ring 30 is sized/configured such that o-ring seals 26 and 68 remain sealingly engaged with smooth annular regions 42 and 44 , respectively, at all rotational positions of ring 30 . Ring 30 is sized/configured to control the operating range of valve assembly 100 . That is, ring 30 is configured to provide for axial movement of intake portion 10 and venturi portion 50 that, in turn, provides a range of exposure of holes 58 to annular channel 20 . The range of exposure could extend from the complete exposure of all holes 58 to the complete closure of all holes 58 to annular channel 20 (e.g., when ledge 60 abuts the open end of sleeve 22 ). The total number of completely (and/or partially) exposed holes 58 defines a total flow area in fluid communication with air flow 200 moving through intake portion 10 .
[0029] By way of example, FIG. 6 illustrates valve assembly 100 with ring 30 positioned such that some of holes 58 are exposed to annular channel 20 . As long as some of (or portions of) holes 58 are exposed to annular channel 20 , natural gas 202 is drawn into channel 20 and through the exposed portions of holes 58 , and then into venturi 62 as air flow 200 moves through venturi 62 . That is, the increase in velocity and pressure drop associated with movement through venturi 62 will draw natural gas 202 through exposed one of holes 58 . Accordingly, natural gas 202 can be maintained at zero pressure. The concentration of natural gas 202 is precisely and readily adjusted by simply rotating ring 30 to thereby expose more/less of holes 58 . The resulting precise mixture of air and gas flows through venturi 62 to outlet 52 for admittance to engine manifold 304 .
[0030] As mentioned above, a variety of devices/mechanisms could be employed to lock adjustment ring 30 in place to thereby maintain a desired air/gas mixture. For example and as shown in FIGS. 7 and 8 , the locking of adjustment ring 30 can be accomplished with a locking bar 70 that attaches to intake portion 10 and venturi portion 50 . More specifically, locking bar 70 is a rigid bar that defines a channel 72 that fits over ring 30 . The length of channel 72 allows for axial travel of ring 30 during the rotation thereof on portions 10 and 50 . Locking bar 70 has two holes 74 that receive screws/bolts 76 for threaded coupling to mating holes (not shown) in venturi portion 50 . A slotted hole 80 receives a screw/bolt 82 for threaded coupling to a mating hole (not shown) in intake portion 10 . During adjustment/rotation of ring 30 , channel 72 provides for axial travel of ring 30 . Once the desired rotational position of ring 30 (i.e., indicative of a desired mixture of air and gas) is achieved, a clamping screw/bolt 86 passing through a threaded hole 84 in locking bar 70 is tightened such that the end of screw/bolt 86 bears against ring 30 to lock it in place.
[0031] The advantages of the present invention are numerous. The mixing valve assembly provides a simple and precise approach to mixing two gases. Since there is no air or gas pressure on the adjustment ring, precise adjustments in gas concentrations are readily achieved.
[0032] Although the invention has been described relative to specific embodiments thereof, there are numerous variations and modifications that will be readily apparent to those skilled in the art in light of the above teachings. It is therefore to be understood that the invention may be practiced other than as specifically described.
[0033] What is claimed as new and desired to be secured by Letters Patent of the United States is: | A method of mixing two fluids uses three open-ended tubular sections assembled to define a mixing valve. An axial relationship between two of the tubular sections is defined by the third tubular section. A first fluid is introduced into an annular channel defined by the tubular sections. A flow of a second fluid is introduced along a flow path through the tubular sections. The first fluid is drawn into the flow of the second fluid via holes linking the annular channel to the flow path. | 5 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 60/579,369 filed Jun. 14, 2004, assigned to the assignee of this application and incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates to hearing aid testing systems. More particularly, the present invention relates to administering a hearing-aid test on a low-cost, standardized device such as a compact disk (CD) or videotape that is playable on a standard CD/VHS player. The CD/videotape is programmed with a set of tests including frequencies at various amplitudes on different tracks. Each track has verbal instructions that guide the person being tested (the user) to other preprogrammed tracks based upon the user's hearing response to the current track. In so doing, the user ends up in a unique track that then guides him or her to take a related action based upon the test results, for instance, to seek a further test.
BACKGROUND OF THE INVENTION
[0003] More than 25 million Americans have hearing loss, including one out of four people older than 65. Hearing loss may come from infections, strokes, head injuries, some medicines, tumors, other medical problems, or even excessive earwax. It can also result from repeated exposure to very loud noise, such as music, power tools, or jet engines. Changes in the way the ear works as a person ages can also affect hearing.
[0004] For most people who have a hearing loss, there are ways to correct or compensate for the problem. If an individual has trouble hearing, that individual can visit a doctor or hearing health care professional to find out if he or she has a hearing loss and, if so, to determine a remedy. The U.S. Food and Drug Administration (FDA) and similar governing bodies in other countries have rules to ensure that treatments for hearing loss—medicines, hearing aids, and other medical devices—are tried and tested.
[0005] However, most people do not even know that they have a hearing loss. Typical indications that an individual has hearing loss include: (1) shouting when talking to others, (2) needing the TV or radio turned up louder than other people do, (3) often having to ask people to repeat what they say because the individual cannot quite hear them, especially in groups or when there is background noise, (4) not being able to hear a noise when not facing the direction it is coming from, (5) seeming to hear better out of one ear than the other, (6) having to strain to hear, (7) hearing a persistent hissing or ringing background noise, and (8) not being able to hear a dripping faucet or the high notes of a violin. If an individual experiences one of more of the above indications, the individual should see his or her doctor or hearing health care professional for further testing for potential hearing loss.
[0006] To find out what kind of hearing loss the individual has and whether all the parts of the individual's ear are functioning, the person's doctor may want him or her to take a hearing test. A health care professional that specializes in hearing, such as an audiologist, often gives these tests. Audiologists are usually not medical doctors, but they are trained to give hearing tests and interpret the results. Hearing tests are painless.
[0007] If the hearing test shows that the individual has a hearing loss, there may be one or more ways to treat it. Possible treatments include medication, surgery, or a hearing aid. Hearing aids can usually help healing loss that involves damage to the inner ear. This type of hearing loss is common in older people as part of the aging process. However, younger people can also have hearing loss from infections or repeated exposure to loud noises.
[0008] In a well-known method of testing hearing loss in individuals, the threshold of the individual's hearing is typically measured using a calibrated sound-stimulus-producing device and calibrated headphones. The measurement of the threshold of hearing takes place in an isolated sound room, usually a room where there is very little audible ambient noise. The sound-stimulus-producing device and the calibrated headphones used in the testing are known as an audiometer.
[0009] A professional audiologist performs a professional hearing test by using the audiometer to generate pure tones at various frequencies between 125 Hz and 12,000 Hz that are representative of a variety of frequency bands. These tones are transmitted through the headphones of the audiometer to the individual being tested. The intensity or volume of the pure tones is varied until the individual can just barely detect the presence of the tone. For each pure tone, the intensity at which the individual can just barely detect the presence of the tone is known as the individual's air conduction threshold of hearing. Although the threshold of hearing is only one element among several that characterizes an individual's hearing loss, it is the predominant measure traditionally used to acoustically fit a hearing compensation device.
[0010] Although the professional test is complete and allows for a thorough diagnostic, most hearing-impaired individuals are not even aware that they are in need of a hearing test, even if some of the aforementioned symptoms exist. What is required is a way to recognize early onset of hearing loss without the need to visit the audiologist.
[0011] Indeed, there are some new methods for testing hearing loss, albeit at a less professional level, such as programs available on the Internet. To use such a program, a user logs onto a free hearing test Web site, adjusts his or her computer speaker volume to a supplied test frequency, and uses a mouse to click on various hyperlinks on a Web page on which the user can listen to various tones and determine how many tones he or she is able to hear. The user then is guided to instructional and “next step” pages. There are a number of problems associated with this method. First, most people that have hearing loss are older, and the Internet may truly not be accessible because of their level of use of technology. Second, many low-income families cannot afford computers to run the Internet programs. Lastly, this system does not “pull” users to the site; an individual has to know both that he or she wants to be tested and that a site like this exists (i.e., from advertisements). No business entity could afford to mass market such a site. Therefore, even though some low-cost non-professional hearing tests are available, there exists a need for an improved means for hearing tests that is more accessible, portable and can be driven in the market to reach and test more people.
[0012] Another problem with current methods for testing hearing loss is the inability to store user-specific information in a database and provide clear step-by-step guidance on the actions needed to find a solution once a hearing loss problem is detected. In the case of the Internet hearing test Web site previously described, the results of the test are not directed to another step, nor are they available to another entity, i.e., an audiologist. Therefore, an audiologist must retest the same frequencies and re-question the patient. Thus, there exists a need to streamline the testing process so that low-cost non-professional hearing tests lead to a more professional hearing test.
[0013] Another problem with both conventional non-professional hearing tests and the audiologist-administered professional hearing test is that the tests are simple frequency versus amplitude tests and do not take into account speech intelligibility issues. For example, even though an individual may have some hearing loss, he or she may be able to function quite normally, whereas others may have limitations in understanding certain spoken words. Thus, there exists a need to address some of these speech intelligibility issues.
[0014] Another problem with current testing methods is that the individual being tested has no idea at the hearing test what having a hearing aid would do to improve his or her quality of life. That is, even if the patient in either the non-professional test or the professional test recognizes hearing loss, the patient has no idea what the improvement would be if a corrective hearing aid were used. Thus, the motivation to get the problem fixed is much less than if the individual could experience the benefits of correction at the time of the test.
SUMMARY OF THE INVENTION
[0015] It is therefore an object of this invention to find a way for the mass market of individuals with potential hearing loss to recognize early onset of hearing loss without the need to visit an audiologist.
[0016] Another object of this invention is to have an improved means for testing hearing that is more accessible and can be driven in the market to reach and test more people.
[0017] Another object of this invention is to streamline the testing process so that low-cost non-professional hearing tests lead to a more professional hearing test.
[0018] Another object of this invention is to address speech intelligibility issues at some level in hearing aid tests.
[0019] Another object of this invention is to show patients what the result of having a hearing aid would do to improve their quality of life, in order to improve the patients' motivation to fix the problem.
[0020] It is another object of the present invention to provide step-by-step guidance on the next steps to be taken once a hearing loss is detected.
[0021] The present invention provides a hearing-test stored on a standard low-cost CD or other low-cost devices, such as a videotape or a DVD, that is easily mass marketed as a give-away and is easily used by the mass market. This would allow the mass market of individuals with potential hearing loss to recognize early onset of hearing loss without the need to visit the audiologist. The present invention streamlines the hearing testing process and connects low-cost non-professional hearing tests to a more professional hearing test by providing the results of the CD hearing test to the user as a code that can be quickly identified by a professional, e.g., an audiologist. This invention provides testing of speech intelligibility issues, where the tests are administered around words and based upon the specific results of the hearing test. The present invention also provides step-by-step guidance on the next steps to be taken, once the hearing test stored on the CD detects a hearing loss.
[0022] In a preferred embodiment of the present invention, a portable data storage media is provided for use in testing hearing of an individual. The media comprises a plurality of selectably accessible data storage units, e.g., tracks on a CD or DVD. A first of the units includes a hearing test query, which for example causes a frequency tone, word or sentence to be played at a speaker, and instruction data. The instruction data instructs an individual to access a predetermined second of the units in accordance with the results of the hearing test query, for example, based on whether the individual heard the tone or found the word or sentence to be intelligible. The predetermined second unit includes at least one of a hearing test query and instruction data. The instruction data on the second unit instructs the individual to access another predetermined second of the units in accordance with results of the hearing test query of the predetermined second unit, or provides for output of a hearing deficiency code whose value is associated with the predetermined second unit being accessed.
[0023] In a preferred embodiment, the instruction data of the predetermined second unit including the provision for the output of the code further instructs the individual to access a predetermined final code unit on the media including the code.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] Other objects and advantages of the present invention will be apparent from the following detailed description of the presently preferred embodiments, which description should be considered in conjunction with the accompanying drawings in which like references indicate similar elements and in which:
[0025] FIG. 1A is a high-level system diagram of a low-cost-hearing testing system that collects user information.
[0026] FIG. 1B is a diagram of a low-cost CD on which a hearing testing system is stored.
[0027] FIG. 2 is a high-level method of using the low-cost hearing testing system that collects user information.
[0028] FIG. 3 shows a flow chart of a method of operating a low-cost hearing testing system.
[0029] FIG. 4 is an example of a hearing test checklist.
[0030] FIGS. 5A and 5B illustrate a hearing test questionnaire.
DETAILED DESCRIPTION OF THE INVENTION
[0031] FIG. 1A is a high-level diagram of a preferred system 100 including a user 105 , an optimized pick-up location 110 , a hearing test CD 120 , a CD player 130 , a telephone 143 , a PC 147 , an audiologist 145 and a next hearing test means 150 .
[0032] User 105 represents the individuals (mass market) on whom a hearing test is to be administered. This is generally any and all individuals, but more specifically, the more than 10% of the population (e.g., 25 million Americans) that have hearing loss, including one out of four people older than 65.
[0033] Optimized pick-up location 110 is a location where it would make sense for a hearing test CD 120 to be available toga large number of the general populace. For instance, optimized pick-up location 110 could be in a popular public location, such as a shopping mall where user 105 has easy and frequent access. For example, optimized pick-up location 110 could be a CD music store in a mall, a CD player store, a consumer electronics retail store such as a music showroom, a computer store, a health store, the lobby of a pilot training building, a mail order campaign, the lobby of a nursing home, or a general practitioner's office. Each of these locations is optimized since they have something to do with CD technology, health, mass market testing; older individuals, or selected professionals that may have hearing loss. By providing hearing test CD 120 as a give-away to the mass market focused on where there is need or capability for the hearing test, the large potential market can be tapped and those in need can be assisted in understanding their early onset or advanced hearing loss.
[0034] Hearing test CD 120 contains a hearing test that helps determine hearing loss. Hearing test CD 120 also provides follow-up actions for user 105 . The hearing test is described in more detail in reference to FIG. 2 .
[0035] CD player 130 is a standard player that can play hearing test CD 120 . Because the hearing test guides the user to select or skip tracks based upon the response of the user 105 to a given track, CD player 130 in system 100 needs to have some means for user 105 to know what track they are on. Almost all conventional CD players come equipped with at least a two-element display to show up to 99 tracks. These 99 tracks available on a standard CD player are adequate for the hearing test to be performed. Note that CD player 130 can be a stand-alone player or part of another electronic device such as a computer or a car music system.
[0036] Telephone 143 and PC 147 are conventional communication means enabling user 105 to conduct a second, more thorough, hearing test. After user 105 takes hearing test CD 120 on CD player 130 , instructions on hearing test CD 120 guide user 105 to call a toll-free phone number using telephone 143 , or to log onto the Internet using PC 147 to connect to a specific Web site, both of which are sources of additional testing. User 105 could also call or visit audiologist 145 directly. Any of these three next steps, defined as a group as next hearing test means 150 , can provide user 105 with a second-level hearing test. The second-level hearing test can be performed at the toll-free phone number, the Web site, or audiologist 145 .
[0037] In a preferred embodiment, hearing test CD 120 provides user 105 with a code to use prior to taking the second-level hearing test that can streamline the testing process. For example, a user 105 that has a severe hearing loss in a given frequency range may be specifically guided to a final test track on hearing test CD 120 that contains a specific code relating to that deficiency. At the second level of testing, user 105 could provide that code and start further testing immediately at the range in which he or she is deficient.
[0038] Note that in alternative modes of system 100 , hearing test CD 120 can easily be replaced with other devices such as a videotape or DVD. If so, CD player 130 can also be replaced with a standard VHS player for the videotape or DVD player for the DVD.
[0039] FIG. 1B illustrates a detailed schematic of hearing test CD 120 with multiple tracks, i.e., Track 1 through Track N. Each track on hearing test CD 120 has information on it organized in such a manner to enable a portion of a hearing test to be performed and instructions to be given to guide user 105 to another track based upon his or her response to the given track.
[0040] FIG. 2 illustrates a high-level method 200 of using system 100 , including the steps of:
[0041] Step 210 : Obtaining Hearing Test CD
[0042] In this step, user 105 obtains hearing test CD 120 at any of a number of optimized pick-up locations 110 . In addition, there can be many other low-cost ways for user 105 to obtain hearing test CD 120 . For example, hearing test CD 120 can be sent through a mail-order campaign.
[0043] Step 220 : Using Hearing Test CD
[0044] In this step, user 105 runs hearing test CD 120 on CD player 130 to take the hearing test.
[0045] Step 230 : Following Up
[0046] In this step, based on the follow-up instructions on hearing test CD 120 , user 105 is directed (if necessary) to any number of communication means. These means may include using telephone 143 to dial a toll-free phone number provided on hearing test CD 120 , using PC 147 to connect to the Internet through a Web site provided on hearing test CD 120 , or going directly to audiologist 145 to eventually obtain a second-level hearing test. In this step, user 105 provides the code that is unique to the result of his or her initial hearing test.
[0047] For example, a user 105 that has a severe hearing loss in a given frequency range may be specifically guided to a final test track on hearing test CD 120 that contains a specific code relating to that deficiency. At the second level of test, user 105 could provide that code and start further testing immediately at the range in which he or she is deficient. To further prompt user 105 to conduct a second level of test, an added incentive such as cost savings “coupon” can also be provided via means such as in the cover of hearing test CD 120 , or web site link to electronic “coupons”.
[0048] FIG. 3 illustrates a method 300 of conducting a hearing test using hearing test CD 120 . The basic concept of method 300 is to guide user 105 from track to track on hearing test CD 120 by verbal commands. Each track has a number of recorded information units, which represent logical steps in the flow of a program. Therefore, the availability of any succeeding tracks is dependent upon the parameters of the current track. In this way, user 105 is guided through a program. The method includes the steps of:
[0049] Step 310 : Greeting User
[0050] In this step, user 105 plays hearing test CD 120 in CD player 130 and is greeted with a message, such as a message to welcome the user, introduce the hearing test, and give general instructions on how to use hearing test CD 120 . User 105 is instructed to move to the track number that is used for calibration of CD player 130 to hearing test CD 120 . In order to make hearing test CD 120 more “fun” to use, a well-known recording artist such as Robin Williams can record the voice over. This feature will be especially attractive in case of testing young adults and small children. More so, if the costs of hiring using the well-known recording artists are spread across millions of hearing test CD 120 's, the overall cost per CD will not increase sharply.
[0051] Step 315 : Calibrating CD Player
[0052] In this step, hearing test CD 120 provides a verbal set of directions that tells user 105 to set the volume on CD player 130 to a level that is “just audible” by a third party with normal hearing, e.g., a person younger than 20 with perfect hearing is asked to set the volume to a minimum level of speech understandability. Setting the volume on CD player 130 to a “just audible” level is an optimal environment to conduct an accurate hearing test, and this volume level is maintained throughout the test. Then user 105 is instructed to play the next group of tracks to find the track by which user 105 can barely hear the tone again. Once user 105 selects this track, the program logic flow, or branch of the logic tree containing tracks calibrated in volume to the selected track, begins. User 105 is then guided to the first frequency test track based upon the correct volume level. Alternatively, hearing test CD 120 can provide a verbal set of directions that tell user 105 to set the volume on CD player 130 to the lowest audible level for user 105 . However, this may prevent the determination of absolute loss levels in each frequency range for user 105 .
[0053] Step 320 : Playing Frequency Tone
[0054] In this step, user 105 hears a verbal instruction and is played a set frequency tone corresponding to the track on hearing test CD 120 . For example, track T 3 on hearing test CD 120 plays a frequency tone of 500 Hz.
[0055] Step 325 : Isolating Hearing Deficiency
[0056] In this step, user 105 is asked to follow a detailed logic tree 400 of tracks on hearing test CD 120 . The operation of a sample logic tree 400 is explained in detail in FIG. 4 . The specific progression that user 105 takes through logic tree 400 is dependent upon how user 105 responds as to whether each set frequency tone is audible. In this way, hearing test CD 120 determines whether user 105 has a hearing deficiency and, if so, in which specific frequency bands the deficiency occurs.
[0057] Step 330 : Moving to Next Track
[0058] In this step, user 105 is asked to move onto a specific next track of hearing test CD 120 that corresponds both to any hearing deficiencies previously isolated and to the next frequency tone in the series. In the given example, if user 105 has indicated that the 500 Hz tone played in track T 3 was audible, track T 5 plays a frequency tone of 2000 Hz.
[0059] Step 335 : Last Frequency Tone Track?
[0060] In this decision step, through completion of logic tree 400 , hearing test CD 120 determines whether all of the set frequency tones in the hearing test have been played. If so, method 300 proceeds to step 340 ; if not, method 300 returns to step 320 .
[0061] Step 340 : Completing Test
[0062] In this step, user 105 is asked to move on to a specific final track of hearing test CD 120 that congratulates user 105 on completing the hearing test and reports whether the test has found that user 105 may have hearing deficiencies. Tracks corresponding to specific hearing deficiencies assure user 105 that there are many possible means for rectifying the deficiency, and that knowing that one has a deficiency is a first positive step. These tracks also provide user 105 with a code specific to his or her hearing deficiency, which can later be used in conducting a second-level hearing test. User 105 is directed to use next hearing test means 150 , i.e., to call a toll-free phone-number or to log onto a specific Web site on the Internet for further testing, or, if the hearing loss is significant, to contact professional audiologist 145 directly. The name and contact information for preferred audiologists can also be provided. Furthermore, an added incentive, such as “coupon” savings on detailed hearing tests or hearing aid accessories, can also be provided to further prompt user 105 to use next hearing test means 150 . Method 300 ends. Note that, if the test detected that user 105 does not have any hearing deficiency, then user 105 is congratulated on his/her good hearing and no follow up action may be directed to user 105 .
[0063] Note that in this mode of operation, user 105 uses a device such as a CD player remote control to advance through tracks on hearing test CD 120 , however alternative modes of automated track to track advancement on hearing test CD 120 can easily be suggested.
[0064] FIG. 4 shows logic tree 400 . Each track, e.g., T 3 , T 5 , T 7 , has a set frequency tone, e.g., 500 Hz, 2000 Hz, 8000 Hz, and instructions articulating decision tree yes or no steps based on user 105 's ability to hear the tone. The track at the end of each branch contains a message with a specific code for that branch, e.g., codes 1 , 2 , 3 , and z. Continue branches “C” represent a continuation of the logic flow branch repetition, which has been truncated for the sake of clarity.
[0065] In this example, if user 105 provides responses indicating that all tones played were audible, logic tree 400 follows the branch including tracks T 3 , T 5 , T 6 , T 7 , and T 8 , and user 105 is assigned a code 1 , representing perfect hearing. If user 105 provides responses indicating that all tones played were audible except 500 Hz, logic tree 400 follows the branch including tracks T 3 , T 50 , T 51 , T 52 , and T 53 , and user 105 is assigned a code 3 representing this information.
[0066] It should be obvious to those skilled in the programming art that there are many combinations of frequency loss; for example, one could hear 500 Hz, 5000 Hz, 8000 Hz, and 12000 Hz, but not 2000 Hz. All these branches lead to unique codes. The number of branches of logic tree 400 is limited only by the available storage, space for the tracks on hearing test CD 120 . Depending on the number of possible codes and the number of tracks necessary to arrive at those codes, the branches of logic tree 400 may need to be limited to a certain number of possibilities, or the hearing test may need to span more than one hearing test CD 120 .
[0067] It should also be obvious to those skilled in the programming art, and basic mathematics, that the results from typical binary logic trees can be K N where N is the number of test frequency nodes and K is the possible outcomes. For example, a basic frequency test that has 5 test frequency nodes, (i.e. 500 Hz, 2000 Hz, 5000 Hz, 8000 Hz, and 12000 Hz) with 2 outcomes (i.e. yes or no), has a logic tree that can be programmed to contain as many as 32 different results.
[0068] FIGS. 5A and 5B illustrate a questionnaire 500 that can be inserted in the case of hearing test CD 120 . By answering questionnaire 500 , user 105 can further confirm his or her hearing loss, providing further incentive for user 105 to arrange a second hearing test. These questions, in addition to tones, can be, the basis, of decision branches to obtain even more unique information about user 105 .
[0069] Thus, the inventive system and method increase the public's awareness that hearing impairment is common, and allows an individual to easily assess any hearing loss and to provide diagnostic results, which are obtained from the assessment, to a hearing professional for use in further assessment of hearing loss.
[0070] Although preferred embodiments of the present invention have been described and illustrated, it will be apparent to those skilled in the art that various modifications may be made without departing from the principles of the invention. | System and method for diagnosing hearing loss in an individual using a self-executable, interactive electronic hearing loss diagnosis apparatus including a data storage media and a media player for accessing data on the media. The diagnostic apparatus provides hearing loss diagnostic data to the individual in the form of coded data. A hearing loss professional can use the coded data to further diagnose the hearing loss of the individual. | 7 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to divided wall exchange columns for heat and/or mass transfer processes. The invention has particular application in cryogenic air separation processes utilizing distillation, although it also may be used in other heat and/or mass transfer processes which use trays and packing (e.g., random or structured packing).
[0002] As used herein, the term “column” (or “exchange column”) means a distillation or fractionation column or zone, i.e., a column or zone where liquid and vapor phases are countercurrently contacted to effect separation of a fluid mixture, such as by contacting of the vapor and liquid phases on packing elements or on a series of vertically-spaced trays or plates mounted within the column.
[0003] The term “column section” (or “section”) means a zone in a column filling all or part of a cross section of the column. The top or bottom of a particular section or zone ends at the liquid and vapor distributors (discussed below) respectively.
[0004] The term “packing” means solid or hollow bodies of predetermined size, shape, and configuration used as column internals to provide surface for the liquid to allow mass transfer at the liquid-vapor interface during countercurrent flow of two phases. Two broad classes of packings are “random” and “structured.”
[0005] “Random packing” means packing wherein individual members do not have any particular orientation relative to each other or to the column axis. Random packings are small, hollow structures with large surface area per unit volume that are loaded at random into a column.
[0006] “Structured packing” means packing wherein individual members have specific orientation relative to each other and to the column axis. Structured packings usually are made of thin metal foil, expanded metal, or woven wire screen stacked in layers or as spiral bindings; however, other materials of construction, such as plain sheet metal, may be used.
[0007] In processes such as distillation or direct contact cooling, it is advantageous to use structured packing to promote heat and mass transfer between counter-flowing liquid and vapor streams. Structured packing, when compared with random packing or trays, offers the benefits of higher efficiency for heat and mass transfer with lower pressure drop. It also has more predictable performance than random packing.
[0008] Cryogenic separation of air is carried out by passing liquid and vapor in countercurrent contact through a distillation column. A vapor phase of the mixture ascends with an ever increasing concentration of the more volatile components (e.g., nitrogen) while a liquid phase of the mixture descends with an ever increasing concentration of the less volatile components (e.g., oxygen).
[0009] Various packings or trays may be used to bring the liquid and gaseous phases of the mixture into contact to accomplish mass transfer between the phases. The use of packing for distillation is standard practice and has many advantages where pressure drop is important.
[0010] Initial presentation of liquid and vapor to the packing is usually made by means of distributors. A liquid distributor, the role of which is to irrigate the packing substantially uniformly with liquid, is located above the packing, while a vapor distributor, the role of which is to create substantially uniform vapor flow below the packing, is located below the packing.
[0011] There are several different types of liquid distributors typically used in air separation processes. One type, a pipe distributor, is comprised of an interconnecting network of closed pipes or ducts, typically comprising a central pipe or manifold and a number of arms or branches radiating from the central pipe. The arms are perforated to allow the liquid passing from the manifold and into the arms to be dripped or sprayed onto a packed bed below the pipe distributor. Upwardly flowing vapor passes easily in between each arm. Pipe distributors receive liquid from a separate liquid collector or an external source piped to the wall of the column.
[0012] Trough distributors compromise a collection of interconnecting open troughs having irrigation holes in the base to feed liquid to the packing below. One or more upper collection troughs, or a simple pot on top of the lower troughs feeds liquid to the lower troughs through a series or holes or overflowing notches. Vapor from the packing below passes upward between the liquid-containing troughs.
[0013] A divided wall column is in principle a simplification of a system of thermally coupled distillation columns. In divided wall columns, a dividing wall is located in the interior space of the column, such as shown in FIGS. 1 and 2 . FIG. 1 illustrates a typical divided wall column 10 using a chord wall 12 , while FIG. 2 illustrates another typical divided wall column 10 using an annular wall 14 . The dividing wall generally is vertical.
[0014] The support of the dividing wall should not interfere with the installation of either the trays or the packing. The use of structured packing in a divided wall column requires that the liquid be uniformly fed over the top of the structured packing by the use of a liquid distributor. These requirements raise serious problems which must be addressed in the design and manufacture of divided wall columns.
[0015] For example, since two different mass transfer separations occur on either side of the dividing wall, which may have different operating pressures and temperatures, the dividing wall may have to withstand a pressure differential and/or a temperature differential across the dividing wall. The pressure differential can exert a significant force on the dividing wall, which must be countered by the mechanical design of the wall, and the temperature differential can give rise to an unwanted change in the distillation process adjacent to the dividing wall, which must be countered by some form of thermal resistance (insulation) between the two sides.
[0016] In the case of a chord wall design, the force of the pressure differential can be substantial. Prior art designs for countering such force are difficult and/or expensive to manufacture, often lead to an unacceptable loss in the column area available for distillation, or substantially interfere with the distillation process.
[0017] Another problem is that the prior art does not satisfactorily address how to design the layout of structured packing and/or trays in divided wall columns or, in the case of structured packing, how to design and arrange the liquid distributor.
[0018] U.S. Pat. No. 4,615,770 (Govind) and U.S. Pat. No. 4,681,661 (Govind) disclose dual interrelated distillation columns similar to the annular divided wall column illustrated in FIG. 2 herein. Neither patent addresses the need to increase the strength of the annular wall.
[0019] U.S. Pat. No. 5,709,780 (Ognisty, et al.) does recognize the need to minimize mechanical stresses on partition walls in an integrated distillation column having a partitioned stripping or absorption section due to a large pressure differential across the partitioning walls. The patent suggests that a curved or angled wall could be used rather than a substantially planar wall, which is preferred for ease of installation. It also suggests that mechanical stresses can be addressed by using a transverse rib or honeycomb type reinforcement of the partition walls or any trays in the partitioned section. It further suggests that the partition walls can have a laminate construction to establish an air gap or a layer of insulation between adjacent layers, apparently to help minimize stresses induced by temperature differentials.
[0020] U.S. Pat. No. 5,785,819 (Kaibel, et al.) discloses a distillation column separated in the middle by two walls with a gas space in between the two walls mounted in a longitudinal direction. The patent suggests the possibility of mounting spacers in the gas space between the two walls in order to increase the mechanical stability.
[0021] As discussed, the force on a chord wall can be significant due to pressure differential between the two sections. In addition, the chord geometry itself could require that the chord wall be supported even in cases with minimal or no pressure differential. The simplest way of dividing the column would be to use a flat sheet. However, although the thickness of the sheet can be increased, the increase in strength obtained is relatively poor, especially at large column diameters. Moreover, if the thickness of the chord wall is too dissimilar to that of the outer wall, there are complications associated with the welding of the chord wall to the column wall, as well as simply occupying a greater portion of the column area.
[0022] As discussed above, the prior art has attempted to avoid these problems by strengthening the chord wall in a way other than simply increasing the thickness, such as by using laminated or honeycomb walls, strengthening ribs, or even using the trays (if present) as stiffeners. True honeycomb walls and laminated walls are difficult and expensive to manufacture, although such walls do provide the benefit of higher thermal resistance if that is required.
[0023] For example, welding ribs to a wall tends to be expensive, since welding can distort a flat sheet, especially if the ribs must be attached only to one side. Also, if ribs are used in a packed column, the ribs may intrude into the structured packing and cause problems both with the installation of the packing and/or the distillation process. In the case of a preassembled stack of self-supporting trays being installed in a column, strengthening ribs on a dividing wall may intrude into the area where the tray stack is to be installed, leading to greater difficulty in installation; additionally, the trays may rest on the ribs when the column is lying on its side for manufacture or transportation and thereby be distorted, as well as cause problems with the distillation process.
[0024] It is desired to have a divided wall exchange column utilizing structured packing as a distillation device wherein the dividing wall is strengthened by strengthening means which do not cause a significant loss in distillation performance.
[0025] It is further desired to have a divided wall exchange column wherein the dividing wall is adequately strengthened to withstand pressure differentials and minimize temperature differentials across the dividing wall.
[0026] It is still further desired to have strengthening means to strengthen the dividing wall in a divided wall exchange column which means are relatively easy to design, manufacture, and install without excessive costs or expense.
[0027] It is still further desired to have a divided wall exchange column design which allows for use of a liquid distributor which is relatively easy to design and manufacture.
[0028] It is still further desired to have a divided wall exchange column in which the dividing wall can withstand the pressure differentials and minimize the temperature differentials during operation better than the prior art divided exchange columns.
[0029] It is still further desired to have an improved divided wall exchange column which overcomes many of the difficulties and disadvantages of the prior art to provide better and more advantageous results.
[0030] It also is further desired to have an improved cryogenic air separation plant having an improved divided wall exchange column which overcomes many of the difficulties and disadvantages of the prior art to provide better and more advantageous results.
BRIEF SUMMARY OF THE INVENTION
[0031] The present invention is an apparatus used in heat and/or mass transfer processes, including but not limited to cryogenic air separation processes using distillation. There are many embodiments of the invention and many variations of those embodiments.
[0032] A first embodiment is an apparatus including an exchange column, a dividing wall, and at least one elongated stiffening member. The exchange column has a longitudinal axis and an inner wall spaced apart from and surrounding the longitudinal axis, thereby being an interior space between the inner wall and the longitudinal axis. The dividing wall is disposed in the interior space, has a first side and a second side, and divides the interior space into at least a first longitudinal space adjacent the first side of the dividing wall and a second longitudinal space adjacent the second side of the dividing wall. The at least one elongated stiffening member has a first end connected to the inner wall of the exchange column and a second end opposite the first end, the second end being connected to the first side or the second side of the dividing wall.
[0033] In a variation of the first embodiment, the second end of one elongated stiffening member is connected to the first side of the dividing wall, and the second end of another elongated stiffening member is connected to the second side of the dividing wall.
[0034] A second embodiment of the invention includes five elements. The first element is an exchange column having a primary longitudinal axis and an inner wall spaced apart from and surrounding the primary longitudinal axis, thereby being an interior space between the inner wall and the primary longitudinal axis. The second element is a dividing wall which is disposed in the interior space, has a first side and a second side, and divides the interior space into at least a first longitudinal space adjacent the first side of the dividing wall and a second longitudinal space adjacent the second side of the dividing wall. The third element is a first layer of structured packing disposed in the first longitudinal space and having a first longitudinal axis at a first angle relative to the dividing wall. The fourth element is a second layer of structured packing disposed in the first longitudinal space adjacent and below the first layer of structured packing. The second layer of structured packing has a second longitudinal axis at a second angle relative to the dividing wall, the second longitudinal axis being at a rotated angle relative to the first longitudinal axis. The fifth element is at least one elongated stiffening member having a first end connected to the inner wall of the exchange column and a second end opposite the first end. The second end is connected to the first side of the dividing wall, and at least a portion of the at least one elongated stiffening member is disposed in the second layer of structured packing and is substantially parallel to the second longitudinal axis.
[0035] In a variation of the second embodiment, the rotated angle is about 90°. In another variation, the first longitudinal axis is substantially parallel to the dividing wall and the second longitudinal axis is substantially perpendicular to the dividing wall.
[0036] A third embodiment of the invention includes six elements. The first element is an exchange column having a primary longitudinal axis and an inner wall spaced apart from and surrounding the primary longitudinal axis, thereby being an interior space between the inner wall and the primary longitudinal axis. The second element is a dividing wall which is disposed in the interior space, has a first side and a second side, and divides the interior space into at least a first longitudinal space adjacent the first side of the dividing wall and a second longitudinal space adjacent the second side of the dividing wall. The third element is a first layer of structured packing disposed in the first longitudinal space and having a first longitudinal axis at a first angle relative to the dividing wall, the first angle being greater than 0° degrees and less than 180°. The fourth element is a second layer of structured packing disposed in the first longitudinal space below the first layer of structured packing and having a second longitudinal axis at a second angle relative to the dividing wall, the second angle being greater than 0° degrees and less than 180°. The fifth element is at least one elongated stiffening member having a first end connected to the inner wall of the exchange column and a second end opposite the first end, the second end being connected to the first side of the dividing wall. At least a portion of the at least one elongated stiffening member is disposed in the first layer of structured packing and is substantially parallel to the second longitudinal axis. The sixth element is at least one another elongated stiffening member having a first end connected to the inner wall of the exchange column and a second end opposite the first end, the second end being connected to the first side of the dividing wall. At least a portion of the at least one another elongated stiffening member is disposed in the second layer of the structured packing and is substantially parallel to the second longitudinal axis.
[0037] In a variation of the third embodiment, the at least one elongated stiffening member is at a first position and the at least one another elongated stiffening member is at a second position spaced both horizontally and vertically apart from the first position of the at least one elongated stiffening member.
[0038] A fourth embodiment of the invention includes two elements. The first element is an exchange column having a longitudinal axis and an inner wall spaced apart from and surrounding the longitudinal axis, thereby being and interior space between the inner wall and the longitudinal axis. The second element is a dividing wall disposed in the interior space. The dividing wall includes four sub-elements. The first sub-element is a first plate having an outer surface and an inner surface opposite the outer surface. The second sub-element is a second plate having an exterior surface and an interior surface opposite the exterior surface and spaced apart from the inner surface of the first plate. The third sub-element is at least one projection fixedly connected to the inner surface of the first plate and adapted to be spaced apart from the interior surface of the second plate. The fourth sub-element is at least one another projection fixedly connected to the interior surface of the second plate. The another projection is adapted to be spaced apart from the inner surface of the first plate and spaced apart laterally from the at least one projection. In the fourth embodiment, the dividing wall divides the interior space into at least a first longitudinal space adjacent the outer surface of the first plate and a second longitudinal space adjacent the exterior surface of the second plate.
[0039] There are many variations of the fourth embodiment. In one variation, at least one of the at least one projection and the at least one another projection has a tapered surface. In another variation, at least a portion of the first plate has a first thermal conductivity and at least a portion of the at least one projection has another thermal conductivity different from the first thermal conductivity. In yet another variation, at least a portion of at least one of the at least one projection touches a portion of the interior surface of the second plate, or at least a portion of at least one of the another projection touches a portion of the inner surface of the first plate. In still yet another variation, the at least one projection is horizontal and has at least one aperture adapted to transmit a vertically ascending fluid.
[0040] A fifth embodiment of the invention is similar to the fourth embodiment but also includes at least one elongated stiffening member having a first end connected to the inner wall of the exchange column and a second end opposite the first end, the second end being connected to the outer surface of the first plate or the exterior surface of the second plate.
[0041] A sixth embodiment of the invention includes four elements. The first element is an exchange column having a first longitudinal axis and an inner wall spaced apart from and surrounding the first longitudinal axis, thereby being an interior space between the inner wall and the first longitudinal axis. The second element is a dividing wall which is disposed in the interior space, has a first side and a second side, and divides the interior space into at least a first longitudinal space adjacent the first side of the dividing wall and a second longitudinal space adjacent the second side of the dividing wall. The third element is a layer of structured packing disposed in the first longitudinal space, the layer of structured packing having a second longitudinal axis. The fourth element is a distributor adjacent the layer of structured packing and having at least one fluid distributing device adapted to distribute at least a portion of the fluid from the distributor to the layer of structured packing. The fluid distributing device has a third longitudinal axis substantially parallel to the first side of the dividing wall. In the sixth embodiment, the second longitudinal axis of the layer of structured packing is at an angle relative to the dividing wall, the angle being greater than about 0° and less than about 90°.
[0042] There are several variations of the sixth embodiment. In one variation, the angle is between about 30° and about 60°. In a variant of that variation, the angle is about 45°.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0043] The invention will be described by way of example with reference to the accompanying drawings, in which:
[0044] FIG. 1 is a schematic diagram illustrating a prior art divided wall column using a chord wall;
[0045] FIG. 2 is a schematic diagram illustrating another prior art divided wall column using an annular wall;
[0046] FIG. 3 is a schematic diagram illustrating an embodiment of the present invention using tie bars or other stiffening members;
[0047] FIG. 4 is a schematic diagram illustrating another embodiment of the present invention using tie bars or other stiffening members;
[0048] FIG. 5 is a schematic diagram illustrating a typical column containing structured packing segments;
[0049] FIG. 6 is a schematic diagram illustrating a typical column containing structured packing segments utilizing shims;
[0050] FIGS. 7 through 10 are schematic diagrams illustrating an embodiment of the present invention using tie bars or other stiffening members in staggered positions within several layers of structured packing in a repeating sequence ( 7 , 8 , 9 , 10 ) of layers of structured packing within a column;
[0051] FIG. 11 is a schematic diagram illustrating a cross-sectional elevation view of another embodiment of the present invention using internal projections in a double-wall design for the dividing wall in a divided wall column, and FIG. 11A is a schematic diagram illustrating a cross-sectional plan view of this embodiment;
[0052] FIG. 12 is a schematic diagram illustrating a cross-sectional elevation view of another embodiment of the present invention using internal projections in a double-wall design for the dividing wall in a divided wall column, and FIG. 12A is a schematic diagram illustrating a cross-sectional plan view of this embodiment;
[0053] FIGS. 13 and 14 are schematic diagrams illustrating cross-sectional elevation views of two other embodiments of the present invention similar to those shown in FIGS. 11 and 12 wherein the projections are made of two materials, one of the materials having a thermal conductivity different than the thermal conductivity of the plate to which the projections are attached; and
[0054] FIGS. 13A and 14A are schematic diagrams illustrating cross-sectional plan views of the two embodiments shown in FIGS. 13 and 14 ;
[0055] FIG. 15 is a schematic diagram illustrating a typical packed column having a liquid pipe distributor with the distributor arms positioned at a 45° angle relative to the sheets of the structured packing;
[0056] FIG. 16 is a schematic diagram illustrating a typical design of a liquid pipe distributor required for a divided wall column having structured packing on one side of the divided wall; and
[0057] FIG. 17 is a schematic diagram illustrating another embodiment of the present invention wherein the design of the distributor is less complex (than the distributor design in FIG. 16 ) because the top layer of the structured packing has been oriented at a 45° angle relative to the dividing wall of the divided wall column.
DETAILED DESCRIPTION OF THE INVENTION
[0058] The present invention is discussed herein in the context of divided wall exchange columns used for air separation processes. Persons skilled in the art will recognize, however, that the invention may be utilized in other processes which use divided wall exchange columns.
[0059] In modern air separation plants, structured packing is most often used as the preferred mass transfer device, although trays may still be used in specific circumstances for specific applications. For some applications, structured packing may be used on one side of the dividing wall, while trays are used on the other side of the dividing wall.
[0060] One embodiment of an exchange column 20 using the present invention is shown in FIG. 3 where one end of a stiffening member 22 , such as a tie-bar, is connected to the inner wall 24 of the column and the other end of the stiffening member is connected to the dividing wall 26 to stiffen the dividing wall. More than one stiffening member (e.g., tie-bar), as shown in FIG. 3 , may be used for this purpose.
[0061] The stiffening members 22 , such as tie-bars, may be used on both sides of the dividing wall 26 to stiffen it when structured packing (not shown) is used as the mass transfer device on both sides of the divided column, as illustrated in FIG. 4 . If, as illustrated in FIG. 3 , trays (not shown) are used on one side of the dividing wall and structured packing (not shown) is used on the other side, then the preferred position of the stiffening members 22 is on the structured packing side (the right side of the column, as shown in FIG. 3 ).
[0062] FIG. 5 illustrates a typical column 10 containing structured packing segments 30 made from individual sheets of packing. In order to make installation of the structured packing easier, especially in large columns, it is common to make each layer of packing in segments.
[0063] On occasion, shims 32 may be placed between each segment of packing, as shown in FIG. 6 , to make sure that the structured packing is positioned centrally within the column 10 , thus leaving approximately equal gaps around the column circumference between the edge of the packing and the inner wall of the column. Shims also are sometimes used to ensure tightness of fit of the segments of packing by compensating for differences in tolerances. Sometimes the shims run parallel to the packing elements, as shown by the longitudinal shims 32 in FIG. 6 , and sometimes other shims (not shown), called butt shims, run perpendicular to the elements at the ends of the segments.
[0064] Consequently, there often is extra material (e.g., metal) placed in parallel with the structured packing segments 30 , as shown by the longitudinal shims 32 in FIG. 6 . Therefore, the stiffening members 22 (e.g., tie-bars) used in the present invention may be installed between the segments of structured packing in a manner similar to the longitudinal shims 32 shown in FIG. 6 without inducing any further effects beyond the comparable effect created by the presence of a shim.
[0065] In addition, the stiffening members 22 may be staggered from layer to layer within a packed divided wall exchange column. An example of this is illustrated in FIGS. 7 through 10 . In this embodiment of the invention 20 , the stiffening members 22 (e.g., tie-bars) are in staggered positions within several layers of structured packing 40 in a repeating sequence (e.g., A, B, C, D) of four layers of structured packing within the column, as illustrated in FIG. 7 (type A), FIG. 8 (type B), FIG. 9 (type C), and FIG. 10 (type D). As shown, the adjacent layers of packing in the repeating sequence (A, B, C, D) are aligned such that the elements of the packing in one layer are at a 90° angle relative to the next layer of packing. (Persons skilled in the art will recognize that the angle may be some angle other than 90°.)
[0066] In FIG. 7 , the sheets of type “A” packing 40 are substantially parallel to the dividing wall 26 . The next layer of packing, i.e., type “B,” illustrated in FIG. 8 , is at an angle of 90° (i.e., perpendicular to the dividing wall). The next layer of packing, type “C,” is substantially parallel to the dividing wall, as shown in FIG. 9 . However the elements of the type “A” packing and type “C” packing slope in different directions, as shown in FIGS. 7A and 9A , although this may not necessarily be so. The fourth layer of packing is type “D” at 90° (i.e., perpendicular to the dividing wall), as shown in FIG. 10 .
[0067] The embodiment shown in FIGS. 7-10 illustrates the repeating sequence A, B, C, D, a sequence which may be repeated down through the column. Layer types A ( FIG. 7 ) and C ( FIG. 9 ) differ in that the structured packing elements 40 lying against the dividing wall 26 are oriented in different directions, although this may not necessarily be so. Layer types B ( FIG. 8 ) and D ( FIG. 9 ) differ in that the location of the stiffening members 22 are staggered, although this may not necessarily be so.
[0068] Since the stiffening members 22 passing through segments of structured packing 40 , as shown in FIGS. 8 and 10 , are not significantly different than the shims 32 typically used, as shown in FIG. 6 , the stiffening members 22 have little or no impact on the mass transfer performance of the structured packing beyond the comparable impact created by the presence of one or more shims.
[0069] Additional embodiments of the present invention are illustrated in FIGS. 11-14 and 11 A- 14 A. These embodiments may be employed where there is a significant temperature difference across the dividing wall, making it necessary to provide some form of thermal resistance between the two sides of the dividing wall as well as extra strength. One way to do this would be to make one or the other of the dividing walls out of a material with a lower thermal conductivity. However, this could lead to problems with welding two different materials together. Such problems may be avoided by using the double-wall design shown in FIGS. 11-14 and 11 A- 14 A, which provides both strength and thermal resistance while causing only some minor loss of column area.
[0070] As shown in FIGS. 11-14 and 11 A- 14 A, the two plates ( 52 , 54 ) forming the double-wall dividing wall 50 have projections ( 56 , 56 ′) welded on each of the facing sides of the plates. Each projection is connected to one plate, but not the opposing plate. However, the plates may be brought close enough together so that the tips of the projections may actually touch the opposing plates. The projections preferably are horizontal, but may be vertical if required. In either case, the projections should allow the free entry and exit of gas or vapor between the opposing plates so as to eliminate pressure differences occurring between the plates.
[0071] The projections ( 56 , 56 ′) on plate 52 should not but may touch plate 54 , and the projections ( 56 , 56 ′) on plate 54 should not touch plate 52 , as shown by the gaps between the projections and the plates in FIGS. 11-14 and 11 A- 14 A. The projections act as baffles, minimizing convection currents and transferring heat from one plate to the other. If the gap is closed, resulting in the projections touching the plates (e.g., in a situation where the dividing wall distorts slightly more than expected during manufacture or when in operation), some of the force will be transferred locally from one plate to the other plate. Even if this happens, the projections are designed to minimize heat transfer. To allow pressure equalization in such a situation, the projections have a series of apertures 55 which allow fluid to pass from one side of the projection to the other.
[0072] In order to reduce heat transfer between the two plates ( 52 , 54 ), the “contacting” edges of the projections ( 56 , 56 ′) may be angled to minimize the material in contact, as shown in FIGS. 12 and 14 . Also, as shown in FIGS. 13 and 14 (and in 13 A and 14 A), different materials with different thermal conductivities may be used for the projections 56 ′. A material with a lower thermal conductivity is used on that part of the projection 56 ′ that would come in contact with the opposite plate ( 52 , 54 ).
[0073] The embodiments of the present invention illustrated in FIGS. 11-14 and 11 A- 14 A provide several advantages. First, substantially flat surfaces on both sides of the double-wall dividing wall 50 are presented to the column for ease of installation of the structured packing and/or the trays. Also, the double-wall dividing wall is simpler and less expensive to manufacture than a laminated or honeycomb wall, and it provides good heat transfer resistance. Each wall of the double-wall dividing wall can be manufactured separately without requiring extremely high accuracy, since each wall is supposed to remain apart as a separate item after installation but will still perform as substantially as desired if they should come into contact at any point.
[0074] Persons skilled in the art will recognize that the double-wall dividing walls 50 shown in FIGS. 11-14 and 11 A- 14 A also may be used in combination with other wall strengthening and/or thermal insulating techniques. For example, the stiffening members 22 shown in FIGS. 3 and 4 may be used in conjunction with the double-wall dividing walls shown in FIGS. 11-14 and 11 A- 14 A.
[0075] Typically, a section of an exchange column containing structured packing preferably is fed with a substantially uniform liquid feed across the top. For a cylindrical column 10 , it is common to have a liquid distributor with “arms” 16 fed by a manifold 18 such as shown in FIG. 15 . As illustrated, the arms of the liquid distributor may be positioned at a 45° angle (or another desired angle) relative to the sheets of structured packing 40 in order to improve the irrigation pattern with respect to the packing sheets while minimizing complexity of manufacturing. The liquid is fed to the arms of the distributor through the manifold. This arrangement provides for the desired irrigation of the structured packing with liquid flowing from rows of holes in the arms of the liquid distributor.
[0076] In the case of a divided wall column, where the column is divided roughly in half by a chord wall, the arrangement of the holes in the arms of the liquid distributor must still be such that the structured packing is properly irrigated. Preferably, in a divided wall column the sheets in the layers of structured packing will be aligned such that the manufacture and installation of the packing is easy, preferably with the packing sheets lying either substantially perpendicular or parallel to the chord wall. Since the section of packing in one section of the divided column is no longer circular in shape, and given the preferred packing orientation, it is not possible to simply rotate the liquid distributor so that the rows of holes are at or around 45° to the packing sheets in the top layer. The arms 16 and manifold 18 of the required liquid distributor would be something like that shown in FIG. 16 . This results in problems with the design and extra manufacturing costs of the liquid distributor, since the arms must now be constructed such that the rows of holes are angled and so a standard design may no longer be used.
[0077] An embodiment of the divided wall column 60 of the present invention shown in FIG. 17 avoids this problem by orienting the top layer of structured packing 62 at some angle such as 45° relative to the dividing wall 26 . This arrangement of the packing is referred to herein as type “E.” This arrangement allows a normal design of the liquid distributor to be used, having arms 66 substantially parallel to the dividing wall and a manifold 68 substantially straight and perpendicular to the dividing wall, as shown in FIG. 17 . This eliminates the design and manufacturing problems required for the arrangement shown in FIG. 16 by using existing proven technology of existing liquid distributor designs. Persons skilled in the art will recognize that the invention also may be used with other types of distributors, including trough distributors.
[0078] Although illustrated and described herein with reference to certain specific embodiments, the present invention is nevertheless not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the spirit of the invention. | A divided wall exchange column includes a dividing wall strengthened by stiffening members and/or a double wall design to better withstand pressure differentials and minimize temperature differentials. When a double wall is used, cost of manufacture and installation is minimized by reducing the manufacturing tolerances required while providing a design robust in construction, installation, and operation. When structured packing is used, the stiffening members, combined with positioning the layers of packing at preferred angles relative to the dividing wall, result in minimal interference with the heat and/or mass transfer process while minimizing the complexity of manufacture and construction of the packing. Further, by positioning the top layer of structured packing at other preferred angles relative to the dividing wall, a simplified liquid distributor design may be used in the divided wall exchange column while the layers below may still be orientated as described above with all the associated benefits. | 5 |
BACKGROUND
Unless otherwise indicated herein, the elements described in this section are not prior art to the claims and are not admitted to be prior art by inclusion in this section.
A user-equipment (UE) device, such as a cellular phone, operating within a first radio frequency (RF) coverage area provided by a base station can be handed over from that base station to a base station providing a second RF coverage area. Handing over the UE device permits a communication session (such as voice call or internet browsing session) occurring via the UE device to continue as the UE device is moved from the first coverage area to the second RF coverage area.
RF signals transmitted from a base station within a coverage area to the wireless UE device can be referred to as forward-link signals. RF signals transmitted from the UE device to the base station can be referred to as reverse-link signals. Handing over the UE device from the first RF coverage area to the second RF coverage area can be based on a forward-link signal.
OVERVIEW
This application describes several example embodiments, at least some of which pertain to using reverse-link measurements to make decisions regarding whether to hand over a user-equipment device from a serving base station to another base station.
In one respect, an example embodiment can take the form of a method comprising (i) determining, at a first base station, a first reverse-link noise measurement pertaining to one or more reverse-links to the first base station, (ii) receiving, at the first base station, a second reverse-link noise measurement pertaining to one or more reverse-links to a second base station neighboring the first base station, (iii) determining, at the first base station, a difference between the first reverse-link noise measurement and the second reverse-link noise measurement, and (iv) transmitting, from the first base station to a user-equipment device served by the first base station, data indicating the difference between the first reverse-link noise measurement and the second reverse-link noise measurement.
In another respect, an example embodiment can take the form of a method comprising (i) determining, at a user-equipment device operating in an idle mode, a difference in reverse-link noise measured by a first base station currently serving the user-equipment device and reverse-link noise measured by a second base station that neighbors the first base station, (ii) selecting, based on the difference in reverse-link noise determined at the user-equipment device, the second base station to serve the user-equipment device instead of the first base station, and (iii) initiating, using the user-equipment device in response to selecting the second base station, handoff of the user-equipment device from the first base station to the second base station.
In yet another respect, an example embodiment can take the form of a user-equipment device comprising: (i) a wireless communication interface that receives first reverse-link noise data that indicates a difference in reverse-link noise measured by a first base station currently serving the user-equipment device and reverse-link noise measured by a second base station that neighbors the first base station, (ii) a processor, and (iii) a data storage device storing computer-readable program instructions executable by the processor to perform a set of functions. The set of functions comprises (i) selecting, based on the first reverse-link noise data received by the wireless communication interface, the second base station to serve the user-equipment device instead of the first base station, and (ii) initiating, in response to selecting the second base station, handoff of the user-equipment device from the first base station to the second base station.
These as well as other aspects and advantages will become apparent to those of ordinary skill in the art by reading the following detailed description, with reference where appropriate to the accompanying drawings. Further, it should be understood that the embodiments described in this overview and elsewhere are intended to be examples only and do not necessarily limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Example embodiments are described herein with reference to the drawings, in which:
FIG. 1 is a diagram depicting a system in accordance with one or more of the example embodiments;
FIG. 2 is a block diagram of a user-equipment device in accordance with one or more of the example embodiments;
FIG. 3 is a block diagram of a base station in accordance with one or more of the example embodiments;
FIG. 4 is a flowchart depicting a set of functions that can be carried out in accordance with one or more of the example embodiments; and
FIG. 5 is a flowchart depicting a set of functions that can be carried out in accordance with one or more of the example embodiments.
DETAILED DESCRIPTION
I. Introduction
In addition to handing over a user-equipment (UE) device performing a communication session, the UE device can be handed over from a serving base station to another base station while the UE device is operating in an idle mode. This description describes example embodiments that pertain to using reverse-link measurements to make decisions regarding whether to hand over a UE device. The reverse-link measurements can, for example, include parameters indicating reverse-link noise measurements made by base stations within a wireless communication network, Random Access Channel (RACH) capacity parameters, or Uplink Data Error rate parameters that indicate how well the reverse-link is performing.
In this description, the articles “a” or “an” are used to introduce elements of the example embodiments. The intent of using those articles is that there is one or more of the elements. The intent of using the conjunction “or” within a described list of at least 2 terms is to indicate that any of the listed terms or any combination of the listed terms. The use of ordinal numbers such as “first,” “second,” “third” and so on is to distinguish respective elements rather than to denote a particular order of those elements. For purposes of this description, the terms “hand off” and “hand over” can be used interchangeably as can the terms “handing off” and “handing over” and the terms “handed off” and “handed over.”
The diagrams and flow charts shown in the figures are provided merely as examples and are not intended to be limiting. Many of the elements illustrated in the figures or described herein are functional elements that can be implemented as discrete or distributed components or in conjunction with other components, and in any suitable combination and location. Those skilled in the art will appreciate that other arrangements and elements (for example, machines, interfaces, functions, orders, or groupings of functions) can be used instead. Furthermore, various functions described as being performed by one or more elements can be carried out by a processor executing computer-readable program instructions or by any combination of hardware, firmware, or software.
II. Example Architecture
FIG. 1 is a diagram depicting a system 100 in accordance with one or more of the example embodiments. System 100 can be referred to as a communication network or, more particularly, a wireless communication network. System 100 includes multiple base stations, represented by base stations 102 , 104 , and 106 . System 100 can include a different number of base stations than is shown in FIG. 1 . Each base station shown in FIG. 1 can include a transceiver to transmit and receive radio frequency (RF) signals. Each of those base stations can include a transceiver tower, as shown in FIG. 1 , but is not so limited.
The RF signals transmitted by each base station provide a coverage area in which UE devices can carry out wireless communications over an air interface within the coverage area. In FIG. 1 , the coverage areas provided by the base stations 102 , 104 , and 106 are coverage areas 108 , 110 , and 112 , respectively. The air interfaces within those coverage areas are air interfaces 114 , 116 , and 118 , respectively. For simplicity, each coverage area is area is shown as a hexagon, but each coverage area is not so limited. For clarity of FIG. 1 , none of the coverage areas of system 100 is shown as overlapping another coverage area. A person skilled in the art will understand that each coverage area can overlap or be overlapped by another coverage area.
System 100 includes multiple UE devices, represented by UE devices 120 , 122 , 124 , 126 , 128 , and 130 . In one respect, a UE device can be a mobile UE device. A mobile UE device can be moved from a first coverage area to a second coverage area and operate with a base station while moving between those coverage areas. In another respect, a UE device can be a stationary UE device that is configured for operating at a fixed location. The fixed location may be limited to a location at which the stationary UE device can receive electrical power to operate the UE device.
The RF signals transmitted via a UE device to a base station can be referred to as reverse-link signals or reverse-link communications. The RF signals transmitted from a base station to a UE device can be referred to a forward-link signals or forward-link communications.
In practice, each base station can communicate with a UE device over an air interface (for example, air interface 114 , 116 , or 118 ) according to one or more air interface protocols, examples of which include LTE, CDMA, WiMAX, IDEN, GSM, GPRS, UTMS, EDGE, MMDS, WIFI, BLUETOOTH, and other protocols now known or later developed. The principles of the example embodiments may be applicable in various ones of these protocols. For simplicity, however, this description will focus specifically on implementation in LTE as described herein.
System 100 can include inter-base-station communication link 132 that connects each base station to at least one neighbor base station. In accordance with the LTE implementation, communication link 132 can comprise an X2 link. System 100 can include communication links 134 to provide base stations 102 , 104 , and 106 with connectivity to one or more transport networks 136 , such as the public switched telephone network (PSTN) or the Internet for instance. With this arrangement, a UE device that is positioned within the coverage area of a base station and that is suitably equipped may engage in air interface communication with the base station and can thereby communicate with remote entities on the transport network(s) and/or with other UE devices served by a base station of system 100 .
Next, FIG. 2 is a block diagram of a user-equipment (UE) device 200 in accordance with one or more of the example embodiments. UE device 200 includes a processor 202 , a wireless communication interface 204 , a user interface 206 , and a data storage device 208 , all of which can be linked together via a system bus, network, or other connection mechanism 210 . UE device 200 can operate within system 100 . One or more of the UE devices shown in FIG. 1 can be configured as UE device 200 . UE device 200 can comprise or be configured as a cellular telephone, a personal digital, a tablet computing device, or a laptop computer.
Processor 202 can comprise one or more general purpose processors (for example, INTEL single core microprocessors or INTEL multicore microprocessors) or one or more special purpose processors (for example, application specific integrated circuits (ASICs) or digital signal processors (DSPs)). Processor 202 can execute computer-readable program instructions, such as computer-readable program instructions (CRPI) 212 .
Wireless communication interface 204 can include one or more components for transmitting data to a base station of a wireless communication network and for receiving data from a base station of the wireless communication network. Those components can include a transmitter and a receiver, distinct from one another, or a transceiver including both a transmitter and a receiver. Wireless communication interface 204 can be arranged as a multiple-input-multiple-output (MIMO) system including multiple transmit antennas (for example, 2 or 4 antennas) and multiple receive antennas (for example, 2 or 4 antennas).
User interface (UI) 206 can include one or more components for a user of UE device 200 to input data or information to UE device 200 . Those component(s) can be referred to as UI input component(s). As an example, the UI input components can include a touchscreen (for example, a capacitive touchscreen or a resistive touchscreen) to input selections made by the user. As another example, the UI input components can include a power switch to power on and power off UE device 200 . As another example, the UI input components can include a microphone to receive voice communication, spoken by the user, for transmission within system 100 .
User interface 206 can include one or more components to present data or information to the user of UE device 200 . Those component(s) can be referred to as UI output component(s). As an example, the UI output components can include an audio speaker to output audible sounds such as voice communications and streaming music received via wireless communication interface 204 . As another example, the UI output components can include a display device, such as a thin film transistor display, a thin film diode display, an organic light-emitting diode display, a capacitive touch screen, or a resistive touchscreen.
Data storage device 208 can comprise a non-transitory computer-readable storage medium readable by processor 202 . The computer-readable storage medium can comprise volatile and/or non-volatile storage components, such as optical, magnetic, organic or other memory or disc storage, which can be integrated in whole or in part with processor 202 . Data storage device 208 may also or alternatively be provided separately, as a non-transitory machine readable medium. Data storage device 208 can include CRPI 212 and a neighbor list 214 .
CRPI 212 can comprise a variety of program instructions, executable by processor 202 , to cause the elements of UE device 200 to perform one or more of the functions described herein, including one or more of the functions shown in FIG. 5 .
CRPI 212 can comprise program instructions to allow a user to engage in communication sessions using UE device 200 , and to cause UE device 200 to operate in an idle mode while UE device 200 is not engaging in a communication session. Operating in the idle, mode can include UE device 200 performing discontinuous reception (DRX) to conserve power in a battery of UE device 200 . As an example, UE device 200 can operate in a low power mode and can wake up every 1.28 seconds (or other defined cycle period) to check for any page messages destined to UE device 200 . If UE device 200 detects a page message while awake during a DRX cycle, UE device 200 can then process the page message. Otherwise, UE device 200 can return to the low power mode before waking up again for the next DRX cycle.
CRPI 212 can comprise program instructions to receive reverse-link measurement parameters from a base station serving UE device 200 . While being served by base station 104 , wireless communication interface 204 can receive the reverse-link measurement parameters via the forward-link of air interface 116 . Execution of CRPI 212 can cause the reverse-link measurement parameters, received at wireless communication interface 204 , to be provided to processor 202 or data storage device 208 . Any data provided to data storage device 208 can be stored at data storage device 208 . In particular, the reverse-link measurement parameters provided to data storage device 208 can be stored with measurement parameters 216 . As an example, the reverse-link measurement parameters can include parameters for reverse-link noise measurements.
The reverse-link noise measurements received at UE device 200 can be arranged in various configurations. For example, the reverse-link noise measurements can indicate the noise measured on the reverse-links to the base station serving UE device 200 (RLN Serving ) and noise measured on the reverse-links to a base station neighboring the base station serving UE device 200 ((RLN Neighbor(x) ), where x=a number 1 to n, and n=the number of base stations considered to neighbor the base station serving UE device 200 . As another example, the reverse-link noise measurements can indicate a difference between reverse-link noise measurements of the base station serving UE device 200 and a neighboring base station. For instance, the difference can equal RLN Serving −RLN Neighbor(x) or RLN Neighbor(x) −RLN Serving . The reverse-link noise measurements can, for example, be specified as a number of decibels (dB).
CRPI 212 can comprise program instructions to receive forward-link measurement parameters from a base station serving UE device 200 . Execution of CRPI 212 can cause the forward-link measurement parameters, received at wireless communication interface 204 , to be provided to processor 202 or data storage device 208 (for storing as measurement parameters 216 ).
CRPI 212 can include program instructions to provide the received reverse-link noise measurements to data storage device 208 and to determine an arithmetic mean (that is, average or mean) of a given number of most-recently received noise measurements for a base station or noise measurement differences. As an example, the given number can be 3. In that case, if the 5 most recent noise measurement differences for base stations 102 and 104 are 12 dB, 8 dB, 11 dB, 4 dB, and 3 dB, then execution of the CRPI 212 can cause processor 202 to determine the mean for those noise measurement differences to be 6 dB (that is, (11 dB+4 dB+3 dB)/3=6 dB). The arithmetic means can be provided to data storage device 208 and stored as aggregated parameters 218 .
Neighbor list 214 can comprise data indicating which base stations of system 100 are neighbors to the base station serving UE device 200 . In accordance with an embodiment in which base station 102 is serving UE device 200 , the neighbor base stations for UE device 200 can be base stations 104 and 106 . Tables 1 and 2 illustrate examples of neighbor list 214 . The data in Tables 1 and 2 identify that base station 102 is the base station serving UE 200 and base stations 104 and 106 are the neighbor base stations. The “Null” values in Tables 1 and 2 indicate that no data is stored in that field of the table. The “Null” values can change when or in response to UE device handing over to another base station.
Table 1 illustrates that neighbor list 214 includes the most-recent reverse-link noise measurements and an average of the most-recent reverse-link noise measurements for the serving and neighboring base stations. Table 2 illustrates that neighbor list 214 includes the most-recent differences in reverse-link noise measurements and an average of the most-recent differences in reverse-link noise measurements for the serving and neighboring base stations.
TABLE 1
BS Serving
BS Neighbor
RLN (1)
RLN (2)
RLN (3)
RLN (Mean)
102
Null
15 dB
10 dB
9 dB
11.3 dB
Null
104
4 dB
6 dB
6 dB
5.3 dB
Null
106
13 dB
3 dB
6 dB
7.3 dB
TABLE 2
BS Serving
BS Neighbor
RLN DIFF(1)
RLN DIFF(2)
RLN DIFF(3)
RLN DIFF(Mean)
102
Null
Null
Null
Null
Null
Null
104
11 dB
4 dB
3 dB
6 dB
Null
106
2 dB
7 dB
3 dB
4 dB
Referring to the data in Tables 1 and 2, the values of RLN DIFF(x) are determined by subtracting the measured reverse-link noise for the neighbor base station from the measured reverse-link noise for the serving base station. The value of (x)=1 to n, wherein n=the number of measurements to be used to determine the arithmetic mean. The values of RLN DIFF(x) can be negative. In accordance with other embodiments, the values of RLN DIFF(x) can be determined by subtracting the measured reverse-link noise for the serving base station from the measured reverse-link noise for the neighbor base station.
The reverse-link noise measurement data in Tables 1 and 2 can be stored in area of data storage device 208 that is distinct from neighbor list 214 , such as measurement parameters 216 . CRPI 212 can comprise program instructions to calculate the values of RLN (Mean) , RLN DIFF(1) , RLN DIFF(2) , RLN DIFF(3) , and RLN DIFF(Mean) from the values of RLN (1) , RLN (2) , and RLN (3) received at wireless communication interface 204 . In response to UE device 200 being handed off from base station 102 to a neighbor base station, such as base station 104 , the data in the example neighbor lists shown in Tables 1 and 2 can be updated to indicate that base station 102 is a BS Neighbor and base station 104 is the BS Serving .
CRPI 212 can comprise program instructions to select another base station to be the base station serving UE device 200 . Selecting another base station can be referred to as reselecting a base station. Executing the program instruction to select the other base station can include processor 202 determining the base station that, most recently, is experiencing the highest quality of service (for example, the lowest amount of reverse-link noise). Considering the reverse-link noise measurement data in Table 1, processor 202 can select base station 104 as the next base station to serve UE device 200 because the lowest average reverse-link noise was measured for base station 104 .
Considering the reverse-noise measurement data in Table 2, processor 202 can select base station 104 as the new serving base station since the largest difference in measured reverse-link noise is for the pair of base stations 102 and 104 . In accordance with the embodiments in which the values of RLN DIFF(x) are determined by subtracting the measured reverse-link noise for the serving base station from the measured reverse-link noise for the neighbor base station, processor 202 can select a base station as the new serving base station if that base station has the smallest difference (or largest negative) value of RLN DIFF(x) .
Next, FIG. 3 is a block diagram of a base station 300 in accordance with one or more example embodiments described herein. Base station 300 comprises a processor 302 , a network interface 304 , a wireless communication interface 306 , and a data storage device 308 , all of which can be linked together via a system bus, network, or other connection mechanism 310 . For the example embodiments using the LTE protocol, the base station serving a UE device can be referred to as “eNodeB” or “eNB.”
Processor 302 can comprise one or more general purpose processors (for example, INTEL single core microprocessors or INTEL multicore microprocessors) or one or more special purpose processors (for example, ASICs or DSPs). Processor 302 can execute computer-readable program instructions, such as computer-readable program instructions (CRPI) 312 .
Network interface 304 can comprise a wired or wireless interface for communicating with a network infrastructure (such as a switch, gateway, mobility manager, or the like), which provides connectivity or facilitates communication with one or more of the transport networks 136 .
Wireless communication interface 306 can engage in air interface communication with base stations such as those shown in FIG. 1 . As such, wireless communication interface 306 can include an antenna structure and a chipset arranged to support wireless communication according to one or more air interface protocols, such as those discussed above for instance. The chipset can, for example, include a power amplifier and a cell site modem.
Data storage device 308 can comprise a non-transitory computer-readable storage medium readable by processor 302 . The computer-readable storage medium can comprise volatile and/or non-volatile storage components, such as optical, magnetic, organic or other memory or disc storage, which can be integrated in whole or in part with processor 302 . Data storage device 308 may also or alternatively be provided separately, as a non-transitory machine readable medium.
Data storage device 308 can include CRPI 312 , a neighbor list 314 , reverse-link measurement parameters 316 , reverse-link noise measurement differences, and UE device data 320 . Other examples of data that can be contained in data storage device 308 are also possible, some of which are described in other parts of this description.
CRPI 312 can comprise a variety of program instructions, executable by processor 302 , to cause the elements of base station 300 to perform one or more of the functions described herein, including one or more of the functions shown in FIG. 4 .
CRPI 312 can comprise program instructions to receive reverse-link measurement parameters from one or more neighbor base station, such as one of the base stations shown in FIG. 1 . The neighbor base station can transmit the reverse-link measurement parameters to network interface 304 . Execution of CRPI 312 can cause the reverse-link measurement parameters, received at network interface 304 , to be provided to processor 302 or data storage device 308 . Any data, such as reverse-link measurement parameters, provided to data storage device 308 can be stored at data storage device 308 .
In one respect, some or all of the reverse-link measurement parameters received at network interface 304 can be unsolicited. In another respect, some or all of the reverse-link measurement parameters received at network interface 304 can be received in response to base station 300 requesting the reverse-link measurement parameters. In that regard, CRPI 312 can comprise program instructions to generate a request for reverse-link measurement parameters to cause network interface 304 to transmit the request to one or more neighbor base stations. As an example, the reverse-link measurement parameters can comprise reverse-link noise measurement parameters that indicate reverse-link noise measured by a base station.
CRPI 312 can comprise program instructions to determine reverse-link measurement parameters for reverse links to wireless communication interface 306 , provide the determined reverse-link measurement parameters to data storage device 308 for storage as reverse-link measurement parameters 316 , generate a message comprising one or more of the determined reverse-link measurement parameters, and transmit, using network interface 304 , the message comprising one or more of the determined reverse-link measurement parameters to one or more neighbor base stations. Examples of the reverse-link noise measurement parameters are shown in Table 1 (for example, RLN (1) , RLN (2) , and RLN (3) ).
CRPI 312 can comprise program instructions to determine differences between reverse-link noise measurement parameters for reverse links to wireless communication interface 306 and reverse-link noise measurement parameters from a neighbor base station, provide the determined differences to data storage device 308 for storage as reverse-link measurement parameter differences 318 , generate a message comprising one or more determined differences, and transmit, using network interface 304 , the message comprising the one or more determined differences. Examples of the determined reverse-link parameter differences are shown in Table 2 (for example, RLN DIFF(1) , RLN DIFF(2) , and RLN DIFF(3) ).
UE device data 320 can comprise data that identifies the UE devices being served by base station 300 and whether each UE device is engaged in a communication session or is operating in an idle mode. UE device data 320 can include data that indicates or that can be used to determine when each UE device is operating in an idle mode and will transition to or operate in a discontinuous reception (DRX) mode. CRPI 312 can comprise program instructions that are executable to refer to UE device data 320 to determine when UE device 200 is operating in the idle mode and the DRX mode. Processor 302 can execute the program instructions to send reverse-link measurement parameters or differences to UE device 200 while UE device 200 is operating in the idle and DRX modes.
In addition to operating as a serving base station that serves UE device 200 , a base station, such as base station 300 , can operate as a neighbor base station to one or more other base stations. Those other base stations can transmit reverse-link measurement parameters obtained from base station 300 to UE devices serviced by those other base stations so that those UE devices can make a determination whether to select a new base station. Therefore, CRPI 312 can include program instructions to cause network interface 304 to transmit the reverse-link measurement parameters from base station 300 to another base station via inter-base-station communication link 132 .
III. Example Operation
Next, FIG. 4 is a flow diagram depicting a set of functions 400 that can be carried out in accordance with one or more example embodiments. The functions identified in FIG. 4 refer to a UE device, a first base station, and a second base station. For purposes of describing FIG. 4 , the UE device is referred to as UE device 200 , the first base station is referred to as base station 102 , and the second base station is referred to as base station 104 . As indicated above, base stations 102 and 104 can be arranged like base station 300 , and therefore, contain the elements of base station 300 .
In FIG. 4 , block 402 includes determining, at base station 102 , a first reverse-link noise measurement pertaining to one or more reverse-links to base station 102 . Processor 302 can execute program instructions 312 to determine the noise measurements. Execution of those program instructions can include referring to signals provided to base station 102 from UE devices via the reverse-links. Base station 102 may measure reverse-link noise while one or more UE devices serve by base station 102 are idle and operating in a DRX mode.
Block 404 includes receiving, at base station 102 , a second reverse-link noise measurement pertaining to one or more reverse-links to base station 104 neighboring base station 102 . Processor 302 can execute program instructions 312 to receive the second reverse-link noise measurement via network interface 304 . In that regard, network interface 304 can receive the second reverse-link noise measurement via transmission of that measurement via inter-base-station communication link 132 or a communication link 134 .
Block 406 includes determining, at base station 102 , a difference between the first reverse-link noise measurement and the second reverse-link noise measurement. Processor 302 can execute program instructions 312 to determine the difference. In one respect, processor 302 can execute CRPI 312 to determine the difference by subtracting the first reverse-link noise measurement from the second reverse-link noise measurement. In another respect, processor 302 can execute CRPI 312 to determine the difference by subtracting the second reverse-link noise measurement from the first reverse-link noise measurement.
A person skilled in the art will understand that the amount of noise experienced by the reverse-links to a base station can vary over time. As the noise on the reverse-links to base station 102 increases, the noise on the reverse-links to a neighboring base station can decrease. Providing a UE device with information regarding those noise levels can lead to the UE device selecting the base station experiencing less noise on the reverse-links to be a new serving base station for the UE device.
Base station 102 can be configured to determine additional differences of distinct reverse-link noise measurements. For example, base station 102 can determine multiple differences of distinct reverse-link noise measurements for a given pair of base stations, such as base stations 102 and 104 . As another example, base station 102 can determine differences of distinct reverse-link noise measurements for more than one pair of base stations. For instance, base station 102 can determine differences of reverse-link noise measurements for base stations 102 and 104 and differences for base stations 102 and 106 .
Block 408 includes transmitting, from base station 102 to UE device 200 served by base station 102 , data indicating the difference between the first reverse-link noise measurement and the second reverse-link noise measurement. Processor 302 can execute program instructions 312 to cause wireless communication interface 306 to transmit the data. In accordance with the LTE implementation, transmission of the data indicating the difference can occur over a physical downlink control channel (PDCCH) between UE device 200 and base station 102 , and that transmission can include transmitting a paging radio network temporary identifier (PRNTI) having the difference encoded within the PRNTI.
In an alternative arrangement, the base station serving UE device 200 can transmit the first and second reverse-link noise measurements to UE device 200 . In accordance with that alternative arrangement, UE device 200 can compare the first and second reverse-link noise measurements to determine whether UE device 200 should select a new base station to be the serving base station. Alternatively, UE device 200 can determine the difference between the first and second reverse-link noise measurements for use in determine whether a new serving base station should be selected.
In accordance with one or more example embodiments, transmitting data indicating the difference can occur while UE device 200 has awaken during a DRX cycle. Processor 302 can refer to UE device data 320 to determine when UE device 200 awakes for the DRX cycle and then transmit the data indicating the difference while UE device 200 is awake during the DRX cycle so that UE device 200 can receive the transmitted data.
Although FIG. 4 provides an example of when the reverse-link measurement parameters are reverse-link noise measurements, a person having ordinary skill in the art will understand that the functions of FIG. 4 can be carried out for other reverse-link measurement parameters as well or in addition to the reverse-link noise measurements.
Next, FIG. 5 is a flow diagram depicting a set of functions 500 that can be carried out in accordance with one or more example embodiments. The functions identified in FIG. 5 refer to a UE device, a first base station, and a second base station. For purposes of describing FIG. 5 , the UE device is referred to as UE device 200 , the first base station is referred to as base station 102 , and the second base station is referred to as base station 104 .
In FIG. 5 , block 502 includes determining, at UE device 200 operating in an idle mode, a difference in reverse-link noise measured by base station 102 currently serving UE device 200 and reverse-link noise measured by base station 104 that neighbors base station 102 . Processor 202 can execute program instructions 212 to determine the difference in the reverse-link noise measurements.
In order to determine the difference in reverse-link noise measurements, wireless communication interface 204 can receive the difference in reverse-link noise measurements, as determined by base station 102 . For instance, the difference in reverse-link noise can comprise data indicating a difference between a first reverse-link noise measurement and a second reverse-link noise measurement. In that regard, the first reverse-link noise measurement pertains to one or more reverse-links to the base station 102 , and the second reverse-link noise measurement pertains to one or more reverse-links to base station 104 .
Alternatively, in order to determine the difference in reverse-link noise measurements, wireless communication interface 204 can receive data indicating the first reverse-link noise measurement pertaining to the one or more reverse-links to base station 102 , and data indicating the second reverse-link noise measurement pertaining to the one or more reverse-links to base station 104 , and then determine the difference between those two measurements.
Execution of CRPI 212 to determine the difference in reverse-link noise measurements can occur during a DRX cycle. In that regard, UE device 200 can receive reverse-link noise measurement data while awake during a DRX cycle. Moreover, UE device can receive reverse-link noise measurements during a plurality of DRX cycles while UE device is operating in an idle mode. Data storage device 208 can be configured to store a plurality of the received noise measurements or a sum of a given number of the most-recently received noise measurements.
Furthermore, the base station serving UE device 200 (for example, base station 102 ) can have more than one neighboring base station. Each of those base stations neighboring base station 102 can measure reverse-link noise and provide the reverse-link noise measurements to base station 102 . Base station 102 can transmit the reverse-link noise measurements from the other neighboring base stations to UE device 200 to provide UE device with information for determining differences in reverse-link noise between base station 102 and those other neighboring base stations. Alternatively, base station 102 can determine the differences in reverse-link noise between base station 102 and those other neighboring base stations and transmit those differences to UE device 200 .
Block 504 includes selecting, based on the difference in reverse-link noise determined determined at UE device 200 , base station 104 to serve UE device 200 instead of base station 102 . Processor 202 can execute program instructions 212 to select base station 104 . Execution of those program instructions can cause UE device 200 to select a base station that can provide a greater quality of service than the serving base station.
In one respect, the greater quality of service can be based on the reverse-links to the selected base station relative to the quality of service that can be provided by reverse-links to the serving base station. The quality of service for each base station can be based, at least in part, on the noise measured on the reverse-links to that base station. In that regard, selecting the second base station based on the difference in reverse-link noise comprises can include determining that the first reverse-link noise measurement is greater than the second reverse-link noise measurement.
In another respect, the greater quality of service can be based on the forward-links to the selected base station relative to the quality of service that can be provided by forward-links to the serving base station. In addition to receiving parameters regarding reverse-links of the serving and neighboring base stations, UE device 200 can receive parameters regarding forward-links of the serving and neighboring base stations. The parameters regarding the forward-links can identify noise measured on the forward-links or some other parameter regarding quality of the forward-links. As an example, the forward-link parameters can comprise a Reference Signal Received Power (RSRP) parameter or a Reference Signal Received Quality (RSRQ) parameter.
Block 506 includes initiating, using UE device 200 in response to selecting base station 104 , handoff of UE device 200 from base station 102 to base station 104 . Processor 202 can execute program instructions 212 to initiate the handoff. Execution of those program instructions can cause processor 202 to generate a message to request handoff of UE device 200 from base station 102 to base station 104 , and to cause wireless communication interface 204 to transmit the message to request handoff to base station 102 . Execution of those program instructions can cause UE device 200 to synchronize to base station 104 . Synchronization to base station 104 can include decoding synchronization signals (such as a primary synchronization signal and a secondary synchronization signal) transmitted by base station 104 . Decoding the synchronization can allow UE device 200 to establish appropriate frequency and time synchronization with base station 104 . After initiating hand off, the user device can hand off to the other base station.
Although FIG. 5 provides an example of when the reverse-link measurement parameters are reverse-link noise measurements, a person having ordinary skill in the art will understand that the functions of FIG. 5 can be carried out for other reverse-link measurement parameters as well or in addition to the reverse-link noise measurements.
In accordance with one or more of the example embodiments, the UE device can continue to be served by the serving base station if the reverse-link measurement parameters, reverse-link measurement parameters differences, forward-link measurement parameters, or forward-link measurement parameters differences being compared indicate that the quality of service being provided by the serving base station exceeds or is not surpassed by the quality of service that might be provided by a neighbor base station by a threshold amount. Subsequent comparisons based on updated parameters or parameter differences may result in the UE device handing over to a neighbor base station.
IV. Conclusion
Example embodiments have been described above. Those skilled in the art will understand that changes and modifications can be made to the described embodiments without departing from the true scope and spirit of the present invention, which is defined by the claims. | Methods and systems for making decisions regarding handing off a user-equipment device from a serving base station to a neighboring base station. Base stations in a wireless communication network measure parameters regarding forward-links from the base stations and reverse-links to the base stations. Each base station transmits its measured parameters to its neighboring base station(s). Each base station can determine differences between the parameters it measures and the parameters measured by a neighboring base station. The differences indicate whether the quality of service provided by the serving base station is greater than the quality of service provided by a neighboring base station. The servicing base station transmits the differences to user-equipment devices served by that base station. The user-equipment device compares the differences pertaining to the serving base station and multiple neighboring base stations and selects a neighboring base station to which the user-equipment device is to be handed over. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to the field of personal hand tools. More specifically, the present invention relates to hand tools useful in removing snow, frost, sleet and ice from window glass.
[0003] 2. Description of the Related Art
[0004] In colder climates, automobiles not stored in enclosed garages accumulate snow, ice and frost on the windows and exterior surfaces after intemperate weather, particularly after sitting for periods of several hours or more in crystalline water ice precipitation such as snow, hail, or sleet. Snow, ice, frost and sleet which accumulate on automobiles' exterior surfaces must be removed in whole or part before drivers and passengers can see through the automobiles' windows and operate the vehicles safely.
[0005] A variety of hand-tools exist, such as that described in U.S. patent application Ser. No. 11/623,867 (Tucker et al), for removing snow, ice, frost and the like from the windows and exterior surfaces. Most of these tools rely on pressure, and forward-backward motion, manually applied by a human operator to a scrapper-blade in contact with the vehicle to remove the precipitate from the windows.
[0006] Certain operators find that it is difficult to apply sufficient pressure to the scrapper to remove the precipitate. Others operators find that they lack the reach to apply the tool over all the target surfaces of the vehicle. Other operators find that certain types of ice and frost cannot be easily eradicated from the exterior surfaces with pressure and scrapping alone.
SUMMARY
[0007] From the foregoing discussion, it should be apparent that a need exists for a means of eradicating crystalline water ice precipitate from the exterior of automobiles. Beneficially, such a means would provide a method and apparatus involving deicing agents, such as ethylene glycol or propolyene glycol, which do not rely strictly on the force applied by human operators to deice surfaces.
[0008] The present invention has been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available inventions. Accordingly, the present invention has been developed to provide a means of eradicating ice, sleet, snow, frost and condensate from the exterior surfaces of an automobile that overcomes many or all of the above-discussed shortcomings in the art.
[0009] It is an object of the present invention to provide a tool for removing ice from an exterior surface of an automobile, which tool comprises, in certain embodiments, a rigid handle, a squeegee fabricated from a flexible elastomer material, the squeegee mounted to a bracket such that the squeegee's leading edge is fixed in a direction perpendicular to the axis of the handle, the bracket mounted on a forward end of the handle; a brush mounted to the tool with flexible bristles; and a fluid canister mounted within the handle for retaining deicing fluid, accessible from a hollow opening in the rearward end of the handle.
[0010] The tool may also additionally comprise a twist-off cap affixed to the rearward end of the handle covering the hollow opening; hollow tubing connected between the fluid canister and a nozzle mounted on the forward end of the handle; and a rearward grip surrounding the exterior surface of the rearward end of the handle;
[0011] The tool may further comprise a fluid pump mounted to the handle that is activated by hand. The fluid pump may be configured to disperse deicing fluid from the nozzle by transferring deicing fluid from the canister to the nozzle.
[0012] The canister incorporated into the too may be mounted adjacent to the handle instead of within the handle, and the tool may further comprise a scraper in place of the squeegee, the scrapper having teeth for breaking ice.
[0013] The tool may additionally, or alternatively, comprise a pistol grip affixed to the rearward end of the handle; and a fluid pump mounted to the handle that is activated by a trigger pivotally mounted to the handle forward of the pistol grip. The fluid pump may be configured to disperse deicing fluid from a nozzle mounted on the forward end of the handle by transferring deicing fluid from the canister to the nozzle.
[0014] The tool may further comprise hollow tubing connected between the fluid pump and the forward end of the handle. The canister may be mounted adjacent to the handle rather than within the handle.
[0015] The tool may further comprise a scrapper in place of the squeegee, the scraper having teeth for breaking ice. The squeegee may be mounted to a bracket such that the squeegee's leading edge is fixed in a direction perpendicular to the axis of the handle, the bracket mounted on a forward end of the handle.
[0016] The fluid pump may be electronically activated by an electrical switch, and the tool may further comprise one or more batteries housed within the handle and conductively connected to the fluid pump.
[0017] The pistol grip may be telescopically connected to the rearward end of the handle, such that the pistol grip may be extended and retracted from the rearward end of the handle. The pistol grip may be foldably connected to the rearward end of the handle, such that the pistol grip may be folded forward against the handle and folded back to extend away from the rearward end of the handle.
[0018] The tool may further comprise a fluid canister mounted to the handle for retaining deicing fluid and pressurized air, the fluid canister slidably movable along the axis of the handle; as well as a pressure release valve mounted on the fluid canister; and, in some embodiments, a pressurization pump mounted to the handle for compressing air into the canister.
[0019] The trigger may actuate a flow control valve for ejecting a continuous stream of water from the nozzle in various embodiments of the present invention.
[0020] Reference throughout this specification to features, advantages, or similar language does not imply that all of the features and advantages that may be realized with the present invention should be or are in any single embodiment of the invention. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment of the present invention. Thus, discussion of the features and advantages, and similar language, throughout this specification may, but do not necessarily, refer to the same embodiment.
[0021] Furthermore, the described features, advantages, and characteristics of the invention may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize that the invention may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments of the invention.
[0022] These features and advantages of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] In order that the advantages of the invention will be readily understood, a more particular description of the invention will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which:
[0024] FIG. 1 sets forth a top perspective view of one embodiment of an ice eradicator in accordance with the present invention;
[0025] FIG. 2 sets forth a top perspective view of a second embodiment of an ice eradicator in accordance with the present invention;
[0026] FIG. 3 sets forth a top perspective view of a third embodiment of an ice eradicator in accordance with the present invention;
[0027] FIG. 4 sets forth a top perspective view of a fourth embodiment of an ice eradicator in accordance with the present invention;
[0028] FIG. 5 sets forth a top perspective view of a fifth embodiment of an ice eradicator in accordance with the present invention; and
[0029] FIG. 6 sets forth a top perspective view of a sixth embodiment of an ice eradicator in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0030] Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
[0031] The described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided. One skilled in the relevant art will recognize, however, that the invention may be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.
[0032] FIG. 1 sets forth a top perspective view of one embodiment of an ice eradicator 100 in accordance with the present invention. The ice eradicator 100 comprises, in this embodiment, a scraper 102 , a brush 104 , a handle 106 , a fluid canister 108 , tubing 110 , a rearward grip 112 , a twist-off cap 114 , and a nozzle 116 .
[0033] The scraper 102 comprises a blade mechanically adapted to scrap ice, snow, sleet and frost from glass, and is well-known to those of skill in the industry. The scraper 102 , in various embodiments, may comprise a plastic blade or metal blade. The scraper 102 comprises a generally flat blade which may be curved in some embodiments to trace curved surfaces, such as curved glass surfaces of automobiles.
[0034] The brush 104 comprises bristles, wire, or other filaments for removing snow from the exterior surfaces of vehicles, and is well-known in the industry.
[0035] The handle 106 comprises a rigid stick-shaped object meant to be held and used ergonomically by human hands. The handle 106 may be tubular. The handle 106 may be formed from one or more of plastic, rubber, wood, metal, glass or any other inflexible or semi-flexible material to which other object may be mounted or affixed with adhesives, screws, nails, tape and the like. Because the handle 106 is meant to be used economically, it may be shaped in off-straight shapes as shown in FIG. 1 .
[0036] The fluid canister 108 , in the shown embodiment, comprises a container or reservoir for holding deicing fluid. The fluid canister 108 may comprise a container of any shape, including cylindrical, round, bottle-shaped, spherical, and the like. The fluid canister 108 may comprise metal, plastic, or organic components, and may be designed to withstand a predetermined amount of pressure.
[0037] The deicing fluid used by the ice eradicator 100 may comprise any chemical well-known to those of skill in the art, including ethylene glycol, propylene glycol, saline, and the like.
[0038] In various embodiments, the deicing fluid is dispensed from the ice eradicator 100 by activating an electrical or mechanical switch (not shown) on the handle 106 , which disperses the deicing fluid pneumatically, electrically or mechanically from the nozzle 116 . In some embodiments, the deicing fluid may be dispersed from the ice eradicator 100 by simply squeezing the segment of the handle 106 comprising the fluid canister 108 . In some embodiments, both the handle 106 and the canister 108 may comprise flexible materials that can be squeezed by human hands to pressure and disperse the deicing fluid.
[0039] The tubing 110 comprises tubing with appropriate chemical resistance to deicing fluid. Tubing is well-known to those of skill in the art. The tubing 110 may comprise polyvinyl chloride (PVC) tubing, silicone rubber tubing, fluorolpoymer tubing, and the like.
[0040] The rearward grip 112 comprises, in various embodiments, a sheath or coating over the handle 106 that provides friction against the hand of a human operator, thus reducing the gripping force necessary to operate the ice eradicator 100 and/or reduces the pressure necessary to scrap ice, sleet, snow and/or frost from the exterior surfaces of automobiles. Alternatively, the rearward grip 112 may comprise a deformation in the handle 106 itself rather than a separate component. Such a deformation may change the circumference of the handle 106 irregularly to distribute the surface of the handle 106 more evenly across the hand and fingers of human operator of the ice eradicator 100 .
[0041] The twist-off cap 114 comprises a threaded screw closure to mechanically seal deicing fluid within the fluid canister 108 . The twist-off cap 114 , in some embodiments, comprises a metal skirt with threads that screw into threads inside the handle 106 . In other embodiments, the rearward end of the handle 106 comprises a skirt with threads over which corresponding threads inside the twist-off cap 114 are screwed.
[0042] The present invention may incorporate other types of caps well-known to those of skill in the art, including snap on caps, slide on caps, or doors which open and close over the hollow opening.
[0043] The nozzle 116 comprises a mechanical device that controls the direction that the deicing fluid is dispersed when ejected from the ice eradicator 100 . The nozzle 116 may be used to control the flow, speed, direction, and shape of the stream of deicing fluid dispersed from the ice eradicator 100 . The nozzle 116 well-known to those of skill in the art.
[0044] FIG. 2 sets forth a top perspective view of a second embodiment of an ice eradicator 200 in accordance with the present invention. The ice eradicator 200 comprises, in this embodiment, a squeegee 202 , a bracket 204 , a brush 104 , a handle 106 , a fluid canister 108 , tubing 110 , and a rearward grip 112 .
[0045] The brush 104 , the handle 106 , the fluid canister 108 , the tubing 110 , and the rearward grip 112 are all substantially described above in relation to FIG. 1 .
[0046] The scraper 102 in FIG. 1 is replaced in this embodiment with a squeegee 202 . The squeegee 202 is used to remove sleet, ice and frost from the windows and glass, and is well-known to those of skill in the art. The squeegee 202 comprises smooth blade, usually made of rubber. The leading edge of the squeegee 202 in the only segment of the squeegee 202 that comes in contact with the glass or window which the ice eradicator 200 is used to clean.
[0047] In various embodiments, the squeegee 202 comprises sponges or foam wipers on its leading edge in place of a rubber blade.
[0048] The bracket 204 is a rigid component in the ice eradicator 200 mounted between the squeegee 202 and the forward end of the handle 106 .
[0049] The scraper 102 , the brush 104 , the handle 106 , the fluid canister 108 , the tubing 110 , the twist-off cap 114 and the nozzle 116 are all substantially described above in relation to FIGS. 1-2 .
[0050] FIG. 3 sets forth a top perspective view of a third embodiment of an ice eradicator 300 in accordance with the present invention. The ice eradicator 300 comprises, in this embodiment, a scraper 102 , a brush 104 , a handle 106 , a fluid canister 108 , tubing 110 , a pistol grip 302 , an electric fluid pump 304 , batteries 306 , a trigger 308 , and a twist-off cap 114 , and a nozzle 116 .
[0051] The scraper 102 , the brush 104 , the handle 106 , the fluid canister 108 , the tubing 110 , the twist-off cap 114 and the nozzle 116 are all substantially described above in relation to FIGS. 1-2 .
[0052] The pistol grip 302 comprises a secondary handle protruding laterally from the handle 106 on the rearward end of the handle 106 . The pistol grip 302 is shaped such that it orients the hand of the human operator using the ice eradicator 300 in a natural position for comfortably cycling the ice eradicator back and forth across the exterior surface of an automobile.
[0053] In various embodiments of the present invention, the pistol grip 302 serves multiple functions, such as housing the canister 108 and/or other mechanical and electrical components necessary to facilitate the ejection of the deicing fluid from the nozzle 116 .
[0054] The pistol grip 302 , in various embodiments, is telescopically connected to the rearward end of the handle 106 , such that the pistol grip 302 may be extended from, or collapsed to, or retracted to, the handle 106 along the axis of the handle 106 .
[0055] In still further embodiments, the pistol grip 302 is hingedly connected to the rearward end of the handle 106 such that the pistol grip 302 can be folded up against the handle 106 to save space when storing the ice eradicator 300 . The pistol grip 302 may be connected, in various other embodiments, to the handle 106 using a variety of means well known to those of skill in the art.
[0056] The electric pump 304 transfers deicing fluid from the fluid canister 108 to the nozzle 116 through the tubing 110 . The electric pump 304 may comprises any fluid pump well-known to those of skill in the art, including a peristaltic pump, a electroosmotic pump, a rotary pump, one or more impellers, and the like.
[0057] The electric pump 304 is powered by an internal power supply. The internal power supply in the shown embodiment comprises batteries 306 . The batteries 306 are installed and replaced via access provided by, in the shown embodiment, the twist-off cap 114 . Batteries 306 are well-known to those of skill in the art.
[0058] The present invention may incorporate various simple pumps well-known to those of skill in the art, including positive displacement pumps like those found on common spray bottles.
[0059] In other embodiments of the present invention, a second twist-off cap 114 in mounted at the protruding end of the retractable pistol grip 302 to provide access to the canister 108 .
[0060] The trigger 308 is well-known to those of skill in the art. In the shown embodiment, the trigger 308 is a mechanism that actuates the sequence of mechanical or electrical processes that eject the deicing fluid from the present invention when the trigger 308 is depressed with the index finger of the human operator wielding the ice eradicator 300 . The trigger 308 may activate, in various embodiments, a flow control valve mounted to the canister 108 .
[0061] FIG. 4 sets forth a top perspective view of a fourth embodiment of an ice eradicator 400 in accordance with the present invention. The ice eradicator 400 comprises, in this embodiment, a squeegee 202 , a bracket 204 , a brush 104 , a handle 106 , a rail 402 , a pressurized canister 404 , tubing 110 , a pistol grip 302 , and a twist-off cap 114 .
[0062] The squeegee 202 , the bracket 204 , the brush 104 , the handle 106 , the fluid canister 108 , the tubing 110 , the pistol grip 302 , and the twist-off cap 114 are all substantially described above in relation to FIGS. 1-3 .
[0063] The pressurized canister 404 incorporates the canister 108 , but is further designed to hold pressurized air forced into the pressurized canister 404 by pumping, or cycling, the pressurized canister 404 back-and-forth along the axis of the handle 106 . The pressurized canister 404 imparts pneumatic deicing fluid ejection to the present invention.
[0064] In still further embodiments, the pressurized canister 404 is non-slidably mounted to the handle 106 and a separate grip not comprising the pressurized canister 404 mounted below the ice eradicator 400 is pumped to pressurize the pressurized canister 404 .
[0065] The pumping motion of the pressurized canister 404 pressurizes the pressurized canister 404 using mechanisms and means well-known to those of skill in the art, including one or more pressurization pumps mounted to the handle 106 and/or the pressurized canister 404 , and one or more flow control valves mounted to the handle 106 and activated by the trigger 308 .
[0066] The rail 402 comprises a track built into, or affixed upon, the handle 106 over which the pressurized canister 404 slides when it is pumped by a human operator. The rail 402 guides the pressurized canister 404 as it is cycled back-and-forth.
[0067] Various embodiments of the shown embodiment may comprise a trigger 308 . Various embodiments of the present invention may incorporate the use of CO2 cartridges in place of a pressurized canister 404 . The present invention may also incorporate detachable pre-pressurized canisters in place of the canister 108 and/or the pressurized canister 404 , including various types of aerosol canisters.
[0068] FIG. 5 sets forth a top perspective view of a fourth embodiment of an ice eradicator 500 in accordance with the present invention. The ice eradicator 500 comprises, in this embodiment, a squeegee 202 , a brush 104 , a handle 106 , a fluid canister 108 , tubing 110 , and a rearward grip 112 .
[0069] The squeegee 202 , the brush 104 , the handle 106 , the fluid canister 108 , the tubing 110 , and the rearward grip 112 are all substantially described above in relation to FIGS. 1-4 .
[0070] The shown embodiment of the ice eradicator 500 is meant to teach that the fluid canister 108 may comprise a container of any shape, connected in any manner to the handle 106 . In the shown embodiment, the canister 108 comprises a bottle screwed into a threaded skirt on the handle 106 . The canister 108 may be removable, and may clip or snap into place in the handle 106 .
[0071] FIG. 6 sets forth a top perspective view of a fourth embodiment of an ice eradicator 600 in accordance with the present invention. The ice eradicator 600 comprises, in this embodiment, a scraper 102 , a brush 104 , a handle 106 , a fluid canister 108 , tubing 110 , and a rearward grip 112 .
[0072] The scraper 102 , the brush 104 , the handle 106 , the fluid canister 108 , the tubing 110 , and the rearward grip 112 are all substantially described above in relation to FIGS. 1-5 .
[0073] The shown embodiment of the ice eradicator 600 is meant to teach that the fluid canister 108 may comprise a container of any shape, connected in any manner to the handle 106 . In the shown embodiment, the canister 108 comprises a gun-stock shaped forward grip, in which the canister 108 is housed.
[0074] The ice eradicator 600 may also comprise a squeegee 202 in place of the scraper 102 . In all embodiments of the present invention, the squeegee 202 may be affixed directly to the handle 106 without the bracket 204 .
[0075] The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. | A hand tool adopted to remove ice, snow, sleet, frost and the like from the exterior surfaces of a vehicle, including the windows of automobiles. The ice scrapper comprises a rearward grip, a handle, a brush, a squeegee, and a canister containing deicing fluid which is mechanically or electronically operated to disperse deicing fluid onto the window of an automobile to facilitate more efficient removal of crystalline precipitation and condensate. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application No. 62/107,926, filed on Jan. 26, 2015, the entire contents of which are incorporated herein by reference.
FIELD OF THE DISCLOSURE
The present disclosure relates to holsters for handguns, and more particularly, to a holster engaging a handgun by a pin penetrating the barrel of the handgun.
BACKGROUND
Holsters are used to support handguns on the body of a user of the handgun. In many situations, it is not desirable to have it known that the user is in possession of a handgun. Yet many holsters increase bulk and conspicuousness of a holstered handgun on the body.
In an emergency situation, it may be necessary for the user to withdraw the handgun from the holster very quickly. Holsters often interfere with rapid withdrawal of the associated handgun.
There exists a need for a holster which obscures the nature of the contained handgun, and which enables expeditious withdrawal of the handgun.
SUMMARY
The disclosed concepts address the above stated situation by providing a holster which obscures presence and identity of the handgun held by the holster. To this end, the novel holster has a shape which complements that of a handgun, and which does not add to the thickness of the handgun. The holster has a similar or smaller thickness than its associated handgun. Moreover, the complementary shape may include three sides of a parallelepiped, thereby creating a visual impression that the item, when contained in a pocket of an item of apparel, is some other object such as a cellular telephone or a wallet for example.
The novel holster may be generally L-shaped to interfit with the handgun. The holster has a pin which engages the handgun by being inserted into the barrel of the handgun. The holster may be placed in a pocket of an item of apparel, may be clipped to the inside of apparel, or may be otherwise carried on the body to provide ready access to the handgun without visually revealing the nature and presence of the handgun.
It is an object to provide improved elements and arrangements thereof by apparatus for the purposes described which is inexpensive, dependable, and fully effective in accomplishing its intended purposes.
This and other objects will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Various objects, features, and attendant advantages of the disclosed concepts will become more fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein:
FIG. 1 is a side view of a handgun received in a holster, according to at least one aspect of the disclosure;
FIG. 2 is a side view of the holster of FIG. 1 ;
FIG. 2A is a perspective view of the elongated slot of the holster as illustrated in FIG. 2 ;
FIG. 3 is a perspective view of the holster of FIG. 2 ; and
FIG. 4 is a plan view representing fabric of a panel of an article of apparel, shown distended due to the handgun and holster of FIG. 1 having been concealed beneath the fabric.
DETAILED DESCRIPTION
Referring first to FIG. 1 , according to at least one aspect of the disclosure, there is shown a handgun 10 received in a holster 100 . Turning momentarily to FIG. 2 , holster 100 is shown isolated from handgun 10 .
Holster 100 is for holding and obscuring identity of handgun 10 . Holster 100 comprises a base 102 having a proximal end 104 , a distal end 106 , an inner surface 108 between proximal end 104 and distal end 106 , and an outer surface 110 between proximal end 104 and distal end 106 . Outer surface 110 is opposite inner surface 108 . Base 102 includes a pin 112 (visible in FIG. 2 ) projecting from inner surface 108 of base 102 proximate proximal end 104 . Pin 112 is dimensioned and configured to slidingly engage the inside of a barrel of handgun 10 . A bolster 114 projects from inner surface 108 of base 102 at distal end 106 of base 102 . Bolster 114 is longer than pin 112 . In FIG. 1 , length of bolster 114 is along an imaginary projection line 116 .
Base 102 is a structural member of holster 100 supporting pin 112 against which a muzzle end 12 of handgun 10 seats. Bolster 114 is a structural member of holster 100 supporting other components to be described hereinafter. Bolster 114 may be perpendicular to base 102 , when considering surface 118 of bolster 114 and outer surface 110 of base 102 . Base 102 has a maximum width 120 about equal to a width 30 of handgun 10 . Holster 100 further comprises a web 124 projecting from bolster 114 towards pin 112 . Web 124 extends about the full length 126 of bolster 114 and has a thickness 124 ( FIG. 3 ) less than a width 128 ( FIG. 3 ) of bolster 114 .
Referring particularly to FIGS. 1 and 4 , but also to FIGS. 2 and 3 , holster 100 complements the shape of handgun 10 to simulate at least three sides of a parallelepiped when handgun 10 and holster 100 are covered by a fabric 14 when handgun 10 is installed on holster 100 with pin 12 penetrating a barrel 16 of handgun 10 , and with the trigger guard (not individually shown) and a handle 18 ( FIG. 1 ) of handgun 10 received in close cooperation with holster 100 . As used herein, simulating at least three sides of a parallelepiped signifies that a bulge 20 ( FIG. 4 ) produced when fabric 14 is distended due to covering holster 100 and handgun 10 has at least three straight sides 22 , 24 , 26 ( FIG. 4 ) corresponding to outer surface 110 , surface 118 , and a top surface 28 ( FIG. 1 ) of handgun 10 . It is desired to conceal the nature and identity of handgun 10 when the latter is contained within an article of apparel (not shown) and covered by a panel (represented as fabric 14 in FIG. 4 ) of that article of apparel. This goal is satisfied by having bulge 20 visually suggest that the enveloped item be a parallelepiped such as a cellular telephone or wallet (neither shown), rather than displaying the generally L-shaped configuration of handgun 10 . Therefore, it is important that those portions of holster 10 which will influence bulge 20 be straight at their outer surfaces, and complement an available straight line (i.e., top surface 28 ) of handgun 10 . A non-linear fourth border or surface of a true parallelepiped, such as that generated by the somewhat irregular profile of handgun 10 at the rear of handgun 10 , the rear being handle 18 and hammer (not shown, but immediately adjacent handle 18 ), is deemed not objectionable since the overall visual impression will be largely formed by those three straight sides 22 , 24 , 26 of bulge 20 resulting from outer surface 110 and surface 118 of holster 100 , and top surface 28 of handgun 10 . Handgun 10 need contact holster 10 only at pin 112 , although web 122 may be L-shaped or otherwise configured to interfit in close cooperation with handgun 10 when the latter is installed on pin 112 .
Alternatively stated, and now considering the overall thickness of the combination of holster 100 and handgun 10 , holster 100 is dimensioned and configured to complement handgun 10 to define a three dimensional envelope with handgun 10 installed on holster 100 with pin 112 penetrating barrel 16 of handgun 10 with the trigger guard and handle 18 of handgun 10 received in close cooperation with holster 100 . The envelope has straight first side 22 , a parallel opposed second side 26 , a third side 24 perpendicular to and between first side 22 and second side 26 , and a generally uniform width. The generally uniform width is defined by and about equal to width 120 of base 102 , and of course, handgun 10 . FIG. 4 provides a plan view of the three dimensional envelope.
Bolster 114 has a maximum width about equal to a width 30 of handgun 10 . Therefore, base 102 , bolster 114 , and handgun 10 all have about equal width. “About equal” signifies that bulge 20 ( FIG. 4 ) generates a visual impression of a parallelepiped to casual observation, thereby concealing the nature of handgun 10 .
Views intended to generate the visual impression of the parallelepiped are taken from an angle wherein handgun 10 is viewed from the side, as shown in FIG. 1 .
Holster 100 further comprises a recess 130 on an outer side (e.g., surface 118 ) of bolster 114 , for receiving a finger (not shown) of a user, to assist the user in maneuvering holster 100 into place in a pocket of apparel (not shown) worn by the user.
In an option shown in FIGS. 1 and 3 , holster 100 further comprises a trigger guard plate 132 and a clamp operable to clamp trigger guard plate 132 to handgun 10 . The clamp may comprise a Chicago screw having a male portion 134 A and a female portion 134 B.
Trigger guard plate 132 is positioned to obstruct lateral finger access to the trigger of handgun 10 . To provide versatility in positioning trigger guard plate 132 , trigger guard plate 132 includes an elongated slot 138 extending parallel to pin 112 , to facilitate adjustment of position of trigger guard plate 132 along an axis parallel to pin 112 . Web 122 includes an elongated slot 136 ( FIG. 2 ) extending perpendicularly to elongated slot 138 of trigger guard plate 132 , to facilitate adjustment of position of trigger guard plate 132 along an axis (not shown) perpendicular to pin 112 .
Referring again to FIG. 1 , trigger guard plate 132 may include two posts 140 A, 140 B projecting perpendicularly therefrom, to surround and immobilize the trigger of handgun 10 .
The invention may be thought of as holster 100 , or alternatively, as handgun 10 and holster 100 for holding and obscuring identity of handgun 10 .
Holster 100 may be fabricated from any rigid material such as a thermosetting plastic, metal, wood, or another synthetic material, or combinations of these. Trigger guard plate 132 may be fabricated from a stiff leather, polymeric material, wood, or other synthetic material.
In the preceding description, numerous specific details are set forth in order to provide an understanding of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without these specific details. In other instances, well known components or methods have not been described in detail but rather in a block diagram in order to avoid unnecessarily obscuring the present invention. Thus, the specific details set forth are merely exemplary. The specific details may be varied from and still be contemplated to be within the spirit and scope of the present invention.
It should be understood that the various examples of the apparatus(es) disclosed herein may include any of the components, features, and functionalities of any of the other examples of the apparatus(es) disclosed herein in any feasible combination, and all of such possibilities are intended to be within the spirit and scope of the present disclosure. Many modifications of examples set forth herein will come to mind to one skilled in the art to which the present disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings.
Therefore, it is to be understood that the present disclosure is not to be limited to the specific examples presented and that modifications and other examples are intended to be included within the scope of the appended claims. Moreover, although the foregoing description and the associated drawings describe examples of the present disclosure in the context of certain illustrative combinations of elements and/or functions, it should be appreciated that different combinations of elements and/or functions may be provided by alternative implementations without departing from the scope of the appended claims. | A holster which obscures presence and identity of the handgun held by the holster is disclosed. The holster comprises an L-shaped frame having a pin. The handgun is installed on the holster by inserting the pin into the barrel of the handgun. The L-shaped frame combined with the installed handgun collectively form a parallelepiped of thickness equal to that of the handgun. The handgun is disguised by visually meshing in complementary fashion with the holster, when concealed beneath a fabric of an article of apparel. | 5 |
PRIORITY INFORMATION
[0001] This application claims the benefit of U.S. Provisional Application No. 60/591,058, filed on Jul. 26, 2004.
FIELD OF THE INVENTION
[0002] The field of this invention related to surface cementing heads for dropping balls and wiper plugs into a wellbore.
BACKGROUND OF THE INVENTION
[0003] In cementing casing or liners the procedure typically involves dropping one or more balls for engagement with a downhole seat sized for that ball to allow pressure buildup to set downhole devices such as external casing packers. After the ball is dropped and the downhole equipment is set, the delivery of the cement occurs in conjunction of delivery of one or more wiper plugs or darts down the casing. These plugs separate mud from cement or clean the inside of the casing.
[0004] Typically the ball-dropping device is located below the dart-releasing device so that the darts must travel past the ball-releasing device after it has dropped the balls. One problem with this layout is that the ball dropping device, after release of the ball, presents either a large opening or edges that can engage the trailing cups on the dart as it is pumped by. What has happened is that tears can develop in these cups allowing fluid bypass around the dart. This can stop the forward motion of the dart or impede its ability to separate fluids or to clean the inside wall of the casing or tubular as it is forced downhole. Accordingly, as described below with regard to the preferred embodiment, as solution to this problem has been devised to try to minimize the tendency to tear the darts as they pass the ball release device.
[0005] In another aspect, a provision is made to prevent the darts from coming back uphole, in the event of a pressure surge. Such darts are retained from traveling above their release mechanism. The release mechanism for the darts features, in the preferred embodiment, individual release barrels for each dart allowing for the darts to be dropped in any order. It further allows observation of what dart is in which barrel without affecting the operation of the other barrels holding other darts. Each barrel is movable between a fully misaligned and fully aligned position with the casing or tubular and can be locked in at least two positions. A handle assembly stays with the dart dropping unit and manipulation of the integrated operating handle acts to defeat the lock and rotate a barrel into an aligned position with the casing for launch of the dart.
[0006] U.S. Pat. No. 6,182,752 shows a tool that drops darts by continuing rotation in a fixed direction requiring a predetermined order of dropping once the darts are loaded and no provision for checking which dart is in which barrel after loading.
[0007] The above described advantages and other features of the invention will be more readily apparent to those skilled in the art from a review of the description of the preferred embodiment and the claims, which appear below.
SUMMARY OF THE INVENTION
[0008] A tool for dropping one or more balls and then one or more darts features a closable ball drop opening that works automatically after the ball release to minimize damage to the subsequently released dart. A retainer keeps the darts from coming back up above the dart launcher in the event of a pressure surge in the well. The dart launcher features a dedicated movable barrel for each dart that can be locked in a fully misaligned and fully aligned position with the casing or tubular. A handle is retained to the dart housing and can be manipulated to defeat the lock and rotate a given barrel. The darts may be inspected in their respective barrels before launch and the launch order is variable.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is an elevation view of the assembly showing the dart dropping housing above the ball dropping housing;
[0010] FIG. 2 is a section view of a ball trapped in the dropper before release;
[0011] FIG. 3 is the view of FIG. 2 showing the door opened and the ball having been released;
[0012] FIG. 4 shows the door to the casing closed before the darts are dropped;
[0013] FIG. 5 is the view along line 5 - 5 of FIG. 1 ;
[0014] FIG. 6 is the view along line 6 - 6 of FIG. 1 ; and
[0015] FIG. 7 is an enlarged view of the dart dropper showing the lock and handle feature.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] Referring to FIG. 1 , the plug or dart dropping housing 10 is mounted above the ball dropping housing 12 . While one of each is illustrated those skilled in the art will appreciate that more than one of each can be used. The housing 12 is shown in greater detail in FIGS. 2-4 . FIG. 4 will be used to describe the components of the housing 12 . A handle 14 is mounted for 360 degree rotation of a cam 16 . The handle 14 is secured by a pin 18 to cam 16 . The casing or tubular 20 has an interior wall 22 . A door 24 has a curved surface 26 designed to approximate the curvature of the interior wall 22 of the casing 20 when in the position shown in FIG. 4 . The cam 16 has a guide rod 28 that extends into the door 24 . A spring 30 surrounds rod 28 to bias the door 24 into a position where curved surface 26 is positioned as close as possible to the interior wall 22 . Door 24 has an upper tapered surface 32 to ease its travel path up the outside wall 34 of the casing 20 when the handle 14 is rotated 180 degrees from the position shown in FIG. 4 . The door 24 moves in tandem with the cam 16 because pin 28 secures the door 24 to the cam 16 .
[0017] The operation is best understood by going back to FIG. 2 . There a ball 36 is loaded and retained by an extension 38 of the cam 16 . Note that rod 28 extends from extension 38 into door 24 for tandem movement. A curved ramp 41 can be seen in the out of contact position from the ball 36 when the handle 14 is pointing left in FIG. 2 . As the handle 14 is rotated, the extension 38 takes rod 28 with it forcing the ramp 32 and subsequently the door 24 up the outside wall 34 of the casing 20 and up against the bias of spring 30 that surrounds rod 28 .
[0018] The movement of handle 14 180 degrees to the FIG. 3 position takes door 24 away from opening 42 in the casing 20 allowing the curved ramp 41 to push the ball 36 through opening 42 and allow it to fall or be pumped downhole through casing 20 .
[0019] After release of ball 36 , the handle 14 is rotated another 180 degrees to allow door 24 to be again aligned with opening 42 and to allow the spring 30 to bias door 24 so that its curved surface 26 stays as closely aligned as possible with the inner wall 22 . What will happen next is that a plug or dart will be dropped from housing 10 . Because the door 24 with its curved surface 26 now sits in actual or near alignment with interior wall 22 , there is a reduced chance of damage to the plug or dart 44 as it clears housing 12 . The dart typically has one or more cups for sealing against the wall 22 of the casing 20 to allow it to be easily pumped down. These cups have caught on openings, sharp edges or ledges presented by the ball droppers of the prior designs and the result has been damage or destruction of the cups on the dart 44 . The assembly described above with door 24 addresses this issue by closing the opening 42 after the ball is released and in a manner that minimizes pinch points that can damage the dart 44 that is subsequently dropped past opening 42 .
[0020] FIG. 5 illustrates that housing 12 can have mirror image ball dropping assemblies each having a door 24 that works in the above described manner and closes with surface 26 as nearly flush as possible with the interior surface 22 of the casing 20 so as to minimize subsequent damage to the dart 44 . While reference has been made to a ball 36 those skilled in the art will appreciate that other shapes can be used and that fluid pressure rather than curved ramp 41 can be used to get the ball 36 out.
[0021] Referring now to FIGS. 6 and 7 , the details of the dart dropping housing 10 will be explained. Housing 12 has a central bore 45 . For illustrative purposes, there are three barrels 46 , 48 and 50 that are each independently rotatable into or out of alignment with bore 45 and two of which 46 and 48 are shown in FIG. 7 . Each barrel can be locked in either position and features an integral handle assembly that can defeat the lock to facilitate rotation. An open barrier 52 is within the inner wall 22 that continues below as part of the casing 20 , as shown in FIG. 4 . This barrier keeps the darts 44 from going further up beyond housing 10 in the event of a pressure surge in the well. At the same time, because barrier 52 is open, flow can pass through it to allow pumping the dart 44 down the casing 20 . FIG. 6 shows the operating shaft assemblies 54 , 56 and 58 that respectively operate barrels 46 , 48 and 50 . One shaft assembly will be described in detail, as in the preferred embodiment they are all identical. A lower shaft 60 is linked for relative rotation to a barrel such as 46 . An upper shaft 62 is keyed to lower shaft 60 at connection 64 . A handle 66 is screwed to bolt 68 in the stowed position. A ball 70 at the lower end of handle 66 keeps the handle within cap 72 after the handle is unthreaded from bolt 68 and lifted away from bolt 68 . A dog 74 extends into a groove 76 in cap 72 . When the handle 66 is pulled away from bolt 68 until ball 70 stops further outward travel of the handle 66 , the handle 66 is rotated to engage the dog 74 to cam it away from groove 76 along mating tapers 78 . Thereafter the handle 66 can be turned in a manner to rotate shafts 62 and 60 to place barrel 46 into alignment with bore 45 . At this point dog 74 snaps into another groove 76 to lock the barrel 46 in the position of alignment with bore 45 . An indicator 80 of a type known in the art signals the passage of dart 44 out of barrel 46 . The other darts 44 in the other barrels 48 and 50 can then be released in the same way, after barrel 46 is retracted out of alignment with bore 45 .
[0022] This arrangement offers advantages over prior dart dropping designs. One is that each barrel can be inspected to be sure there is a dart 44 in it before the cementing procedure starts. The darts 44 can then be dropped in any desired order. The handle 66 that operates an individual barrel cannot be lost as it is made to be retained by the cap 72 . Any of the barrels can be selectively locked in the drop position where there is alignment with bore 45 . The locking is automatic upon rotation into position and dog 74 falling into slot 76 when barrel 46 aligns with bore 45 , for example. By manipulating the handle, after dropping the dart 44 the dog is retracted allowing the reverse movement to occur to fully misalign barrel 46 from bore 45 and lock that position as dog 74 falls into another slot (not shown) on cap 72 . Again the other barrels preferably work in the same manner.
[0023] While three barrels in one housing 10 are shown, varying numbers of barrels can be used in each housing. Shafts 60 and 62 can be in one piece and can also be power driven as opposed to manual handle 66 .
[0024] Using the combination of equipment described above, one or more objects of the same or different dimensions can be dropped from housing 12 followed by closure of the opening or openings 42 with a door 24 to present a flush or nearly flush surface 26 adjacent the inner wall 22 of the casing 20 . The darts 44 can then be dropped in any order from a given housing 10 with little concern about damage as they pass openings 42 that are covered with a door 24 that is flush or nearly so. If there is a pressure surge as the darts are being dropped, the barrier 52 prevents them from being blown past the housing 10 . The built in handle 66 can't be lost. The barrels 46 , 48 and 50 can be selectively locked in a fully aligned position with bore 45 or in a fully misaligned position or any other desired position. The dog 74 engages a groove such as 76 automatically and can be defeated by permitted movements of the handle 66 within cap 72 .
[0025] While the preferred embodiment has been set forth above, those skilled in art will appreciate that the scope of the invention is significantly broader and as outlined in the claims which appear below. | A tool for dropping one or more balls and then one or more darts features a closable ball drop opening that works automatically after the ball release to minimize damage to the subsequently released dart. A retainer keeps the darts from coming back up above the dart launcher in the event of a pressure surge in the well. The dart launcher features a dedicated movable barrel for each dart that can be locked in a fully misaligned and fully aligned position with the casing or tubular. A handle is retained to the dart housing and can be manipulated to defeat the lock and rotate a given barrel. The darts may be inspected in their respective barrels before launch and the launch order is variable. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to a heat generating body and, more particularly, to a heat generating body comprising a heat generating composition which can generate heat merely by a contact with oxygen in the air and a bag containing the heat generating composition.
Hitherto, various types of heat generating composition have been known which presents heat through a chemical reaction caused merely by a contact with air. Examples of such heat generating composition are: (1) a mixture of powders of metal such as iron, aluminum or the like and an oxidation assistant such as active carbon, electrolyte, water or the like; and (2) a mixture of a metal sulfide or polysulfide and carbonaceous material.
Such a heat generating material is packed in a container such as a bag made of an air-permeable material having an air-permeability sufficient for producing heat or a material which is inherently impermeable to air but perforated to permit air to pass therethrough. Such heat generating bodies are put into practical use as, for example, body warmers. The heat generating body is wrapped by and preserved in a material having low oxygen-permeability until it is used.
This type of heat generating body in one hand offers various advantages such as easiness and safety in use, but on the other hand suffers the following disadvantages. Namely, when this heat generating body is used as a human body warmer or as a heat source for heating mechanical equipment, parts or the like, the heat generating composition in the bag is undesirably distributed to the lower part of the bag by gravity to give quite and unnatural feel of use and to change the heat generating characteristics and reduce the amount of heat thus generated, not only when the heat generating body is subjected to a vibration or vigorous action but even when it is held stationarily.
SUMMARY OF THE INVENTION
Accordingly, it is a primary object of the invention to provide a heat generating body improved to eliminate any undesirable local distribution of the heat generating composition and to maintain the required heat generating performance for a long period of time, thereby to overcome the above-described problems of the prior art.
To this end, according to the invention, there is provided a heat generating body comprising a heat generating composition and a bag provided with at least one group of fine pores, each pore having a diameter equivalent of less than 20 microns.
This body advantageously prevents any undesirable local distribution of heat generating composition in the bag. The space inside the bag is maintained at a reduced pressure during the use. This bag, therefore, can maintain a uniform distribution of heat generating composition during the use of the heat generating body, while ensuring the supply of fresh air at a rate sufficiently large for achieving the desired temperature.
In the heat generating body of the invention, at least one group of fine pores, each pore having a diameter equivalent of an order of less than 20 microns, is provided locally in the bag containing the heat generating composition. For instance, the bag may be formed from an air-impermeable material and is locally cut to provide at one or more portions thereof to provide openings or windows which are then covered by films having fine pores of a diameter equivalent less than 20 microns (referred to simply as "microporous film", hereinafter) thereby to form the air-permeable portion. It is also possible to produce the bag by preparing a microporous film and a perforated air-impermeable film having many relative large holes of a diameter such as ranging between 0.05 and 50 mm and jointing these films to each other. In the latter case, the air-permeable portions are constituted by the apertures formed in the air-impermeable film.
In this specification, the term "diameter equivalent" is used to mean a diameter of a hypothetical circle having the same area with a sectional portion perpendicular to a hypothetical axis of the micropore and having the smallest sectional area, while the sectional portion of the micropore varies in its diameter as well as shape along the hypothetical axis thereof. The "diameter equivalent" of the micropores is measured, for example, by a bubble pressure method or by a method using a mercury porosimeter.
According to the invention, it is essential that the diameter equivalent is not more than 20 microns, for otherwise it is impossible to prevent the undesirable local distribution of the heat generating compositions. The diameter equivalent is suitably selected in accordance with the kind, quantity and the desired heat output of the heat generating composition, and preferably ranges between 0.005 and 5 microns from a practical point of view.
The microporous film used in the invention can be made, although not exclusively, from a synthetic resin such as polyethylene, polypropylene, polyfluoroethylene or the like, and the pores are formed chemically or physically in the course of the manufacture or after the manufacture of the film.
The following commercially available films are usable as the microporous film of the invention: TYVEK (manufactured by E. I. Du Pont De Nemours & Co., Inc.), DURAGARD (manufactured by Celanese Fibers Co., Ltd., U.S.A.), FP-2 (manufactured by Asahi Chemical Industry Co., Ltd., Japan), NOP (Nippon Petrochemicals Co., Ltd., Japan), NITOFLON NTF (manufactured by Nitto Electric Industrial Co., Ltd., Japan), NF SHEET (manufactured by Tokuyama Soda Co., Ltd., Japan), CELLPORE (manufactured by Sekisui Chemical Co., Ltd., Japan), GORETEX (manufactured by W. L. Gore & Associates, Inc., U.S.A.) and POLYFLON PAPER (manufactured by Daikin Kogyo Co., Ltd., Japan). There is no substantial limitation in the air-permeability of the microporous film but films having Gurley air-permeability of an order of 20 to 10,000 sec/100 ml are usable suitably.
Various films substantially impermeable to air, particularly to oxygen, can be used as the air-impermeable film. Examples of material of such films are: polyolefins such as polyethylene, polypropylene, polybutadiene or the like, synthetic resins such as polyvinyl chloride, polyvinylidene chloride, polyester, polyether, polysulfone, polyvinylon, polyamide or the like. These films can be used solely or in the form of a laminated sheet in combination with a non-woven fabric. Alternatively, a non-woven fabric coated with such synthetic resins is used as the air-impermeable film. No specific selection is imposed on the selection of the kind of non-woven fabric. For instance, a non-woven fabric of natural fibers or synthetic resin fibers such as polyamide e.g. nylon, polyolefin or polyester are usable as the non-woven fabric in the invention.
Alternatively, the microporous film is locally or partially coated by resin material such as natural resin, synthetic resin or the like, and the air-permeable portion can be defined by non-coated portion thereof.
The total area of the air-permeable portion per bag cannot be defined strictly because it varies depending on various factors such as kind and quantity of heat generating composition, aimed temperature and duration of heat generation, as well as air-permeability of the microporous film. This total area, however, may fall within a range of between 0.2 and 40 cm 2 per bag which usually contains about 30 to 70 g of heat generating composition. This air-permeable portion may be formed only in one side of the bag or in both sides of the same.
Ordinary heat generating compositions adapted to generate heat upon contact with the oxygen in the air can be used as the heat generating composition used in the heat generating body of the invention. For instance, the heat generating composition may be one which makes use of an oxidation reaction of a metal such as iron, aluminum, zinc, tin or the like. It is also possible to use, as the heat generating composition, sodium sulfide, iron sulfide, sodium polysulfide and other sulfides, as well as a compound obtained in the course of oxidation such as sodium sulfite and iron sulfite. Such compositions may be used solely or, alternatively, in the form of a mixture containing such composition as the main agent and an assistant such as an electrolyte, water, filaments, silica gel, zeolite, diatom earth, active carbon or the like. The main agent and the assistant may be wrapped separately until the heat generating body is actually used or may be prepared as the mixture from the beginning. From the practical point of view, the heat generating composition preferably contains iron as the main agent.
The above and other objects, features and advantages of the invention will become clear from the following description of the preferred embodiments taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a heat generating body in accordance with one embodiment of the invention, in which a group of fine pores constituting an air-permeable portion is formed in one portion of a bag; and
FIG. 2 is a partly cut-away perspective view of a heat generating body in accordance with another embodiment of the invention, in which groups of fine pores constituting air-permeable portions are formed in a plurality of portions of a bag.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIG. 1 showing one embodiment of the invention, a rectangular air-impermeable film 1 is cut substantially at the central portion thereof to provide a window (not shown in the drawings). This window is covered and closed by a microporous film 2 having a size slightly greater than the size of the window to form an air-permeable portion. Then, another sheet of air-impermeable film 3 having substantially same size and shape as the first-mentioned air-impermeable film 1 is superposed to the latter, and two sheets of air-impermeable sheets 1 and 3 are jointed to each other at their peripheral edges 4 to form a bag. Then, a heat generating composition is put in the bag to complete a heat generating body of the invention.
Referring now to FIG. 2 showing another embodiment of the invention, a rectangular microporous film 5 having fine pores is laminated to a perforated air-impermeable film 7 having substantially same size and shape as the microporous film 5 and provided with a multiplicity of comparatively large holes 6 to form a laminated sheet. Then, an air-impermeable film 8 having substantially same size and shape as the rectangular microporous film 5 is superposed to the laminated sheet and is jointed to the latter at their peripheral edges 9 thereby to form a bag containing a heat generating composition to complete a heat generating body in accordance with the invention.
In the embodiments shown in FIGS. 1 and 2, the air-permeable portions are designated at numerals 2 and 6.
Although not exclusively, the bag in accordance with the invention usually has a rectangular form.
In the heat generating body as described above, the heat generating composition has to be maintained without contact with the air until it is put into practical use. To this end, the heat generating body as a whole is wrapped by an air-impermeable film or only the air-permeable portions are covered by pieces of air-impermeable film.
According to the invention, partly because the undesirable local distribution of the heat generating composition in the bag is prevented and partly because a reduced pressure is maintained within the bag, the uniform distribution of the heat generating composition is maintained so that the heat generating body as a whole is kept in the form of flexible sheet to impart a comfortable feel of use to the user. In addition, the heat generating body of the invention can maintain its heat generating performance over a long period of time.
Some practical examples of the invention will be described hereinbelow.
EXAMPLE 1
An open cell polyethylene foamed film was prepared to have a pore distribution of 0.05 to 10 microns (maximum pore diameter of 1 micron), porosity of 70%, Gurley air-permeability of 70 seconds/100 ml and a thickness of 150 microns. The polyethylene film contains calcium carbonate as a filler. Prepared also was a perforated polyethylene sheet having one hole of 0.5 mm×0.4 mm per square centimeter. The open cell polyethylene foamed film and the perforated polyethylene sheet were laminated to each other to form a laminated sheet. Two laminated sheets thus formed were then jointed to each other at their peripheral edges such that the perforated polyethylene sheets of two laminated sheets face each other, to form a bag having effective breadth and length of 85 mm and 115 mm. A heat generating composition was prepared by blending, within an atmosphere consisting of nitrogen gas, 28 g of powdered iron, 8 g of active carbon, 5 g of sodium chloride, 9 g of water and 5 g of vermiculite, and was put in the bag to complete the heat generating body of the invention.
This heat generating body was then held in contact with human body through the medium of an underwear. The heat generating body maintained a moderate temperature of about 50° C. for about 24 hours. The heat generating composition was dispersed and held in even distribution without making any undesirable local distribution, and the heat generating body as a whole was maintained in the form of flexible sheet to keep a pleasant feel of use.
EXAMPLE 2
A polypropylene microporous film was prepared to have a maximum pore diameter of 1.9 micron, Gurley air-permeability of 300 seconds/100 ml, weight of 82 g/m 2 and a thickness of 150 microns. This polypropylene microporous film was laminated to a perforated polyethylene sheet having one hole of 2 mm diameter per 2 cm 2 to form a laminated sheet. Two laminated sheets thus formed were superposed to each other such that the perforated polyethylene sheets face each other and were jointed at their peripheral edges to form a bag having effective breadth and length of 85 mm and 115 mm. The same heat generating composition as that used in Example 1 was put in the bag to complete a heat generating body in accordance with the invention.
This heat generating body was held in contact with human body through the medium of an underwear and was maintained at a moderate temperature of about 50° C. for about 24 hours. The heat generating composition was held in even distribution without making any undesirable local distribution. The heat generating body was held in a flexible sheet-like form to impart a pleasant feel of use to the user.
EXAMPLE 3
A polyethylene film was laminated to a non-woven fabric of nylon fibers to form a laminated air-impermeable sheet which thereafter was cut substantially at the center thereof to provide a window of 10 mm wide and 20 mm long. This window was covered and closed by a piece of polypropylene microporous film having a maximum pore diameter of 1.9 micron, Gurley air-permeability of 280 seconds/100 ml, and a thickness of 150 microns, thereby to form an air-permeable portion. Then, a polypropylene film substantially of the same size and shape as the laminated sheet was superposed to the laminated sheet and jointed at peripheral edges to form a bag having effective breadth and length of 85 mm and 115 mm. The same heat generating composition as that used in Example 1 was put in this bag to complete a heat generating body of the invention.
This heat generating body was held in contact with human body through the medium of an underwear and maintained a moderate temperature of about 55° C. for about 24 hours. During the use, the heat generating composition was held in even distribution without making any undesirable local distribution. The heat generating body was kept in the form of soft flexible sheet to impart a pleasant feel of use to the user.
EXAMPLE 4
A heat generating body of the invention was made by the same process as Example 3, except that the window has a size of 20 mm×25 mm and that the piece of microporous film covering the window was made from an open cell polyethylene foamed film containing calcium carbonate having a maximum pore diameter of 1 micron, Gurley air-permeability of 70 seconds/100 ml, and a thickness of 150 microns.
This heat generating body was held in contact with the human body through the medium of an underwear and maintained a moderate temperature of about 52° C. for about 24 hours. During the use, the heat generating composition was maintained in even distribution and the heat generating body was kept in the form of a flexible sheet to impart a pleasant feel of use.
Although several preferred embodiments have been described, it is to be noted here that the described embodiments are not exclusive and various changes and modifications may be imparted thereto without departing from the scope of the invention which is limited solely by the appended claims. | A heat generating body suitable for use as a body warmer or the like. The heat generating body is composed of a closed bag locally provided with at least one air permeable portion constituted by a group of fine pores of a diameter equivalent of not more than 20 microns, and a heat generating composition accommodated in the bag. | 0 |
CROSS-REFERENCES TO OTHER APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 07/341,843, filed Apr. 24, 1989, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an apparatus and method for delivering paper stock to a paper machine More specifically this invention relates to apparatus including a preliminary moving wiremesh belt to which the stock is projected under pressure from above. Spaced down the wire-mesh belt is means for removing the drained stock from the belt and bridging it over to the paper machine. The invention also relates to the method of projecting a paper stock down onto a moving wire-mesh belt to create a shearing effect that makes a high-quality paper product.
In some versions of the invention the belt is moving and the projector is stationary; in other versions the belt may be stationary and the projector may be moving. Similarly, the projector may aim the stock in the direction opposite the movement of the belt; in others the projector may be aimed in the same direction.
2. Description of Related Art Including Information DisClosed Under §1.97 & 1.99
On the inlet side of a paper machine there have been various head-box designs to form the paper sheet on the wire-mesh belt or "wire belt" or "wire" as it is called in the trade. These headbox designs are traditionally divided into the following main classes:
(a) low pressure head-boxes
(b) high pressure head-boxes
These were then developed into a multitude of semi- or fullhydraulic designs, such as
multilayer head-boxes
high-turbulence head-boxes
controllable multi-channel head-boxes
bunch tube head-boxes
step diffuser head-boxes
step flow head-boxes
converflow head-boxes
in which all of some basic details are almost the same, e.g.
manifold tubes
impact plates/turbulence plates
perforated rollers
flow chambers
lip units
control and measuring instruments
The well-known technical characteristics are then adjusted to get the stock flow (of pulp etc. fibers) under good control. Notwithstanding this it is anyway impossible to reach a consistent optimum functioning because of the variations in the process conditions and the temperamental nature of the various designs. This has led head-box designing to become more an art than a science, an art in which the structure is not necessarily based on facts but on traditions.
New head-boxes were often developed only for the purpose of creating a new design category with total absence of any underlying sensible reason.
At any rate, the main purposes of the head-box or any other sheet former are the following e.g.
the prevention of the stock/fiber agglomeration
the creation of proper conditions for a defect-free sheet formation
the conversion of the (turbulent) pipeline-flow into an evenly spread stream which can be applied onto the wire
In spite of the elaborate conventional head-box designs, several difficulties arise due to the inability at the head-box itself (or in the so-called short circle, including pipeline with screeners and hydra-cleaners) to deal with various factors:
the stock variation along the paper machine (longitudinal) or across the paper machine
all sorts of paper specifications in a wide range
agglomeration of fiber
foaming
restrictions of paper machine speeds
uncontrolled behavior and adjustment difficulties
capacity problems
corrosion
(With regard to capacity problems, the speed of a modern paper machine is usually between 200 . . . 1600 m/min. In higher machine speeds the head-box has always been a limiting factor, the faults in the sheet formation caused by the head-box cannot be repaired at the paper machine.)
The prior art has not really come to grips with these problem areas.
SUMMARY OF THE INVENTION
Because the modern head-boxes with auxiliaries are quite expensive equipment, as well as not reliable to deal with the above problems, the primary aim in developing the present system has been to abandon the traditional notion of the indispensability of a head-box. It was thus determined to develop a new apparatus for optimum sheet formation and to proceed open-mindedly as though a head-box might not be necessary.
In this "NO-BOX" thinking I reverted to the origins of paper making only in a more elegant version. (In the early days there were no head-boxes at all or merely an open "container" to equalize the flow.) At the same time my goal was to design a head-box substitute which would be easily controlled, even manually if needed, or be controlled with the normal process control devices. In this manner the whole operation would be adjustable continually and at every moment meet the demands coming from the paper machine to the optimum so that the sheet would always be acceptable and better quality paper could be made.
In the present invention the paper stock is conducted towards the wire from a selected direction and under various pressures and speeds in a confined path to be projected in a spray- or jet-form to spread against the wire-mesh belt preliminary to the paper machine itself The confined path is in the form of a feed pipe and nozzle. The pipe has mixing means and laminator plates thereinside. After the nozzle and adjacent the wire belt there may be appropriate spreaders and lips. The belt may include a vibrator unit. From the preliminary wire-mesh belt the relatively dry slurry may be removed for delivery to the paper machine either in direct line or at a right angle (or "side feed").
In one modification (dry forming of the sheet) a second wire-mesh belt operating above and over the preliminary belt may assist in the shaping of stock.
The angle of the feed pipe may be adjusted as may other components of the apparatus including belt speed by electric process control to optimize the product.
The invention has other embodiments.
BRIEF DESCRIPTION OF DRAWINGS
Other objects and features of the invention will be apparent from a study of the following specification and the drawings, all of which relate to non-limiting embodiments of the invention. In the drawings:
FIG. 1 is a schematic elevational view of an apparatus embodying the invention;
FIG. 1A is a fragmentary view showing a modified form of a portion of the apparatus and related to the dry forming of the sheet.
FIG. 2 is a schematic elevational view of a further embodiment which is used in the case of making a multi-ply paper product;
FIG. 2A is a sectional view taken on the line 2A--2A of FIG. 2;
FIG. 2B is a sectional view taken on the line 2B--2B of FIG. 2;
FIG. 3 is a schematic elevational view of a further embodiment;
FIG. 3A is a sectional view taken on the line 3A--3A of FIG. 3;
FIG. 3B is a sectional view taken on the line 3B--3B of FIG. 3;
FIG. 4 is a schematic elevational view of a still further embodiment;
FIG. 4A is a sectional view taken on the line 4A--4A of FIG. 4;
FIG. 4B is a sectional view taken on the line 4B--4B of FIG. 4;
FIG. 5 is a top plan view of a still further embodiment; and
FIG. 6 is a top plan view of a still further embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a NO-BOX preliminary wire-mesh belt system with spreader and spray arrangements. In FIG. 1 the tubelike inlet pipe comes from above in an angle. The angle is chosen from case to case to suit the type of sheet formation proposed. The direction opposite to the direction or the movement of the feed wire belt (shown in FIG. 1) is merely an example of the extreme directional change with maximum shearing effect.
In the inlet-tube there are the static-mixer followed by the impact plates (c) and the laminator plates (d).
The machine end of the inlet-tube expands laterally into a sprayer-jet outlet (f) which can also consist of multi-jets or multi-nozzles. With this arrangement the stock of fibers can be spread on to the wire-mesh belt as a form of a spray. This gives the sheet the wanted properties, e.g. homogeneity etc. The intensity and fineness of the spray (spray-pressure) can be altered from low to high depending on the pumping pressure and inlet angle. In using many outlets with a fine spray, a multilayered paper product can be made.
The sheet pre-formation is made on the inlet-wire or belt (g) which includes a lip (h) or multi-lip device, usually placed onto the middle of the belt. After this comes the bridge (i) to the paper machine and the bridge lip, which can also be of multi-lip type. The multi-lip device consists of several lips working close to each other. The lip can be installed to whatever desired place in the NO-BOX System.
In the case of dry-forming (FIG. 1a) the system uses instead of the lip a press belt g positioned above the belt g with a very close gap to form the sheet. The press belt or "dwarf wire" presses the dry-stock into a sheet. The press belt can be followed by a secondary roller r with a smooth surface for doing the "calendaring" or "polishing" or "finishing" of the sheet. In the dry-forming process, the wire shown is not followed by the usual paper machine.
The other parts of the NO-BOX System are:
the belt of the continuous inlet-wire (g)
the end rollers (l)
the vibra-unit (m) for the belt (ultrasonic unit)
the motors for the rollers (n)
the inverter unit/regulator unit (o)
the control units of the process (p)
The vibrator unit (m) secures a smooth sheet formation on the wire-mesh belt and also gives a defoaming effect.
In operation the fiber stock consistency is usually given as ca. 0.5%, but it can be lower and even considerably higher. If it is 1% or over, the NO-BOX System is not plagued with same difficulties as head-boxes, namely bad flow, agglomeration and foaming due to air.
The stock comes from above to the impact plates c. The agglomerates are disintegrated, and the laminator plates rectify the flow so that it can be spread evenly and remove the turbulence at the same time or in the secondary laminator phase.
The previous parts (i.e. the impact plates c and laminator plates) in the inlet tube can be left out if a lever blade (FIG. 2A) is used in front of the spray head.
The stages prepare the stock flow which is then directed to the spreader-jet (under pumping pressure) from which it can be sprayed or simply "dropped" onto the running belt (wire). This ensures an even spreading longitudinally and across the belt. The possible unwanted "micro" agglomerations can be smoothed out with the lip-pressure and the vibra-unit.
When the belt is running in the opposite direction from the incoming direction from the pipe a (or the flow is coming sidewise or in an angle), there exists a maximum speed-differential between the flow coming out of the spreader and the running belt. This causes a shear effect between the stock fibers and the belt. Thus a high-quality sheet is formed already on the preliminary wire-mesh belt. This can be led over the bridge to the paper machine (the mother machine)
The typical dimensions of the pulp fibers are:
length 1 to 5 mm
the length/diameter-ratio 30 to 200
The system can be used without the inlet-wire (g) so that the spray is applied directly to the paper machine.
The modification shown in FIG. 2 includes the delivery nozzle with its stock stream outlet aimed in the same general direction as the moving belt. The stock stream comes in through a conduit which may be circular in cross-section and is narrowed down by a transition piece to a rectangular main head. The head has a transverse plate with zig-zag slits in it as shown in FIG. 2B and on its upstream side the plate is provided with a moving blade to clean off fibers as they pass through the openings in the head.
As shown (FIG. 2), the stock emanates from the head in separate streams to impact on the wire in a plurality of positions on the wire to produce corresponding layers as shown.
Above the main head is a transverse high pressure stock line called an "overhead booster" which terminates in booster outlets which direct the stock also down toward the belt in a stream which may be made to pulsate. A purpose of the booster is to maximize a spreading to the stock on the wire. The flow from the overhead booster outlets intercepts the flow from the main head at break points as shown in the air above the belt to deflect the main head effluent down toward the belt. This breaks up the possible micro-agglomerations and speeds the spray to positions which meet the specifications of the paper being made. The booster stock line is preferably of the same stock as the main stock line Alternatively it may be a line of water, air or any convenient booster material. While the booster outlets normally are stationary, they may be made to oscillate if desired or necessary For that matter, either the main line or the booster line, or both can be pulsated.
FIG. 3 shows a further modification in which a spray plate which is disposed across the top of the moving belt provides an incline down which the effluent from the main head and the overhead booster may be directed in a sheet flowing onto the moving belt.
FIG. 4 shows an additional modification in which the main head is circular and a cutting or extruding blade rotates on the upstream side of the head outlet to clean off fibers passing through the head openings Again, FIG. 4B shows the spray pattern attributable to the action of the main head. In the FIG. 4 embodiment the booster head is beneath the main head and jets of stock forward to intercept the jets from the main head. Again, the purpose of the booster head is to break up the possible micro-agglomerations and to speed the spray to every possible specification requirement.
FIG. 5 is a top view showing the main head when the main spray MS and the booster spray BS are showing the interception of these two streams at breakpoint BP.
At the margins of the belt, along its edges there are imposed air curtains as shown for the purpose of limiting the edgewise expanse of the main head flow. This serves to keep the stock on the belt. Aside from air, the curtain may be a flow of water or even stock from the booster line as shown.
The NO-BOX System will not be affected by the variation in the stock consistency or variation of the fiber dimension and allows even higher machine speeds than given here or higher than the speed of any existing paper machine.
The NO-BOX System can also work on the basis that the NO-BOX spray head is moving upon the wire and the wire itself stays stationary. This would be the opposite to the traditional paper machines. An example of this arrangement is pictured in FIG. 6 wherein the stock is delivered from a rigid stock line 101 through a flexible hose 102 to a reciprocating spray head 103 which reciprocates back and forth above the traveling wire, as shown. The flow from the traveling spray head may be intercepted by jets 104 from the booster line.
NO-BOX System uses up to or more than 100% higher jet pressures than head boxes. Spray/jet-head or main feed outlet can be combined with rotating blade which automatically cleans the head. The jet head may be a combined spreading head and a high pressure booster head, the latter giving the spray an exceptional speed and crosses the main spray.
The NO-BOX System based on the preliminary wire-mesh belt or inlet-wire can be at every instant adjusted to meet the optimum, if modern process control instrumentation o and e is used. This goes especially for the Twin-Wire arrangement (FIG. 1a related to the dry-forming of the sheet), where the gap and angles of the wires are adjustable. On the other hand, the control is so simple that the system parameters can be found without difficulty also manually. In this case the price of the expensive control apparatus can be saved.
Thus while I have disclosed the invention in only one embodiment, the invention is not so limited but may be defined as having the scope of the following claim language or fair equivalents thereof. | In the absence of the conventional stock feeding box the stock is conducted down through a feed pipe to a nozzle which directs the stock onto a wire belt. The nozzle may be directed in a different direction from the movement of the belt so that shear occurs at the delivery point to the benefit of the finished product. From the preliminary belt or "wire", the stock is delivered to a paper machine. In one embodiment the fibers are conducted dry to the belt and a cooperating "dwarf" wire presses the dry stock into a sheet. Booster heads are used to direct additional feed in a way which intercepts the main feed and breaks up micro-agglomerates. In one version the wire is stationary and the feed nozzle moves. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of U.S. Provisional Application No. 61/766,050 filed Feb. 18, 2013 and U.S. Provisional Application No. 61/904,012 filed Nov. 14, 2013.
FIELD OF THE INVENTION
[0002] This invention relates generally to impact protection for overhead closures and in particular, to impact protection for an overhead coiling door.
BACKGROUND OF THE INVENTION
[0003] Access openings in warehouse, manufacturing and industrial settings are often secured by overhead (vertically traveling) closures.
[0004] Rolling steel doors, also referred to as overhead coiling closures, are metal slatted doors which move in a generally vertical path coiling above the opening as the door is opened. Because rolling steel doors have many fewer parts than sectional doors with less risk for damage and inoperability they often make a better solution for facilities that cannot afford opening downtime.
[0005] An overhead coiling closure is either provided with a powered operator to power the door to an open or closed position or it is manually opened and closed with, for example, a looped chain or crank. A shaft is horizontally mounted above the access opening to wind or unwind the coiling closure while the door sides are maintained within tracks mounted to the building structure on either side of the access opening. The coiling shaft and operator (if present) are usually covered and protected by a hood.
[0006] When doors are installed in high traffic areas, for example, shipping and receiving areas, the door can be damaged if struck by, for example, a fork lift transporting cargo. This damage can be caused not only by the forklift itself but also by the cargo being trucked by the lift. If the door becomes damaged the coiling closure may become non-operational with resultant access opening downtime.
[0007] Accordingly, there is still a continuing need for improved door protection designs. The present invention fulfills this need and further provides related advantages.
BRIEF SUMMARY OF THE INVENTION
[0008] In a first embodiment an impact bar assembly is fixedly mounted to an overhead coiling door.
[0009] In a second embodiment an impact bar assembly is repositionally mounted to an overhead coiling door.
[0010] One advantage of the present invention is the prevention of damage to the overhead coiling closure obviating the need for repair or replacement.
[0011] Another advantage is the reduction in access opening downtime due to damage of the overhead coiling closure from impact force strikes.
[0012] Yet another advantage is the automatic resetting of the impact bar assembly to the protective, starting position removing the need to restrict use of the access opening during a manual reset.
[0013] Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The accompanying drawings are included to provide a further understanding of the present invention. These drawings are incorporated in and constitute a part of this specification, illustrate one or more embodiments of the present invention, and together with the description, serve to explain the principles of the present invention.
[0015] FIG. 1 is a perspective view of the bumper bar mounted to the impact guide bracket assembly.
[0016] FIG. 2 is an exploded perspective view of the bumper bar and impact guide assembly bracket mounting.
[0017] FIG. 3 is a top view of the bumper bar mounted to the impact guide bracket assembly.
[0018] FIG. 4 is a sectional view of the bumper bar mounted to the impact guide bracket assembly taken at A-A of FIG. 3 .
[0019] FIG. 5 is an exploded perspective view of the guide block mounted to the stationary bracket.
[0020] FIG. 6 is an exploded perspective view of a fixedly mounted impact bar assembly with the guide assembly removed.
[0021] FIG. 7 is a perspective view of a fixedly mounted impact bar assembly with the guide assembly in place.
[0022] FIG. 8 is an exploded perspective view of a positionally mounted impact bar assembly.
[0023] FIG. 9 is a perspective view of a positionally mounted impact bar assembly in a partially opened door position.
[0024] FIG. 10 is a perspective view of a positionally mounted impact bar assembly in a closed door position.
[0025] Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0026] As required, detailed embodiments of the present invention are disclosed; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various forms. The figures are not necessary to scale, and some features may be exaggerated to show details of particular components. Therefore, specific structural and functional details disclosed are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention. Where possible, like reference numerals have been used to refer to like parts in the several alternative figures.
[0027] Turning now to FIG. 1 , in an embodiment used with, for example, a rolling steel door, impact bar assembly 2 comprises a bumper bar 4 translationally mounted at each end to an impact guide bracket assembly 6 . Although only one end is shown, it is to be understood that the other end has the same geometry and, therefore, will not be separately described.
[0028] FIGS. 2-5 more fully show the component parts of the impact guide bracket assembly 6 . A bumper bar engagement member, for example, guide block 8 is mounted to a first leg of a stationary bracket 10 . Mounted to the second leg of the stationary bracket 10 is a resistance element, for example, a spring 12 , mounted via bolt 14 and spring shaft 16 .
[0029] As shown in FIGS. 2-4 , a guide block 8 is retained within a hollow end of bumper bar 4 and translationally retains the bumper bar 4 to the impact guide bracket assembly 6 . A bolt 14 passes through the spring shaft 16 which in turn passes through the spring 12 . A thrust plate 18 and retaining plate 20 are mounted outside and within the hollow end of the bumper bar 4 , respectively, to translationally fix the bumper bar 4 to the stationary bracket 10 . This permits an impact force directed against the bumper bar 4 to be dissipated by the spring 12 which subsequently returns the bumper bar 4 to its starting position, determined by the guide block 8 .
[0030] The impact force is ultimately translated to the guide assembly 44 to relieve the impact force from the door curtain itself. The stationary bracket 10 is positioned such that the spring 12 is effectively located over the guide assembly 44 to protect the rolling steel door 26 throughout the opening and closing range of motion.
[0031] The impact bar assembly 2 may be fixedly mounted to the rolling steel door 26 as shown in FIGS. 6 and 7 , or it may be repositionally mounted as shown in FIGS. 8-10 described in detail below.
[0032] Turning now to FIGS. 6 and 7 , the impact bar assembly 2 is fixedly mounted to the rolling steel door 26 , for example, at each end of the rolling steel door bottom bar 28 via bolts 30 which pass through the second leg of the stationary bracket 10 , a bottom bar adapter 32 , the bottom bar 28 , retaining plate 34 , and flat washer 36 to engage nut 38 .
[0033] FIG. 6 is drawn with the guide assembly 44 of FIG. 7 removed for clarity. The bearing assembly 40 is mounted to the bottom bar 28 with button head cap screws 42 . The bearings counteract the moment created by the impact bar assembly 2 when the door 26 is in motion and reduce friction between the bottom bar 28 and the guide assembly 44 . An impact force is always absorbed by the spring 12 and transferred through the stationary bracket 10 and into the guide assemblies 44 .
[0034] Turning now to FIGS. 8-10 which show the repositional mounting of impact bar assembly 2 , an impact bar assembly retaining element, for example, a guide bracket 46 is mounted at each side of the rolling steel door 26 , for example, to each guide assembly 44 at a user determined height. Described in detail below, the location of the guide brackets 46 permits retention of the impact bar assembly 2 at a closed door user defined location different from that of the fixedly positioned bottom bar 28 location shown in FIGS. 6 and 7 .
[0035] A bottom bar retaining member, for example, a bottom bar bracket assembly 48 is mounted to the rolling steel door 26 , for example, mounted at each side of the bottom bar 28 . Bottom bar bracket assembly 48 comprises a first 50 and second 52 leg with effective spacing therebetween to releasably engage the impact guide bracket assembly 6 .
[0036] In use, with the rolling steel door 26 fully closed ( FIG. 10 ), the impact bar assembly 2 is releasably mounted to the guide brackets 46 by releasably inserting the impact guide bracket assembly 6 into the guide brackets 46 . As the rolling steel door 26 is opened the bottom bar bracket assemblies 48 releasably engage the impact guide bracket assemblies 6 to lift the impact bar assembly 2 off the guide brackets 46 thereby raising the impact bar assembly 2 upward with the bottom bar 28 to allow passage through the door opening while continuing to provide rolling steel door 26 impact protection.
[0037] When the rolling steel door 26 is closed, upon reaching the guide brackets 46 , the impact guide bracket assemblies 6 re-engage the guide brackets 46 and the impact bar assembly 2 is released from the bottom bar bracket assemblies 48 and is once again maintained in the guide brackets 46 as the rolling steel door 26 continues to close.
[0038] Optionally, an impact bar retainer, for example, an extension spring assembly 54 is employed to prevent the impact bar assembly 2 from lifting off the guide brackets 46 when not being engaged by the bottom bar bracket assemblies 48 . The extension spring assembly 54 ( FIG. 9 ) comprises, for example, a plurality of fasteners, for example, eye bolts 56 mounted to the bottom bar 28 ( FIG. 8 ). Passing through the eye bolts 56 are steel cables 58 fixed at one end to an extension spring 60 with each cable other end engaging an impact guide bracket assembly 6 ( FIG. 9 ). As shown in FIG. 10 , when the rolling steel door 24 is closed and the impact bar assembly 2 is engaged within the guide brackets 46 , the steel cables 58 are deflected and in combination with the extension spring 60 maintain a retaining pressure on the impact guide bracket assemblies 6 to help retain the impact bar assembly 2 within the guide brackets 46 .
[0039] As the rolling steel door 26 opens and the impact bar assembly 2 is lifted off the guide brackets 46 , the extension spring 60 in its retracted position pulls the cables 58 towards the center of the rolling steel door 26 to help retain the impact bar assembly 2 within the bottom bar bracket assemblies 48 .
[0040] Although the present invention has been described in connection with specific examples and embodiments, those skilled in the art will recognize that the present invention is capable of other variations and modifications within its scope. These examples and embodiments are intended as typical of, rather than in any way limiting on, the scope of the present invention as presented in the appended claims. | An overhead coiling closure is presented. A repositionable impact bar assembly engages a guide bracket mounted adjacent to the coiling closure when the closure is in a closed position. When in an open position, the impact bar assembly is released from the guide bracket and attaches to the coiling closure to provide repositionable impact protection. As the coiling closure closes the impact bar assembly is once again engaged by the guide bracket. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method for processing nonferrous metal hydroxide sludge wastes containing chromium, copper, zinc and nickel as the important nonferrous metals and for simultaneous recovery and separation of the individual nonferrous metals.
2. Description of the Prior Art
The hydroxide sludge wastes which are generally obtained in galvanic processes and in the nonferrous metal processing industry, typically contain the following components (figures refer to percent by weight):
______________________________________Water 40 to 90, on the average: 70Iron 0 to 10, on the average: 2Aluminum 0 to 2, on the average: 0.5Chromium (III) 0 to 10, on the average: 2Zinc 0 to 10, on the average: 2Copper 0 to 5, on the average: 1Nickel 0 to 5, on the average: 1Calcium 0 to 20, on the average: 4Sodium 0 to 2, on the average: 0.5Silicic Acid 0 to 5, on the average: 1Cyanide(as a complex) 0 to 0.1, --Sulfite trace --Carbonate 0 to 5,Chloride trace,Sulfate trace.______________________________________
These hydroxide sludge wastes contain a large quantity of water and the content of the valuable metals is too small to allow economical smelting of these wastes. However, the wastes are a burden on the environment and they can only be deposited in special garbage dumps which is very costly. Therefore, a method for cleanly disposing or destroying of these wastes is highly desirable. Even more desirable, on the other hand, would be a method for processing and recovery of the valuable materials and metal values in the waste.
It has been suggested that such wastes be destroyed by admixing them with the raw materials used in the brick production. Furthermore, processing methods from hydrometallurgy and waste water treatment technology are known. However, these methods provide only unsatisfactory recovery of one or two and, hardly ever of more of the materials contained in the waste.
There are also a number of methods for the separation of metals in fixed bed ion exchangers or for their removal from waste water solutions. However, these do not provide for a selective separation of the valuable nonferrous metals and, usually, mixed solutions are obtained which are precipitated collectively and the thus created residue has to be deposited in the form of waste sludge.
A method for recovering copper and zinc from nonferrous scrap metals is known from the the German disclosure Offenlegungsschrift No. 2,340,399 wherein the sludge is leached by means of an ammonium carbonate solution in the presence of oxygen and then the metals are separated from the leaching liquor as copper ammonium carbonate or zinc ammonium carbonate. Such a method cannot be used for the processing of nonferrous metal hydroxide sludge wastes since the content of calcium would disturb the ammonium carbonate equilibrium and, also, chromium hydroxide would remain in the residue.
The liquid-liquid extraction of copper and nickel from ammoniacal solution is known, as is the liquid-liquid extraction of copper at pH values of 1 to 3. These methods are usually performed in combination with electrolysis wherein the final electrolyte is used for stripping off the metal-charged organic phase. Furthermore, there are known methods for extracting zinc from solutions containing sulfuric acid and zinc with the aid of organic liquids and for stripping off the zinc with the aid of an electrolyte in an electrolysis process. All the described extraction methods have a commonality in that the separation can be performed only when the elements iron, calcium, aluminum, and chromium are not present.
Experiments for selectively precipitating the nonferrous compounds from waste sludge have failed because significant amounts of the accompanying elements have been precipitated too.
SUMMARY OF THE INVENTION
Applicants have discovered a method for the separation and recovery of the individual nonferrous metals from sludge wastes of the above type wherein the metals are recovered sequentially. Thus, the individual nonferrous metals, such as, chromium, copper, zinc, and nickel can be individually and economically separated from the collected nonferrous metal hydroxide sludge wastes in a generally continuously performed method. This is achieved by the combination of the following steps performed in sequence.
a. Chlorinating the aqueous waste sludge suspension at temperatures of 20° to 80° C. and pH values between 4 and 13. The chlorinated sludge is then acidified with sulfuric acid to a pH of 1.0 to 3.0. The insoluble components are then separated, followed by the separation of the chromium (VI) from the solution using a fixed bed anion exchanger (at pH values of <3);
b. The copper is separated from the remaining solution by means of known and conventional liquid-liquid-extraction procedures;
c. The zinc is separated from the remaining solution which also contains chloride and sulfate by means of liquid-liquid-extraction; and
d. The aluminum is precipitated and separated from the remaining solution in the form of the hydroxide and the nickel is separated from the filtrate by means of liquid-liquid-extraction.
The individual nonferrous metal fractions thus obtained in method steps (a) to (d) are then processed in conventional manners.
In the above-described method, the chromium(III) is converted to chromium(VI) and after the subsequent treatment with sulfuric acid, the soluble sulfates of copper, zinc, and nickel are obtained and interfering components, such as calcium sulfate, basic iron sulfate and primarily silicic acid are separated in the form of insoluble residues. The chromium(III) may also be converted into the selectively separable Cr(VI) form by the usual oxidizers, such as, hydrogen peroxide, potassium permanganate, etc. However, oxidation with chlorine has been proven to be the most economical method. The subsequent recovery of chromium(VI) by means of a fixed bed anion exchanger as the first method step is advantageous, because the liquid-liquid-extraction of the nickel would be disturbed by the presence of chromium(III) and, therefore, the acid processing has not been possible up to now.
By means of the liquid-liquid-extraction of copper and zinc, in a combination and sequence of steps not previously known and by the precipitation of aluminum in the form of hydroxide, nickel is obtained in a highly concentrated form by means of the liquid-liquid-extraction. Essential in the sequence of the method steps is the separation of the disturbing accompanying elements, such as, calcium, iron, silicon, and aluminum.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the present process, all of the nonferrous metal hydroxide sludge wastes are transferred to a suspension having a solid matter content of about 15% by weight and a pH value of 4 to 13, preferably close to the neutral value and with a reaction temperature between 20° and 80° C., and, under vigorous stirring and the continuous adding of alkali liquor, chlorine is added until no further significant increase of the chromium(VI) content occurs.
In this chlorination step, iron(II), sulfite, cyanide, and oxidizable organic components are all simultaneously oxidized. After the chlorination, sulfuric acid is added to the suspension while the suspension is stirred until a pH value of less than 3 and preferably from 1.5 to 2.5 is obtained.
This treatment with sulfuric acid leads to the formation of the sulfates of copper, nickel, zinc, and aluminum and, at the same time, dichromate is obtained. Iron and calcium are converted to compounds which are, for practical purposes insoluble and silicic acid is also obtained. By means of filtration, the soluble components are separated from the insoluble residues and the insoluble residues which are primarily the above-mentioned sulfates and silicic acid, may be rejected.
This chlorination treatment of the sludge containing the metal hydroxides and the subsequent treatment with sulfuric acid is a technically superior method to the ammoniacal leaching methods known in the prior art. Whereas the ammoniacal leaching for nickel, copper, and iron achieves leaching percentages of only 50 to 90%, the chlorinating conversion of the copper, chromium, nickel, and zinc in the present process reaches almost 100%.
The filtrate, free of residue, is now transferred to a fixed bed anion exchanger. The anion exchanger may, for example, be a macroporous anion exchanger composed of styrene with weakly basic amino groups, although others are known and conventional and may be used. Such an anion exchanger has an especially high resistance to oxidation.
The anion exchanger is then charged with solutions containing sulfate or dichromate ions. The solutions may contain up to about 10 g/l chromium(VI) in the form of dichromate ions. With the aid of at least two exchangers arranged in series containing the described resin in the form of sulfate or chloride, the dichromate is collected and then eluted by means of alkali liquor having a concentration of about 4 to 8% by weight. The extracted materials contain 100 to 200 g/l alkali chromate or alkali dichromate which, immediately or after their processing into crystals may be used in the tanning industry or for the manufacture of pigments. Furthermore, the chromate or dichromate thus obtained can be used as an intermediate material in the manufacture of chromic oxide.
The chromium-free refined solution discharged from the exchanger columns is essentially free of silicic acid which formerly was in a colloidal state. This silicic acid would have a disturbing influence in the following liquid-liquid extraction since it forms emulsion layers that do not separate. p Liquid-liquid extraction is the method of exchanging metal ions or hydrogen ions between two liquid immiscible phases wherein one phase is the aqueous phase and the other phase is the organic solvent phase. In the subsequent separation of copper by means of liquid-liquid extraction, known extraction means can be used, for example, systems of substituted hydroxy-benzophenonoximes with petroleum. For example, materials, such as, 2-hydroxy-5-nonyl acetophenone oxime, 2-hydroxy-5 sec-dodecylbenzophenone oxime, or 5,8-diethyl-7-hydroxy-6-dodecano-oxime or a compound having the formula: ##STR1## Other complexing systems for copper are known.
In this particular system, the pH value of the aqueous phase should be maintained at about 1.5 and 2.5. The acidic metal salt solution may contain up to 10 g/l copper and the accompanying elements, such as, zinc, nickel, and aluminum, have no disturbing influence in the same concentration. In three to five consecutive mixer-settler-steps of the extraction, the copper content of the aqueous phase, depending on the initial concentration, can be lowered to values below 0.01 g/l.
The mixer-settlers are box-shaped, two-part containers in the first part of which the mixing of the inorganic and organic phases takes place, while in the second part, the two phases are separated. The mixing promotes the intimate contact of the liquid phase with the aqueous phase for the desired exchange of material. The organic phase is carried in countercurrent flow to the aqueous phase.
It is advantageous, especially in chloride-containing solutions, to clean the organic phase containing copper after it leaves the extraction step with water, a sodium sulfate or copper sulfate solution. Subsequently, the organic phase is stripped off in a three-step mixer-settler device by means of a copper end electrolyte (100 to 200 g H 2 SO 4 /l), i.e., a high acid content spent electrolyte from an electrolytic cell. A copper electrolyte or a copper sulfate solution containing more than 50 g Cu/l and less than 0.05 g/l of foreign metals and a regenerated organic phase containing traces of copper are obtained. The obtained copper salt solution can, for example, be used in the production of cathodic copper by copper electrolysis.
From this solution which is freed of chromium and copper, zinc is separated by means of liquid-liquid extraction whereby the above-mentioned mixer-settler device is used. Especially suitable as an extraction means are organo-phosphoric acids having the formula
(OR).sub.2 POOH
wherein R is alkyl. A typical extractant would be di-(2-ethylhexyl-)phosphoric acid dissolved with petroleum solvents. Suitable petroleum solvents include kerosenes or benzines which are low in aromatic substances and have a boiling range of about 190° to 240° C., e.g., Shellsole K. After three to five mixer-settler steps, the zinc content of the refined solution is reduced to less than 0.01 g/l.
The pH value of the inflowing inorganic aqueous phase should be held to about 2 to 3. The charged organic phase which, depending on the content of the di-(2-ethyl-hexyl) phosphoric acid, may contain from about 10 to 30 g/l zinc, is stripped off in three mixer-settler steps by means of diluted sulfuric acid (100 to 200 g H 2 SO 4 /l) using countercurrent flow. The stripped off extracted material contains zinc in a concentration of more than about 100 g Zn/l and can be used in the form of an electrolyte for feeding to a conventional zinc electrolysis process.
Methods are known for recovering zinc from relatively pure sulfatic solutions or from waste water and for extracting zinc from solutions containing large amounts of chloride in the form of a chloro-complex. However, methods for extracting zinc, in addition to nickel and aluminum, from sulfatic solutions so that the stripped-off extracted materials are practically free of heavy metals and to produce a high content of zinc sulfate were not known prior to the present invention.
In the present invention, after chromium, copper and zinc have been separated, it is possible that the aqueous refined solution contains traces of these elements and that the solution contains most of the aluminum and nickel. When preparing the solution for the separation of nickel and aluminum, the pH value of the solution is adjusted to 3.5 to 4.5 by adding soda and/or lime. This precipitation also causes the partial precipitation of the nickel and traces of chromium, copper and zinc. After decantation and filtration, a major part of the nickel is obtained in the filtrate. The residue is treated with alkali liquor, causing the freshly precipitated aluminum to practically entirely dissolve in the form of sodium aluminate while the traces of the metals chromium, copper, zinc and nickel remain undissolved in the form of carbonates or hydroxides and can be returned to the method step (a), i.e., the chlorination step, for reprocessing.
Nickel is then separated from the first filtrate of the hydroxide precipitation by means of liquid-liquid extraction. It has been proven that a suitable extraction means is the sodium-form of the di-(2-ethyl-hexyl-)phosphoric acid dissolved with the free acid of this compound and with high-boiling aromatic solvents, such as, trimethylbenzene or xylene. A disadvantage of the abovementioned sodium-di-(2-ethyl-hexyl-)phosphate lies in the fact that it dissolves well in water but not in organic diluents. However, by the use of conventional solubilizing agents, a homogeneous phase is created during charging as well as after stripping-off. However, in the present invention, we have surprisingly discovered that it is possible to work without the use of solubilizing agents and an excess of di-(2-ethyl-hexyl-)phosphoric acid, if the dilution with the high-boiling aromatic solvent contains more than 40% by volume of di-(2-ethyl-hexyl-)phosphoric acid. When these conditions are observed, distributions of the nickel between the phases are obtained which will allow an economical separation.
It has become apparent that when the nickel-containing aqueous solution is extracted with the sodium salt of the di-(2-ethyl-hexyl-)phosphoric acid in corresponding dilution, practically two mixer-settler steps are sufficient to decrease the nickel content of the aqueous solution (refined solution) from about 6 g/l to <10 mg/l.
The organic phase, fully charged with nickel (30 to 40 g Ni/l), is stripped-off in two mixer-settler steps by means of concentrated hydrochloric acid or a NiCl 2 -solution containing hydrochloric acid or by solutions containing amidosulfonic acid so that highly concentrated nickel salt solutions are directly obtained. Depending on the desired end use of the stripping-off acid, solutions of nickel chloride, nickel sulfate or nickel sulfamate may be obtained. These solutions or the salts obtained on cyrstallization from these solutions can be used directly by the galvanization industry for nickeling.
When the method proceeding according to the present invention is employed, large yields (98.5 to 99.5%) of the valuable nonferrous metals contained in the hydroxide sludge wastes are obtained. The solutions remaining after the method has been performed, contain only traces of these elements. In addition, the chlorinating leaching combined with sulfuric acid and the connected separation of the nonferrous metal elements results in further reduction of the initial amount of waste sludge to about one third.
The following example further demonstrates the method according to the present invention.
EXAMPLE
100 parts by weight of moist galvanic sludge having the following analysis in percent by weight was used:
______________________________________ 69.6 - H.sub.2 O 1.4 - Fe1.5 - Cu 0.4 - Al1.7 - Cr 2.6 - Ca1.3 - Ni 0.7 - SiO.sub.23.0 - Zn______________________________________
This sludge was mixed with 80 parts by weight of water. While constantly stirring at 50° C. and maintaining a pH value of 6.5 by adding soda lye, chlorine gas was supplied to the mixture. The incoming flow was 260 parts by volume of chlorine gas per hour, measured at room temperature. The flow was continued for 5 hours and 24 parts by weight soda lye in a concentration of 32% were used up. The time of cessation of the flow of chlorine gas was determined by measuring the chromium(VI) content in the suspension.
After the oxidation was terminated, within 30 minutes, 23 parts by weight of sulfuric acid were added and the pH value was thus adjusted to 2.5. After another 30 minutes, the suspension was filtered and washed with about 30 parts by weight of water, the first wash water was combined with the filtrate and the residue was rejected.
Obtained were 18 parts by weight filter residue containing 67 parts by weight solid matter, 0.1% by weight Cr, 0.05% by weight Cu, 0.03% by weight Ni, 0.02% by weight Zn, 14% by weight Ca, 3% by weight SiO 2 and 7.5% by weight Fe as well as 280 parts by weight raw solution containing 6.7 g Cr/l, 6.0 g Cu/l, 5.2 g Ni/l, 12 g Zn/l, 1.2 g Al/l, <0.1 g Fe/l and 0.6 g SiO 2 /l.
For separation of the chromium(VI), the raw solution was fed for 2 hours through a column filled with 22 parts by volume of a weakly basic anion exchanger on the basis of styrene in the SO 4 -- form. The anion exchanger was almost fully charged by the amount of chromium(VI) contained in the raw solution.
After the chromium separation step, the filtrate of the raw solution contained 0.08 g/l chromium(III) and <0.1 g SiO 2 /l, while the other components remained almost unchanged.
The ion exchanger, charged with chromium, was first fully charged with a second charge of raw solution to displace impurities in the first charge of raw solution and then rinsed with water and finally eluted with 44 parts by weight of NaOH in a concentration of 6% by weight. The fractions rich in chromium and discharged at pH values of 3 to 8, containined more than 95% of the amount of chromium used in a concentration of 20 to 60 g/l Cr.
The filtrate, free of chromium, was then fed to a solvent extraction step for extraction of the copper. The extraction means used was a solution of benzophenoxime with a concentration of 20% by volume in kerosene which had a low concentration of aromatic substances (<0.1%) and a boiling range of 192°-254° C. The apparatus used in this step are four mixer-settlers arranged in series, each having 1 liter mixer volume and a 4 liter settler volume. The flow through the organic phase was, on the average, 12.5 l/h and the flow through the inorganic phase to be extracted was 10.0 l/h.
The concentration of Cu in the organic phase reached approximately 4.8 g/l, while the so-called refined solution contained 0.002 g/l Cu in the aqueous phase which was extracted in four steps. Between the second and the third step, the pH value of the aqueous phase was adjusted to 2.0 by adding NaOH.
For stripping off the copper, the organic phase charged with copper was brought into contact in three identical subsequent mixer-settler steps with sulfuric acid having a concentration of 140 g/l H 2 SO 4 . In the process, the copper content of the organic phase dropped to 0.1 g/l and the copper content of the acid increased to 82 g/l. In addition, the extracted material obtained in the stripping-off step contained 0.005 g Ni/l, <0.001 g Al/l, 0.001 g Zn/l, <0.001 g Cr/l and <0.1 g Cl/l.
The refined solution obtained after the extraction of copper still contains 12 g Zn/l, 5.2 g Ni/l, 1.2 g Al/l and traces of Cu, Cr, Fe and SiO 2 .
For the separation of the zinc, this solution was treated in four mixer-settler steps having the same design as those used for the copper separation with an extraction solution of 20% by volume di-(2-ethyl-hexyl-)phosphoric acid in kerosene having a low concentration of aromatic substances (<0.1% - boiling point 192-254). The flow through the inorganic phase was 10.0 l/h and the flow through the organic phase 8.0 l/h. In this way, a phase charged with zinc (app. 15 g Zn/l) was obtained.
After the second extraction step, the pH value of the aqueous solution was adjusted to 3.0 by supplying NaOH.
In the "dezinced" refined solution, 0.1 g Zn/l could still be found after the fourth step.
For stripping off the zinc from the organic phase charged with the zinc, the latter was treated with sulfuric acid (200 g H 2 SO 4 /l) in three mixer-settler steps. In this process, the zinc content of the organic phase dropped to about 0.1 g/l and the zinc content of the inorganic phase reached 102 g Zn/l. In the extracted material obtained, when stripping off the zinc, no nickel and no chloride could be detected.
To the refined solution which is now free of zinc, copper and chromium, a soda solution with a concentration of 10% was added at 50° C. until a pH value of 4.5 was reached and a precipitate was produced.
The thus produced precipitate, composed primarily of aluminum compounds, was separated by decantation, washing, and repeated decantation. Thus, an aqueous solution with a pH value of 4.5 g containing 4.5 g Ni/l and also containing alkali chloride and sulfate was obtained.
This solution was fed to a third solvent extraction step at a flow of 10 l/h for the separation of the nickel. This solvent extraction also consisted of three steps. The extraction means employed was a solution of 40% by volume di-(2-ethyl-hexyl-)phosphoric acid in a solvent rich in aromatic substances, such as, trimethylbenzene, with a boiling range of 172°-192° C., the solution having been neutralized to a pH value of 6.5 by adding NaOH.
The flow through the organic phase was app. 1.5 l/h. After three extraction steps, a nickel content of 29.6 g/l was reached in the organic phase while the refined nickel solution contained <0.01 g/l nickel.
To recover the nickel, the organic phase, charged with the nickel, was stripped in three mixer-settler steps with HCl in a concentration of 30% by weight. In this process, 0.34 l of NiCl 2 -solution containing 130 g Ni/l was obtained per hour. | A method for recovering nonferrous metal values from hydroxide sludge wastes containing same by first chlorinating the aqueous waste to oxidize the chromium therein, separating the insoluble components therefrom and treating the resulting Cr(VI) solution in a fixed bed anion exchanger to separate the Cr(VI) from the solution, separating the copper from the aqueous solution by liquid-liquid extraction, separating the zinc from the copper-free solution by liquid-liquid extraction, precipitating and separating the aluminum in the form of hydroxide from the zinc-free solution and then separating the nickel from the aluminum-free solution by liquid-liquid extraction, and recovering the nonferrous metals from the respective solutions and precipitates by conventional procedures. | 8 |
BACKGROUND OF THE INVENTION
The present invention generally relates to superconducting circuits having Josephson devices, and more particularly to a superconducting circuit that includes an output conversion circuit for converting an output of the superconducting circuit to a signal suitable for use in a semiconductor processor.
Superconducting circuits that use the Josephson devices generally produce output logic signals with a logic amplitude determined by the gap energy pertinent to the material used for the Josephson junction. When using niobium (Nb), a typical material for the Josephson junction, for this purpose, a logic amplitude of about 3 mV is obtained. Although this small logic amplitude may be advantageous for reducing the power consumption, this level of logic amplitude is too small for driving the semiconductor circuits that operate in the room temperature environment. It should be noted that the Josephson circuits require an extremely low temperature environment for operation, and for this purpose, a low temperature vessel containing the cooling medium such as liquid helium, is used for accommodating the Josephson circuits. Thus, a processing circuit operating at the room temperature environment is essential for taking over and processing the output of Josephson processors. Generally, a logic amplitude of about several hundred millivolts is necessary for such a processing circuit. For example, when a CMOS device is used for this purpose, the necessary logic amplitude for driving the CMOS device is about 1.5 volts. When using a GaAs FET, on the other hand, the preferred logic amplitude is about 800 mV. When a bipolar transistor is used, the preferred logic amplitude is about 400 mV.
Thus, when the Josephson processor supplies the output directly to these semiconductor processing circuits, the semiconductor processing circuits may not operate properly or at all. Even when operated properly, such a system is extremely vulnerable to external noises. Thus, there is an acute demand for a superconducting output driver that is capable to operating in the low temperature environment together with the Josephson processor as a part of the Josephson integrated circuit for converting the logic amplitude of the Josephson processor to a level suitable for processing by the semiconductor circuits.
FIG. 1 shows a conventional superconducting output driver 10 proposed in the Japanese Laid-open Patent Application No. 61-171551. Referring to FIG. 1, the circuit comprises a first junction group 11 including a plurality of Josephson junctions J11, J12, . . . ,J1n connected in series, a second junction group 12 including a plurality of Josephson junctions J21, J22, . . . , a first resistant R1 connected in series to the first junction group 11, and a second resistance R2 identical with the first resistance R1 and connected in series to the second junction group 12, wherein the junction group 11 and the resistance R1 form a first branch of a bridge circuit, and the junction group 12 and the resistance R2 form a second branch of the bridge circuit. The driver 10 is injected with a drive current Ib at a terminal PVcc connected to a neutral node of the bridge, and the Josephson junctions in the junction groups 11 and 12 have a critical current Is that is identical in each Josephson junction.
In operation, the bias current Ib supplied at the terminal PVcc is divided and caused to flow through the first and second branches with a magnitude identical in the first and second branches. Thus, a current Ib/2 flows through the first and second branches. As long as the current Ib/2 is smaller than the critical current of the Josephson junctions included in the branch, the junction groups 11 and 12 maintain the superconducting state.
When an input current Iin is supplied in this state to an input terminal Pin connected to a node between the junction group 11 and the resistance R1, the current Iin is caused to flow through a path indicated in FIG. 1 by a dotted line, and a current with the magnitude of Iin/2+Ib/2 is caused to flow through the second branch while a current with the magnitude of -Iin/2+Ib/2 flows through the first branch. Thus, when the magnitude Iin/2+Ib/2 in the second branch exceeds the critical current of at least some of the Josephson junctions in the second junction group 12, these Josephson junctions experience a transition to the finite voltage state and there appears a resistance in the second branch. In response to the appearance of the resistance, the drive current Ib/2 hitherto flowing through the second branch is now diverted to the first branch. Thereby, an overshoot of the current Ib flowing through the first junction group 11 occurs and the Josephson junctions J11-J1n in the first group 11 are all switched to the finite voltage state. Further, in response to the switching of the Josephson junctions J11-J1n, all the Josephson junctions J21-J2n are switched to the finite voltage state and a voltage corresponding to the number of stages of the Josephson junctions multiplied by the energy gap of each Josephson junction appears at an output terminal Pout connected to the node between the resistance R2 and the second junction group 12.
FIGS. 2(A)-2(F) show the above described operation wherein FIG. 2(A) defines the parameters in the circuit of FIG. 1 and FIGS. 2(B)-2(F) are waveforms appearing in correspondence to the foregoing operations.
With the rise of the input current Iin at the input terminal Pin as shown in FIG. 2(B), the current IR flowing through the second branch increases and some of the Josephson junctions start to switch to the finite voltage state with a timing designated as T1. After the timing T1, the current IR drops sharply while the current IL flowing through the first branch experiences a surge at a time T2 as shown in FIG. 2(D). In correspondence to the surge in the current IL, the current IR1 flowing through the first resistance R1 expererinces a corresponding maximum as shown in FIG. 2(E). In response to the surge of the current IL, all the Josephson junctions in the first branch cause the switching to the finite voltage state and the current IR again increases as shown in a large peak at the timing T3 as shown in FIG. 2(B). Thereby, all the Josephson junctions in the second branch experience the switching to the finite voltage state and the output voltage corresponding to the gap voltage multiplied by the number of series-connected Josephson junctions appear at the output terminal Pout. In correspondence to this, the output current IRL to a load RLD increases as shown in FIG. 2(F).
In this conventional driver, however, there exits a problem, when a semiconductor processing circuit is connected to the output terminal Pout, such that the current IL or IR supposed to cause the switching of the Josephson junctions is diverted to the semiconductor circuit forming the load RLD because of the low input impedance of the semiconductor circuits. It should be noted that such a loss of the current in the bridge circuit at the time T2 or T3 corresponding to the transition of the Josephson junctions causes an operational instability of the output driver. Further, there is another problem, caused by the large number of Josephson junctions connected in series, such that the expected overshoot of the current at the time T2 or T3 may not occur with sufficient magnitude when there is a large number of Josephson junctions and corresponding large but unpredictable parasitic inductance in the first and second branches. Thus, the conventional circuit of FIG. 1 has suffered from a problem of insufficient reliability.
SUMMARY OF THE INVENTION
Accordingly, it is a general object of the present invention to provide a novel and useful superconducting circuit wherein the previously described problems are eliminated.
Another and more specific object of the present invention is to provide a superconducting circuit having an output driver circuit for increasing the logic amplitude of the output of the superconducting circuit, wherein the reliability in the operation of the output driver circuit is improved.
Another object of the present invention is to provide a superconducting circuit comprising a Josephson processor for carrying out a predetermined logic operation and an output driver circuit supplied with an output logic signal of the Josephson processor for producing an output signal with an increased logic amplitude, wherein the output driver circuit comprises a voltage multiplier circuit supplied with the output logic signal from the Josephson processor for multiplying the logic amplitude thereof, said voltage multiplier circuit including one or more Josephson junctions, and an impedance conversion circuit having an input terminal connected to the output driver circuit for receiving the output signal for the voltage multiplier circuit, said impedance conversion circuit having a high impedance such that the operation of the voltage multiplier circuit is not influenced by the current that flows to the impedance conversion circuit.
According to the present invention, a large output voltage sufficient to drive a semiconductor circuit is obtained from the impedance conversion circuit without causing an adverse effect in the operation of the multiplier circuit. Thereby, a reliable conversion of the voltage can be achieved.
Other objects and further features of the present invention will become apparent from the following detailed description when read in conjunction with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram showing the construction of a conventional output driver circuit used for converting the logic amplitude of a Josephson processor;
FIGS. 2(A)-2(F) are diagrams showing the definition of parameters in the circuit of FIG. 1 (FIG. 2(A)) and various transient characteristics (FIGS. 2(B)-2(F)) of the circuit of FIG. 1;
FIG. 3 is a diagram showing the overall construction of the superconducting circuit according to the present invention;
FIG. 4 is a circuit diagram showing a voltage multiplying part of the superconducting circuit of FIG. 3 according to a first embodiment of the present invention;
FIG. 5 is a diagram showing the threshold characteristic of the circuit of FIG. 4;
FIGS. 6(A) and 6(B) are diagrams respectively showing a circuit diagram of fundamental part of the voltage multiplying part of FIG. 4 configured according to a second embodiment of the present invention and a diagram showing the threshold characteristic of the voltage multiplying part of the second embodiment;
FIG. 7 is a circuit diagram similar to FIG. 4 showing a third embodiment of the present invention corresponding to a modification of the first embodiment circuit of FIG. 4;
FIG. 8 is a circuit diagram similar to FIG. 4 showing a fourth embodiment of the present invention corresponding to another modification of the first embodiment circuit of FIG. 4;
FIG. 9 is a circuit diagram showing the voltage multiplying part according to a fifth embodiment of the present invention;
FIG. 10 is a diagram showing the layout pattern of the voltage multiplying part used in the circuit of FIG. 4;
FIG. 11 is a diagram similar to FIG. 10 showing the voltage multiplying part of the circuit of FIG. 9;
FIG. 12 is a circuit diagram showing the voltage multiplying part according to a sixth embodiment of the present invention;
FIG. 13 is a layout pattern of the voltage multiplying circuit of FIG. 11;
FIG. 14 is a circuit diagram showing a seventh embodiment of the present invention corresponding to a modification of the voltage multiplying circuit of FIG. 12;
FIG. 15 is a circuit diagram showing an eighth embodiment of the present invention about the impedance conversion part of the circuit of FIG. 3;
FIG. 16 is a circuit diagram showing a ninth embodiment of the present invention also about the impedance conversion part of FIG. 3; and
FIG. 17 is a circuit diagram showing a tenth embodiment of the present invention also about the impedance conversion part.
DETAILED DESCRIPTION
FIG. 3 shows the general construction of a superconducting circuit 1 according to the present invention. Referring to FIG. 3, the superconducting circuit 1 comprises a Josephson processor 2 for executing a logic operation and producing an output logic signal with a first, small logic amplitude pertinent to the Josephson devices, a voltage multiplying circuit 3 supplied with the output logic signal of the Josephson processor 2 for producing an output logic signal having an increased logic amplitude in response to the output logic signal of the Josephson processor 2, and an impedance conversion circuit 4 connected to the voltage multiplying circuit 3 for stabilizing the operation of the voltage multiplying circuit 3. It should be noted that the Josephson processor 2, the voltage multiplying circuit 3 and the impedance conversion circuit 4 are all accommodated in a cooling vessel (not shown) for maintaining the Josephson junctions employed in the superconducting circuit 1 in the superconducting state.
The output of the impedance conversion circuit 4 is then supplied to a semiconductor processing circuit 5 that may be provided outside of the cooling vessel. Thereby, the voltage multiplying circuit 3 and the impedance conversion circuit 4 form an output driver circuit 1' that converts the output of the Josephson processor 2 to a signal suitable for processing by the semiconductor processing circuit 5. The impedance conversion circuit 4 has a high input impedance such that the operation of the voltage multiplying circuit 3 is not influenced by the diversion of current to the semiconductor processing circuit.
FIG. 4 shows the detailed construction of the output driver circuit 1', particularly of the voltage multiplying circuit 3 according to a first embodiment of the present invention. In FIG. 4 as well as in FIGS. 7 and 8 to be described later, the Josephson processor 2, the impedance conversion circuit 4 and the semiconductor processing circuit 5 are shown only schematically. The construction of the impedance conversion circuit 4 is described later in detail. The Josephson processor may have the known construction of the IIR filter, for example and includes one or more Josephson devices schematically shown at J. Further, the semiconductor processing circuit 5 may have any known construction and usually is supplied with input logic signals via a low impedance coaxial cables 8.
Referring to FIG. 4, the voltage multiplying circuit 3 includes a number of Josephson interferometer logic (JIL) gates 6 and 6' each including two inductances La and Lb connected in series and three Josephson junctions Ja, Jb and Jc connected in parallel. More specifically, each JIL gate 6 has the inductances La and Lb with respective first ends connected to each other to form a center node, and a bias current IB is supplied from a terminal P1 to the center node via a resistance Rs. Further, the Josephson junction Jb has a first end connected to the center node, the Josephson junction Ja has a first end connected to a second, opposing end of the inductance La, and the Josephson junction Jc has a first end also connected to a second end of the inductance Lb. Furthermore, each Josephson junction Ja, Jb and Jc has a second end and the the second ends are connected with each other to form the superconducting interferometers.
The JIL gate 6' next to the foregoing JIL gate 6 has the construction identical with that of the JIL gate 6 except that the second ends of the Josephson junctions Ja-Jc are shared with the Josephson junctions Ja-Jc of the JIL gate 6 and the bias current is supplied from the JIL gate 6 via the Josephson junctions Ja-Jc. Thus, the JIL gate 6 and the JIL gate 6' are arranged to form a pair, and the bias current Ib is passed to the next pair via the center node of the JIL gate 6'. The Josephson junctions Ja-Jc may be formed by sandwiching a thin film of aluminum oxide (AlOx) by a pair of Nb superconducting layers as usual.
The JIL gate 6 and 6' in FIG. 4 (34 in all in the illustrated example) are coupled magnetically to an external control line 1 extending from an output terminal of the Josephson processor 2 and grounded via a load resistance RL, wherein the control line 1 includes a number of inductances each consisting of a pair of inductances, LA and LB, such that the inductances are connected in series in correspondence to the JIL gates 6 and 6'. Thus, in each pair of the JIL gates formed from the gates 6 and 6', the inductances La of the JIL gates 6 and 6' are magnetically coupled to the inductances LA and the inductances Lb of the JIL gate 6 and 6' are magnetically coupled to the inductances LB.
FIG. 5 shows the static characteristic of the JIL gates 6 and 6' for the case that the Josephson jucntions Ja and Jc have the critical current of 0.1 mA, the Josephson junction Jb has the critical current of 0.2 mA, and the inductances La and Lb both have an inductance value of 3.4 pH. It should be noted that this drawing plots the critical current Io of the gate 6 or 6' as a function of the current IC flowing through the control line 1. It should be noted further that the maximum bias critical IoM that can be supplied without inducing the transition of the JIL gates takes a value of about 0.4 mA with the foregoing setting of the parameters.
As shown in FIG. 5, there appear four distinct modes "00," "01," "10" and "11," wherein the mode "00" corresponds to the case where no flux quantum is stored in the JIL gate 6 or 6' and corresponds to the logic value "0." The mode "01" and the mode "10," on the other hand, correspond to the case where one flux quantum is stored in one of the first superconducting loop that is formed in the JIL gate 6 or 6' by the inductance La and the Josephson junctions Ja and Jb, and the second superconducting loop formed in the same JIL gate by the inductance Lb and the Josephson junctions Jb and Jc. Further, the mode "11" represents the characteristic for the case where both the first and second superconducting loops store a flux quantum. It should be noted that the region hatched in FIG. 5 indicates the region wherein the Josephson junctions forming the JIL gate cause the transition to the finite voltage state. This region corresponds to a logic value "1".
In operation, the bias current IB is set to a value such as the value IB1 shown in FIG. 5, wherein the value IB1 is determined not to cause the transition to the finite voltage state when there is no input current Ic on the line 1. Thereby, each JIL gate in the voltage multiplying circuit 3 is held in the superconducting state at the beginning.
When there is an incoming current Ic on the line 1, on the other hand, the Josephson junctions in the JIL gate 6 or 6' experiences a transition to the finite voltage state in correspondence to when the current Ic exceeds a threshold level Ic1 that is determined by the characteristic curve as a function of the input current Ic on the line 1. In the circuit 3 wherein a large number of JIL gates are connected in series, the gate that has the smallest IC1 value causes the transition first followed by other JIL gates. It should be noted that the voltage multiplying circuit 3 produces the output signal on a line 11 connected to the resistance Rs as a voltage corresponding to the sum of the voltages appearing in each JIL gate. The magnitude of the voltage thus obtained on the line 11 for the logic value "1" of the output signal of the Josephson processor 2 may be about 100 mV. The output voltage for the logic value "0" is of course zero in correspondence to the superconducting state of the JIL gates.
The voltage multiplying circuit 3 thus obtained has various advantages such as large output voltage, reliable operation, easy increase or decrease of the number of JIL gates 6 and 6', and the like. It should be noted that such a change in the number of the JIL gates can be achieved easily, as the supply of the input current Ic to each JIL gates is accomplished by the single control line 1 that is coupled magnetically to all the JIL gates in series. When the supply of the logic signals to the JIL gates is achieved by the parallel fan-out construction of the line 1, on the other hand, the current that is supplied to each JIL gates would change depending on the number of the JIL gates involved, and it is not easy to change the number of the JIL gates and hence the magnitude of the voltage magnification.
FIGS. 6(A) and 6(B) show a second embodiment of the present invention, wherein the JIL gates 6 and 6' of FIG. 4 are replaced with JIL gates 16 and 16' that involve only two Josephson junctions Ja' and Jb'. Thus, each JIL gate 16 or 16' is formed from inductances La' and Lb' connected similarly to the inductances La and Lb of the first embodiment such that the bias current IB is supplied to a node where the first ends of the inductances La' and Lb' are connected to each other. On the other hand, the Josephson junctions Ja' and Jb' shunt the second ends of the inductances La' and Lb', and the JIL gates 16 and 16' are arranged similarly to the JIL gates 6 and 6' of the first embodiment such that the Josephson junction Ja' of the JIL gate 16 and the Josephson junction Ja' of the JIL gate 16' share the ends that are opposite to those ends connected to the inductance La' of the JIL gates 16 and 16'.
FIG. 6(B) shows the characteristic of the JIL gates 16 and 16' wherein both Josephson junctions Ja' and Jb' have a critical current Io set to 0.2 mA and both inductances La' and Lb' have a value L/2 where L is set to 5.18 pH. With the foregoing setting of the parameters, the maximum critical current IoM that can flow without inducing the transition of the JIL gates 16 and 16' takes a value of 4.0 mA in correspondence to the case of FIG. 5. In FIG. 6(B), it should be noted that the curve designated as "0" represents the threshold characteristic current for a mode wherein no flux quantum is stored in the superconducting loop forming the JIL gate 16 or 16' while the curve designated as "1" represents the threshold bias current for a mode wherein one flux quantum is held in the superconducting loop forming the JIL gate. It should be noted that the region provided with hatching represents the region where the Josephson junctions forming the JIL gate have caused the transition to the finite voltage state.
Thus, a similar voltage multiplication operation is obtained in the second embodiment with the JIL gates 16 and 16' used in place of the JIL gates 6 and 6' of the first embodiment. It should be noted, however, that the construction of the first embodiment is preferable as the first embodiment provides a wider operational margin because of the wider region (hatched in FIG. 5 and FIG. 6(B)) for the transition to the finite voltage state.
FIG. 7 shows the construction of the voltage multiplying circuit 3 according to a third embodiment of the present invention. In FIG. 7, the portions corresponding to those parts described already are given identical reference numerals and the description thereof will be omitted.
In this embodiment, the control line 1 of the first embodiment is branched into a first control line 11 and a second control line 11', and the JIL gates 6 and 6' (thirty four in all) are grouped into a first group including seventeen JIL gates 6 and 6' and a second group also including seventeen JIL gates 6 and 6'. The first control line 11 is coupled to the JIL gates 6 and 6' in the first group sequentially while the second control line 11' is coupled to the JIL gates 6 and 6' in the second group sequentially. In this construction, the length of the line 11 or 11' is reduced to about one-half and the delay in the signal caused by the inductance of the control line is reduced significantly.
In the foregoing first through third embodiments, the resistance Rs for supplying the bias current IB may be replaced by an active device such as a transistor 9 as shown in a fourth embodiment shown in FIG. 8. Thus, the embodiment of FIG. 8 shows a modification of the first embodiment. As the construction and operation are obvious, further description thereof will be omitted. Compound transistors such as HEMT (high electron mobility transistors), HBT (heterojunction bipolar transistors), MESFET (metal-semiconductor field effect transistors), and the like that are capable of operating under the low temperature environment of liquid helium, may be employed for the transistor 9.
FIG. 9 shows a fifth embodiment of the present invention corresponding to another modification of the first embodiment circuit of FIG. 4, wherein the same JIL gates 6 are connected in series instead of connecting the JIL gates 6 and 6' alternately. In FIG. 9, only the voltage multiplying circuit 3 is represented. In this case, too, the operational characteristic explained with reference to FIG. 5 holds, and the voltage multiplication can be obtained. In FIG. 9, the portions corresponding to those parts described already with reference to previous drawings are given identical reference numerals and the description thereof will be omitted.
FIGS. 10 and 11 are diagrams showing the layout of the voltage multiplying circuit 3 shown in FIG. 4 and FIG. 9, respectively.
Referring to FIG. 10, there is provided a superconductor pattern 11 in correspondence to the inductances La and Lb of the JIL gate 6 such that the pattern 11 is connected to another superconductor pattern 12 via the Josephson junctions Ja, Jb and Jc. Further, the superconductor pattern 12 extends toward the JIL gate 6' such that the pattern 12 is connected to the superconductor pattern 11 forming the inductances La and Lb of the gate 6' via the Josephson junctions Ja, Jb and Jc. Thereby, the bias current IB flows from the superconductor pattern 11 to the superconductor pattern 12 of the JIL gate 6 via the Josephson Junctions Ja, Jb and Jc, from the superconductor pattern 12 of the JIL gate 6 to the superconductor pattern 11 of the JIL gate 6' via the Josephson junctions Ja, Jb and Jc, and further to the superconductor pattern 11 of the next JIL gate 6.
In the layout of FIG. 10, the control line 1, formed by a superconductor strip, is coupled magnetically to the superconductor strip, is coupled magnetically to the superconductor pattern 11 of the JIL gate 6 by forming a loop that coincides to the superconductor pattern 11 with separation therefrom by an insulator layer. The control line 1 extends further to the JIL gate 6' to form a loop that coincides to the superconductor pattern 11 of the gate 6'. Further, the control line 1 extends to the next JIL gate 6 where the line 1 forms another loop for coupling with the superconductor pattern 11 forming the JIL gate 6. In the layout pattern of FIG. 10, it should be noted that there are formed extraneous paths in the line 1 in those parts designated as X, Y and Z as illustrated. These extraneous paths form a parasitic inductance and hence, the construction of the first embodiment is, although successful in achieving the reliable operation for the voltage multiplication, not satisfactory from the view point of the operational speed of the Josephson circuits. The same problem exists also in the embodiment of FIG. 9. As can be seen in FIG. 11, there appear extraneous paths X and Y that causes a delay in the propagation of the signal on the line 1. In FIG. 11, the portions corresponding to those of FIG. 10 are given identical reference numerals and the description thereof will be omitted. It should be noted, in FIG. 11, that the superconductor pattern 12 of one JIL gate 6 is connected to the superconducting pattern 11 of the next JIL gate 6 via a contact hole 13.
Next, a sixth embodiment of the present invention for minimizing the foregoing problem of delay will be described with reference to FIGS. 12 and 13.
Referring to FIG. 12, the control line 1 includes a number of coupling inductances LA connected consecutively in series and a number of coupling inductances LB also connected consecutively in series after the inductances LA, wherein each inductance LA is coupled magnetically to the corresponding inductance La of the corresponding JIL gate and each inductance LB is coupled magnetically to the corresponding inductance Lb of the corresponding JIL gate. Each of the JIL gates J1, J1', . . . Jn has a construction identical with the JIL gates described previously and further description about the operation of the voltage multiplying circuit will be omitted.
FIG. 13 shows the layout pattern of the circuit of FIG. 12. Referring to FIG. 13, each of the JIL gates J1, J1', . . . Jn includes a superconductor pattern 22 corresponding to the superconductor pattern 11 of FIG. 10 forming the inductances La and Lb, and the superconductor pattern 22 is supplied with the bias current IB from teh terminal P1. The bias current IB is then supplied to a superconductor pattern 25 corresponding to the superconductor pattern 12 of FIG. 10 via the Josephson junctions Ja, Jb and Jc. The bias current IB supplied to the superconductor pattern 25 is then passed to the superconductor pattern 22 forming the inductances LA and LB of the JIL gate J1'. Further, the bias current IB is supplied to the JIL gates of the next stage and finally reaches the last JIL gate Jn.
In this construction, the control line 1 is coupled magnetically to the JIL gates J1, J1', . . . Jn at the parts 23a, 23b and 24, wherein the part 23a is coupled to the superconducting pattern 22 forming the inductance La in each JIL gate, and the part 23b is coupled to the superconducting pattern 22 forming the inductance Lb of each JIL gate. Further, the part 24 extends between the part 23a for one JIL gate and the part 23a for the next JIL gate. More specifically, the part 23a and the part 24 appear alternately in the left half of the line 1 while the part 23b and the part 24 appear alternately in the right half of the line 1. Further, the left half and the right half of the line 1 are connected by the part 24 at the bottom as illustrated. In the construction of FIG. 13, it should be noted that the extraneous inductances accompanied with the portions X, Y or Z of FIG. 10 or FIG. 11 are no longer formed and the circuit operates with an improved response.
FIG. 14 shows a seventh embodiment of the present invention corresponding to a modification of the circuit 3 of FIG. 12, wherein the control line 1 is divided into a first line 11 and a second line 11' such that the line 11 is coupled to the inductances La at the left of the JIL gates J1, J1', . . . sequentially and grounded finally via a resistance RL1, while the line 11' is coupled to the inductances Lb at the right of the JIL gates sequentially and grounded via a resistance RL2. It should be noted that the line 11 includes the inductances LA connected one after another in series while the line 11' includes the inductances LB connected one after another in series. According to the present embodiment, the response of the circuit 3 is further improved because of the reduced signal path for coupling the logic signals on the line to the JIL gates.
Next, an eighth embodiment of the present invention relating to the impedance conversion circuit 4 that has been hitherto shown only schematically will be described. It should be noted that, for the reliable operation of the voltage multiplying circuit 3, the circuit that follows immediately the circuit 3 is required to have a high impedance sufficiently high such that no diversion of the drive current IB occurs during the switching operation of the Josephson junctions Ja, Jb and Jc forming the JIL gates.
Referring to FIG. 15, the output of the voltage multiplying circuit 3 on the line 11 is supplied to a gate of a HEMT designated as TR via a capacitance C1. The HEMT TR has a drain connected to a d.c. voltage source E2 and controls the current flowing therethrough in response to the logic output of the voltage multiplying circuit 3 that is supplied to the gate of the HEMT together with a bias voltage thus is supplied from another d.c. voltage source via an inductance L3. Thereby, an output current is obtained at a source of the HEMT TR, and the current thus obtained is supplied to the secmiconductor processor 5 via the coaxial cable or the strip line 8 that may be the one used commonly having the impedance of 50 ohms. In FIG. 15, the impedance of the processor 5 is schematically shown by a resistance RR.
In the construction of FIG. 15, a very large impedance in the order of several megohms or more is obtained at the input side of the circuit 4 while the circuit 4 provides a low impedance such as 50 ohms for output connection. Thereby, the switching operation of the Josephson junctions included in the JIL gates forming the voltage multiplying circuit 3 is not influenced at all by the output current supplied to the circuit 4 and a reliable operation of the circuit 3 is guaranteed. On the other hand, the circuit 4 provides the low output impedance suitable for driving the semiconductor processor 5 that follows the superconducting circuit 1 via the coaxial cable or the strip line having the relatively low impedance. The transistor TR in the circuit 4 is not limited to HEMT but any of he HBT, MESFET using a GaAs active layer or even silicon MOSFET that operates under the environment of liquid helium temperature may be employed.
FIG. 16 shows a ninth embodiment of the present invention wherein a transformer T is used for the impedance conversion. The transformer T has a primary side superconducting winding L1 connected to the line 11 via a resistance RL' and a secondary side superconducting winding L2 coupled magnetically to the winding L1. The superconducting winding L1 has a number of turns that is at least one time larger than the number of turns of the superconducting winding L2 and provides a large inpedance against the line 11. On the other hand, a low output impedance suitable for taking out the output via the low impedance coaxial cable 8 is obtained at the secondary side superconducting winding L2.
FIG. 17 shows a tenth embodiment wherein HBT TR1 and TR2 are used to form an ECL gate, and the output of the ECL gate is supplied to the coaxial cable 8 via another HBT 8 having an emitter-follower construction. In the illustration example, the logic amplitude of the input logic signal from the voltage multiplying circuit 3 has a value of about 0.1 volts, and the collector current of the transistor TR1 flows through a path including a resistance R1 of 100 ohms, the resistance R2 of 25 ohms and a resistance R5 of 250 ohms. Similarly, the collector current of the transistor TR2 flows through a resistance R3 of 100 ohms and then through a resistance R4 of 25 ohms and merges with the collector current of the transistor TR1 at the resistance R5. Thereby, about 4 mA of total current flows through the resistance R5. The incoming logic signal from the voltage multiplying circuit 2 is supplied to a base of the transistor TR1 while the transistor TR2 is supplied with a reference voltage of 0.05 sistor TR2 is supplied with a reference voltage of 0.05 volts at a base thereof. The transistor TR3, in turn, takes over the output of the ECL gate formed at the collector of the transistor TR1 at the base thereof and supplies the same at the emitter in the emitter-follower construction. For this purpose the emitter of the transistor TR3 is connected to the voltage source VEE via a resistance R6 of about 250 ohms. Thereby a collector current of 4 mA flows through the transistor TR3. In this construction, the input logic amplitude of about 0.1 volts is amplified further, and a logic amplitude of about 0.2 volts is obtained at the coaxial cable 8 forming an output terminal of the circuit 4. Because of the emitter-follower construction of the transistor TR3, a low output impedance matching the impedance of 50 ohms of the coaxial cable is achieved. On the other hand, a large input impedance is realized at the base of the transistor TR1.
With the provision of the impedance conversion circuit 4, the operation of the voltage multiplying circuit 3 is stabilized irrespective of the input impedance of the semiconductor processor 5 that is connected after the superconducting circuit 1.
Further, the present invention is not limited to the embodiments described heretofore, but various variations and modifications may be made without departing from the scope of the invention. | A superconducting circuit for performing a logic operation and producing an output indicative of the result of the logic operation with a logic amplitude suitable for processing by an external circuit, is provided by a Josephson processing circuit which performs the logic operation and produces an output logic signal with a first logic amplitude, a voltage amplification circuit which is supplied with the output logic signal from the Josephson processing circuit and produces an output signal having a second logic amplitude which is substantially larger than the first logic amplitude, and an impedance conversion circuit which is supplied with the output signal of the voltage amplification means and produces the output of the superconducting circuit, with an output impedance suitable for transferring to the external circuit. The voltage amplification circuit includes a plurality of superconducting quantum devices connected in series and produces the output signal of the second logic amplitude as a sum of the voltage transitions caused in response to the respective transitions of the Josephson junctions included therein. The impedance conversion circuit provides a high input impedance such that the operation of the voltage amplification circuit is not influenced by the current associated with the output signal to the impedance conversion circuit. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to apparatus for arresting and controlling the operation of the draw frame of a textile spinning machine.
In (DE-OS No. 24 50 207), a sensor is assigned to monitor the finished yarn and comprises a light source and a light-sensitive cell providing an alternating light intensity signal, the absence of which is utilized to generate an actuating pulse for an arresting mechanism. The light source and the lighe-sensitive cell are arranged diametrically to each other on the inside wall of an annular yarn guide within which the running thread moves. The light-sensitive cell is connected by cable to an amplifier circuit arranged downstream from the latter, which in turn is connected by cable to a relay actuating the arresting mechanism. This cable connection, required between the sensor and the associated arresting mechanism, which is arranged at a distance from the former, cannot be established in practical application, in the shortest distance possible, in all types of machines because moving or adjustable machine parts or sheets of material exist and interfere with the direct wiring area. This is especially the case if the work site to be shut down is the spinning site of a ring spinning frame equipped with a draw frame.
It is also known (DE-OS No. 22 23 638) to provide a solenoid operated locking device for the slubbing running into the draw frame. The stop command for this locking device is given by a sensor which monitors the fiber bundle leaving the draw frame and which provides a switching signal for the locking device in case of yarn breakage. The difficulties mentioned above, nevertheless, continue to exist, since a cable connection is still necessary between the sensor and the solenoid. It is necessary for this reason to arrange the sensor at the front end of the machine with the solenoid by means of a cable laid along the front and then back around one front face in the interior of the machine. Since each machine has many work sites on draw frames, a multitude of connections must be made on the machine. This results in the use of a multi-core harness and high assembly costs, especially when the machine is to be equipped later on with a locking device.
It is also known (DE-OS No. 27 02 745) to separate the slubbing running into the draw frame of a spinning machine by means of a cutting device in the event of yarn breakage. Here, a sensor and a separating device are arranged on a carriage traversing the spinning sites, so that yarn breakage is recognized only when the carriage passes a respective spinning site. Since the yarn break may have been caused long before the carriage reaches the site, lap formation of the slubbing may have occurred with continued running into the draw frame. The arrangement of the sensor and separating device on an expensive carriage arrangement is justifiable only if the carriage bears in addition a threadspreader. In that case, however, the carriage is adapted exactly to the special spinning machine and is unsuited for use with other machines.
The present invention has as its object the creation of means for actuating in a simple and reliable manner a blocking or separating device assigned to the feed material at a fixed site remote from a sensor which may be assigned to the furnished material, without being subjected to restrictions with respect to the kind of material to be monitored and without having high cost regarding its assembly or functional connection, even with a relatively great distance between the sensor and the blocking or separating device.
These and other objects and advantages are set forth and are apparent from the following disclosure of the present invention.
SUMMARY OF THE INVENTION
The passage of material through a textile spinning or twisting machine passes, by means of known feed mechanisms, through or in contact with a control element which is capable of arresting the movement of the material by either blocking or separating the material from its feed mechanism. According to the present invention, each material so fed is provided with a system wherein light effected from the moving material is sensed and converted into an alternating electrical signal which is fed to a separate light emitter, such as a light-emitting diode, the electrical signal modulating the light emission. This modulated light emission is sensed by a remotely positioned receiver, arranged in a direct line of sight and converted into an electrical signal, the absence of which provides the command signal for actuating the control element to arrest the movement of the material. (Conversely, the presence of the material signal maintains the control element in inoperative function).
Since the stop command from the emitter is transmitted optically, only visual contact has to be established between the emitter and the receiver and the receiver may be arranged at another site in the machine. Because the stop command is transmitted by a modulated radiation beam, it is assured that other prevailing effects of light and artifical light, or the like, will not interfere with the transmission, for it is possible to place the modulation in a range outside of potentially interferring radiation. Control elements for blocking or separating the material may be assigned to each path of material, fed to the machine, making it possible to block or separate one or more or even all the material running into the machine immediately upon the disruption of the running of any one of the materials.
The present invention is particularly adaptable to yarn spinning and twisting machines wherein the finished yarn passes through a guide and is wound on a bobbin, while undergoing a ballooning action.
Obtaining an alternating light intensity signal for modulating the emitter from a ballooning thread is especially advantageous because the light portion reflected by the rotating balloon of thread generates an alternating current of such high frequency that it lies far above the range of other potential light interference sources, for instance room illumination by neon light.
In a machine in which more than one starting material is processed into a single finished end material, for instance a twisting machine in which three feed threads are combined into a twisted yarn, several sensor systems may be employed. It is especially advantageous in this case to transmit the alternating current, resulting from the modulated radiations of all the sensors assigned to the individual materials, to a common identification circuit which delivers the actuating pulse to one or all of the associated control means for blocking and/or separating the materials from their respective feed means.
In a machine processing only two starting materials into a single end material, for example in the manufacture of a core yarn, the use of the system for one material to control the operation of the other material can be advantageously effected because the sensors assigned to the starting materials and to the end material can be arranged with their associated control devices relative to one another in such a manner that they cross-control each other. The radiation beam of the sensor assigned to one material is picked up by the light-sensitive receiver assigned to another material, leading with appropriate light output directly to the actuating command for this material. Cable connections between the devices assigned to the individual materials are therefore not required.
According to the present invention, delay means may be provided in a control circuit leading to the advantage that an accidental short-term interruption of the light connection existing between the modulated light source of the sensor and the light-sensitive receiver such as may occur during cleaning, spreading of the thread or other manipulation by the operator in this area, will not immediately cause the actuation of the blocking or separating device. A time delay constant of about 5 seconds between the actuating command and the pulse delivered for the actuation of the blocking or separating device will not cause disruptions in other areas of the machine, even if an actually occurring disruption of the movement of the material has been ascertained.
Two functionally matched structural systems can be mounted to the respective machine independently of each other and may be brought into optical contact with each other. This makes it possible, without complex mounting measures, to use the device with machines of the most varied design and function and to retrofit already operational machines with sensors and associated blocking or separating devices. The required current for the two structural groups can be supplied by electric lines to be wired on the machine and shared by the former, to which the structural groups are individually connected, for instance by means of plugs.
Full details of the present invention are set forth in the following description and are illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a side elevational view of a drawing frame illustrating the application thereto of the present invention;
FIG. 2 is a view similar to FIG. 1 showing a drawing frame, adapted for the processing of multiple yarns, employing the present invention;
FIG. 3 is a view similar to FIG. 2, showing the present invention employed on a drawing frame processing two materials;
FIG. 4 is a circuit diagram of the operating means employed in the apparatus of FIG. 1;
FIG. 5 is a circuit diagram of the operating means employed in the apparatus of FIG. 2; and,
FIG. 6 is a circuit diagram of the operating means employed in the apparatus of FIG. 3.
DESCRIPTION OF THE INVENTION
In all of the following examples, while the starting material is a slubbing passing through a draw frame, the practical application of the process and device pursuant to the present invention is not limited to machines employing draw frames, but they may easily be applied also with other machines in which a continuous and/or staple fiber material is processed.
Turning now to the figures, a draw frame of conventional construction is illustrated, formed by driven lower rollers 1, 2 and 3 and upper rollers 1', 2', and 3' resting freely on top of them. The upper rollers are held in a support and load arm 4, which is mounted to be swivable upward, in a bearing 5 of a support bracket 6. The support bracket 6 is fastened on a rod 7 extending along the length of the machine. Rollers 2 and 2' are respectively provided with endless belts 8 and 9, the lower one of which runs over a curved pallette which defines the run of the belt.
A slubbing 10 is fed into the draw frame between the rollers 1, 2 and 3, and 1', 2', 3', and is stretched to form a fiber bundle 10' exiting from the pair of rollers 3, 3' for delivery to a yarn guide 11 arranged coaxially in relation to a spindle on which is mounted a cop or bobbin 12. The finished yarn 10' is wound on to the bobbin during which time a balloon of thread develops between the yarn guide 11 and the bobbin generally denoted by the numeral 13. The yarn guide 11 is part of a housing 15. The housing 15 is attached, to be swivable upward, on one of the walls 16 of the machine, by a hinge mounting 17.
According to the present invention, there is mounted on the housing 15 a sensor assembly generally depicted by the muneral 14. The sensor assembly comprises a light source 18 such as a fiber optic device or light-emitting diode, having its rays bundled or concentrated into a beam 19, directed onto the thread bundle 10', and specifically to intersect the area lying in running direction behind (i.e. below) the yarn guide 11 so the ballooning thread passes rapidly through the light beam 19 so that its rays are reflected by the moving thread 13. The reflected rays 20 are received by light-sensitive cell 21 as an alternating light intensity signal. The cell 21 produces an alternating electric output signal which is then fed to a modulating pulse generating circuit 22 arranged downstream thereof, which powers a second light-emitting diode 23. The current for the electrical components is supplied through a cable 24 having a plug 25 connected to a power source line 26 wired alongside the machine.
The light-emitting diode 23 produces a modulated beam according to the alternating light intensity signal as altered by the circuit 22 and is arranged so as to project from the housing 15 to which it is fastened by an adjustable mounting 27, as indicated by the pivot bearing 28. In lieu of this pivot bearing 28, the mounting 27 can be arranged in a ball joint permitting universal adjustment. Through this adjustability of the light-emitting diode 23, its modulated luminous radiation beam 29, which is also concentrated by an optical device such as a lens or prism, is directed to a light-sensitive photo receiver 30 which may be arranged at a selected site of the machine and separated by a space from the light-emitting diode 23.
In the example according to FIG. 1 this light-sensitive receiver 30 is mounted on an inverted-U-shaped bearing rail 31, arranged alongside the support and load arm 4, and specifically at the forward end of this bearing rail 31 next to the exit of the drawing frame. The receiver 30 is mounted in a housing 32 which is itself adjustable relative to the bearing rail 31, for instance in a pivot bearing 33. In lieu thereof, a ball joint mounting may be provided by which the housing 32 may be more easily aligned with the light-emitting diode 23. The photo receiver 30, in response to the modulated luminous radiation beam 29 produces an equivalent alternating voltage delivered by way of a line 34 to an amplifier and subsequently to an identification circuit, designated collectively by the numeral 35. The identification circuit is constructed in such a manner that it will trigger an actuating pulse for a blocking device for the slubbing 10 generally denoted by 36, when the alternating voltage is absent. This alternating pulse is a surge of current exciting the solenoid electromagnet 37 causing core 38 to be retracted against the force of a compression spring 39.
The amplifier and the identification circuit 35 which are preferably arranged on a pallette or circuit board, are inserted in a housing 40 accommodating also the electromagnet 37, core 38 and compression spring 39. The housing 40 is fastened to the rear end of the bearing rail 31 and current for the parts accommodated in the housing 40, as well as for the light-sensitive receiver 30, is supplied by a cable 41 having a plug 42 which is connected to the power source line 43 wired along the inside of the machine. This can be a branch line of the already mentioned line 26. The bearing rail 31 with its U-shaped cross-section is adjustable lengthwise and is capable of being locked by means of a clamping bolt 44 in a support bracket 45 integral with a fastening bracket 46 which is fixedly seated on the support rod 7 and fastened to the latter by means of a clamping bolt 47.
A slide 48, adapted to the U-shaped inside cross-section of the bearing rail 31, is inserted into the former. The rear end section of the slide 48, projects into the housing 40, and is provided with a notch 49 which is engaged by a lug at the end of the core 38. The lug serves as a bolt, preventing longitudinal movement of the slide 48 as long as the electromagnet 37 is not excited.
A coupling projection 50 is formed on the forward end of the slide 48. The projection 50 engages a recess formed in a coupling stud 51, integral with a blocking shell 52, rotatably mounted on the axle of the lower roll 1, embracing the circumference of the roll 1 by slightly more than one half. This blocking shell 52 is secured against rotation about or with the lower roll 1 by its coupling with the slide 48. The blocking shell comprises a cylindrical section. The axial length of the blocking shell 52 is such that it extends coextensively with the entire axial length of the upper roll 1'. The rear end of the slide 48 abuts against a compression spring 53, which biases the slide 48 in the forward direction. The slide 48 has a flange at the rear end limiting movement of the slide by its engagement with the wall of the housing 40.
FIG. 1 illustrates the parts in the positions which they assume during full, undisturbed running of the drawing frame. The alternating light intensity signal generated by the rotating ballooning thread 13 is utilized for the modulation of the luminous radiation of the light-emitting diode 23, and the alternating voltage generated as a result by the light-sensitive receiver 30 results in the absence of an initiating pulse for the electromagnet 37. If the finished thread 10' running between the exit 3, 3' of the drawing frame and the cop 12 should break, i.e. if no rotating balloon of thread is present, then no modulated luminous radiation exists and no alternating voltage is supplied to the amplifier and the identification circuit 35. The circuit 35 will then give an actuating pulse in the form of a start-up current surge for the electromagnet 37. The core 38 is then caused to move against the force of the spring 39, disengaging its stud from the notch 49 of the slide 48. The compression spring 53 thereupon acts on the end of the slide 48 and bracing itself against the housing 40, moves the slide 48 toward the front of the drawing frame, (to the left with reference to the drawing). The coupling projection 50 causes the blocking shell 52 to rotate, counter-clockwise in the direction of rotation of the lower roll 1, so that its wedge-shaped longitudinal leading edge penetrates between the slubbing 10 and the lower roll, clamping the leading edge of the slubbing into engagement with and between it on the upper roll 1'. The continued rotation of the blocking shell 52 is prevented by the limited movement of the slide 48. The slubbing 10, which is lifted off the lower roll 1, lies on the outer surface of the blocking shell 52 and also against the upper roll 1' but lifted off the lower roll 1. The slubbing is thus held firm and prevented from further movement but in a position to easily reengage the driven roller when the slide 48 is returned to its operational position. The problems normally caused in the conventional devices by rupture of the end or finished material 10' is thus prevented. Normally, the feed slubbing 10 would continue to be fed to the draw frame through the rotating entry rollers and material would be lost or lap formations would occur. These would be, normally, difficult to eliminate or may even cause damage to the machine by lapping. Since the slubbing 10 is now held out of engagement with the driven roller 1, no such problems occur.
After repair of the cause of disruption, and retying of the thread 10', the parts of the blocking device 36 are moved again into the normally operating position by actuating a handle 54 formed with the coupling stud 51. Movement of the handle 54 to the rear end (right in the drawing) causes the slide 48 to move against the spring 49 into re-engagement with the lug on the solenoid core 38.
It may be expedient in the event of a transitory failure of the modulated radiation 29, to keep the identification circuit 35 from immediately producing the actuating pulse, since it is possible that the failure of the radiation 29 is not caused by a break or other disruption of movement of the end material 10', but by short-term interruptions of the path of rays 29 as a result of manipulations within its area, for instance by cleaning measures or during the respreading or rejoining of previously broken material. In order to prevent this premature actuation, a rectifier with relatively high time constant (thermal or RC-member) and a pulse-shaping circuit may be provided additionally to the identification circuit 35, making it possible to give this actuating pulse only at a predetermined time interval after the stop command. A time lag of 5 seconds, within which the voltage present in the circuit has fallen to the threshold value decisive for the delivery of the actuating pulse would seem sufficient. This short-term time delay for the reaction of the blocking device 36 is immaterial should there be an actual disruption in the material 10', because in such a short time the continued run of the starting material 10 will not yet lead to lapping or another disturbance.
The device described is especially suited for division into the two structural groups, i.e. sensor assembly 14 and the identification circuit 35 together with the blocking device 36, for subsequent attachment to a machine already in place. It is merely necessary to install the two power lines 26 and 43 with the associated sockets for the plugs 25 and 42, respectively along the machine. The structural sensor assembly which forms one structural unit, can be easily assembled. The blocking shell 52 can as easily be placed on the lower roll 1, and its mechanical actuating device can be mounted on the support rod 7. The parts delivering the electrical actuating pulse and the light-sensitive receiver the other structural group can be mounted, without intervention to the existing construction of the machine so as to retrofit the machine. The essential advantage is that the two structural groups are functionally connected with each other without special mechanical coupling or wiring, i.e. only by the modulated luminous path of radiation beam 29.
In the example according to FIG. 2, the invention is easily applied on machines which draw more than one starting material. Although in this case a sensor assembly and receiver assembly are provided for each material, separating devices are provided for each of the starting materials. The essential advantages of the invention, namely the low assembly expenditures and the ability of subsequently equipping machines of different design remain intact.
FIG. 2 shows a spinning or drawing frame for the manufacture of a so-called core yarn, that is a yarn in which a continuous filament is covered with staple fibers. One starting material consists therefore of staple fibers entering the draw frame as a slubbing 10 in the manner shown in FIG. 1. For the sake of simplification only the lower and upper rolls 1, 2, 3 and 1', 2', 3', respectively are shown. In addition, a partial illustration of the support bracket 6 and the rod 7 are shown. The blocking device explained with respect to FIG. 1 is the same and is identified here by numeral 136. The other starting material is a continuous filament 55 which is delivered to the drawing frame in advance of the final rolls 3, 3' and is combined there with the stretched slubbing 10 to form the end material 100', the latter passing through the yarn guide 11, which together with the sensor assembly 14, is structured and works as already described with respect to FIG. 1; its light-emitting diode 23 being aligned so that the radiation beam 29 modulated by the running balloon of thread 13 hits a light-sensitive receiver 130, held in a housing 56 by a pivot or ball joint bearing. The housing 56 holds as well, in equally adjustable manner, still other photo receivers 230 and 330. The receiver 230 is associated with a light source or diode 123 mounted on the pivotal blocking rail 131. The light beam 129 from this source is in response to a sensor assembly 114, sensing the movement of the slubbing 10 into the rollers 1 and 1'. The sensor assembly 114 acts in principle in the same manner as the sensor assembly 14 illustrated in FIG. 1 so that luminous radiation directed to the slubbing 10 results in a reflected alternating light intensity signal when the slubbing is in motion. This signal is received by the light-sensitive cell of the sensor assembly 114 and causes the production of the modulation for the radiation beam 129. The receiver 330 is associated with a light source (diode) 223 mounted on a housing 61 on which a sensor assembly 214 is located, to monitor the continuous filament 55. In this case too, the movement of the filament 55 is reflected and an alternating light intensity signal is received by the photocell 330 caused by a modulated beam 229.
The alternating currents deliverd by the photo cells 130, 230, and 330 are combined in one place, namely in the collective housing 56 and are delivered near an amplifier to an AND-operator 57 and from the latter to an identification circuit 135 which works like the identification circuit 35 previously described with respect to FIG. 1 from which is delivered a switching pulse when any one of the modulated radiations 29, 129, or 229 is absent. The AND-operator 57 and the identification circuit 135 are both accommodated in the collective housing 56. The identification circuit 135 is connected by a first cable 58 with the electromagnet 37 of the blocking device 136, and by a second cable 59 to a second electromagnet 60 which actuates when excited a separating device 61 (scissor) by which the filament 55 is cut. When a disruption of movement of the material assigned to any one of the sensors 14, 114, or 214 is detected by one of the latter and its modulated radiation is absent, the identification circuit 135 generates the start-up surge for both the magnets 37 and 60. This serves to actuate simultaneously the blocking device 136 and the separating device 61, resulting in a disruption of the feed of both starting materials 10 and 55 to the drawing frame. The circuit already mentioned above by which a delay in the delivery of the start-up current surge for the electromagnets 37 and 60 when one of the modulated radiations fails, can be included in the identification circuit 135.
The sensor assembly 14 is connected in the manner already described above by the cable 24 and plug 25 with the power line 26 wired on the machine, and the electrical components of the sensor assemblies 114 and 214 and of the housing 56 are connected in the same way with the additional power feed line 43 by means of the respective cables 62, 64 and 63. The fastening of the housing 56 on the machine does not present any substantial problem even in retrofit because the adjustability of the light-emitting diodes and the light-sensitive receivers provides numerous possibilities for the mutual connection of the structural groups with input to the paths of radiation 29, 129 and 229, in line-of-sight spaced from the mechanical components of the drawing frame. The housing containing the sensor assembly 114 can, for example, be placed on the bearing rail 131 to the side of the blocking device 136. On the other hand, the sensor assembly 214 does not, as shown in the drawing, have to be structurally combined with the separating device 61. It is preferable, however, that the modulated radiations beams emitted from the light-emitting diodes of the individual sensor assemblies be guided to a common structural group and that this structural group (collective housing 56) contains also the sole circuit delivering the actuating pulse for the blocking or separating devices assigned to the individual materials.
The device shown in FIG. 2 is especially suited, because of its simple structure, for use with machines in which also more than two starting materials are processed to an end material, for instance twisting machines, in which a twisted yarn is manufactured from three feed materials. Each of the three feed materials is then assigned a sensor assembly and a separating device, and a sensor is also directed to the manufactured twisted yarn. The alternating currents generated from the modulated radiations of all sensors are then fed to the common AND-operator and identification circuit and the latter delivers the actuating pulses to the three separating devices connected with it in the event of failure of any one of the four modulated radiations.
One of the cable connections between the identification circuit 135 and the electomagnets 37 and 60 respectively illustrated in FIG. 2 can, if need be, be dispensed with if the collective housing 56 and the housing containing one of the magnets are structurally combined, as by mounting the cutting device 60 on the housing 56.
The arrangement shown in FIG. 3 is particularly suited for use with machines producing one end material from two starting materials. In this case, a sensor assembly and a blocking or separating device are assigned to each starting material, the former acting to cross-switching the latter mutually if there is a disruption of the movement of the starting materials, without the existence of a mechanical or cable connection between them.
Although this arrangement can also be employed with machines serving other production purposes, it is again explained in connection with a drawing frame.
FIG. 3 shows only the lower and upper rolls 1, 2, 3, and, respectively, 1', 2', 3', a part of the support bracket 6, and the rod 7 of the drawing frame illustrated in FIGS. 1 or 2. The feed slubbing 10, the sensor assembly 14, and the blocking assembly correspond to those described in FIG. 1. The modulated radiation beam 29 emitted from the light-emitting diode 23 of the sensor assembly 14 acts as shown in FIG. 1, so that the light-sensitive receiver 30 mounted to the bearing rail 31 feeds a pulse signal to the electromagnet 377. The identification circuit 35 is arranged in a housing 140 at the rear end of the bearing rail 31. In the event of trouble with the movement of the end material 100' detected by the sensor assembly 14, this blocking device 36 works in the same manner as is described with the aid of FIG. 1.
As a second starting material, a continuous filament 55 is again fed, as in the example pursuant to FIG. 2, to the site between the pair of rolls 3, 3'. A sensor assembly 314 and a separating device 161 are assigned to this continuous filament 55, preferably combined in one structural group and connected by a cable 65 with the power feed line 43 wired to the machine. A housing containing an additional sensor assembly 414 is joined to the housing 140 and this sensor assembly 414 monitors the slubbing 10 running into the draw frame. The power supply of this sensor assembly 414 and of the electrical components of the blocking device 36 is provided by cable 66 which is connected with the current feed line 43. The modulated radiation 329 originating with the flawless running of the continuous filament 55, from the light-emitting diode 323, is directed to a light-sensitive receiver 430 arranged on the housing 140 which, as the receiver 30, is connected with the identification circuit 35. The modulated radiation 429 emitted with the flawless running of the slubbing 10 from the light-emitting diode 423 of the guard 414 is received by a light-sensitive receiver 530 mounted on the housing of the separating device 161. The thereby generated alternating currents are fed to an identification circuit 235 which is structured the same way as the already described identification circuit 35 and works like the latter, delivering therefore in the absence of the modulated radiation 429 an actuating pulse which excites in this case the electromagnet 160 switching the separating device 161.
The device described consists of three structural groups, and can therefore be easily retrofitted to an existing machine to work in the following manner:
If disruption of the movement of the slubbing 10 (break of the slubbing, end of the run-in of the slubbing) first occurs, it is detected by the sensor assembly 414, resulting in an absence of a modulated radiation beam 429 originating from its light-emitting diode 423. Consequently, the identification circuit 235 delivers therefrom, because no alternating current arrives from the light-sensitive receiver 530, an actuating pulse to the electromagnet 160 for the separating device 161, which severs the thread 55. Thereupon, the sensor assembly 314 detects the absence of the filament 55 and the resultant absence of a modulated radiation beam 329 causes an actuating pulse delivered by the identification circuit 35 for the electromagnet 37 and thus for the blocking device 36. The remainder of the filament 55 and the unblocked part of the slubbing 10 are still processed to the end material 100' which, as already described with regard to FIG. 2, is a core yarn.
If first, a disruption (yarn break, end of the feed thread) occurs in the run of the other starting material, namely the filament 55, it is recognized by the sensor assembly 314, resulting in the omission of the modulated radiation 329 originating from its light-emitting diode and leading, because the alternating current is no longer delivered by the light-sensitive receiver 430, to an actuating pulse delivered by the identification circuit 35 for the blocking device 36 which prevents the continued movement of the slubbing 10. This is registered by the sensor assembly 414 as a steady or unvaried reflection resulting in the absence of a modulated radiation 429. This causes an actuating pulse to be delivered for the separation device 161, originating from the identification circuit 235. This pulse is superfluous since the filament 55 is by now fully absent. In this case, too, the forward portion of the filament 55 and the unblocked part of the slubbing 10 are still processed to an end material 100'.
Due to this cross-switch, the continued run of the one starting material is prevented by being blocked or separated in the event of a disruption of the movement of the other starting material, making the production of a faulty end material 100' impossible.
If a disruption, for instance a break, occurs first in the run of the finished material 100', this will be detected by the sensor assembly 14 whose modulated radiation 29 is then omitted. As already described with respect to FIG. 1, this will cause the delivery of an actuating pulse by the identification circuit 35 for the blocking device 36. The movement of the slubbing 10 will then be arrested. The sensor assembly 414 assigned to the slubbing recognizes this stoppage, and its then omitted modulated radiation 429 causes, as already described, actuation of the separating device 161 which cuts the filament 55. The sensor assembly 314 recognizes this separation and by omission of its modulated radiation 329, a signal is issued for switching the blocking device 36. This signal is superfluous since the device 36 is already in the blocking position. The continued run of the two starting materials 10 and 55 is thus disrupted by their blockage or separation although the remnants of the slubbing 10 and the thread 55 still exit from the drawing frame due to the further rotating of the delivery rolls 3, 3', without lapping or another hindrance.
The sensor assemblies 314, 414 with the blocking or separating device described with reference to FIG. 3 and connected only with each other by their radiation paths 329, 429, transmitting to each other stop commands and associated with each other in pairs, can be used without any problem also on other spinning devices than the one illustrated in FIG. 3. Their employment is especially suited in connection with a Finisher-Bobbin the two slubbings of which should run simultaneously from the bobbin to one spinning position each. If each of these two adjacent spinning positions is equipped with a sensor assembly 414 and the blocking device 36 for the slubbings as illustrated in FIG. 1, and if in addition, as explained with reference to FIG. 3 regarding the filament 55, the spinning positions associated in pairs by the common Finisher-Bobbin are provided additionally with a sensor assembly assigned to the slubbing, with its light-emitting diode directed towards the light-sensitive receiver located at the other blocking device and causing the identification circuit to deliver the actuating pulse for this blocking device when the modulated radiation is not received, it is assured both in the event of a ruptured slubbing at one of the spinning positions, that the blocking device 36 of this spinning position and also the blocking device 36 of the associated other spinning position which is not affected by a disruption of the movement of the material itself, are switched to the blocking position. The slubbing will therefore run off the Finisher-Bobbin only if both spinning positions operate at the same time without interruption.
The light-emitting diode 323, 423 and the light-sensitive receivers 430 and 530, like the respective parts of the device illustrated in FIGS. 1 and 2, can also be arranged on pivot bearings or ball joint mountings, as to make it possible to align them with each other also in other than the mutual alignment illustrated.
The arrangement shown in FIG. 1 is, however, also suited for use at a spinning position supplied by a Finisher-Bobbin if its electromagnet is thereby connected additionally to the identification circuit 35 of the adjacent spinning position served by the same Finisher-Bobbin. Such a connection, by short cable which passes the stationary support 6, can be established simply without any particular problems. Each actuating pulse delivered by one of the two identification circuits in the event of a disruption at their spinning position will then affect also the circuit of the adjacent blocking device 36 so that with the stoppage of the running of the slubbing to one spinning position the run of the slubbing to the other spinning position is also stopped.
The process and device pursuant to the invention are suited to be supplemented by a device or devices capable of determining and identifying the exact nature and position of the disruption in the movement of the material. An electrically or a mechanically switched indicia device can be used for this purpose, for instance a lamp indicating by visual signal the position of disruption. Indicia signals can be derived directly from the existing electrical circuits or from the moving parts of the blocking or separating device. It is also possible to register the number of disruptions occurring at a given spinning position by use of a counting device assigned to the respective sensors or blocking or separating devices, thereby being able in the case of excessive frequency of disruptions to check the particular drawing frame for damaged, faulty or non-functioning components which might cause the disruption of the movement of the material. The number of disruptions may, however, be transmitted to and evaluated by a data collection unit or computer assigned to the machine, to which, if required, several machines are connected.
Various embodiments, modifications and changes have been mentioned here, other such variations will be obvious to those skilled in this art. Accordingly, the present disclosure is to be taken as illustrative and not as limiting of the present invention. | The passage of material through a textile spinning or twisting machine is regulated through operation of a control element associated with the movement of said material. Light reflected from the moving material is converted into a variable electrical signal which is then modulated and used to operate a light-emitter. The modulated output of the light-emitter is sensed by a receiver located remote therefrom, but in direct-line-of sight, into an electrical command signal for operating the control element. | 3 |
BACKGROUND OF THE INVENTION
This invention relates to hydraulic dampers and, particularly to hydraulic dampers of the kind comprising a cylinder containing therein hydraulic fluid, a piston working in the cylinder and partitioning the interior thereof into two liquid chambers, a piston rod secured to the piston and extending through one of the liquid chambers to the outside, and two valve discs provided respectively on opposite surfaces of the piston for generating a damping force in the extension and contraction strokes of the damper respectively.
Conventionally, there is provided in the hydraulic damper of the kind aforementioned a fixed orifice for permanently connecting the two liquid chambers, thereby maintaining the valve discs in the closed condition when the reciprocating velocity of the piston is low. The orifice generates a predetermined damping force both in the extension and contraction strokes and, defines a rising portion in damping force-velocity characteristics of the damper. The effective area of the orifice is the same between the extension and contraction strokes of the damper, and thus it is not possible to change the damping force between the extension and contraction strokes when the piston velocity is low. However, when it is desired to change the damping force between the extension and contraction strokes, it is not sufficient to change only the characteristics of the valve discs, and it is necessary also to change the characteristics of the orifice between the extension and contraction strokes of the damper.
Japanese Utility Model Disclosure (Kokai) No. 55-82539 discloses a hydraulic damper of the kind aforementioned. An orifice and a non-return valve are provided in connection with each of the valve discs, and the non-return valve acts to prevent the fluid flow in the direction closing the corresponding valve disc. Thus, the effective area of respective orifices can be changed with respect to the fluid flow passing through the piston. The damper operates satisfactorily but the construction thereof is complicated.
SUMMARY OF THE INVENTION
One of the objects of the invention is to provide a hydraulic damper having different damping force characteristics between the extension and contraction strokes of the damper and being simple in construction.
According to the invention, there is provided, in the hydraulic damper of the kind aforementioned, an orifice communicating permanently the two chambers, and a restricting member for changing the effective area of the orifice in response to the direction of the fluid flow passing through the orifice.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and advantages of the invention will be clarified from the following description taken in conjunction with accompanying drawings illustrating preferred embodiments of the invention, and in which:
FIG. 1 is a partial sectional view showing the essential portion of a hydraulic damper according to the invention;
FIG. 2 is a plan view showing the relationship between an annular plate and a flexible member in the hydraulic damper of FIG. 1;
FIG. 3 is a diagram showing the relationship between the velocity of the piston and a damping force;
FIG. 4 is a view similar to FIG. 1 but showing a modified form;
FIG. 5 is a partial view showing a further modified form; and
FIG. 6 is a view similar to FIG. 1 but showing a still further modified form.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, a piston 1 is slidably provided in a cylinder 2 and partitions the interior of the cylinder 2 into upper and lower chambers. The piston 1 is secured to a reduced diameter lower end 3A of a piston rod 3, and the upper end (not shown) of the piston rod 3 passes through the upper end (not shown) of the cylinder 2 to the outside. The piston 1 moves upward as seen in FIG. 1 in the extension stroke of the damper and moves downward in the contraction stroke of the damper. Annular valve discs 4 and 5 are respectively provided on the upper and lower surfaces 1A and 1B of the piston 1. Each of the valve discs 4 and 5 consists of two mutually overlapping thin plates, with the inner end thereof being secured to the piston rod 3 by a nut 6. Shown at 7, 8, 9 and 10 are spacers respectively. Passages 11 and 12 open respectively in the upper and lower surfaces 1A and 1B of the piston 1. The passages 11 (only one is shown in FIG. 1) are connected with an annular recess 1D in the piston 1 and transmit the pressure in the upper chamber in the extension stroke of the damper to the valve disc 5. The passages 12 (only one is shown in FIG. 1) are connected with an annular recess 1C in the piston 1 and transmit the pressure in the lower chamber in the contraction stroke of the damper to the valve disc 4.
An annular orifice plate 13 is interposed between the lower surface 1B of the piston 1 and the valve disc 5. The orifice plate 13 has in the outer circumferential portion thereof a plurality of cut-out portions 13A as shown in FIG. 2 to constitute an orifice passage connecting permanently the upper and lower chambers. According to the invention, an annular restricting member 14 is overlappingly disposed on the orifice member 13, and the dimension, and the configuration of the orifice member 13 and the restricting member 14 are determined such that the restricting member 14 partially covers the cut-out portions 13A in the normal condition as shown in FIG. 2. When the hydraulic fluid flows from the upper chamber to the lower chamber, the restricting member engages with the orifice member 13 so as to minimize the effective area of the orifice passage, and when the fluid flows in the opposite direction the outer circumference of the restricting member 14 easily separates from the orifice member thereby increasing the effective area of the orifice passage.
In operation, the piston 1 moves upward in FIG. 1 in the extension stroke of the damper, and when the velocity of the piston 1 is low, the fluid in the upper chamber flows into the lower chamber through the passages 11 and cut-out portions 13A. The restricting member 14 closes a part of cut-out portions 13A, and thus the effective area of the cut-out portions 13A is small and the damping force-velocity characteristics at that condition are depicted by line b 3 in FIG. 3 having a large angle of inclination β. When the velocity of the piston 1 increases further, the outer circumferential portion of the valve disc 5 deflects downward and the damping force at this stage is shown by line b 2 in FIG. 3. It will be noted that the orifice plate 13 and the restricting member 14 also deflect downward together with the valve disc 5, but the rigidity of the plate 13 and the member 14 against the deflection is usually very small as compared with that of the valve disc 5 so that the line b 2 is substantially determined by the valve disc 5. However, the plate 13 and/or the member 14 may have a substantial rigidity to constitute a part of the valve disc 5 in determining the damping force.
In the contraction stroke of the damper, the piston 1 moves downward in FIG. 1 and the valve disc 5 is in the closed condition. When the velocity of the piston 1 is low, the valve disc 4 does not open and the fluid in the lower chamber flows into the upper chamber through the cut-out portions 13A. The outer circumference of the restricting member 14 deflects upward due to the fluid flowing through the cut-out portions 13A. Thus, the effective area of the cut-out portions 13A increases as compared with the extension stroke, and the damping force caused therefrom is smaller than that in the extension stroke. The damping force is depicted by line a 1 in FIG. 3 which has a small inclination angle α. When the velocity of the piston 1 exceeds a predetermined velocity, the outer circumference of the valve disc 4 deflects upward and the fluid in the lower chamber flows substantially through the passages 12 and into the upper chamber. The damping force at this condition is depicted by line a 2 in FIG. 3. Incidentally, the broken line b 1 in FIG. 3 depicts the damping force of typical prior art damper wherein the flexible member 14 is not provided.
FIG. 4 shows another embodiment of the invention wherein parts corresponding to the embodiment of FIG. 1 are denoted by the same reference numerals.
In FIG. 4, the outer circumference of an annular restricting member 14' is secured to the lower surface 1B of the piston 1 and the inner circumference thereof can deflect upwardly, thereby increasing the effective area of the orifice passage.
FIG. 5 shows a further modified form wherein an annular restricting member 14" encircles the outer circumferences of the valve disc 4 and the orifice plate 13 and is secured to the valve disc 4. The member 14" partially covers the cut-out portions 13A in the orifice plate and is deflectable in the radially outward direction when the fluid flows in the contraction stroke of the damper, and maintains the condition shown in FIG. 4 when the fluid flows in the extension stroke of the damper. The damping force-velocity diagram of the embodiment of FIG. 5 is similar to FIG. 3, namely, in the extension stroke, the rising portion b 3 of the diagram has a steep inclination β as compared with the rising portion a 1 of the damping force in the contraction stroke.
FIG. 6 shows a still further modified form wherein an orifice plate 13 having a plurality of cut-out portions 13A is interposed between the lower surface 1B and the valve disc 5 and, further, an additional orifice passage 23 is formed between each or a selected number of passages 12 and the upper surface 1A of the piston 1 to constitute an orifice having a variable effective area. The upper ends of the orifice passages 23 are partially closed by a restricting member 24. The restricting member can deflect upward when fluid flows in the passage 23 in the upward direction. The restricting member 24 may fully close the passage 23 when the orifice plate 13 is provided. Alternatively, the orifice plate 13 may be omitted when the restricting member 24 partially covers the passage 23 in the closed condition. The operation and function of the embodiment of FIG. 6 is similar to FIG. 1.
Although the description has been made with respect to preferable embodiments, the invention is not limited to the such embodiments, and various changes or modifications can easily be performed by those skilled in the art. The restricting member is preferably formed of such as a rubber plate or the like having a good sealing characteristics in the closed condition and being easily deflectable when a relatively low pressure is applied in the opening direction. However, the restricting member may be formed of a rigid material and be lightly biased in the closing direction. In the illustrated embodiments, the restricting member acts to increase the effective area of the orifice passage in the contraction stroke of the damper, but the restricting member may be arranged to increase the effective area of the orifice passage in the extension stroke of the damper. Further, the invention may similarly be applied to a dual-tube type damper and a single tube type damper.
As described heretofore, the restricting member according to the invention decreases the effective area of an orifice passage against the fluid flow in one direction, or increases the effective area against the fluid flow in the opposite direction, and thus, it is possible to adjust or change the damping force in the low piston velocity condition between the extension and contraction strokes of the damper, thereby improving the applicability of the hydraulic damper.
Further, the damping force in the extension and contraction strokes of the damper can easily be adjusted by changing the size and/or the rigidity of the restricting member. | A hydraulic damper includes a cylinder, a piston working in the cylinder and partitioning the interior thereof into two liquid chambers, two valve discs provided respectively on opposite end surfaces of the piston, two sets of passages opening respectively in opposite end surfaces of the piston to cooperate with respective valve discs, and an orifice communicating permanently the two liquid chambers. A restricting member is provided to change the effective area of the orifice in response to the direction of the liquid flow passing through the orifice. | 5 |
TECHNICAL FIELD
[0001] The present invention relates to a refrigerant supply device, a cooling device, and a cooling system.
BACKGROUND ART
[0002] With the development of information society in recent years, the amount of data is expected to increase greatly. To respond to the expected increase in the amount of data, it is necessary to install many high-performance servers and other electronic devices. Generally, high-performance electronic devices consume a large amount of electric power. And most of the electric power consumption of the electronic devices is converted into heat. Therefore, installing high-performance electronic devices cause ambient temperature rising due to their exhaust heat consequently. Particularly, in data centers having many electronic devices such as servers, the electronic devices emit a large amount of heat. In such a case, the electronic devices need to be cooled to maintain their functions, thus the air conditioning system requires a large amount of electric power. Because of that situation, there is a demand for a method of reducing load on the air conditioning of electronic devices.
[0003] As a technique to meet such a demand, there has been devised a method of circulating refrigerant without using a pump by utilizing phase changes of the refrigerant. This technique does not use any power for circulating the refrigerant and is very economical. In addition, by using an insulating refrigerant, short circuits are prevented even when there is a refrigerant leak. Thus, the technique of utilizing phase changes of the refrigerant is very effective for removing heat from servers and other electronic devices in data centers where these devices need to be working constantly.
[0004] Such electronic devices as described above are usually disposed in multiple tiers in a rack when used. In such a case, heat receivers for absorbing heat from the electronic devices are preferably disposed in multiple tiers corresponding to the tiers of electronic devices for higher efficiency.
[0005] A technique for refrigerant supply device for supplying refrigerant evenly among heat receivers disposed in multiple tiers as described above by utilizing force of gravity is disclosed in, for example, PTL 1. This technique employs a liquid distribution mechanism between liquid conduits for supplying liquid phase refrigerant and the heat exchanger. The liquid distribution mechanism is in a shape of container, and a branch conduit through which the refrigerant flows to lower tiers is connected to the liquid distribution mechanism at the same height as the predetermined level of liquid surface of the heat exchanger. When the refrigerant exceeds the predetermined level of liquid surface, the refrigerant overflows to the branch tube and flows down to the liquid distribution mechanism on a lower tier.
[0006] PTL 1 and PTL 2 disclose a configuration in which the liquid distribution mechanism is provided with a float and a valve that moves up and down with the float. In this configuration, when the refrigerant surface goes up to a predetermined level, the valve closes and subsequently the refrigerant flows down to the liquid distribution mechanism on a lower tier. PTL 3 also discloses a related technique.
CITATION LIST
Patent Literature
[0007] [PTL 1] Japanese Unexamined Patent Application Publication No. H5-312361
[PTL 2] Japanese Unexamined Patent Application Publication No. H6-195130
[PTL 3] International Publication No. 2015/087530
SUMMARY OF INVENTION
Technical Problem
[0008] However, PTL 1 and PTL 2 have problems as the following.
[0009] In PTL 1, the branch conduit is provided on a side of the liquid distribution mechanism to allow the refrigerant to flow down to the liquid distribution mechanism below. In order to allow the refrigerant to flow down from the side, the branch conduit is formed with a bent portion. The bent portion increases the lateral width of the refrigerant supply device.
[0010] Furthermore, with the configurations with a float and valve disclosed in PTL 1 and PTL 2, the float provided inside also increases the lateral width of the liquid distribution mechanism. These configurations also have a problem of making the mechanism of the refrigerant supply device more complicated.
[0011] The present invention has been made in view of the above problems, and an object of the invention is to provide a refrigerant supply device with a small lateral width and a capacity to supply refrigerant evenly among heat receivers disposed in multiple tiers.
Solution to Problem
[0012] To address the above-described problems, the refrigerant supply device of the present invention is a refrigerant supply device for distributing, by force of gravity, liquid phase refrigerant to heat receivers disposed in a plurality of tiers, the device including: a first conduit for supplying the refrigerant to the heat receivers; a second conduit provided in parallel with the first conduit; a first aperture provided in the first conduit for supplying the refrigerant to one of the heat receivers; a first blocking means provided below the first aperture for blocking the first conduit; a first communication opening provided above the first aperture and communicating the first conduit and the second conduit; a second communication opening provided below the first blocking means and communicating the first conduit and the second conduit; and a second blocking means provided below the second communication opening for blocking the second conduit.
Advantageous Effects of Invention
[0013] The present invention has effects of providing a refrigerant supply device with a small lateral width and a capacity to supply refrigerant evenly among heat receivers disposed in multiple tiers.
BRIEF DESCRIPTION OF DRAWINGS
[0014] FIG. 1 is a cross-sectional view illustrating a first example embodiment.
[0015] FIG. 2 is a cross-sectional view illustrating a second example embodiment.
[0016] FIG. 3 is a cross-sectional view illustrating a third example embodiment.
[0017] FIG. 4 is a block diagram illustrating a fourth example embodiment.
[0018] FIG. 5A is a latitudinal plan view of a dual passage tube used in a fifth example embodiment.
[0019] FIG. 5B is a longitudinal cross-sectional view of the dual passage tube used in the fifth example embodiment
[0020] FIG. 6A is a cross-sectional view illustrating a process in the fifth example embodiment.
[0021] FIG. 6B is a cross-sectional view illustrating another process in the fifth example embodiment.
[0022] FIG. 6C is a cross-sectional view illustrating yet another process in the fifth example embodiment.
DESCRIPTION OF EMBODIMENTS
[0023] Example embodiments of the present invention will be described below in detail. It should be noted that, although technically preferable limitations are applied to the following example embodiments, it is not intended to limit the scope of the present invention to the following.
First Example Embodiment
[0024] FIG. 1 is a cross-sectional view illustrating a first example embodiment. The present example embodiment is a refrigerant supply device for distributing, by force of gravity 10 , liquid phase refrigerant to heat receivers disposed in a plurality of tiers. A refrigerant supply device according to the present example embodiment 100 includes a first conduit 1 for supplying refrigerant to heat receivers, and a second conduit 2 provided in parallel with the first conduit 1 and sharing part of its conduit wall with the first conduit 1 . The first conduit 1 includes a first aperture 4 through which the refrigerant flows to a heat receiver 3 and a first blocking means 5 provided below the first aperture 4 for blocking the first conduit 1 . The refrigerant supply device 100 also includes a first communication opening 6 provided above the first aperture 4 and communicating the first conduit 1 and the second conduit 2 . The refrigerant supply device 100 also includes a second communication opening 7 provided below the first blocking means 5 and communicating the first conduit 1 and the second conduit 2 . The second conduit 2 includes a second blocking means 8 provided below the second communication opening 7 for blocking the second conduit 2 . Herein, “lower”, “lowest”, “below”, “down”, and “downward” should be understood in accordance with the direction of the force of gravity 10 .
[0025] When the liquid phase refrigerant 20 is supplied to the refrigerant supply device according to the present example embodiment 100 , the liquid phase refrigerant 20 flows downward as indicated by the dashed arrow in the drawing. First, the liquid phase refrigerant 20 is blocked by the first blocking means 5 , and flows through the first aperture 4 to a heat receiver 3 . When the heat receiver 3 is filled with the refrigerant, the liquid surface reaches the first communication opening 6 and the refrigerant overflows to the second conduit. This flow is blocked by the second blocking means 8 and the refrigerant flows through the second communication opening 7 to the first conduit 1 . This flow is blocked by the first blocking means 5 on the next tier, and the refrigerant is supplied through the first aperture 4 of the next tier to the heat receiver 3 of the next tier. The liquid phase refrigerant is supplied evenly among the heat receivers disposed in the plurality of tiers by repeating this process.
[0026] As described above, according to the present example embodiment, refrigerant is supplied evenly among heat receivers disposed in a plurality of tiers while using a space no wider than two straight tubes disposed in parallel. Furthermore, this is achieved by a simple structure with apertures and blocked parts at predetermined positions of the conduits.
Second Example Embodiment
[0027] FIG. 2 is a cross-sectional view illustrating a present example embodiment. The present example embodiment is a cooling device equipped with the refrigerant supply device 100 of the first example embodiment. Herein, the refrigerant supply device 100 is also referred to as liquid phase tube 30 for the sake of simplicity and in light of its function in the cooling device 200 .
[0028] The cooling device 200 includes a liquid phase tube 30 , heat receivers 3 disposed in a plurality of tiers, and a gas phase tube 40 . The gas phase tube 40 is provided with apertures 41 at positions corresponding to respective heat exhaust ports of the heat receivers 3 , and connected with the heat receivers 3 . Note that the heat receivers 3 used in the present example embodiment is an application of so-called ebullient cooling system, that is, heat is absorbed when the liquid phase refrigerant 20 boils in the heat receivers 3 . The heat receivers 3 need only to be suitable to the ebullient cooling system, and the present example embodiment can be realized regardless of what specific inner structure the heat receivers 3 may have.
[0029] The operation of the cooling device 200 of the present example embodiment will be described below. Upon supplied to the liquid phase tube 30 from above, the liquid phase refrigerant 20 is supplied through the first conduits 1 and then the first apertures 4 to the heat receivers 3 . The liquid phase tube 30 supplies the liquid phase refrigerant 20 evenly among the heat receivers 3 disposed in a plurality of tiers in a similar manner as in the first example embodiment.
[0030] The heat receivers 3 receive heat from heat sources, and the liquid phase refrigerant 20 boils and turns into gas phase refrigerant 21 by undergoing a phase change. This lowers the temperature of the heat receivers 3 . The gas phase refrigerant 21 flows through the apertures 41 into the gas phase tube 40 . In the gas phase tube 40 , the liquid phase refrigerant from the heat receivers moves upward by cubical expansion and buoyancy. Here, the refrigerant need not completely evaporate and a small amount of liquid phase refrigerant 20 may remain in the gas phase refrigerant 21 . The gas phase refrigerant 21 is then cooled in a radiator not shown and flows back to the liquid phase tube 30 . Through this cycle, cooling of the heat sources is achieved without using external power.
[0031] As described above, the present example embodiment enables a configuration of a cooling device that supplies liquid phase refrigerant evenly among heat receivers on a plurality of tiers and performs an efficient cooling of heat sources.
Third Example Embodiment
[0032] FIG. 3 is a cross-sectional view illustrating a third example embodiment. The present example embodiment provides a configuration example of the cooling device 200 applied to a heat receiver 3 on the lowest tier. At the end 30 a of the liquid phase tube 30 on the lowest tier, the first conduit 1 and the second conduit 2 are both blocked. The end 40 a of the gas phase tube 40 is also blocked. It is not necessary to provide a first communication opening 6 at the lowest tier of the liquid phase tube 30 because the liquid phase refrigerant 20 need not be supplied further downward.
[0033] The lowest tier of the liquid phase tube 30 supplies the liquid phase refrigerant 20 to the heat receiver 3 of the lowest tier, and the lowest tier of the gas phase tube 40 receives the gas phase refrigerant from the heat receiver 3 of the lowest tier. Together with the radiator not shown, a closed circuit cooling system is thus formed.
[0034] As described above, the present example embodiment enables a circuit cooling system to be formed with a simple structure.
Fourth Example Embodiment
[0035] FIG. 4 is a block diagram illustrating a fourth example embodiment. The present example embodiment provides a configuration example of a cooling system 300 provided with a cooling device according to the second or third example embodiment. In the drawing, flows of the liquid phase refrigerant 20 and the gas phase refrigerant 21 are schematically illustrated. The liquid phase tube 30 is connected with a radiator 50 by a liquid phase conduit 31 . The gas phase tube 40 is connected with the radiator 50 by a gas phase conduit 42 . The liquid phase tube 30 and the gas phase tube 40 are connected with the plurality of heat receivers 3 and form a circuit type cooling system 300 .
[0036] The operation of the cooling system 300 will be described below, starting from the radiator 50 . First, liquid phase refrigerant is supplied from the radiator 50 to the liquid phase conduit 31 and then to the liquid phase tube 30 . The liquid phase refrigerant 20 is supplied evenly among the heat receivers 3 from the liquid phase tube 30 in a manner similar to the first example embodiment. The flow of the liquid phase refrigerant 20 is indicated by the solid arrow. FIG. 5 illustrates an example with four heat receivers 3 , but naturally the number of the heat receivers 3 is not limited thereto.
[0037] The liquid phase refrigerant 20 boils in the heat receivers 3 and turns to the gas phase refrigerant 21 . The heat receivers 3 are cooled by this phase change and absorb heat from the heat sources. This process is schematically illustrated by bubbles and dashed arrows in FIG. 5 . The gas phase refrigerant 21 then flows to the gas phase tube 40 , and returns through the gas phase conduit 42 to the radiator 50 . The gas phase refrigerant then returns to a liquid phase by releasing heat and is supplied to the liquid phase conduit 31 again.
[0038] As described above, the present example embodiment enables a cooling system in which refrigerant is supplied evenly among a plurality of heat receivers to be easily constructed.
Fifth Example Embodiment
[0039] The present example embodiment relates to a manufacturing method of the refrigerant supply device. FIGS. 5A and 5B are a plan view and a cross-sectional view of a dual passage tube used for production of the refrigerant supply device. FIG. 5A is a latitudinal plan view. As illustrated in the drawing, in the present example embodiment, a dual passage tube 60 having a passageway 61 and a passageway 62 is used. FIG. 5B is a longitudinal cross-sectional view. As illustrated in the drawing, this tube is a straight tube having two passageways. This type of dual passage tube 60 may be produced by, for example, extrusion. It also may be produced by piercing and rolling, reducing rolling, presswork and welding or the like. Methods for manufacturing the dual passage tube 60 are not particularly limited but, to avoid any leakage, there should be no defects such as a void on the conduit wall.
[0040] FIGS. 6A, 6B, and 6C are cross-sectional views illustrating the manufacturing method of the refrigerant supply device. First, as illustrated in FIG. 6A , a straight dual passage tube 60 with passageways 61 , 62 is made ready for processing.
[0041] Next, as illustrated in FIG. 6B , apertures 63 and communication openings 64 are formed at predetermined positions.
[0042] Next, as illustrated in FIG. 6C , plugs 65 are provided at positions where the conduits should be blocked, and lids 66 are provided for apertures 63 located outwardly at positions corresponding to the communication openings 64 . The apertures 63 to be connected with the heat receivers are provided with ports 67 for the connection with the heat receivers, while the end of the dual passage tube 60 to be connected with the liquid phase conduit is provided with a port 68 . Depending on the manners of connection with the heat receivers and connection conduits, ports 67 , 68 may be unnecessary. The lower end of the dual passage tube 60 is provided with a lid 69 . Thus the manufacturing of the refrigerant supply device is complete.
[0043] As described above, simply by forming apertures in a dual passage tube and providing plugs and other members, the refrigerant supply device can be manufactured.
[0044] Hereinabove, the present invention has been described using the above-described example embodiments as exemplary examples. The present invention, however, is not limited to the above-described example embodiments. In other words, various aspects that can be recognized by those skilled in the art can be applied to the present invention within the scope of the invention.
[0045] This application claims priority based on Japanese Patent Application No. 2014-212152, filed Oct. 17, 2014, the disclosure of which is incorporated herein by reference in its entirety.
REFERENCE SIGNS LIST
[0000]
1 first conduit
2 second conduit
3 heat receiver
4 first aperture
5 first blocking means
6 first communication opening
7 second communication opening
8 second blocking means
10 force of gravity
20 liquid phase refrigerant
21 gas phase refrigerant
30 liquid phase tube
31 liquid phase conduit
40 gas phase tube
41 aperture
42 gas phase conduit
50 radiator
60 dual passage tube
61 , 62 passageway
63 aperture
64 communication opening
65 plug
66 , 69 lid
67 , 68 port
100 refrigerant supply device
200 cooling device
300 cooling system | [Problem]
A refrigerant supply device with a small lateral width and a capacity to supply refrigerant evenly among heat receivers disposed in multiple tiers needs to be provided.
[Solution]
A refrigerant supply device for distributing, by force of gravity, liquid phase refrigerant to heat receivers disposed in a plurality of tiers includes: a first conduit for supplying the refrigerant to the heat receivers; a second conduit provided in parallel with the first conduit; a first aperture provided in the first conduit for supplying the refrigerant to one of the heat receivers; a first blocking means provided below the first aperture for blocking the first conduit; a first communication opening provided above the first aperture and communicating the first conduit and the second conduit; a second communication opening provided below the first blocking means and communicating the first conduit and the second conduit; and a second blocking means provided below the second communication opening for blocking the second conduit. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to place mats and, in particular, to customizable place mats for visually displaying planar objects of varying sizes and shapes.
BACKGROUND OF THE INVENTION
[0002] Place mats are available in a variety of shapes, colors, designs and materials to suit the desires of the user. For example, place mats exist for use during formal occasions as well as for less formal occasions. Place mats formed from plastic exist for use by children who are prone to create a mess during meals while place mats formed from fine fabrics exist for use by adults. Place mats also exist which are aimed primarily at entertaining the user, in addition to protecting the surface on which they are placed. For example, place mats exist which include familiar cartoon characters printed thereon.
[0003] However, while place mats exist which might be directed towards a particular class of individuals, e.g., adults or children, place mats are generally mass produced and are therefore not customized to each individual user. It is generally not possible for a user to customize his or her place mat to include photos of friends or family members or mementos from a special occasion. This presents a problem since individuals enjoy using items which are customized to their own particular likes. Attempts have been made to fill this void as discussed below.
[0004] U.S. Pat. No. 5,096,752 to Wagner appears to disclose a place mat having pockets for holding celebrity cards such as baseball cards. Specifically, the mat purportedly includes a front panel having a plurality of rectangular cut outs dimensioned to accommodate cards bearing the likeness of celebrities such as athletes. Each of the cut outs is covered with a clear plastic film overlay to provide a window for viewing the cards. A base panel is laminated to the front panel and encloses the cut outs to form a pocket for each card. Provided in the base panel adjacent an edge of each cut out is a slot for insertion and removal of cards. The front panel is imprinted with indicia coordinated with the activity of the celebrities on the cards to be inserted in the various pockets.
[0005] U.S. Pat. No. 4,510,006 to Lawson purports to disclose a personalized laminated display for use as a poster or a place mat which includes a backing sheet having a selected photograph adhesively applied thereto and two sheets of transparent plastic film encasing the backing sheet, i.e., the backing sheet is laminated using a professional laminating machine.
[0006] While these patents purport to disclose customizable place mats, drawbacks exist with the arrangements disclosed in each. With regard to the arrangement disclosed by Wagner, among other drawbacks, since the place mat is formed having discrete pockets formed in the front panel, the place mat is limited with regard to the sizes and shapes of the items to be displayed. The user is required to choose items which are able to fit within the pockets provided by the manufacturer. In addition, the user is restricted as to how the items can be arranged on the place mat. The items must be placed within the pockets or slots provided in the front panel. Moreover, the use of pockets in the front panel does not appear to provide a fluid-tight seal for the baseball cards inserted into the pockets such that the place mat cannot be washed without contaminating the baseball cards.
[0007] With regard to the arrangement of Lawson, among other drawbacks, since the method of forming the place mat requires the use of a professional lamination machine, it is not possible for users to customize their place mats at home. It therefore would not be possible to purchase the place mat of Lawson as a gift for a friend or family member without first customizing the place mat.
OBJECTS AND SUMMARY OF THE INVENTION
[0008] It is therefore an object of the present invention to avoid the above drawbacks of current place mat assemblies.
[0009] It is another object of the present invention to provide a new and improved place mat assembly which is capable of being customized for a particular user.
[0010] It is yet another object of the present invention to provide a new and improved place mat assembly which is capable of being customized to display photographs and mementos having varying sizes and shapes.
[0011] It is still another object of the present invention to provide a new and improved place mat assembly which is capable of being customized to display photographs and mementos in various arrangements.
[0012] It is a further object of the present invention to provide a new and improved place mat assembly which is capable of being customized to display photographs and mementos in a fluid-tight manner such that the place mat can be washed without contaminating the photographs and mementos.
[0013] It is another object of the present invention to provide a new and improved place mat assembly which is capable of being customized to display photographs and mementos and which can be so customized by both children and adults at their homes.
[0014] It is another object of the present invention to provide a new and improved place mat assembly which is capable of being customized so that it can be used to aid in the education of young children during meals.
[0015] To achieve these objects, and others, a place mat assembly is provided which is capable of displaying a plurality of substantially planar objects having various shapes and sizes. The place mat assembly includes a substantially continuous base sheet having a first surface and a second surface, at least one of the surfaces having an adhesive layer applied thereto for retaining the planar objects on the base sheet. The place mat assembly also includes a substantially continuous transparent cover sheet structured and arranged to sealably secure the planar objects between the base sheet and the cover sheet.
[0016] In the preferred embodiment of the invention, the planar objects consist of any objects capable of being sealed between the base sheet and cover sheet including, but not limited to, photographs, letters, poems, wedding invitations, dried flowers, business cards, etc. Since the objects are adhered to the base sheet without the use of discrete pockets or the like, the objects can be of varying sizes and shapes. In addition, the objects can be arranged on the base sheet in any manner desired by the user such as in a collage.
[0017] The objects are typically chosen so that the place mat takes on a particular theme. For example, the place mat can be customized so that it includes photographs of family members. The place mat can also be customized so that it acts as a memento from a particular occasion such as a wedding or a vacation. The place mat can also be customized to exhibit the user's hobbies and/or collections.
[0018] The base sheet of the place mat assembly is formed from an opaque rigid plastic material, preferably calendered rigid vinyl, having one of a variety of colors. For example, the base sheet can be white, black, red, yellow, blue, green, purple, orange, or any other color desired to form the background of the planar objects placed thereon. The cover sheet is formed from a transparent plastic material, preferably transparent calendered vinyl. The base and cover sheets are formed to have lengths ranging from approximately 15 to 19 inches and widths ranging from approximately 9 to 13 inches. The base sheet is approximately 1 to 2 millimeters thick and the cover sheet is approximately 0.5 to 2 millimeter thick. The corners of the base and cover sheets are preferably rounded to protect the user from injury.
[0019] The place mat assembly further includes a paper backing sheet applied to the adhesive layer of the base sheet which, as discussed further below, is peeled back when customizing the place mat assembly. The adhesive forming the adhesive layer is a double-sided pressure sensitive adhesive, preferably acrylic transfer tape. Such an adhesive is known to those skilled in the art as being strong enough to sealably secure the cover sheet to the base sheet to thereby secure the planar objects between the base sheet and the cover sheet in a fluid-tight manner. In other words, the adhesive is strong enough to provide a fluid-tight seal between the base and cover sheets such that the place mat can be washed without contaminating the planar objects arranged between the base and cover sheets. Indeed, the adhesive is so strong that, once the cover sheet is placed on the base sheet to cover the planar objects, the cover sheet cannot be removed from the base sheet without damaging the place mat.
[0020] The place mat assembly of the present invention is customized by first choosing objects to be arranged on the adhesive layer of the base sheet. The objects can be of varying shapes and sizes and will typically relate to one another so that the place mat takes on a particular theme. The paper backing sheet is then peeled back from the base sheet exposing the adhesive layer, after which the objects are arranged on the adhesive layer. The objects can be arranged in any manner desired by the user. Lastly, the transparent cover sheet is laid on top of the base sheet thereby sealably retaining the objects between the base and cover sheets.
[0021] The place mat assembly is sold as a kit, with the base sheet and cover sheet being two separate and distinct components. The cover sheet and base sheet are sold together in a plastic bag, box, or the like. However, in alternate embodiments of the invention, the cover sheet is hingedly coupled to the base sheet along one of their respective edges.
[0022] Accordingly, with the place mat assembly of the present invention, individuals are able to create customized place mats which display photographs and mementos of varying shapes and sizes in a fluid-tight manner such that the place mat can be washed without contaminating the photographs and mementos. The place mat assembly of the present invention is sold as a kit and is customizable by users at home or at work. The photographs and mementos can be arranged on the place mat in various ways.
[0023] In another embodiment of the invention, a method of making a place mat for displaying substantially planar objects, e.g, photographs, mementos and the like, is provided which includes the steps of providing a substantially continuous base sheet having a first surface and a second surface, at least one of the surfaces having an adhesive layer applied thereto, selecting the planar objects having any sizes or shapes for arrangement on the adhesive layer of the base sheet, positioning the planar objects on any area of the adhesive layer of the base sheet, providing at least one substantially continuous transparent cover sheet, and laying the transparent cover sheet over the sheet to thereby sealably secure the planar objects between the base sheet and the cover sheet.
[0024] In another embodiment of the invention, a place mat assembly for displaying substantially planar objects is provided which has a first position and a second position. The place mat assembly includes a substantially continuous base sheet having a first surface, a second surface, a top edge, a bottom edge opposed to the top edge, and opposed side edges, at least one of the surfaces having an adhesive layer applied thereto. The place mat assembly also includes a transparent cover sheet having a top edge, a bottom edge opposed to the top edge, and opposed side edges, wherein the top edge of said cover sheet is hingedly coupled to the top edge of the base sheet such that when the place mat is in its first position, the bottom edge of the cover sheet is spaced apart from the bottom edge of the base sheet such that the planar object is able to be positioned and retained on the adhesive layer of the base sheet. When the place mat assembly is in its second position, the bottom edge of the cover sheet is flush with the bottom edge of the base sheet such that the planar object is sealably retained between the base sheet and the cover sheet.
[0025] In another embodiment of the invention, a method for protecting a table top during meals is provided including the steps of providing a substantially continuous base sheet having a first surface and a second surface, at least one of the surfaces having an adhesive layer applied thereto, selecting planar objects for arrangement on the adhesive layer of the base sheet, positioning the planar objects on the adhesive layer of the base sheet, providing a transparent cover sheet, laying the transparent cover sheet over the continuous base sheet to thereby sealably secure the planar objects between the base sheet and the transparent cover sheet and to thereby form a place mat, placing the place mat on a surface of a table, and placing dishes and the like on the place mat.
[0026] In another embodiment of the invention, the objects placed between the base sheet and cover sheet are educational objects such that a method for educating a young child during meals is provided. In this method of the invention, a substantially continuous base sheet is provided having a first surface and a second surface, at least one of the surfaces having an adhesive layer applied thereto. Planar objects having educational values are then selected for arrangement on the adhesive layer of the base sheet. Such educational objects include, for example, the letters of the alphabet, numbers, shapes, simple words with corresponding objects, and the like. The educational planar objects are positioned on the adhesive layer of the base sheet and a transparent cover sheet is laid on the continuous base sheet to thereby sealably secure the educational planar objects between the base sheet and the transparent cover sheet to thereby form a place mat. The place mat is laid on a surface of a table and dishes and the like are placed on the place mat. The young child is then quizzed during the meal using the educational planar objects of the place mat.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] A more complete appreciation of the present invention and many of the attendant advantages thereof will be readily understood by reference to the following detailed description when considered in connection with the accompanying drawings in which:
[0028] [0028]FIG. 1 is an exploded perspective view of a place mat assembly in accordance with the invention;
[0029] [0029]FIG. 2 is a plan view of the place mat assembly shown in FIG. 1;
[0030] [0030]FIG. 3 is a cross-sectional view along line 3 - 3 of FIG. 2;
[0031] [0031]FIG. 4 is a perspective view of a place mat assembly in accordance with another embodiment of the invention;
[0032] [0032]FIG. 5 is a plan view of a place mat assembly in accordance with an another embodiment of the invention;
[0033] [0033]FIG. 6 is a perspective view of the place mat assembly shown in FIG. 5 being used; and
[0034] [0034]FIG. 7 is a front view of a place mat assembly in accordance with the invention as sold in stores.
DETAILED DESCRIPTION OF THE INVENTION
[0035] Referring to the drawings, wherein like reference characters designate identical or corresponding parts throughout the various views, FIGS. 1 - 3 show a place mat assembly 10 in accordance with the present invention which is capable of being customized to display one or more planar objects 6 such as photographs, letters, poems, wedding invitations, dried flowers, business cards, educational items and the like. As discussed below, place mat assembly 10 is designed such that planar objects 6 can be of varying sizes and shapes and can be arranged in any manner.
[0036] Place mat assembly 10 includes a base sheet 2 and cover sheet 4 . Base sheet 2 is formed from a rigid opaque plastic material, preferably calendered rigid vinyl, having a matte finish on both sides. The base sheet 2 can be any color, including white, black, red, yellow, blue, green, purple, orange, or any other color desired to form the background of the place mat. The base sheet 2 is rectangular in shape having a width of between approximately 9 and 13 inches, preferably 11 inches, and a length of between approximately 15 and 19 inches, preferably 17 inches. The thickness of base sheet 2 is approximately 1 to 2 millimeters. The corners of the base sheet 2 are rounded so that the user is not easily injured. While the base sheet 2 is preferably substantially rectangular in shape, it can also be other shapes known by those skilled in the art to be used for place mats such as square, round and oval.
[0037] The base sheet 2 of place mat 10 includes a layer of adhesive 4 covering substantially one entire surface of base sheet 2 . The adhesive is a double sided pressure sensitive adhesive, preferably acrylic transfer tape, which is known in the art to be a relatively strong adhesive. While the adhesive layer 4 preferably covers substantially one entire surface of base sheet 2 , in other embodiments of the invention, the adhesive layer only covers a portion of one surface of base sheet 2 such that a narrow border remains around the periphery of the base sheet.
[0038] A backing sheet 8 is applied to the exposed side of the adhesive layer 4 of base sheet 2 . That is, when the place mat assembly 10 is sold as a kit (see FIG. 7), i.e., prior to the customization of the place mat assembly to form the customized place mat, the base sheet 2 includes a backing sheet 8 applied over the entire adhesive layer 4 . Backing sheet 8 is a waxy paper material which is easily releasable from the adhesive layer.
[0039] Place mat assembly 10 also includes a cover sheet 12 which is structured and arranged to be laid on top of adhesive layer 4 when the place mat assembly 10 is customized to form a place mat. Cover sheet 12 is a transparent plastic material, preferably transparent calendered vinyl. Cover sheet 12 is formed to have substantially the same dimensions as base sheet 2 except that the thickness of cover sheet 12 is approximately 0.5 to 2 millimeters. The corners of cover sheet 12 are also rounded to prevent injury to the user.
[0040] In alternate embodiments of the invention, the base and cover sheets can have dimensions which are larger or smaller than the dimensions stated above. For example, the base and cover sheets can be formed to have larger dimensions than stated above such that the place mat can be used as a blotter for an office desk.
[0041] Both the cover sheet 12 and base sheet 2 are substantially continuous. That is, the cover sheet 12 and base sheet 2 are devoid of perforations or holes such that the objects placed therebetween will be sealably retained when the place mat is formed. This is important since it is a goal of the present invention to keep the objects free from contamination when the place mat is being washed.
[0042] The method of customizing the place mat assembly 10 will now be discussed. Place mat assembly 10 is sold as a kit (see FIG. 7) such that base sheet 2 , having the adhesive layer 4 and backing sheet 8 applied thereto, and cover sheet 12 are separate and distinct components. As discussed further below, in another embodiment of the invention, base sheet 2 and cover sheet 12 are hingedly coupled to one another along respective edges of each sheet (see FIG. 4). The place mat assembly 10 is typically sold in a transparent plastic bag. However, it is understood by those skilled in the art that the place mat assembly 10 can be sold in other packages such as a box or large envelope.
[0043] After removing the components of place mat assembly 10 from the package, the user chooses at least one, preferably several, planar objects 6 to be displayed by the place mat. For example, if the place mat is being customized for use by a young child, the user might choose several photographs of the child's family members so that, during meals, the child can be quizzed as to the name of each family member. Alternatively, the user might choose to customize the place mat so that it includes mementos from a vacation or special occasion such as a wedding. Such mementos can include photographs from the wedding, the wedding invitation, a dried flower from the bride's bouquet, and a piece of the bride's veil. It is an important aspect of the place mat assembly 10 of the invention that the objects 6 chosen by the user can be of varying sizes and shapes. The user is not limited to objects of uniform sizes as with prior art place mats. Alternate objects 6 for use with place mat assembly 10 will be discussed further below in connection with alternate embodiments of the invention.
[0044] After objects 6 are chosen, backing sheet 8 is peeled off from base sheet 2 to expose the adhesive layer 4 and the objects 6 are arranged on the adhesive layer 4 . It is an important aspect of the place mat assembly 10 of the invention that the objects 6 chosen by the user can be arranged on the base sheet 2 in any desired manner. In contrast to prior art place mats, the user is not confined to placing the objects 6 in predetermined slots or pockets provided in the backing sheet. However, it is pointed out that the objects 6 must not cover the entire adhesive layer 4 since at least a portion of adhesive layer 4 around the periphery of the base sheet 2 must remain exposed so that the cover sheet 12 can adhere to the base sheet 2 and sealably retain the objects 6 between the sheets in a fluid-tight manner. It is preferred that a border of between approximately 0.5 and 1.5 inches remain around the periphery of the base sheet 2 .
[0045] After objects 6 are arranged on the adhesive layer 4 , the cover sheet 12 is placed on top of base sheet 2 such that cover sheet 12 adheres to the exposed portions of the adhesive layer 4 and the objects 6 are sealably retained between base sheet 2 and cover sheet 12 in a fluid-tight manner. It is important that cover sheet 12 is positioned on base sheet 2 such that the respective edges of each sheet are perfectly aligned. At this stage of the process, a customized place mat is provided which can be washed without the possibility of contaminating the objects 6 since the objects 6 are sealed between base sheet 2 and cover sheet 12 in a fluid-tight manner. As shown in FIG. 3, the adhesive used to form adhesive layer 4 is so strong that the portions of the base and cover sheets surrounding each object 6 are adhered together to form a barrier to fluids during meals and when washing the place mat. In this manner, the place mat assembly 10 is not reusable such that it can only be customized a single time.
[0046] [0046]FIG. 4 shows another embodiment of the place mat assembly 10 of the present invention. The place mat assembly 10 of this embodiment is similar to the place mat assembly of FIGS. 1 - 3 except that the place mat assembly 10 of FIG. 4 is a unitary device rather than two separate and distinct components. In this embodiment of the invention, the cover sheet 12 is hingedly coupled to base sheet 2 at edge 13 . Specifically, the cover sheet 12 is heat sealed to base sheet 2 along area 14 and the adhesive layer 4 is arranged on the top side of base sheet 2 except for area 14 . The paper backing sheet (not shown) is applied to adhesive layer 4 .
[0047] The place mat assembly 10 of FIG. 4 is sold as a kit similar to the place mat assembly of FIGS. 1 - 3 . When the user customizes the place mat assembly 10 , the cover sheet 12 is lifted from base sheet 2 by the edge of the cover sheet opposite edge 13 and the paper backing sheet is peeled from the adhesive layer 4 of base sheet 2 . The objects 6 are then chosen and arranged on the adhesive layer, after which the cover sheet 12 is laid on base sheet 2 thereby forming the customized place mat.
[0048] It is understood by parents that a large portion of the day is spent attempting to feed children. It is an advantage of the place mat assembly 10 of the present invention that it can be customized in such a manner that the place mat can be used to aid in educating children during meal times. Specifically, with reference to FIGS. 5 and 6, a method for educating a child during meals is provided in which the objects 6 are specifically chosen by the user in order to aid in educating the child during meals.
[0049] In this embodiment of the invention, the place mat is customized in a similar manner as discussed above with regard to FIGS. 1 - 3 . However, the planar objects 6 are educational objects which are chosen by a parent based on the educational level of his or her child. For example, if the child is of the age that he or she is learning simple addition or the letters of the alphabet, examples of such addition or letters are used as objects 6 and placed on the adhesive layer between the base and cover sheets. The place mat is then placed beneath the child's plate, bowl or the like during meals and the parent can quiz the child about the objects 6 . For purposes of this application, it is understood by those skilled in the art that the term “educational objects” refers to objects which are used by parents solely to educate their children. Examples of such objects are numbers, letters, shapes, common objects, colors, word games, etc. The term educational objects does not refer to objects used solely for entertainment such as baseball cards and the like.
[0050] Accordingly, with the place mat assembly of the present invention, individuals are able to create customized place mats which display photographs and mementos of varying shapes and sizes in a fluid-tight manner such that the place mat can be washed without contaminating the photographs and mementos. The place mat assembly is sold as a kit and is therefore customizable by users at home or at work. In addition, the photographs and mementos can be arranged on the place mat in various ways. Moreover, the place mat can be customized to display educational objects so that the place mat can be used in order to aid in educating a child during meals.
[0051] Obviously, numerous modifications and variations of the present invention are possible in light of the teachings hereof. Therefore, it is to be understood that the invention can be varied from the detailed description above within the scope of the claims appended hereto. | A customizable place mat assembly capable of displaying a plurality of substantially planar objects. The place mat assembly includes a substantially continuous base sheet having a first surface and a second surface, at least one of the surfaces having an adhesive layer applied thereto for retaining the planar objects on the base sheet. The place mat assembly also includes a substantially continuous transparent cover sheet structured and arranged to sealably secure the planar objects between the base sheet and the cover sheet. | 1 |
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