description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] The present invention relates to electronic systems operable under program control to create and edit electronic documents.
[0004] A conventional feature of computer program applications that create and edit documents is an undo command. Applications written for the Microsoft® Windows 95 operating system often use Ctrl-Z as a keyboard shortcut for the undo command.
[0005] One mechanism for implementing undo in applications is based on a command object that knows how to do, undo, and redo an operation. This is described, for example, in Gamma et al., Design Patterns, Addison-Wesley Publishing Co., © 1995, pages 233 to 242. Multiple undo may then be implemented by keeping a command history. Gamma notes on page 239 that such an implementation has a strong potential for error accumulation and recommends using the “memento” pattern as part of the command object. Some applications provide a user with a list of the most recent actions and allow the user to select one of the actions, thereby undoing the selected action and all actions above it (that is, all more recent actions) in the list.
[0006] A related feature available in some applications allows a user to save a document that is being edited and later revert to the saved version, thereby discarding intervening changes to the document.
[0007] The conventional behavior of an undo command restores the document to the state it had before the operation being undone was done.
SUMMARY OF THE INVENTION
[0008] In general, in one aspect, the invention provides methods and apparatus embodying techniques for performing operations on documents having states. The techniques include performing operations to maintain in a memory a state history of a document for storing document states; and, whenever an interesting operation has occurred, automatically capture the state of the document as it exists after the operation and adding the captured state to the state history.
[0009] In general, in another aspect, the techniques include operations to maintain a first history of interesting operations and a second history of all operations requested by a user, the second history but not the first history including operations global to the state of the application.
[0010] In general, in another aspect, the techniques include operations to receive from the user a sequence of commands to change the document; change the document state in response to each command; add the changed document state to a state history maintained in a computer-readable memory device each time the document state is changed; for each document state added to the state history, add a corresponding entry to a history list displayed to the user on a computer-controlled display device operated as part of a graphical user interface; and, in response to a user action stepping backward to an item in the history list, update the document to have the corresponding document state saved in the state history.
[0011] In general, in another aspect, the techniques include operations to keep a history list; go back to a previous state in the history list; select a future state from the history list, being a state created after the previous state, as a source of data for an operation; and perform the operation with the future data on the previous state.
[0012] In general, in another aspect, the techniques include operations to keep a history of document states created by a user; enable the user to discard any of the history; and enable the user to step backward and forward through the history and thereby to alter the state of the document to be any of the document states in the history.
[0013] In general, in another aspect, the techniques include operations to keep a history of document states created automatically whenever a user command to the application changes the state of a document; enable the user to discard any user-selected set of the document states in the history; and enable the user to designate any one of the document states in the history and thereby install the designated state as the current state of the document.
[0014] In general, in another aspect, the techniques include operations to create and modify a document; identify for a user on a display device a set of states that the document has been in by operation of the application; and enable the user to designate any arbitrary one of the identified states.
[0015] Particular implementations of the invention will have one or more of the following advantages. Use of a state history supports a quick and efficient multiple undo operation, particularly in the context of an application like a image editing application whose operations often act on an entire document. It enables a user to access prior states of a document randomly. It enables a prior state of a document to be turned into its own document. It provides a way to implement multiple undo efficiently while avoiding operation sequence dependencies. A large history of commands on a document may be navigated quickly and without increasing time cost for navigating over many commands. It somewhat simplifies treating multiple contiguous user commands—such as multiple commands moving the same object in an image—as a single command for undo purposes. Where revisions to one document may be made using data from another document, the invention provides a multiple undo feature without risk of inter-document dependencies.
[0016] Further advantages include the following. In a non-linear mode of operation, a user may edit a document starting from an earlier-captured document state without losing later-captured states. For example, using a digital painting application, a user may apply a series of filters to an image, then go back to the original image state, and then selectively paint in the effects of those filters using a history paintbrush tool. Use of a smooth-moving control interface element allows a user easily to scan through a document's history while viewing the history states as they are selected by the control, creating a movie-like presentation of at least a portion of the document creation and editing process.
[0017] Other features and advantages of the invention will become apparent from the following description and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 is a schematic block diagram of a computer system running an application program in accordance with the invention.
[0019] [0019]FIG. 2 shows a history palette user interface element of an implementation of the invention.
[0020] [0020]FIG. 3 is a flowchart of steps performed by an application operating in accordance with the invention.
[0021] [0021]FIG. 4 is a flowchart elaborating on FIG. 3.
[0022] [0022]FIG. 5 is a flowchart elaborating on FIG. 4.
DETAILED DESCRIPTION
[0023] As shown in FIG. 1, a conventional programmable computer system 100 has at least a processor component 114 capable of executing computer program instructions, a memory component 112 for storing programs and data, and a user interface device or devices 116 by which a person—a user—may interact with programs running on the system 100 . These and other components are connected to interact with each other by one or more buses 118 . The memory component will generally include a volatile random access memory (RAM), a non-volatile read-only memory (ROM), and one or more large disk drives. The system may run one or more programs. Application 120 is a computer program designed for a particular task, and, as is typical, it acts on a central depository called a document, whose content a user creates and edits. Some applications, as illustrated, may allow a user to have more than one document, such as documents 130 and 140 , open at a time, and allow the user to select one or the other of them as the active document that is the focus or target of editing and other document-directed actions.
[0024] A document is typically displayed in a rectangular region of the display screen called a document window. A spreadsheet application displays a spreadsheet document designed to look and act like a 2-dimensional table. A word-processing application displays a document designed to look like a sheet of paper. An image processing application displays a document designed to look like a photograph or a drawing.
[0025] As is conventional, application 120 is illustrated as having program instructions 122 that may be executed to operated on data 124 . Application 120 is programmed to implement a state history feature, and so associates with each open document 130 and 140 a corresponding state history 132 and 142 and a corresponding undo buffer 134 and 144 , respectively. The application also has an undo buffer 126 for the application itself. In an alternative implementation, the application undo buffer is the only undo buffer and the commands stored there include a reference to the relevant document, if any. If the application undo buffer contains a command to undo, then all of the document undo buffers should be empty, to maintain intuitive operation of the undo-redo feature.
[0026] As shown in FIG. 2, an application implementing a history list provides, as part of a graphical user interface, a floating history palette 200 that a user may show or hide with menu commands or other user interface commands. Pertinent aspects of the operation of the application will now be described in terms of the information made available on the history palette 200 and the operations a user may perform using the history palette.
[0027] When a document is opened or newly created, the application generates a snapshot of the document and updates the snapshot or upper region 204 of the palette with a thumbnail image representing the snapshot and the name of the snapshot, which the user may edit. The lower portion 206 of the palette is initialized with an item named “Open” or “New”, for the initial document state, so that the user will be able to step backward from his or her first state-changing operation. (This may be viewed as characterizing opening and creating a document as “interesting” operations, as described below.) The history palette 200 is associated with a particular document. If the user has two documents 130 and 140 (FIG. 1) open, each will have a separate history palette, and the history palette shown when one of the documents is active will reflect the state history 132 or 142 , respectively, of the corresponding document 130 or 140 .
[0028] Viewing parameters, such as a viewing magnification, which affect how the application displays the document but do not affect the actual document data, may be considered interesting in a particular implementation. For example, a viewing parameter that applies to all views of a document may well be treated as interesting and considered part of the state of the document; whereas, if the document can be viewed in multiple open windows with a viewing parameter that can be set differently for each view, the parameter would more naturally not be considered interesting or part of the document state.
[0029] The state of the document is recorded in the state history after the user makes a change to the document that changes the state of the document. The application may—implicitly or expressly—categorize commands into those that change the document state (the “interesting” ones) and those that do not. As an example, some commands, such as successive, consecutive commands moving a single object, may be interesting only in the aggregate, when they have been collapsed into a single move-object command. As another example, some commands are global, such as a change to a palette or to preferences, in that they change the state of the application, and are not made to a particular document.
[0030] When a document state is recorded, it is appended as an item at the end of the history list portion 206 . Each item has an icon and a brief textual description of corresponding command. The icon shows the tool used to perform the command or, for menu and dialog commands, it is a menu or dialog icon. Both the upper portion 204 and the lower portion 206 are specific to the current document and will change when a different document is made active.
[0031] The user may grab a small control 208 on the left side of the palette and drag it up and down to cause states of the document to be displayed, according to the position of the control. Doing so causes the current state—the one being displayed as a result of the dragging action—to be highlighted and those after it to be dimmed. In FIG. 2, the state corresponding to the second history list item, “Selection”, is highlighted, and those following it are dimmed. Other user interface gestures, such as clicking on an item, will have the same effect. If the user then begins to alter the document, all items in the history list 206 below the selected item will be deleted. (An alternative and more powerful mode of operation—non-linear history mode—will be described later.)
[0032] The leftmost column of the floating palette has buttons 210 that may be selected to establish the corresponding state—whether a state in the state history or a snapshot—as the state that will be used as a source state by history-based tools. Such a selection is recorded on the palette with an icon to mark the selected state. As illustrated, a history paintbrush icon is used to indicate that the corresponding state will be used when a history paintbrush tool is used on the active document. If no more than one state may be selected as a source for history-based tools, the buttons 210 will behave like radio buttons, in that selecting one state will deselect any other selected state. As will be described, both earlier and later document states (that is, both items above and below the current state item in the history list) may be selected as a history source.
[0033] The history paintbrush tool may be selected from a tool palette like any of the other tools that the user may select to perform operations on a document. In operation, the history paintbrush operates to paint on a target document input from the source. In an image application, the input may be pixel data, blending modes, clipping paths, or any other data that is part of the source document state. The semantics of the tool may—but need not—require the source to be a state (present, past, or future) of the target document; alternatively, the semantics may permit a tool to use as a source a state derived from a document entirely independent from the target document.
[0034] The history palette 200 may also be used as a source for a drag and drop command. When the user grabs an item on the palette and drags it to another document, the source state (the document state corresponding to the drag item) will be applied to the targeted document. The semantics of applying a state to a document are application specific, and may depend on the nature of the source state. (For example, it may be a complete document state, such as is found in the state history, or it may be a partial state, such as is captured when a snapshot is taken of a single layer of an image document.) In the semantics of one implementation, to apply a complete document state appends the source state to the history list and installs it as the current state of the target document. If the source is a partial state such as an image layer, it could be added as a layer to the target document. Alternatively, even a complete source image document could be flattened to a single layer and added to the target document.
[0035] The history palette also has a pop-up menu 202 . This menu provides commands to step forward through a history list, to step backward through a history list, to create a new snapshot, to delete a history or snapshot item, to clear the history list 206 (and corresponding state history), to create a new document from a saved document state, and to set options for the history features.
[0036] The step forward and step backward commands enable the user to walk backward and forward through the current history list 206 , as was described earlier in reference to control 208 .
[0037] A user may create a snapshot of any point in the document's history either by using the new-snapshot command in the pop-up menu 202 or by using the command button 214 in the palette. For example, a user may select a history state by moving control 208 to the corresponding list item and then selecting snapshot button 214 , which will bring up a dialog window for the user to name the snapshot and optionally set snapshot control options. In particular, the user may choose to snapshot a full document from the state, a composition of all the layers of the document state, or the current layer as it exists in the selected document state. An item for the newly created snapshot will be appended to the upper list 204 of the palette.
[0038] As has been mentioned, the features associated with the history palette 200 operate differently in non-linear history mode from what has been described above in two important respects. In non-linear history mode, deleting an item from the history list 206 does not cause the items below the deleted item to be deleted. Because the later document states are complete in themselves, earlier ones may be deleted with no adverse effect. Also, in non-linear history mode, a user may step backward to an earlier document state, begin working from there, and not cause the later document states to be deleted. Rather, the new document states are added to the end of the history list, which as a result will show two branches of state history.
[0039] Operation of the history palette records some, but not all, changes made by a user. Changes that are local to the document will be recorded, while changes that are global to the application will not be recorded. A global change, like changing a setting for a tool, will not cause a document state to be saved in a state history or an item to be added to the history list, because the document state has not been changed and therefore any previously captured state is still the state of the document. On the other hand, a local change, like creating or modifying a document path, layer, or channel, will cause a document state to be saved and an item to be added to the history list.
[0040] In conjunction with the history palette, it remains useful to have a conventional undo-redo feature that allows a user to undo and redo the most recent command without regard to whether it was local or global. This is accomplished by saving an undo item for the most recent user command in a document-specific buffer and applying the undo menu command or its keyboard shortcut as a toggle to undo and redo the operation.
[0041] [0041]FIG. 3 and FIG. 4, along with the accompanying description, are intended to explain the operation and use of the state history feature so that they may be readily understood, and so details of implementation and optimization are omitted. A practical implementation of the pertinent command dispatch and processing functions would be expected to combine and reorganize the illustrated steps and implement them in accordance with well-understood software engineering techniques.
[0042] As shown in FIG. 3, the operation of an implementation of the state history feature may be seen to begin when a user enters a command (step 302 ). A command is a request made by the user to the application, through a graphical user interface, for example, to change the state of the application or the state of the active document. The application performs the corresponding action (step 304 , which will be elaborated in reference to FIG. 4). If the action is one categorized as not affecting the state of a document (the no branch of decision step 306 ), the state history and history list are unaffected. Otherwise, if the action of the command was performed with the document in the state of the temporally most recent entry in the history list, which corresponds to the temporally most recent state in the state history, the state of the document after the action is stored in the state history and the history list on the history palette is updated (the yes branch of step 308 , and steps 312 , 314 , and 320 ). On the no branch of step 308 , if non-linear history mode is in effect, nothing is discarded from the history list or the state history merely because an interesting command has been entered (the yes branch of step 310 ). In linear history mode (the no branch of step 310 ), the history list items below the current state item and the corresponding states in the state history are discarded, other than any item selected as a source for history-based tools, such as the history paintbrush (see description of buttons 210 , above).
[0043] If the maximum size of the history list or state history had been reached, the top (earliest) item from the history list—excluding any item selected as a source for history-based tools—is discarded, along with its corresponding document state in the state history, before the new document state is stored (the no branch of step 312 and step 318 ).
[0044] To produce a practical implementation, it is advantageous to store document states in a form that allows a great deal of sharing between saved states, to keep to a minimum the amount of memory consumed in storing redundant information, and the processor resources consumed in writing and reading it. A data representation suitable for this purpose is described in commonly-owned U.S. patent application Ser. No. 08/702,941 to Hamburg for “Shared Tile Image Representations” filed Aug. 26, 1996, the disclosure of which is incorporated here by this reference.
[0045] Referring to FIG. 4, aspects of the perform action step (step 30 , FIG. 3) pertinent to an implementation of a state history feature will not be described. If the user's command is not an undo or a redo, that is, not the Ctrl-Z toggle, the command is stored in an undo buffer associated with the active document, such as buffers 134 and 144 of FIG. 1 (the yes branch of decision step 410 and step 412 ). If the command is an undo or a redo, the undo or redo operation of the command in the undo buffer is executed (step 412 ). It should be noted that the history-related commands, and in particular changes to the history list and the state history, can be subject to the conventional undo and redo (step 412 ). The provides an advantageous and elegant user interface that allows, for example, a user to toggle between two document states previously selected from anywhere in the state history with a single repeated keystroke.
[0046] Returning to FIG. 4, the next pertinent step considers whether the command relates to the history list or the history palette. If not, the command is performed (step 418 ) and operation continues (step 420 ) with decision step 306 (FIG. 3). Otherwise, the command is one that uses the history list (the yes branch of decision step 416 ), and the processing of it will now be described.
[0047] If the command navigates the history list—for example, a step backward command, step forward command, or list item selection command—the document state corresponding to selected item is installed as the current state of the active document (steps 430 and 432 ).
[0048] If the command designates a source for history-based commands—for example, a command selecting a column 210 button to designate a source for the history paintbrush—the targeted history state is linked as the source document to the tools that can take a source document state as an input (steps 434 and 436 ). The history-based commands that may be implemented in a painting application include the history paintbrush, which paints from the source state onto the active document; a fill-from-history command that performs a fill operation on the active document with input from the source state; and an eraser that erases the active document to the source state. As has been mentioned, the source state may be either earlier or later than the current state, enabling a user to paint from either the future or the past.
[0049] If the command deletes a history list item (the yes branch of step 438 ), the behavior depends on whether the operating mode is linear history mode or non-linear history mode and where in the history list the selected item falls (step 444 ). As shown in FIG. 5, in non-linear history mode, only the selected item and its document state are deleted (the yes branch of decision step 502 and step 504 ). Otherwise, the position of the selected item with respect to the current state of the document is considered (step 506 ). If the selected item is below (was created later than) the current state or the same as the current state, both the selected item and its state, and any later items (below the selected item in the history list) and their states are also deleted (step 510 ). If the selected item is above (was created earlier than) the current state, both the selected item and its state, and any earlier items (above the selected item in the history list) and their states are also deleted (step 508 ). Where a range of states is deleted (steps 508 and 510 ), a special check is made not to delete any item selected as a source for history-based tools.
[0050] Returning to FIG. 4, if the command creates a new document (the yes branch of decision step 446 ), the initial state of the new document is copied from the document state in the state history corresponding to the selected history list item (step 448 ).
[0051] A clear history command may also be implemented, with which a user may delete all non-snapshot states other than the current state and any history paintbrush source state.
[0052] A state history feature is particularly advantageous in an image manipulation application, such as the Photoshop® program available from Adobe Systems Incorporated of San Jose, Calif. In this application, each document is, as is typical, a single-page image that is generally viewed as a whole by the user in the process of creation and editing. This application has many powerful painting and selection tools, supports multiple layers, each with multiple channels, special effects filters, and lighting effects. In this sophisticated environment, the state history feature with its non-linear operating mode is particularly advantageous, in that it permits a user to step backward and forward through a set of states, picking up effects from a future state and applying them to a past state to create a new branch of development of an image.
[0053] The invention may be implemented in digital electronic circuitry, or in computer hardware, firmware, software, or in combinations of them. Apparatus of the invention may be implemented in a computer program product tangibly embodied in a machine-readable storage device for execution by a programmable processor; and method steps of the invention may be performed by a programmable processor executing a program of instructions to perform functions of the invention by operating on input data and generating output. The invention may advantageously be implemented in one or more computer programs that are executable on a programmable system including at least one programmable processor coupled to receive data and instructions from, and to transmit data and instructions to, a data storage system, at least one input device, and at least one output device. Each computer program may be implemented in a high-level procedural or object-oriented programming language, or in assembly or machine language if desired; and in any case, the language may be a compiled or interpreted language. Suitable processors include, by way of example, both general and special purpose microprocessors. Generally, a processor will receive instructions and data from a read-only memory and/or a random access memory. Storage devices suitable for tangibly embodying computer program instructions and data include all forms of non-volatile memory, including by way of example semiconductor memory devices, such as EPROM, EEPROM, and flash memory devices; magnetic disks such as internal hard disks and removable disks; magneto-optical disks; and CD-ROM disks. Any of the foregoing may be supplemented by, or incorporated in, specially-designed ASICs (application-specific integrated circuits).
[0054] Other embodiments are within the scope of the following claims. For example, the order of performing steps of the invention may be changed by those skilled in the art and still achieve desirable results. Forms of user interface other that a list on a palette to show state history may be used, such as a stack of items or a pull-down or pop-up menu, and that revision branches created in non-linear history mode may be shown as a tree or other representation of an directed acyclic graph. To satisfy user preferences for how an undo-redo feature or a state history feature should behave in a particular application, the application may be implemented to treat selected commands or operations as not interesting and therefore not captured in an undo buffer or a state history, to conform the design of the user interface of the application to user expectations. The user interface aspects of the invention may be embodied using methods of preserving document state information other than storing an entire state, for example, by storing state differences or even command histories. | Methods and apparatus embodying techniques useful in systems for creating and modifying documents. A state history of a document for storing document states is maintained; and, whenever an interesting operation has occurred, the state of the document is automatically captured as it exists after the operation. The captured state is added to the state history. In another aspect, the techniques identify for a user on a display device a set of states that the document has been in by operation of the system; and enable the user to designate any arbitrary one of the identified states for further operations. The techniques may provide both linear and non-linear history. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to shrub trimmers and more particularly pertains to means which may be utilized to present a shrub trimmer operatively to the upper horizontal surfaces of high hedges or shrubs.
2. Description of the Prior Art
The use of extension handles for hedge or shrub trimmers is known in the prior art. More specifically, such extensions heretofore devised and utilized for the purpose of using hedge trimmers above an operator's head are known to consist basically of familiar, expected and obvious structural configurations, notwithstanding the myriad of designs encompassed by the crowded prior art which have been developed for the fulfillment of countless objectives and requirements. As shown in the art, specifically U.S. Pat. Nos. 4,976,031 and 5,070,576, such extensions have been axially in line with the blade of the cutter to which it is affixed.
As such these extensions work to raise the cutter or trimmer to a desired height, but only by the operator positioning himself at a substantial distance from the shrub being trimmed can the cutting blade begin to reach horizontally across the top of the shrub. Practically, this is not viable since leverage exerted by the weight of the trimmer in such a position makes it impossible for an operator to hold or control the trimmer. Consequently a ladder or the like to raise the operator is necessary to reach into and trim the horizontal surfaces of the top of the shrubs.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of shrub trimmer extensions now present in the prior art, the present invention provides an improved extension wherein the same can be utilized to hold a shrub trimmer operatively engaging the horizontal top surfaces of high shrubs. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved shrub trimmer apparatus which has all the advantages of the prior art devices and none of the disadvantages.
To attain this, the present invention essentially comprises: an extension for positioning a powered shrub trimmer to reach and cut off the upper horizontal surfaces of high hedges which comprises a tubular elevating handle, an angulated cutter support base extending from the upper end of such elevating handle; means on such cutter support base to secure a powered shrub trimmer thereto; and a tubular brace extending from said elevating handle to the bottom of said cutter support base.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
It is therefore an object of the present invention to provide a new and improved shrub trimmer extension which has all the advantages of the prior art devices and none of the disadvantages.
It is another object of the present invention to provide a new and improved shrub trimmer extension which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new and improved shrub trimmer extension which is of a durable and reliable construction.
An even further object of the present invention is to provide a new and improved shrub trimmer extension which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such devices economically available to the buying public.
Still yet another object of the present invention is to provide a new and improved shrub trimmer extension which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
Still another object of the present invention is to provide a new and improved shrub trimmer extension which permits reaching the top horizontal surfaces of high shrub or hedges.
Yet another object of the present invention is to provide a new and improved shrub trimmer extension which may be used with a variety of powered shrub trimmers.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a perspective view of the shrub trimmer extension of the present invention being applied to a shrub.
FIG. 2 is a perspective detail view of the device of the present invention.
FIG. 3 is a sectional side plan view taken on line 3--3 of FIG. 2.
FIG. 4 is an enlarged sectional view of the shrub trimmer securing means taken on line 4--4 of FIG. 3.
FIG. 5 is a side plan view of a modified version of the device of the present invention.
FIG. 6 is a partial sectional view taken on line 6--6 of FIG. 5.
FIG. 7 is a perspective view showing a modified version of the invention.
FIG. 8 is an enlarged perspective view of a portion of FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIG. 1 thereof, a new and improved shrub trimmer extension embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
More specifically, it will be noted that the shrub trimmer extension 10 has an elevating handle member 11; a support base member 12 for a powered shrub trimmer 13 (shown in broken lines); and an angled brace member 14 extending between said handle member 11 and said base member 12. Mounted on the support base member 12 is a means 15 for securing a shrub hedge trimmer thereto. As shown in this FIG. 1, an operator, standing on the ground, can position the shrub trimmer above his head and move the same laterally into or over the top of the shrub being trimmed.
FIG. 2 shows the extension 10 in greater detail, illustrating that the support base member 12 extends from handle member 11 at an obtuse angle thereto. Consequently, the blade of the shrub trimmer (13 in FIG. 1) is likewise extending at an obtuse angle to handle member 11. The securing means 15 for such shrub trimmer, while more visible in this drawing, is detailed in FIGS. 3 and 4 described below.
In FIGS. 3 and 4, the securing means 15 is shown as consisting of a grooved flat plate member 16 adapted to seat the usual projecting flange of a shrub trimmer therein and a pair of threaded u-bolt clamps 17 adapted to fit around base support member 12, which is preferably formed from a rigid plastic tubing as is handle member 11, and through flat plate member 16 to firmly affix the assembly to support member 12 when the nuts 18 are threaded down on bolts 17. As best illustrated in FIGS. 2 and 4 of the drawings, the flat plate member includes a top side and a bottom side with the plate member additionally including an unlabeled center channel extending along a longitudinal length of the top side thereof. The channel is defined as having a first depth from the top side, a first width, and first and second sides. Further, the plate member includes both an unlabeled first lateral channel extending into the top side and along the first side of the center channel, and an unlabeled second lateral channel extending into the top side and along the second side of the channel. The first and second lateral channels are characterized as having a second depth from the top side of the plate member and a second width, wherein the first depth of the center channel is substantially greater than the second depth of both of the lateral channels. Also, the center channel is distinguished from the lateral channels wherein the first width of the center channel is substantially greater than the second width of the lateral channels. As is particularly shown in FIG. 4, a fastening plate 19 having bolt holes 20 therein is positioned with bolts 17 extending through such holes 20 and the plate 19 being adapted to extend across or through the frame of the shrub trimmer to secure it in place on support base member 12. Also as is shown in FIG. 3, the device 10 may be simply and economically assembled using conventional PVC tubing and fittings therefor. A standard 45°elbow fitting 21 is slip-fitted with the usual adhesive onto tubing forming base support member 12 and handle member 11. The brace member 14 uses similar tubing cut at angles as shown at 22 to fit snugly against the tubing forming said members to which it may be adhesively secured. Alternatively, brace member 14 may be held against such other members by conventional pipe clamp extending around each such engagement (not illustrated).
FIG. 5 and 6 shows that the device 10 of the present invention may be fitted with a telescoping extension member 23 if desired. As shown in FIG. 6 such telescoping extension member 23 fits over handle member 11 and is adjustably positioned with respect thereto by an adjustable compression ring 24.
A useful adjunct to device 10 of the present invention is shown in FIG. 7 and 8 wherein an adjustable mirror 25 is mounted adjacent the connection between base support member 12 and handle member 11 to afford the operator a view of the surface being contacted by the shrub trimmer mounted on base support member 12.
Preferably, the obtuse angle between base member 12 and handle member 11 will be approximately 130° to 135°. Use of a 45° elbow as described above will produce approximately an obtuse angle of 135°.
As to the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | An extension for positioning a powered shrub trimmer to reach and cut off the upper horizontal surfaces of high hedges which comprises a tubular elevating handle, an angulated cutter support base extending from the upper end of such elevating handle; means on such cutter support base to secure a powered shrub trimmer thereto; and a tubular brace extending from said elevating handle to the bottom of said cutter support base. | 8 |
BACKGROUND OF THE INVENTION
Electric and hybrid electric vehicles have been available for many years. A hybrid electric vehicle is a vehicle that generally has two sources of energy. One of the sources of energy is electric, and the other source of energy is derived from an internal combustion engine that typically burns diesel or gasoline fuel. A hybrid electric vehicle typically has a greater range than that of an electric vehicle before the batteries need recharging. Moreover, a hybrid electric vehicle is typically equipped with means for charging the batteries through its onboard internal combustion engine.
Generally, a hybrid electric vehicle employs an internal combustion engine and an electric motor to either alternately or in combination provide a driving force for a vehicle. There are several types of electric propulsion systems for hybrid electric vehicles. For example, a pure electric drive system, a series hybrid system, a parallel hybrid system, and a combined series-parallel hybrid system are a few of the designs currently being considered.
Since many of the functions of a hybrid electric vehicle involve an energy storage system (e.g., batteries) and then using this energy at a later time, the performance of the hybrid system is highly dependent on the energy storage system. Some of the factors that are associated with the energy storage system requirements are: power capability, energy capacity, life, cost, volume, mass, temperature, characteristic, etc.
SUMMARY OF THE INVENTION
In an exemplary embodiment, a hybrid powertrain system comprises: an electric motor for providing a mechanical driving force to a vehicle; an engine mechanically coupled to the electric motor for providing mechanical power to drive the electric motor; a fuel cell unit electrically coupled to the electric motor for providing electrical power to power the motor, the fuel cell unit configured in a parallel relationship with respect to the engine; and a battery electrically coupled to the electric motor for providing electrical power to power the motor, the battery configured in a parallel relationship with the engine and the fuel cell.
The hybrid powertrain system further includes power conditioning electronics for conditioning, controlling and/or regulating the electrical power from the fuel cell unit provided to power the motor.
The hybrid powertrain system further includes a clutch disposed between the combustion engine and the motor for selectively providing pure electrical or mechanical propulsion power for a vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
The hybrid powertrain system will now be described, by way of example only, with reference to the accompanying drawings, which are meant to be exemplary, not limiting, and wherein like elements are numbered alike in several figures.
FIG. 1 is a schematic diagram illustrating a hybrid powertrain system according to an embodiment of the present invention;
FIG. 2 is a schematic diagram illustrating a solid oxide fuel cell used in the fuel cell auxiliary power unit in FIG. 1 ;
FIG. 3 is a table showing fuel efficiency of the hybrid powertrain system of the present invention; and
FIG. 4 is a graph showing a propulsion power derived from the fuel cell power unit or the internal combustion engine in different hybrid powertrain systems of the present invention.
DETAILED DESCRIPTION OF INVENTION
Referring to FIG. 1 , there is provided hybrid powertrain system according to an exemplary embodiment of the present invention, which is employed in a vehicle. Propulsion of the vehicle is powered by one of the energy sources: a combustion engine 111 , a battery buffer 113 , and a fuel cell unit 115 . The combustion engine 111 may be an internal engine using, as its fuel, gasoline, diesel, liquefied petroleum gas (LPG), alcohols, compressed natural gas (CNG), hydrogen and/or other alternative fuels. The combustion engine is coupled to a motor 119 to mechanically drive the motor 119 , rather than electrically power the motor 119 . The fuel cell auxiliary power unit 115 provides, through a power level control unit 117 , electric energy sufficient to power the motor 119 . The battery buffer 113 is provided to handle electrical transient responses, but may also be used to start the engine, to power electrical accessories, and other such uses. The battery buffer 113 may also be used to provide electric energy sufficient to power the motor 119 .
The fuel cell unit 115 (or fuel cell auxiliary power unit) is comprised of multiple fuel cells, which are often configure in a fuel cell stack, as is well known and is discussed in more detail below. The fuel cells provide the power level control unit 117 (or power conditioning electronics) with a DC (direct current) voltage to power a motor 119 for providing mechanical energy to a transmission 121 of the vehicle. The fuel cells may be any one of the various types of fuel cells such as polymer electrolyte membrane fuel cell, phosphoric acid fuel cell, direct methanol fuel cell, alkaline fuel cell, molten carbonate fuel cell, solid oxide fuel cell, regenerative fuel cell, etc. In the preferred embodiment, the fuel cell auxiliary power unit employs solid oxide fuel cells.
The power conditioning electronics 117 captures electrical energy from the fuel cell auxiliary power unit 115 . The power conditioning electronics 117 includes a controller (not shown) for delivering the electrical energy to the motor. The controller is designed to deliver zero power (e.g., when the vehicle is stopped), full power (e.g., when the vehicle is accelerated), or any power level in between.
The battery buffer 113 also provides electric power to the motor 119 to be used as the propulsion power. For example, the battery buffer 113 provides electric power to the motor 119 while the fuel cell auxiliary power unit 115 is warmed up to a selected temperature. The electric power from the battery buffer 113 may also be used to power electrical accessories such as headlights, radios, fans, wipers, air bags, computers and instruments inside the vehicle.
The motor 119 is mechanically coupled to the combustion engine 111 so that mechanical power generated by the combustion engine 111 is delivered through the motor 119 . The battery buffer 113 and the fuel cell auxiliary power unit 115 (through the power conditioning electronics 117 ) are connected to electrical inputs of the motor. The battery buffer 113 preferably provides a buffer of electrical energy such that when operated with the fuel cell auxiliary unit 115 reliable continuous electrical energy is provided to the motor 119 . The combustion engine 111 , the battery buffer 113 , and the fuel cell auxiliary unit 115 are arranged or connected in a parallel relationship with each other with respect to the motor 119 . The motor 119 is mechanically coupled to the transmission 121 , which provides a driving force to a drive shaft of the vehicle. The motor 119 may be a DC electric motor or an AC electric motor. In case of an AC motor, an AC controller (not shown) is provided to control a three-phase current to the inputs of the motor.
The electric motor 119 in this embodiment may also act as a generator as well as a motor. In other words, the electric motor 119 draws the electric energy from the battery buffer 113 and/or the fuel cell auxiliary power unit 115 (through the power conditioning electronics 117 ), for example, at the time of accelerating the vehicle. But the electric motor 119 also returns electric energy to the battery buffer 113 , for example; when powered by the combustion engine 111 , at the time of slowing down, or when braking the vehicle.
A power transfer control unit 123 is provided in the hybrid powertrain system between the combustion engine 111 and the motor 119 for selectively providing pure electric or mechanical propulsion power. In this embodiment, a clutch is employed as a power transfer control unit 123 . The clutch 123 when engaged provides for a direct connection of mechanical power to be transferred from the engine 111 through the motor 119 to the transmission 121 . When the clutch 123 is not engaged, only electrical power is available, whereby the motor 119 is powered by the electrical power, from the battery buffer 113 or the fuel cell auxiliary power unit 115 , which in turn delivers mechanical power through the transmission 121 . On the other hand, when the clutch 123 is engaged, the motor 119 is powered by the mechanical power from the combustion engine 111 . For example, when the engine 111 is in an active mode (i.e., turned-on mode), the clutch 123 is engaged so that the motor 119 receives the mechanical power from the engine 111 . When the engine is in an inactive mode (i.e., turned-off mode), the clutch 123 is not engaged so that the motor 119 receives the electrical power from either the fuel cell auxiliary power unit 115 (through the power conditioning electronics 117 ) or the battery buffer 113 or from both the fuel cell auxiliary power unit 115 and the battery buffer 113 .
Referring to FIG. 2 , the fuel cell auxiliary power unit 115 in FIG. 1 has solid oxide fuel cells each of which includes an anode 211 , a cathode 213 and an electrolyte 215 sandwiched between the thin electrodes, i.e., the anode 211 and cathode 213 . Hydrogen is fed to the anode 211 where a catalyst separates hydrogen's negatively charged electrons from positively charged ions as shown in the following reaction formula:
2H 2 →4H + +4e −
At the cathode 213 , oxygen combines with electrons and the negative ions travel through the electrolyte 215 to the anode 211 where they combine with hydrogen to produce water as shown in the following reaction formula:
O 2 +4H + +4e − →2H 2 O
During the above reactions, the electrons from the anode side of the cell cannot pass through the electrolyte 215 to the positively charged cathode 213 . The electrons should travel around the electrolyte 215 via an electrical circuit to reach the other side of the cell. This movement of the electrons produces electrical current.
The amount of power produced by a fuel cell depends on several factors, such as fuel cell type, cell size, temperature, pressure at which the gases are supplied to the cell. The fuel cell auxiliary power unit contains multiple fuel cells which are combined in series into a fuel cell stack.
The fuel cells may also be fueled with hydrogen-rich fuels, such as methanol, natural gas, gasoline or gasified coal. In this case, a reformer (not shown) is additionally provided to extract hydrogen from the fuel. In other words, the reformer turns hydrocarbon or alcohol fuels into hydrogen, which is then fed to the fuel cells.
As describe above, the hybrid powertrain system of the present invention is provided with the hybrid power sources such as the combustion engine 111 , the battery buffer 113 , and the fuel cell auxiliary power unit 115 . Since the hybrid powertrain system draws electric energy from either the battery buffer 113 or the fuel cell auxiliary power unit 115 , or the combination thereof, it advantageously provides additional fuel efficiency and power electrification for propulsion and accessories of the vehicle.
FIG. 3 is a table showing fuel efficiency of the hybrid powertrain system of the present invention. In the first column of the table, different types of the hybrid powertrain systems are listed. In the first three lines, listed are the hybrid powertrain systems providing power only for propulsion (i.e., no electrical loads). In the next three lines, listed are the hybrid powertrain systems providing power for both the propulsion and electrical loads. The second column shows four different vehicle speeds, 40 MPH, 50 MPH, 60 MPH and 70 MPH. As shown in the table, the power for propulsion and electrical loads is derived from a solid oxide fuel cell unit alone at the lower vehicle speeds (here, 40 and 50 MPH), and derived from the combination of a solid oxide fuel cell unit and an internal combustion engine at the higher vehicle speeds (here, 60 and 70 MPH).
The data in FIG. 3 shows that the hybrid powertrain system provides substantial improvement in fuel efficiency compared with those of the conventional powertrain system. For example, there is 34% improvement in fuel efficiency at vehicle speed 40 MPH when comparing the solid oxide fuel cell powertrain system for propulsion (50.4 MPG) with the conventional powertrain system for propulsion (37.6 MPG). Also, there is 16% improvement in fuel efficiency at vehicle speed 70 MPH when comparing the solid oxide fuel cell and internal combustion engine combined powertrain system (27.4 MPG) with the conventional powertrain system (23.6 MPG).
FIG. 4 is a graph showing a propulsion power derived from the fuel cell power unit or the internal combustion engine in different hybrid powertrain systems. In the graph, Option 1 represents a mild hybrid powertrain system, for example, a vehicle with a 2.5 liter cylinder gasoline engine, a 5 kw solid oxide fuel cell power unit, and a 42 volt generator for accessories; Option 2 represents a heavy hybrid powertrain system, for example, a vehicle with a 2.5 liter cylinder gasoline engine, a 20 kw ISG (integrated starter generator), a 20 kw solid oxide fuel cell power unit, and a 20 kw lithium battery; and Option 3 represents a “range extender” hybrid powertrain system, for example, a vehicle with a 10 kw solid oxide fuel cell power unit and 100 kg lithium battery.
In the hybrid powertrain system of Option 1, most propulsion power is derived from the gasoline engine as mechanical propulsion, and the fuel cell power unit makes little contribution to the propulsion power. In the hybrid powertrain system of Option 2, the propulsion power derived from the fuel cell power unit (i.e., electrical propulsion) substantially increases, while that derived from the gasoline engine (i.e., mechanical propulsion) decreases. Lastly, in the hybrid powertrain system of Option 3, most propulsion power is derived from the fuel cell power unit, and the gasoline engine makes little contribution to the propulsion power.
While the invention has been described with reference to the preferred embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention may not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention. | A hybrid powertrain system includes a combustion engine, a battery buffer for storing electric energy by converting it onto chemical energy, which can be converted back into electrical energy when need, a fuel cell unit having multiple fuel cells each of which is an electrochemical energy conversion device that converts hydrogen and oxygen into water, producing electricity and heat in the process, a power level control unit for capturing electrical energy from the fuel cell unit for delivering zero power, full power, or any power level in between, and an electric motor having inputs for receiving energy from the combustion engine, the battery buffer and the fuel cell auxiliary power unit, and an output for generating activation power to a transmission providing a driving force to a vehicle. | 1 |
This application is a U.S. National Phase under 35 U.S.C. §371 of International Application No. PCT/IB2013/059945, filed Nov. 6, 2013, which claims priority under 35 U.S.C. §§119 and 365 to Swedish Application No. 1251281-0, filed Nov. 9, 2012.
TECHNICAL FIELD
The present document relates to a method for producing a composite comprising nanofibrillated polysaccharide (NFP), such that it is easily re-dispersible. The present document further relates to a method for drying such a composite. More particularly, the present disclosure relates to a method for producing and drying a composite comprising microfibrillated cellulose and precipitated calcium carbonate and a substantially dry composite material obtained through the method and uses thereof.
BACKGROUND
Nanofibrillated polysaccharides, such as microfibrillated cellulose (MFC) has many end uses, such as in food, cosmetics, paints, plastics, paper, paperboard, medical products and composites, in which it would be good to be able to dosage microfibrillated cellulose in a dry form so that the original properties of wet micro fibrillated cellulose would be retained. Microfibrillated cellulose used in composites, is typically added in a dry form.
A dispersion of microfibrillated cellulose in water is a gel having pseudoplastic or thixotropic viscosity properties because fibrils are very well dispersed in the matrix (water). On drying, however, the properties of micro fibrillated cellulose are severely changed. It's dispersibility, hydration and viscosity properties may be lost or substantially reduced, depending on the severity of drying. Typically after drying, micro- and nano fibrils are bound together and much less amounts of small scale micro- or nano fibrils can be found via e.g. optical microscope.
When microfibrillated cellulose is dried it would be beneficial that not too much fibril/fibril bonds are formed, so that micro fibrils are free from each other or at least easily liberated when dispersed in a solvent or matrix. At the moment, this can be done by freeze drying or by using solvent exchange type of drying technologies. Also one possibility is to add chemicals such that fibril/fibril contacts are essentially reduced during drying.
When microfibrillated cellulose is used in composites one should ensure that micro fibrils are clearly separated from each other and that micro fibrils are very well dispersed in the matrix.
Conventional drying techniques for drying MFC are currently freeze drying which provides the best quality MFC. However, both the operating and investment costs are high and the process can be difficult to scale up to industrial processing. Spray drying, which on the other hand, can rather easily be scaled up, has high operation costs and feature in which hornification of fibrils is prone to occur.
Typical chemicals used to prevent hornification of cellulose or fibrillated cellulose or cellulose fibrils has been, surface active agents or surface active polymers, carbohydrates and more specifically low molecular weight carbohydrates, starch, CMC and similar derivatives thereof. Processes utilizing chemicals can be up-scaled. However, the costs related to these chemicals can be high, and many of the chemicals are disadvantageous or even harmful in different applications.
The term “hornification” may refer to the stiffening of the polymer structure that occurs in lignocellulosic materials when they are dried or otherwise dewatered. Because of structural changes in the wood pulp fibers upon drying the internal fiber shrinks. Often the fibers needs to be rewetted, or re-suspended in water for practical use and due to these structural changes the original properties, i.e. being in a gel form having pseudoplastic or thixotropic viscosity, is not fully regained. The effect of hornification may be identified in those physical paper or wood pulp properties that are related to hydration or swelling, such as burst or tensile properties. (Hornification—its origin and interpretation in wood pulps, J. M. B. Fernandes Diniz, M. H. Gil, J. A. A. M. Castro, Wood Sci Technol 37 (2004) 489-494).
Further to this nanofibrillated polysaccharides such as MFC often form the basis of, or a part of composites suitable for applications such as plies for paper or paperboards, for use in rheology applications, in paints, foods, pharmaceuticals etc. These composites are often formed by adding a filler, such as precipitated calcium carbonate to the MFC, thus forming a PCC/MFC composite material. The calcium carbonate, or filler material, may be added in a conventional process, such as disclosed in EP2287398 or in a so called in-line process which is disclosed in for instance WO2001/110744. The formation of PCC on fibers may be achieved today in processes where lime milk is mixed in the presence of natural fibers, or dissolved cellulose, cellulose whiskers or fibrils or fibrillated aggregates, or synthetic polymer fibers and carbon dioxide. The precipitation of calcium carbonate then may occur on fibers or into fiber lumen, dissolving pulp, cellulose whiskers or synthetic polymer fibers or mixtures thereof.
Currently, PCC or even nanoPCC can be used with various technologies. The nanoPCC may be provided through methods such as those disclosed in US2009/0022912. It is also known that additives such as PVOH and PAA can be used to control crystal growth and nucleation during the precipitation of calcium carbonate. Such methods are shown in for instance WO 2009/074491 A1.
The problem with the commercially available in-line method is that it is limited to the so called wet end of a paper machine and therefore to very dilute pulp conditions. Typically, pulp composition is preferably below 1.0 wt % or more preferably below 0.5 wt %.
Another disadvantage with the present techniques is that it generates very large particle sizes of the PCC on the fibers and obviously a large fraction is formed in the liquid phase. The formation of large particles is in some cases not preferred since it further affects e.g. optical properties or wettability.
There is therefore a need for an improved process producing composites comprising nanofibrillated polysaccharide and subsequently drying these composites, which is simpler to carry out while yielding a dry or semi-dry MFC composite material, without loss of important re-dispersibility properties, since, if strong hornification or agglomeration occurs during drying the beneficial properties of cellulosic fibrils or fibrillated aggregates are not obtained. It is thus preferable that the dried composite maintains its characteristics when dispersed in other solvents or e.g. polymeric matrices.
SUMMARY
It is an object of the present disclosure, to provide an improved method of producing a composite comprising nanofibrillated polysaccharide which subsequently can be dried, while not deteriorating the re-dispersibility properties of the composite. It is further an object of the present disclosure to provide for a composite having PCC particles or even nanoPCC particles coated on the fibers of the nanofibrillated polysaccharide.
The object is wholly or partially achieved by a method according to the appended independent claims. Embodiments are set forth in the appended dependent claims, and in the following description and drawings.
According to a first aspect, there is provided a method for the production of a composite material comprising any one of a microfibrillated cellulose and a nanofibrillated cellulose, the method comprising the following steps, (i) providing a liquid suspension of the microfibrillated or nanofibrillated cellulose; wherein the solids content of the microfibrillated or nanofibrillated cellulose is over 2%, (ii) bringing said liquid suspension in contact with at least one additive, wherein the at least one additive is calcium carbonate or a precursor thereof, thereby forming a composite material suspension, wherein the composite comprises the microfibrillated or nanofibrillated cellulose and the calcium carbonate or the precursor thereof, and wherein said calcium carbonate is formed or precipitated onto fibers or fibrils of the the microfibrillated or nanofibrillated cellulose; and (iii) increasing the solid contents of said composite material suspension, thereby forming a high solid contents composite material suspension; (iv) drying said high solid contents composite material suspension, through a simultaneous heating and mixing operation, whereby a substantially dry composite product is formed.
The nano- och microfibrillated cellulose may be obtained through conventional methods such as acid hydrolysis of cellulosic materials, e.g. disclosed in WO 2009021687 A1, or MFC suspension produced by enzymatic hydrolysis of Kraft pulp cellulose, e.g. disclosed in WO2011004300 A1, acid hydrolysis followed by high pressure homogenization, e.g. disclosed in US20100279019, or by any other means known to the skilled person. The nanofibrils can thus be liberated from untreated or pre-treated fibers by using mechanical forces such as refiners or grinders. The concentration of MFC in such suspensions is usually about 1-6% and the remaining part is water. It is also possible to use ionic liquids to create nanocellulose or microfibrillated cellulose.
Through this method is thus possible to, in a cost and energy efficient manner, achieve a substantially dry composite material, comprising MFC, wherein the problems associated with hornification have been greatly reduced or completely abolished.
By substantially dry composite material is meant that the composite may contain some water, and be semi-dry, i.e. about 50-1 wt-% water or less.
The liquid suspension may contain water, and also other co-solvents, such as ethanol or isopropanol. These co-solvents may be recycled during the mixing and heating operation.
The at least first additive may be an alkaline earth carbonate or a precursor thereof and the alkaline earth carbonate may be any one of a calcium carbonate, a magnesium carbonate, a combination thereof, a precursor or a combination of precursors thereof.
This means that the composite may be formed by adding precursors of e.g. calcium carbonate such that the calcium carbonate may be formed or precipitated onto or into the fibers or fibrils of the polysaccharide. This means that the CaCO 3 forms a composite with the MFC.
According to one embodiment of the first aspect the solids content of the nanofibrillated polysaccharide in step (i) may preferably be higher than 0.5 wt-%, and more preferably higher than 1 wt-%, and even more preferably higher than 4 wt-%.
This method allows for the adsorption of lime milk or CO 2 on fibrils thus allowing carbonation or precipitation of e.g. calcium carbonate in a suspension of nanofibrillated polysaccharide, such as MFC, where the concentration of pulp, is relatively high compared to conventional methods, where the concentration is preferably below 0.5 wt-%. It has surpisingly been found that by increasing the pulp concentrations, preferably over 2% and more preferably over 4%, a higher fraction of small nanoparticles may be formed on the cellulose fiber surface. At higher MFC concentrations, it gave very high coverage of PCC on the microfibers which usually is not obtained with the traditional techniques. Feeding ratios of precursor materials such as carbon dicoxide (CO 2 ) and lime milk did not have an effect, whereas the use of certain additives had some effect on particle morphology when performing tests at higher MFC solid contents.
The said process is prefereably performed as a batch or continuous process, but not excluding an in-line process. The end uses for a composite formed through this method may be in paper or other applications such as plastics, food, medicine, tooth paste, paints, etc., where a fine coating of the PCC or nanoPCC on the fibers is advantageous.
According to this embodiment, in step (ii) of bringing said liquid suspension in contact with at least one additive, thereby forming a composite material suspension, the ratio between the nanofibrillated polysaccharide and the at least one additive may be greater than 1:1, or greater than 3:1, or greater than 6:1, or greater than 9:1.
According to the first aspect the additive may provided by an in-line production method, wherein the additive or additives are provided into the liquid flow of a paper machine by feeding said additive simultaneously as said aqueous suspension of nanofibrillated cellulose, thereby forming a composite material suspension in the liquid flow of the paper machine.
It is also possible to have a parallel stream of reacted product to be fed into the surface size or to coating colors thus forming an improved end product with the said material on the surface.
According to one embodiment, when there are two or more additives, the method further may comprise a step of allowing these to react with one another.
The additives may be carbon dioxide and lime milk. The carbon dioxide an lime milk thus forms precursors of the alkaline earth carbonate calcium carbonate. It has been found that precipitation of calcium carbonate (CaCO 3 ) onto MFC works very well and it is simple and cost efficient process.
Further it has been found out that by precipitating CaCO 3 on the surface of micro fibrillated cellulose no or extremely little amount of free CaCO 3 is present in the composite, the CaCO 3 stay on the MFC surface even after high shear (even after refining and fluidization), which makes a big difference if ready made nanoparticles would be have been post-added to the MFC suspension. Even further precipitating CaCO 3 on the surface of coarse MFC improved fibrillation and runnability in pressure homogenization.
Thus the composite formed in the short circulation may thus be a MFC and PCC composite, where the PCC is precipitated onto the surface of the fibrils of the microfibrillated cellulose.
This process may also be both efficient and cost effective and may be performed as described in WO2011/110744 A2.
The MFC/PCC ratio may be in the range of 80/20 to 20/80, or even more preferred 50/50 ratio.
Also the dewatering, i.e. increase of the solids content of MFC/PCC composite may be performed more easy than for an MFC suspension alone, and the drying of MFC/PCC may be easier than for a MFC suspension alone.
Further, drying shrinkage is essentially reduced compared to pure MFC, and the MFC/PCC composite is very compatible with plastics. The rewetting of dry MFC/PCC composite may also be easy and essentially major part of the fibrils are re-dispersed in water phase. Also wet mixing of MFC/PCC composite will improve amount of re-dispersable fibrils much more than with MFC.
The addition of carbon dioxide and lime milk may be performed as described in CA449964.
According to the first aspect the solid contents of the composite material in step (iii) may be increased to >20% by weight, or more preferably to >25% by weight, or even more preferably to >30% by weight.
According to one alternative step (iv) may comprise a mixing and grinding operation.
This grinding operation may be performed in a PVC mixer or by any similar method, such as a high speed mixer, where the mechanical energy is converted into heat in the suspension whereby water is caused to evaporate. Alternativley part of the energy may be used to provide for a fibrillation or to cut fibers. Since the solids content, or the dry contents of the suspension is relatively high at the onset of mixing the shear forces, and friction evolved in the suspension becomes greater thus resulting in an increased temperature. At a solids content of >10 wt-% the MFC-PCC composite suspension is viscous, thus causing greater friction.
According to one alternative solution step (iv) may comprise any one of a centrifugal force operation, mechanical pressing operation and dewatering operation. The dewatering operation may comprise an electro-osmosis operation. The mechanical pressing operation may comprise any one of a wet pressing operation or a screw pressing operation.
The step of increasing the solids content, or dewatering of the MCC/PCC composite may also be performed with a paper machine (head box, dewatering on wire, press section and drying section).
According to one alternative the temperature, at/in step (iv), of the composite material is in the range of 75-99° C., preferably about 85° C.
The temperature is thus kept relatively low, which is advantageous not only in that less energy is consumed, but also in that the effect on hornification of the micro fibrils may be reduced, as hornification is prone to occur at a higher temperature. This increase in temperature is created through the mechanical energy provided to the suspension by the mixing operation. The temperature increase could also, alternativley be achieved trough actively heating the suspension, depending on the desired properties of the dry product.
The composite material at step (iv) may be heated from about room temperature to the range of 75-99° C.
According to one alternative step (iv) may be performed under vacuum.
By introducing a vacuum, or performing the drying step under vacuum it is further possible to reduce both the energy needed and the drying temperature, which may lead to a further reduction in the hornification of the micro fibrils. If vacuum is introduced the heat developed trough the mechanical energy provided to the suspension may be lower than under normal pressure.
According to one alternative of the first aspect there may further be provided a drying additive in step (iv).
By introducing a drying additive the drying process may be event further improved. Such additives are disclosed in CA1208631. The drying additive may also be a solvent.
According to a second aspect there is provided a substantially dry composite material comprising a nanofibrillated polysaccharide and at least one additive, obtainable by the method according to the first aspect.
By “substantially dry composite material comprising NFP” is meant that the water content in the composite product is reduced to a level where the product may be in a powder form or even a gel form, but still being suitable for re-dispersion, in a solvent such as water or into a water or gel phase. The product may also be in a semi-dry state having a water content of about 10-15 wt-%
As such the solids content of the product may be in the range of 50-99 wt-%. In a preferred embodiment the solids content is in the range of 75-90 wt-%.
The dry composite product obtained through the method described above may have very good and well separated straight individual micro fibrils when re-dispersed, i.e. the hornification problems normally associated with drying of MCF-PCC has been greatly reduced. The applicability of this dried composite product may therefore be greatly increased for applications such as composites, food and pharmaceutical uses.
According to the second aspect the nanofibrillated polysaccharide may be a microfibrillated cellulose.
According to the second aspect the additives may be lime milk and carbon dioxide, forming a precipitated calcium carbonate on the nanofibrillated polysaccharide, thereby forming a composite product comprising precipitated calcium carbonate and nanofibrillated polysaccharide.
According to a third aspect there is provided the use of the composite material according to the second aspect, for the production of sheet like paper materials. Such sheet like paper materials may include substrate for copy machines (copy paper), printing (printing paper), packaging (packaging paper), cellulose films, and substrate for printed electronics.
According to a fourth aspect there is provide the use of the composite material according to the second aspect, for mixing with plastics materials.
According to a fifth aspect there is provided the use of the composite material according to the second aspect, for further pressing and forming of a composite product.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present solution will now be described, by way of example, with reference to the accompanying schematic drawings.
FIG. 1 shows schematically a short circulation arrangement according to prior art.
FIG. 2 shows schematically a short circulation arrangement according to one embodiment of the invention.
FIGS. 3 a - b show schematically a short circulation arrangement according to one alternative embodiment of the invention.
FIG. 4 shows schematically a short circulation arrangement according to yet an alternative embodiment of the invention.
FIG. 5 shows schematically a short circulation arrangement according to yet another alternative embodiment of the invention
FIG. 6 is a microscope picture captured of coarse microfibrillated cellulose/PCC composite with a ratio 65:35. It shows that there was not formed any free PCC (CaCO 3 ) in the water phase and thus the reaction preferably occurs on the fibrils. The scale of the bar is 200 um.
FIG. 7 is a microscope image captured of microfibrillated cellulose/PCC composite with a ratio of 65:35.
FIG. 8 is a microscope image of microfibrillated cellulose/PCC composite (ratio 75:25) after drying and subsequent re-dispersion in water without mixing or refining.
FIG. 9 is a SEM image of a microfibrillated cellulose/PCC composite.
FIG. 10 is a SEM image of a microfibrillated cellulose/PCC composite
DESCRIPTION OF EMBODIMENTS
Definition of Nanofibrillated Polysaccharide
This definition includes bacterial cellulose or nanocellulose spun with either traditional spinning techniques or with electrostatic spinning. In these cases, the material is preferably a polysaccharide but not limited to solely a polysaccharide. A polysaccharide can be e.g. starch, protein, cellulose derivatives, etc.
Also microfibrillated cellulose as defined more in detail below is included in this definition.
Definition of Microfibrillated Cellulose
The microfibrillated cellulose (MFC) is also known as nanocellulose. It is a material typically made from wood cellulose fibers, both from hardwood or softwood fibers. It can also be made from microbial sources, agricultural fibers such as wheat straw pulp, bamboo or other non-wood fiber sources. In microfibrillated cellulose the individual microfibrils have been partly or totally detached from each other. A microfibrillated cellulose fibril is normally very thin (˜20 nm) and the length is often between 100 nm to 10 μm. However, the microfibrils may also be longer, for example between 10-200 μm, but lengths even 2000 μm can be found due to wide length distribution. Fibers that has been fibrillated and which have microfibrils on the surface and microfibrils that are separated and located in a water phase of a slurry are included in the definition MFC.
Furthermore, cellulose whiskers, microcrystalline cellulose (MCC), nanocrystalline cellulose (NCC) or regenerated cellulose fibers and particles are also included in the definition MFC.
The fibrils may also be polymer coated fibrils, i.e. a modified fibril either chemically or physically.
Definition of Precipitated Calcium Carbonate (PCC)
Almost all PCC is made by direct carbonation of hydrated lime, known as the milk of lime process. Lime (CaO) and carbon dioxide, which can be captured and reused is formed in this process. The lime is slaked with water to form Ca(OH) 2 and in order to form the precipitated calcium carbonate (insoluble in water) the slaked lime is combined with the (captured) carbon dioxide. The PCC may then be used in paper industry as a filler or pigmentation agent or coating agent. It can also be used as filler in plastics or as additive in home care products, tooth pastes, food, pharmaceuticals, paints, inks etc.
In the definition of PCC, other divalent metal ions can be used instead of Calcium ion when forming the crystals. One example is the use of Mg(OH) 2 and carbon dioxide which forms the Magnesium carbonate.
Below is a definition and description of the term “in-line process” and different possible ways to operate such a process. However the present invention is not to be limited to this process only, but may be performed in a batch or continuous operation also. The below description is thus included in the present document in order to clarify and exemplify one way of achieving the composite material. Other embodiments, such a conventional off-line operations etc. are also described in the below.
Definition of In-line Precipitated Calcium Carbonate Process
By “in-line production” is meant that the precipitated calcium carbonate (PCC) is produced directly into the flow of the paper making stock, i.e. the captured carbon dioxide is combined with slaked lime milk inline, instead of being produced separately from the paper making process. Separate production of PCC further requires the use of retention materials to have the PCC fastened, adhered or adsorbed to the fibers. An in-line PCC process is generally recognized as providing a clean paper machine system, and there is a reduced need of other retention chemicals. An in-line PCC process is for instance disclosed in WO2011/110744.
In the in-line production the PCC is formed, not in the aqueous phase but directly onto the fibrils of for instance microfibrillated cellulose. This means that the PCC may be very tightly bound to the microfibrillated cellulose and thus forming a PCC/MFC-composite material, instead of the PCC merely being admixed into the MFC suspension or slurry.
FIG. 1 shows a prior art method for inline production of precipitated calcium carbonate, as disclosed in US2011/0000633 and a schematic process arrangement for a paper making machine 2 . The white water F, is carried to e.g. a mixing tank or filtrate tank 4 , to which various fibrous components are introduced for the paper making stock preparation. From fittings at least one of virgin pulp suspension (long-fiber pulp, short-fiber pulp, mechanical pulp, chemo mechanical pulp, chemical pulp, microfiber pulp, nanofiber pulp), recycled pulp suspension (recycled pulp, reject, fiber fraction from the fiber recovery filter), synthetic fibers, additive suspension and solids-containing filtrate is carried to the mixing tank, and from there conveyed by a mixing pump 14 to a vortex cleaner 16 , where heavier particles are separated. The accept of the vortex cleaning continues to a gas separation tank 18 , where air and/or other gases are removed from the paper making stock. The paper making stock is then transported to a feed pump 20 of the headbox, which pumps the paper making stock to a so-called headbox screen 22 , where large sized particles are separated from the paper making stock. The accept faction is carried to the paper making machine 2 through its headbox. The short circulation of fiber web machines producing less demanding end products may, however, not have a vortex cleaner, gas separation plant and/or headbox.
In the prior art process the PCC production is performed in the short circulation of the paper making machine, before the vortex cleaning plant 16 . The carbon dioxide (CO 2 ) is injected on the pressure side of the vortex cleaner and the lime milk (MoL) is injected a few meters after the carbon dioxide has dissolved in the same pipe. It is however conceivable that this PCC production could take place closer to the headbox, or that the distance between the injectors is very small, virtually injecting carbon dioxide and lime milk at the same location in the short circulation. This depends on the requirements of the end product and the design of the paper making machine,
According one alternative an inline production method may be provided where additives, such as carbon dioxide, milk lime etc., are fed into the short circulation of the paper making machine, i.e. into the fibrous web or paper making stock, and where a suitable amount of a microfibrillated cellulose, MFC, is provided substantially simultaneously as these additives are being fed into the short circulation.
This allows for the above mentioned formation of PCC on the fibrils of the MFC.
What is meant by “substantially simultaneously” may vary as described below, however in this context it is to be understood that the MFC is provided such that the additive, such as e.g. PCC may be formed, i.e. crystallized onto or into the MFC.
Where two or more additives are fed into the short circulation these are preferably allowed to react with one another, which means that they are fed into the short circulation in a manner which allows for the additives to react, in the case of lime milk and carbon dioxide, such that precipitated calcium carbonate is formed onto or into the MFC.
According to one embodiment, an in-line PCC process is combined with the dosage of MFC into the in-line PCC process. This provides for a completely new way of providing PCC to for instance a fibrous web in a paper making process.
In one embodiment, as shown in FIG. 2 lime milk, carbon dioxide and MFC are injected separately into the short circulation and fibrous web of the paper making machine.
In an alternative embodiment, as shown in FIGS. 3 a and 3 b the MFC is provided e.g. in the preparation of the paper making stock, and thus is present in the paper making stock and the carbon dioxide and lime milk are injected separately ( FIG. 3 a ) or simultaneously ( FIG. 3 b ) into the short circulation.
In yet an alternative embodiment, as shown in FIG. 4 the lime milk and the MEG are mixed before the injection into the short circulation and the carbon dioxide is injected separately from this mixture.
In yet another alternative embodiment the, as shown in FIG. 5 , the MFC is mixed with other additives and this mixture is injected separately from the lime milk and carbon dioxide.
In all of the above described embodiments it is to be understood that the order of injection of the additives, i.e. lime milk, carbon dioxide, MFC and possibly other additives may occur in a different order or at a different stage in the short circulation. It is conceivable that the injection occurs very close to the headbox, or that the MFC is dosage prior to the addition of the carbon dioxide or that the distances between the “injection points” is shorter or longer than described above. Thus the MFC, lime milk and carbon dioxide may be injected into the short circulation substantially at the same injection point.
The point or point where the injection takes place thus forms a “PCC reaction zone”, where the PCC is formed onto and into the MFC fibers.
According to one embodiment the MFC provides for an increased fiber surface area onto which the PCC may precipitate.
By modifying and adjusting the surface energy, surface area, surface pH and surface chemistry of the MFC there is provided a completely new way of controlling how the PCC crystals are formed on the surface of the MFC. The crystals formed on the surface of the MFC particle may take on different shapes and configurations.
By combining the in-line PCC process with a dosing or introduction of MFC there is provided a new way of controlling the paper making process without, e.g. modifying the entire white water circulation.
This in-line process allows one way of forming of a composite comprising PCC and MFC, or between any an alkaline earth carbonate and nanofibrillated polysaccharide (as defined above).
The composite thus comprises the alkaline earth carbonate in the form of a precipitate, e.g. PCC, onto or into the fibrils of the nanofibrillated polysaccharide, e.g. MFC.
The alkaline earth carbonate may also precipitate and be formed on virtually any fibers and/or fibrils present in e.g. a paper making stock, even though the main aim of the present invention is that the alkaline earth carbonate is precipitated onto the fibrils of e.g. MFC.
The alkaline earth carbonate is thus according to one embodiment, as such not added to the suspension comprising the nanofibrillated polysaccharide. Instead precursors of the alkaline earth carbonate is added, such as for instance carbon dioxide and milk of lime, or carbon dioxide and magnesium hydroxide Mg(OH) 2 .
The composite formed between the alkaline earth carbonate and the nanofibrillated polysaccharide may further contain other substances such as stabilizing chemicals such as polyphosphate-, polyacrylate-, polyacrylic-dispersants, different types of surfactants such as SDS, SDBS, CTAB, etc. The composite might also containing compounding or coupling chemicals such maleic anhydride functionalized chemicals, acrylic co-polymers, acrylic acids, as needed when mixing with plastics. The composite might also contain other functional additives such as optical brighteners, lubricants, primers, absorbents, dyes, and charge controlling agents. The said composite might also contain other fillers or synthetic polymers providing e.g. improved barrier properties or e.g. thermoplasticity.
According to an alternative embodiment the FCC, or precipitated alkaline earth carbonate is formed in a traditional off-line method, such as a batch or continuous process, and brought into contact with the MFC anywhere in the paper making process, trough conventional methods, such as those disclosed in EP2287398, where calcium carbonate particles are introduced into a suspension comprising cellulosic or starch fibrils, where the calcium carbonate particles have a well defined size, and wherein further calcium ions (calcium oxide or calcium hydroxide) and carbon dioxide is introduced into the fibril suspension in order to induce the calcium carbonate to precipitate on the fibrils.
According to one embodiment the precipitation of the alkaline earth carbonate takes place directly onto or into the fibrils of the nanofibrillated polysaccharide, according to such an embodiment the nanofilbrillated polysaccharide is of course brought into contact with precursors of the alkaline earth carbonate, as described above, but not necessarily in an in-line process. This may also be performed in an batch or continuous operation.
In the above processes including the production and formation of a precipitated calcium carbonate onto or into the fibers of a nanofibrillated polysaccharide, such as MFC, is described.
The skilled person would, however, easily recognize that also other alkaline earth carbonates may be used to form the desired composite material. Such alkaline earth carbonates may be magnesium carbonate, or a combination of magnesium and calcium carbonate. The production processes may then, evidently, be adjusted for these types of carbonates or combinations of carbonates.
The present invention combines the production of a composite material, comprising a nanofibrillated polysaccharide, an alkaline earth carbonate precipitated onto and into the particles thereof, thus forming a hybrid material or composite, with a process and method of effectively drying the hybrid material or composite to achieve a substantially dry composite material.
According to a preferred embodiment the alkaline earth carbonate is a calcium carbonate, which is already commonly and widely used within the paper making industry, for instance as a filler for the production of paper materials, plies for boards.
The method of providing the composite material may thus be an in-line PCC process with simultaneous dosing of MFC as described in detail above, or an off-line PCC process.
According to yet an alternative the concentration of the nanofibrillated polysaccharide, when adding or contacting the alkaline earth carbonate or the precursors thereof to the suspension of the nanofibrillated polysaccharide to form the composite material, may be in the range of 0.5-4 wt-%, or in a preferred embodiment at least above 0.5 wt-%, or more preferred above 3 wt-%, or even more preferred above 4 wt-%. In this embodiment the formation of the composite is preferably made in a batch or continuous process.
The advantage of the in-line PCC process for the provision of the composite material is that the PCC may be tightly bound to the fibrils of the nanofibrillated polysaccharide, and the composite thus formed may be even easier to process through the drying process, which is also shown in FIG. 10 . It should however be understood that other alkaline earth carbonates may be used instead of and as equivalents to calcium carbonate.
The process of achieving an substantially dry composite material is described in the below.
An aqueous suspension of nanofibrillated polysaccharide is provided. The solid contents of this suspension may be in the range of 0.001 to 1 wt-%.
The nanofibrillated polysaccharide suspension is then brought into contact with at least one additive, thereby forming a composite material between the NFP, MFC or nanofibrillate cellulose, and the additive or additives.
According to one alternative, as described above, the additive may be a calcium carbonate, or any other alkaline earth carbonate, which is allowed to precipitate onto the fibrils, i.e. the additives are precursors of the alkaline earth carbonate.
The nanofibrillated polysaccharide may also, according to another embodiment, be brought into contact with two (or more) additives. These additives may be, as described for the inline-PCC process, carbon dioxide and lime milk, this forming PCC directly onto or into the NFP fibrils.
The solids content or the consistency of the resulting composite material suspension is then increased to at least 20% by weight. According to one embodiment the solids content of the suspension is raised to 30-35%.
This increase may be performed by a mechanical dewatering. According to one embodiment this dewatering is performed by centrifugation. According to another embodiment it is performed through pressing, such as wet pressing in a paper making machine. According to yet an alternative embodiment the dewatering is performed through electro-osmosis. Other alternative ways to provide for an increase in the solids content of the suspension may include, but is not limited to any one of a decanter centrifuge, wire press, belt press, extended dewatering nips, and magnetic dewatering.
The dewatering may also be performed by heating to a suitable temperature, evaporation, or adsorption e.g. into felt or using radiation such as IR, NIR or microwave. When selecting the suitable manner to increase the solids content care must however be taken that the chosen method does not, in a negative way, influence the occurrence of hornification, which the skilled person would readily be able to determine.
According to the method, after the solids content has been increased the composite material suspension is dried. This drying operation is performed through a simultaneous grinding and heating of the suspension, for instance in a mixing apparatus, and thereby effecting removal of water by evaporation. Alternatively the drying operation is performed under vacuum, i.e. the suspension is treated under vacuum.
The composite can also be dried with spray drying or freeze drying or other conventional methods typically used for drying nano- and micropigments.
According to one alternative the drying is performed through a mixing or grinding-drying operation, e.g. by PVC mixer or similar method where heat and mechanical energy is introduced at the same time as water is allowed to evaporate.
According to one embodiment, at the drying operation, the temperature of the suspension is in the range of 75-99° C., preferably about 85° C. For instance the mixing apparatus may heat the dispersion from about room temperature to the range of 75-99° C.
According to one alternative embodiment the temperature of the suspension may be further increased, for instance in the mixing apparatus after the MFC suspension has been dried to a water content of at most 10 wt-% According to this embodiment the temperature may be increased from 75-90° C. to about 95° C.
The drying may also be performed at other temperatures, which may be higher or lower than the temperatures stated above.
According to one embodiment the drying can be done in presence of different additives, such as those disclosed in CA1208631.
According to one embodiment the suspension may be cooled or kept at a constant temperature by cooling or heating the suspension. The cooling or heating may be performed by conventional means know to the skilled person.
The total drying time at the drying operation step may be in the range of 15-40 min, preferably about 30 min, thus allowing for a relatively fast drying operation which may be incorporated into a industrial process. The drying time may be dependent on the initial solids content of the suspension, the energy input, any additives and the batch size.
The drying operation may thus results in a substantially dry MFC/PCC composite material.
This composite material may be subsequently processed or used for a variety of different applications.
It may be dried and processed into sheet like materials such as substrates for different paper types, e.g. copy paper, printing paper, specialty paper and packaging paper or paperboard or formable moulds. It may also be processed into substrate for printed electronics.
According to another alternative the MFC/PCC composite material may be mixed with different types of plastics to achieve a plastics composite.
The composite may also be used in different types of foods, pharmaceuticals, toothpaste, paints etc.
The MFC/PCC composite material may also in itself be pressed and formed into different types of composite products.
One advantage of said method is that either one of the components may act as a carrier material and the other as an active chemical and hereby be incorporated into another matrix.
Example 1
Different composite materials were formed through the below described process or method.
A pure microfibrillated cellulose was made from pre-treated pulp which is then fibrillated and dispersed into a suspension using a homogenizator, having a solids content of about 1.5% by weight, which thus formed the starting concentration of the process.
The composite was then formed through an in-line process, such as described in WO 2011/110744A2, by adding suitable amounts of CO 2 , MFC and milk of lime. In the process that carbon dioxide and milk of lime were introduced substantially simultaneously. Depending on the amounts used of carbon dioxide and microfibrillated cellulose the ratio of the PCC:MFC formed can be controlled.
The temperature of the MFC suspension was about 55° C.
FIG. 6 illustrates a coarse microfibrillated cellulose/PCC composite at a 65:35 ratio. No free precipitated calcium carbonate could be seen in the water phase, which implies that substantially all calcium carbonate has been precipitated onto the surface of the MFC fibrils and fiber particles.
FIG. 7 illustrates a MFC/PCC composite at a 65:35 ratio after mechanical treated in a pressure homogenization at approximately 1500-2000 bars. From the picture it is clear that there is very little free precipitated CaCO 3 in the water phase despite the high shearing force, thus showing that the composite material is stable against shearing forces.
This implies that the calcium carbonate particles are so tightly adhered to the MFC, through the fact that precipitation occurs directly onto the fibrils of the MFC, that it they remain adhered to the MFC even after being subjected to high shear forces.
This image was taken of the sample after pressure homogenization demonstrating that there MFC/FCC forms a very strong hybrid material which is shear stable. It is thus difficult to remove the PCC from the surface although using high shear pressure.
FIG. 8 illustrate a MFC/PCC composite in ratio 75:25 after drying and rewetting without wet mixing. This shows the excellent re-dispersible properties of the composite material, i.e. there is no need to use high mechanical shearing to achieve the re-dispersion. The PCC particles on the MFC fibrils keeps the fibrils separated from each other and thus prevent hornification and improves the redispersion in water after drying.
Example 2
Batch experiments were made with microfibers (Arbocel UFC 100, JRS). In FIG. 9 the result from an experiment using a suspension having a consistency of microfiber was 1 wt-%. Lime milk was then added after which CO 2 was fed. The reaction took place under continuous stirring at approximately 25° C. In the image the presences of large PCC particles which are particles fixed on the cellulose but also particle co-agglomerated. The picture was taken after 8 minutes reaction time.
In FIG. 10 the result of a similar batch experiment made at 4% microfiber consistency is shown.
The order of the addition of chemicals and other conditions were the same as in the experiment with 1 wt-% above. The initial pH value was about 12, whereas it dropped to around 7.5-8.5 during the progress of the reaction. The feeding of CO 2 was about 1.5 l/min. The reaction was usually stopped at about 10-15 min. The pictures was taken after 10 min reaction time. In this case, the fibers have been totally coated with nanoPCC particles and much less particles can be seen in the water phase. | A method for the production of a composite material comprising nanofibrillated polysaccharide, the method comprising the following steps:
(i) providing a liquid suspension of the nanofibrillated polysaccharide; (ii) bringing said liquid suspension in contact with at least one additive, thereby forming a composite material suspension, wherein the composite comprises the nanofibrillated polysaccharide and the at least one additive, (iii) increasing the solid contents of said composite material suspension, thereby forming a high solid contents composite material suspension. | 3 |
FIELD OF THE INVENTION
The present invention relates to integrated circuit devices, and more particularly to integrated circuit devices having buffer circuits therein.
BACKGROUND OF THE INVENTION
Semiconductor memory devices such as DRAMs and SRAMs are making significant gains in data output speed and bandwidth and their integration density is increasing. The timing gap between the output data hold time (tOH) and the clock to valid output delay time (tSAC) is an important parameter in synchronous memories because of the importance of the burst access mode of operation. This is because the clock cycle time (tCC) depends on the timing gap. The clock cycle time is the sum of tOH, tSAC, and the timing gap between tOH and tSAC. The tOH and tSAC are determined by the rising and falling transition times, respectively. Accordingly, if the timing gap increases, the clock cycle time will increase and the bandwidth will decrease. Increases in the timing gap between tOH and tSAC may be caused by variations in power supply voltage and temperature, or by impedance mismatch between data output pins.
To inhibit increases in the timing gap between tOH and tSAC due to power supply voltage variations, a data output buffer may be supplied with a stable internal power supply voltage and an external power supply. For example, a conventional data output buffer may include a pull-up MOS transistor having its current path electrically coupled in series between an external power supply voltage and a data output pad and a pull-down transistor having its current path electrically coupled in series between the data output pad and a reference power supply voltage (such as ground voltage). In order to gain speed, the gate electrode of the pull-up MOS transistor may be supplied with a boosted voltage which is determined by the internal power supply voltage.
However, if a higher external power supply voltage is applied to semiconductor memory device with the above-described data output buffer arrangement, the source-drain voltage of the pull-up MOS transistor may increase and this increase may cause additional skew between the output high voltage (VOH) and the output low voltage (VOL) since the current driving capability of the pull-up MOS transistor is increased. When this occurs, the rising transition time becomes shorter while the falling transition time remains unchanged. Thus, the bandwidth of the memory device may be reduced because tOH becomes shorter and tSAC becomes longer.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide improved integrated buffer circuits.
It is another object of the present invention to provide integrated buffer circuits which can be powered by internal and external supply voltages.
It is still another object of the present invention to provide integrated buffer circuits which are less susceptible to variations in power supply voltages and enable high bandwidth operation.
These and other objects, advantages and features of the present invention are provided by integrated buffer circuits which comprise an output driver powered at a first power supply voltage (EVC) and a voltage boosting circuit which drives an input (DOK) of the output driver and is powered at a second power supply voltage (VINTQ) having a magnitude less than a magnitude of the first power supply voltage. In addition, a preferred internal power supply voltage generator is provided which generates the second power supply voltage at a level which varies inversely with increases in the first power supply voltage in order to minimize timing skew associated with the output driver. This is achieved by lowering the voltage of an input signal provided to the output driver (by the voltage boosting circuit) to compensate for the output driver being powered at an increased first power supply voltage.
In particular, the preferred internal power supply voltage generator comprises a first voltage generator which is electrically coupled to a first power supply line and generates a first reference voltage (VREF) having a magnitude less than the first power supply voltage (EVC) at an output thereof. A second voltage generator is also provided. The second voltage generator is electrically coupled to the output of the first voltage generator and the first power supply line and generates a second reference voltage (VREFQ) which varies inversely with increases in the first power supply voltage (EVC) above a threshold power supply voltage.
In addition, a third voltage generator is provided. This third voltage generator is electrically coupled to the output of second voltage generator and the first power supply line and generates the second power supply voltage (VINTQ) at a level which varies directly with changes in the second reference voltage (VREFQ).
The first voltage generator is configured so that the magnitude of the first reference voltage (VREF) is not significantly influenced by changes in the first power supply voltage when the first power supply voltage is greater than the second power supply voltage. The second voltage generator may comprise a first differential amplifier having a first input electrically connected to the output of the first voltage generator (VREF), a first pull-up driver having an input electrically coupled to an output of the first differential amplifier and an output electrically coupled to the output of the second voltage generator and a voltage divider having an input electrically connected to the output of the second voltage generator (VREFQ) and an output (Vdiv) electrically coupled to a second input of the first differential amplifier. The third voltage generator (buffer power supply) may also comprise a second differential amplifier having a first input electrically connected to the output of the second voltage generator (VREFQ) and a second pull-up driver having an input electrically coupled to an output of the second differential amplifier. The output of the second pull-up driver is also electrically connected to a second input of the second differential amplifier and the second power supply line (VINTQ).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 diagram of an integrated circuit memory device according to an embodiment of the present invention.
FIG. 2 is an electrical schematic of the data output buffer of FIG. 1.
FIG. 3 is an electrical schematic of the first reference voltage generator of FIG. 1.
FIG. 4 is an electrical schematic of the second reference voltage generator of FIG. 1.
FIG. 5 is an electrical schematic of the output buffer power supply generator of FIG. 1.
FIG. 6 is a graph of output voltage (DOUT) versus time which illustrates a change in timing skew associated with the data output buffer of FIG. 2 when increases in an external power supply voltage (EVC) are applied thereto and the internal power supply voltage (VINTQ) is held at a constant level.
FIG. 7 is a graph of the second reference voltage (VREFQ), generated by the second reference voltage generator of FIG. 4, versus the external power supply voltage (EVC).
DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout and signal lines and signals thereon may referred to by the same reference symbols. In addition, references to logic gates which perform boolean functions are intended to include alternative logic gates and circuits which can be constructed to perform the same boolean functions.
Referring now to FIG. 1, a preferred embodiment of an integrated circuit semiconductor memory device according to the present invention is shown in block diagram form. The memory device 100 includes a row address buffer circuit 110 for receiving a row address Ai, a column address buffer circuit 120 for receiving a column address Aj, a memory cell array 125 having a plurality of memory cells therein (not shown) arranged in rows and columns, a row decoder circuit 130 for selecting a row of the memory cell array 125 on the basis of the row address Ai, a column decoder circuit 140 for selecting at least one column of the memory cell array 125, a sense amplifier and input/output (I/O) gate circuit 150 for sensing and amplifying data DBi from the selected memory cell(s), and a data output buffer circuit 160 for outputting the data DBi to I/O pad(s) DQi. The memory device 100 also includes an internal power supply voltage generator circuit 200 for generating an internal power supply voltage VINTQ based on an external power supply voltage EVC. The internal power supply voltage VINTQ and the external power supply voltage EVC are provided to the data output buffer 160.
The internal power supply voltage generator 200 includes a first reference voltage generator 170 which generates a first reference voltage VREF, a second reference voltage generator 180 which generates a second reference voltage VREFQ, and a third reference voltage generator (buffer power supply) 190 which generates the internal power supply voltage VINTQ as a buffer power supply voltage. The first and second reference voltage generators 170 and 180 and the buffer power supply voltage generator 190 are supplied with the external power supply voltage EVC.
FIG. 2 illustrates a detailed circuit schematic of the data output buffer 160 of FIG. 1. The data output buffer 160 comprises NAND gates G1, G2 and G3, first and third inverters IV1 and IV3, a boosting circuit 162, and a output driving circuit 164. A first NAND gate G1 has a first input for receiving a data signal DBi from the sense amplifier and I/O gate circuit 150 and a second input for receiving a control signal PTRST from an internal control circuit (not shown). The first inverter IVI has an input for receiving the data signal DBi and an output for providing an inverted data signal DBi. A second NAND gate G2 has a first input for receiving the inverted data signal DBi and a second input for receiving the control signal PTRST. A third NAND gate G3 has a first input for receiving the data signal DBi and a second input for receiving the control signal PTRST. The third inverter IV3 has an input electrically coupled to the output of the second NAND gate G2 and an output electrically coupled to the output driving circuit 164 on the second drive input (DOK).
The boosting circuit 162 includes a second inverter IV2 having an input electrically coupled to the output of the first NAND gate G1, a charge pump capacitor C1 having a first electrode electrically coupled to an output of the second inverter IV2 and a second electrode which is electrically coupled to the internal power supply voltage VINTQ via a diode-connected NMOS transistor MN9. The boosting circuit 162 also includes a pull-up PMOS transistor MP10 having a source commonly coupled to both the second electrode of the capacitor C1 and the diode-connected transistor MN9, a drain electrically coupled to the first drive input (DOK) of the output driving circuit 164, and a gate electrode electrically coupled to the output of the first NAND gate G1. In addition, a pull-down NMOS transistor MN10 is provided having a drain electrically coupled to the drain of the pull-up transistor MP10, a source electrically coupled to a reference or lower power supply voltage (e.g., ground voltage GND), and a gate electrically coupled to the output of the third NAND gate G3. The pull-down NMOS transistor MN10 may also be electrically coupled to the output of the first NAND gate G1, in the event the third NAND gate G3 is not provided.
The output driving circuit 164 includes a pull-up NMOS transistor MN11 having a drain electrically coupled to an external power supply voltage EVC, a source electrically coupled to an output signal line DOUT and a gate electrically coupled to the drains of the transistors MP10 and MN10 within the boosting circuit 162 (i.e., first drive input DOK). The output driving circuit also includes a pull-down NMOS transistor MN12 having a drain electrically coupled to the output pad DOUT, a source electrically coupled to the reference power supply voltage GND, and a gate electrode electrically coupled to the output of the third inverter IV3 (i.e., second drive input DOK).
Operation of the preferred data output buffer 160 will now be described in detail. When the data signal DBi is at a logic high level (and the inverted data signal DBi is at a logic low level) and the control signal PTRST is at a logic high level, the outputs of the first and third NAND gates G1, and G3 go to a logic low level while the output of the second NAND gate G2 goes to a logic high level. In the boosting circuit 162, the pull-up transistor MP10 turns on and the pull-down transistor MNIO turns off. As a result, the charge pump capacitor C1 supplies a predetermined boosted voltage (e.g., about VINTQ×1.8 volts) through the first pull-up transistor MP10 to the first drive input DOK (i.e., the gate of the pull-up transistor MN11 within the output driving circuit 164). The boosted voltage at the first drive input is provided to increase operating speed and depends on the magnitude of the internal power supply voltage VINTQ. Based on the output of the second NAND gate G2, a logic low level is supplied to the second drive input DOK (i.e., the gate of the pull-down transistor MN12 within the output driving circuit 164) so that the pull-down transistor MN12 turns off. Because the voltage level at the first drive input DOK is approximately equal to the sum of the pumping potential generated by the charge pump capacitor C1 and the potential passing the inverter IV2, the second pull-up transistor MN11 turns on and the voltage level on the output signal line DOUT goes to a logic high level.
On the other hand, when the data signal DBi is at a logic low level and the control signal PTRST is at a logic high level, the outputs of the first and third NAND gates G1, and G3 go to a logic high level while the output of the second NAND gate G2 goes to a logic low level. Accordingly, the pull-up transistor MP10 turns off, the pull-down transistor MN10 turns on, the pull-up transistor MN11 turns off, and the pull-down transistor MN12 turns on. Accordingly, the voltage level on the output signal line DOUT goes to a logic low level.
If, however, a higher external power supply voltage HEVC beyond a normal external power supply voltage LEVC (e.g., about 2.5 volts) is supplied to the output buffer 160 while the first drive input DOK is provided with the predetermined boosted voltage (which is almost constant regardless of the external power supply voltage variation), then the current driving capability (or conductivity) of the pull-up transistor MN11 may increase significantly. As a result of this increase in conductivity of the pull-up transistor MN11, the parasitic skew between an output high voltage VOH and an output low voltage VOL on the output signal line DOUT may increase. In FIG. 6, reference symbols A and B represent the output high and low voltage waveforms when EVC is no greater than 2.5 Volts and the reference symbol A' represents the output high voltage waveform in a conventional circuit when EVC is greater than 2.5 Volts and no compensation of the internal power supply voltage is provided.
To inhibit timing skew (t skew ), a preferred internal power supply voltage generator circuit 200 is provided. In particular, FIG. 3 illustrates a detailed circuit construction of the first reference voltage generator 170 of FIG. 1. The first reference voltage generator 170 is comprised of resistors R1 and R2, NMOS transistors MN1 and MN2 and a PMOS transistor MP1. One end of the resistor R1 is electrically coupled to the external power supply voltage EVC and the other end thereof is electrically coupled to a first node 14 for providing a first reference voltage VREF (e.g., about 1.1 volts). One end of the resistor R2 is electrically coupled to the first node 14 and the other end thereof is electrically coupled to a second node 16. The NMOS transistors MN1 and MN2 have their source-drain conduction paths (i.e., channels) are electrically coupled in series between the second node 16 and the reference ground voltage GND. Gates of NMOS transistors MN1 and MN2 are electrically coupled to the first node 14 and the external power supply voltage EVC, respectively. The PMOS transistor MP1 has a source electrically coupled to the first node 14, a drain electrically coupled to the ground voltage GND, a gate electrode electrically coupled to the second node 16, and a body (or bulk) connection electrically coupled to the first node 14.
The first reference voltage VREF is equal to the sum of the threshold voltage V TP1 of the PMOS transistor MP1 and the drain voltage V DN1 of the NMOS transistor MN1 at node 16. The first reference voltage VREF is thus expressed as: ##EQU1## where R TR indicates the sum of the equivalent resistance of the NMOS transistors MN1 and MN2.
From equation 1, it is noted that the external power supply voltage EVC has little if any impact on the magnitude of the first reference voltage VREF. Moreover, the impact of any temperature variation on the first reference voltage is minimized since the threshold voltage V TP1 is inversely proportional to temperature while the resistance sum R TR is proportional to temperature.
Referring now to FIG. 4, a detailed circuit construction of the second reference voltage generator 180 is illustrated. The second reference voltage generator 180 includes a differential amplifier 212, a pull-up driver 214, and a voltage divider 216. The differential amplifier 212 is comprised of a current mirror formed by PMOS transistors MP2 and MP3, an output node 17, a differential pair formed by NMOS transistors MN3 and MN4, and a current sink formed by NMOS transistor MN5. The current mirror transistors MP2 and MP3 are supplied with the external power supply voltage EVC. Bodies of the transistors MP2 and MP3 are also electrically coupled to the external power supply voltage EVC. The first reference voltage VREF is applied to gates of the transistors MN3 and MN5. The gate of the transistor MN4 is electrically coupled to the voltage divider 216. The output node 17 is electrically coupled to the pull-up driver 214. The differential amplifier 212 compares the first reference voltage VREF with a divided voltage Vdiv of the divider 216 and generates a comparison voltage Scomp at node 17. When the divided voltage Vdiv is lower than the first reference voltage VREF, the comparison voltage Scomp decreases so that the second reference voltage VREFQ increases. On the contrary, when the divided voltage Vdiv is higher than the first reference voltage VREF, the comparison voltage Scomp increases so that the second reference voltage VREFQ decreases. The pull-up driver 214 includes a PMOS transistor MP4 which has a gate electrically coupled to node 17. The source-drain channel of the transistor MP4 is electrically coupled between the external power supply voltage EVC and a node 18 for providing the second reference voltage VREFQ. The pull-up driver 214 drives the second reference voltage VREFQ by means of the external power supply voltage EVC. The voltage divider 216 is comprised of two PMOS transistor MP5 and MP6 electrically coupled in series as resistors between the node 18 and the ground voltage GND. The junction node 19 of the transistors MP5 and MP6 is electrically coupled to the gate of the transistor MN4 within the differential amplifier 212. The body of the transistor MP5 is electrically coupled to the node 18 while that of the transistor MP6 is electrically coupled to the external power supply voltage EVC. The voltage divider 216 divides the second reference voltage VREFQ into the voltage Vdiv. This voltage Vdiv is provided to the differential amplifier 212 via node 19.
In the event a higher external power supply voltage EVC (e.g., beyond a threshold external power supply voltage VPS th of about 2.5 Volts) is supplied to the semiconductor memory chip of the invention, the threshold voltage V TP6 of the PMOS transistor MP6 (within the divider circuit 216) increases, causing the divided voltage Vdiv to be increased. Consequently, when a external power supply voltage EVC in excess of VPS th is supplied to the memory device 100, the second reference voltage VREFQ decreases, as shown in FIG. 7, because the divided voltage Vdiv is relatively increased while the first reference voltage VREF remains constant (e.g. about 1.1 volts).
FIG. 5 illustrates a detailed circuit schematic of the buffer power supply voltage generator 190. The buffer power supply voltage generator 190 includes a differential amplifier 230, a pull-up driver 232 and an output node 234 for providing the internal power supply voltage VINTQ to the data output buffer 160. The differential amplifier 230 is comprised of a current mirror formed by PMOS transistors MP7 and MP8, an output node 50 for providing a comparison voltage, a differential pair formed by NMOS transistors MN6 and MN7, and a current sink formed by NMOS transistor MN8. The current mirror transistors MP7 and MP8 are supplied with the external power supply voltage EVC. Bodies of the transistors MP7 and MP8 are electrically coupled to the external power supply voltage EVC. The second reference voltage VREFQ is applied to gate of the transistor MN6, and the internal power supply voltage VINTQ is fed back to the gate of the transistor MN7. The current sink transistor MN8 is responsive to a control signal PVINTQE from an internal control circuit (not shown). The pull-up driver 232 includes a PMOS transistor MP9 which has a gate electrically coupled to the node 50. The source-drain channel of the transistor MP9 is electrically coupled between the external power supply voltage EVC and the VINTQ signal line at node 234. The pull-up driver 232 drives the internal power supply voltage VINTQ by use of the external power supply voltage EVC.
When the internal power supply voltage VINTQ is lower than the second reference voltage VREFQ, the comparison voltage on the node 50 decreases so that the internal power supply voltage VINTQ increases.
On the contrary, when the internal power supply voltage VINTQ is higher than the second reference voltage VREFQ, the comparison voltage on the node 50 increases so that the internal power supply voltage VINTQ decreases. Accordingly, when a higher external power supply voltage EVC beyond a threshold external power supply voltage VPS th is supplied to the semiconductor memory device 100, the internal power supply voltage VINTQ decreases relatively since the second reference voltage VREFQ decreases (see FIG. 7). Referring now to FIG. 2, this decrease in VINTQ causes the gate-source voltage Vgs of the second pull-up transistor MN11 to be decreased as well. This decrease in gate-source voltage preferably compensates for the increase of the drain-source voltage Vds across MN11 caused by the high EVC. Accordingly, the transistor MN11 can be controlled to have a constant current driving capability regardless of the variations in the external power supply voltage EVC and so any skew between the output high voltage VOH and the output low voltage VOL due to the variation of the external power supply voltage EVC can be reduced.
In the drawings and specification, there have been disclosed typical preferred embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being set forth in the following claims. | Integrated buffer circuits include an output driver powered at a first power supply voltage (EVC) and a voltage boosting circuit which drives an input (DOK) of the output driver and is powered at a second power supply voltage (VINTQ) having a magnitude less than a magnitude of the first power supply voltage. An internal power supply voltage generator is provided which generates the second power supply voltage at a level which varies inversely with increases in the first power supply voltage in order to minimize timing skew associated with the output driver. This is achieved by lowering the voltage of the signal applied to the input (DOK) of the output driver to compensate for the output driver being powered at an increased first power supply voltage. | 6 |
RELATED APPLICATIONS
This application is a divisional application of U.S. Ser. No. 09/608,853, filed Jun. 30, 2000, now U.S. Pat. No. 6,340,473 B1 which is a continuation-in-part application and is based on U.S. Provisional Application Serial No. 60/142,704; filed Jul. 7, 1999.
FIELD OF THE INVENTION
This invention relates to capsules and, more specifically, to soft capsules typically made using a rotary die apparatus. More specifically, it relates to novel compositions that are capable of forming films from which soft capsule shells can be made.
BACKGROUND OF THE INVENTION
Encapsulation within a soft capsule of a solution or dispersion of a nutritional or pharmaceutical agent in a liquid carrier offers many advantages over other dosage forms such as compressed, coated or uncoated solid tablets or bulk liquid preparations. Encapsulation of a solution or dispersion permits accurate delivery of a unit dose, an advantage which becomes especially important when relatively small amounts of the active ingredient must be delivered, as in the case of certain hormones. Such uniformity is more difficult to achieve via a tableting process wherein solids must be uniformly mixed and compressed, or via incorporation of the total dose of active ingredient into a bulk liquid carrier which must be measured out prior to each oral administration.
Soft capsules, most commonly, soft gelatin capsules, provide a dosage form which is more readily accepted by patients, since the capsules are easy to swallow and need not be flavored in order to mask the unpleasant taste of the active agent. Soft capsules are also more easily transported by patients than bulk liquids, since only the required number of doses need be removed from the package.
Soft encapsulation of drugs further provides the potential to improve the bioavailability of pharmaceutical agents. Active ingredients are rapidly released in liquid form as soon as the gelatin shell ruptures. Complete disintegration of the capsule is not necessary for the active ingredients to become available for absorption, unlike the case of tableted compositions. Also, relatively insoluble active ingredients can be dispersed in a liquid carrier to provide faster absorption.
Traditionally, both soft and hard-shell capsules have been manufactured using mammalian gelatin as the material of choice for producing the capsule envelope. The rotary die process developed by Robert Scherer in 1933 for producing one piece soft capsules utilized the unique properties of gelatin to enable a continuous soft capsule manufacturing process. The inventive, gelatin-free composition disclosed in this patent application is especially useful in the rotary die method of soft capsule manufacture.
Conventional manufacturing of soft capsules using the rotary die process utilizes mammalian gelatin in a process essentially as follows. Dry gelatin granules are combined with water and suitable plasticizers and the combination is then heated under vacuum to form a molten gelatin mass. The gelatin mass is held in its molten state while being formed or cast as films or ribbons on casting wheels or drums. The films or ribbons are fed under a wedge and between rotary encapsulation dies. Within the encapsulation dies, capsules are simultaneously formed from the films or ribbons, filled, cut and sealed. The seals are formed via a combination of pressure and heat as the capsule is filled and cut. Rotary die manufacture of soft gelatin capsules is disclosed in detail in The Theory and Practice of Industrial Pharmacy (Lachman, Lieberman and Kanig, Editors), 3 rd Edition, published by Lea & Febiger. A good description of gelatin encapsulation techniques can also be found in WO 98/42294 (PCT/GB98/00830).
Gelatin formulations used to produce films suitable for making capsules within the rotary die process typically contain between 25% to 45% by weight mammalian gelatin. Levels below 25% by weight tend to lead to poor sealing of the capsule. The physical properties of the gelatin film are critical to the economic production of soft capsules. For example, the film must be strong enough to survive manipulation in the encapsulation machine, provide good sealing properties at temperatures below the melting point of the film, evidence rapid dissolution in gastric juices, and have sufficient elasticity to allow for the formation of the capsule. The wholly non-animal composition of the present invention meets all of these requirements without the use of mammalian gelatin, and surprisingly evidences several improved properties.
The composition according to the present invention, like mammalian gelatin, has many properties that favor its use in soft capsule manufacture. One important property of the inventive compositions with respect to the rotary die process is the ability of the compositions to be cast to form films that are mechanically strong and exhibit elasticity sufficient to allow the film to stretch during filling. In other words, the inventive films have dimensional stability, elasticity and strength adequate for use in a continuous commercial process.
Another important and unique property of the inventive compositions is that the films forming the two halves of the capsule will fuse together during the filling and cutting process when subjected to sufficient pressure and elevated temperature. This fusing together relies on a particular property of the films that allows fusion under conditions of elevated temperature, supplied by the injection wedge, and pressure, supplied by the rotary cutting dies. The temperature at which fusion of two opposing films occurs should be below the melting point of the film, i.e., the fusion or sealing temperature is less than the melting point of the film composition. It has proven difficult to find this combination of properties in other polymer systems. Thus, most proposed substitutes for mammalian gelatin have failed due to a lack of one or more of these properties. This is the main reason why mammalian gelatin has been used almost exclusively as the shell forming material in soft capsule manufacture.
The property of fusion temperature being lower than melting temperature is crucial to the sealing of capsules using the continuous rotary die process. If the fusion and melting temperatures are about the same, the film will nearly completely melt as it passes through the wedge and the rotary die. At this temperature, the film loses its structure. As a result, capsules cannot be produced.
Disadvantages of mammalian gelatin includes the cost and continuity of supply. Gelatin has a variety of other drawbacks. For example, bovine sources are somewhat unattractive to individuals that prefer vegetarian food sources. Also, gelatin is prone to cross-linking, either caused by aging or due to reaction with compounds such as aldehydes. Cross-linking reduces the gelatin insoluble in gastric fluids, a generally undesirable quality for soft capsules. Thus, there is a need in the soft capsule industry for a replacement for the gelatin based compositions.
Other hydrocolloids form films but they lack the attributes of mammalian gelatin required to allow their use in the rotary die process. For example, a variety of modified food starches such as those available from Grain Processing Corporation as Pure-Cote®, are low viscosity starches that provide film-forming and adhesive properties. Such starches form clear, flexible films that are fast drying and flavor free. These materials are suitable as binders for seasonings on snacks and cereals and as smooth, glassy coating agents for confections and baked goods. However, these materials are unable to form hydrated films with the requisite strength and elasticity required for use in the rotary die process. Further, films made entirely from starch have insufficient elasticity and strength to be transferred from the casting drum to the rotary dies. Also, the films adhere too tightly to the casting drum, further diminishing transferability. Thus, compositions are needed that mimic the behavior and characteristics of mammalian gelatin while overcoming its shortcomings.
BACKGROUND ART
Japanese Patent Application Kokai Publication No. 63-164858 discloses a composition for the outer skin of soft capsules that allows the filling of hydrophilic materials into the capsule. The composition is a mixture of at least one natural polysaccharide selected from alginic acid, alginic acid derivatives, agar, locust bean gum, carrageenan, guaic gum, tamarind seed polysaccharide, pectin, xanthan gum, glucomannan, chitin, pluran, and cyclodextrin; and at least one substance selected from polyvalent alcohols, sugar alcohols, monosaccharides, disaccharides, and oligosaccharides. The oligosaccharides are described as enzyme and acid decomposition products of sweet potato, potato, corn and the like. While carrageenan is disclosed, there is no distinction made between the various forms of carrageenan (i.e., iota versus kappa). Further, there is no suggestion that the combination of two gelling agents, iota-carrageenan and a modified starch having a hydration temperature below about 90° C. would advantageously produce a soft capsule having outstanding physical properties. Further, there is no disclosure or suggestion that a weight ratio of modified starch to iota-carrageenan of at least 1.5:1 is required to produce a film that can be used in a rotary die encapsulation machine to make soft capsules.
International Patent Application No. PCT/FR98/01744 (WO 97/07347) discloses a composition for the manufacture of soft and hard capsules that uses iota-carrageenan as the only gelling agent at concentrations of greater than 5% by weight. This reference does disclose the use of starches and surfactants in the composition at levels of up to 20% by weight for the purpose of accelerating the disintegration of the capsule after contacting gastric juices. No specific teaching on the type of starch is given, other than substances such as wheat, rice, maize or manioc starch which may or many not have been modified, may be used. This reference fails to suggest or disclose the use of gelling starches and iota-carrageenan at weight ratios of at least 1.5:1 to form films useful in making soft capsules, wherein the starch is a modified starch with a hydration temperature of less than 90° C.
U.S. Pat. No. 5,342,626 to Winston et al. discloses a composition comprising gellan, carrageenan and mannan gums for producing soft capsules. This patent further discloses that the tri blend of gums can be combined with additional ingredients to form a film-forming polymer composition. This reference, however, fails to disclose the benefits that can be arrived at through the use of iota-carrageenan with certain modified starches.
Japanese Patent Application No. HEI9-25228 discloses a soft capsule film having as essential components agar and water-soluble high polymers, such as the carrageenans. This reference fails to suggest or disclose the combination of iota-carrageenan with a modified starch having a hydration temperature below about 90° C. to form films that have outstanding properties in the preparation of soft capsules.
In similar fashion, Japanese Patent Application Disclosure No. HEI5-310529 discloses a capsule forming film comprising agar and carrageenan. The reference points out that kappa carrageenan was found to be preferable. This reference does not make any mention of modified starches being incorporated into the film forming composition.
Japanese Public Patent Disclosure Bulletin No. 61-10508 discloses capsules made from polysaccharides which contain carrageenan and a base which contains multivalent alcohols. The multivalent alcohols include sorbitol, ethylene glycol, glycol, glycerin and the like. No mention is made of iota-carrageenan nor of modified starches.
Another reference suggesting the use of kappa-carrageenan to form capsules is seen in Japanese Patent Application Disclosure No. SHO60-12943. This reference teaches the exclusive use of kappa carrageenan in concentrations of about 1 to about 12% by weight. This reference also suggests that suitable plasticizers or gelatins can be included for increasing film strength.
PCT Application WO 00/10538 to Banner Pharmacaps discloses a gelatin free capsule comprising:
a) 8-50% by weight of a water dispersible or water-soluble plasticizer;
b) 0.5-12% by weight kappa carrageenan;
c) 0-60% by weight dextrins; and
d) 1-95% by weight water
wherein the kappa carrageenan comprises at least 50% by weight of all gums forming or contributing to formation of thermo-reversible gels in the composition. This application does not suggest the combination of a film-forming starch and iota-carrageenan to produce a film of exceptional properties for the formation of soft capsules.
U.S. Pat. No. 5,089,307 to Ninomiya et al. discloses a heat sealable, edible film comprising a film layer consisting essentially of: 1) a water soluble polysaccharide composed chiefly of carrageenan; 2) a polyhydric alcohol; and 3) water. The film of this patent has a water content of not greater than 25% by weight and a weight ratio of the polyhydric alcohol to the water soluble polysaccharide being in the range from 1:5 to 1:1. While this reference does mention all three (3) forms of carrageenan, kappa, iota and lambda, it fails to suggest or disclose a soft capsule formulation containing iota-carrageenan and a modified starch, such as hydroxypropylated tapioca starch.
U.S. Pat. No. 5,817,323 to Hutchison et al. discloses a composition for use in the shell of a comestible capsule comprising gelatin and a plasticizer, such as glycerol, together with a further compound which forms a secondary matrix for the plasticizer. This further component is disclosed as typically being unbleached potato starch acetate. This patent makes no suggestion or disclosure of the use of iota-carrageenan as an elasticizing agent for the film forming modified starches.
U.S. Pat. No. 4,804,542 to Fischer et al. describes gelatin capsules comprising a capsule sheath and a filling wherein the sheath contains a gelatin and at least 1% by weight of an agent selected from the group consisting of starches, starch derivatives, celluloses, cellulose derivatives, milk powder, non-hygroscopic mono-, di- and oligo saccharides, magnesium trisilicate and silicon dioxide. These agents are described as being capable of absorbing water in an amount of at least 10% by weight of its own weight. This patent teaches that the capsule sheath can then be used in containing water miscible, water soluble, water sensitive or hydrophilic materials. This patent makes no mention of iota-carrageenan.
U.S. Pat. No. 3,865,603 to Szymanski et al. relates to modified starch-extended gelatin compositions. This patent discloses modified starches with hydration temperatures above 99° C. for use with mammalian gelatin at weight ratios of about 1:9 to 1:1 (starch to gelatin). No mention is made of iota-carrageenan or the special need for soft capsule manufacture with sealing temperatures substantially below the melting point of the film.
SUMMARY OF THE INVENTION
The present invention provides compositions for manufacturing capsules, in particular, soft capsules, and especially soft capsules manufactured using the rotary die encapsulation apparatus. The invention provides compositions that do not employ mammalian gelatin and, therefore, overcome the disadvantages associated with collagen-derived material. Compositions of the invention do not contain any significant amounts of gelatin but, instead, require at least two (2) agents: 1) a modified starch having a hydration temperature below about 90° C. and 2) iota-carrageenan.
As those skilled in the art of soft capsule manufacture will appreciate, the film formed on the drum of the encapsulation machine is called the “wet film”. This film is used in the rotary encapsulation machine to form the filled capsules. The capsules are then dried using any number of techniques. During the drying process, water is removed from the fill material (when the fill material is hydrophilic) and the capsule shell. The result is a soft capsule with a “dry film”. The dry film comprises the various components, i.e., carrageenan, plasticizer, modified starch and the like and “bound water”. The bound water, from about 6 to 12% by weight of the dry film, is not easily removable using conventional drying techniques and is not considered when describing the components of the dried film as a percentage of the composition. The dried film numbers are calculated numbers based upon a assumed weight percent of the bound water.
Thus, for example, Table I sets out the components of the inventive film forming composition and representative weight percent ranges for the wet film and the dry film.
TABLE I
Prototypic Formula
Component
Weight % of Wet Film
Weight % of Dry Film
Iota-carrageenan
6-12
12-24
Modified starch
12-30
30-60
Plasticizer
5-30
10-60
Buffer
0.5-2
1-4
Preservative
0-0.2
0-0.4
As will be demonstrated in the Examples, one aspect of the present invention resides in the discovery that the weight ratio of the modified starch to the iota-carrageenan is crucial to forming a satisfactory film. The weight ratio of the modified starch to the iota-carrageenan is at least 1.5:1, with a preferred range being 1.5:1 to 4:1. Another feature useful in characterizing the inventive film is fusion pressure. The mixture of modified starch, iota-carrageenan and other components should result in a wet film that fuses at pressures above 207 kPa.
Thus, there is disclosed, a composition suitable for forming a film for encapsulating materials, the composition comprising a modified starch and iota-carrageenan in a ratio by weight of at least 1.5:1; said film capable of fusion under a pressure of at least about 207 kPa (30 psi). There is further disclosed a composition wherein the weight ratio of modified starch to iota-carrageenan ranges from 1.5:1 to 4:1, more preferably from 2:1 to 3:1. Further, the invention relates to a film forming composition that is capable of fusion, under pressure, in the range of 207 kPa to 2070 kPa (30 to 300 psi) and at temperatures in the range of from 25-80° C. In a yet more preferred embodiment, the film according to the present invention has a melting temperature of from 2 to 25° C., more preferably 3-15° C. and most preferably 4-9° C. above its fusion temperature.
More specifically, the compositions according to the invention (expressed as wet film) comprise from 5-50% by weight modified starch; more preferably 15-40% by weight and the preferred modified starch is hydroxypropylated acid modified corn starch. The invention is also most preferably a composition wherein iota-carrageenan comprises at least 6 and up to 12% by weight of the composition. The composition according to the present invention may also contain a plasticizer such as glycerin and the plasticizer may comprise up to 50% by weight of the composition, more preferably up to 30% by weight.
There is also disclosed a dried film composition for soft capsules, the composition consisting essentially of from 42-84% by weight gel formers comprising a mixture of iota-carrageenan and modified starch; a plasticizer; and a buffer.
There is further disclosed a composition suitable for forming a soft capsule, the composition comprising iota-carrageenan and at least one modified starch selected from the group consisting of hydroxypropylated tapioca starch, hydroxypropylated maize starch, acid thinned hydroxypropylated corn starch, potato starch, pregelatinized modified corn starches, and wherein said starch has a hydration temperature below about 90° C. and wherein the weight ratio of modified starch to iota-carrageenan ranges from 1.5:1 to 4.0:1. The invention also relates to a soft capsule comprising a shell and a fill material wherein the shell is a film according to the present invention.
In general, the invention provides compositions that function effectively as replacements for the conventional mammalian gelatin based compositions. Thus, the compositions of the invention possess many of the desirable important characteristics of gelatin. The inventive compositions form films that are mechanically strong and exhibit elasticity sufficient to allow the film to stretch during filling (blow-molding). Thus, the invention films have dimensional stability, elasticity and strength adequate for use in a continuous process which requires their removal from a casting drum and subsequent transport to rotary dies. Unexpectedly, the fusion or sealing temperature is substantially less than the melting point of the inventive film. Thus, films formed from the compositions of the invention simultaneously fuse together during the filling and cutting portion of the rotary die process when subjected to sufficient pressure and elevated temperature.
An additional unexpected property of the films according to the invention is that sealing occurs at substantially lower pressures than those experienced with mammalian gelatin based compositions. For example, conventional mammalian gelatin based films seal at pressures of about 1,724 kPa (250 psi) whereas the new films according to the present invention seal at about 207 kpa, more preferably about 552 kPa (30-80 psi). This saves energy and reduces the wear experienced by the rotary die. Also, the inventive film, when dry, (the film contains about 6 to 12% by weight water) is durable and impermeable to hydrophobic liquids.
As used herein and in the claims, the term “fusion” is meant to mean the welding of two (2) films by the use of pressure so as to result in a bond that is not easily separated. The fusion of the two films during the rotary die process results in a seal that is adequate to hold the liquid fill of the soft capsule during its anticipated shelf life.
In a preferred embodiment, the invention provides compositions comprising at least one modified starch and iota-carrageenan in a ratio by weight in the range of 1.5:1 to 4:1; plasticizers; buffers and optionally preservatives. Such materials can be formed into films that have sufficient structure, elasticity and strength to be removed from a temperature-controlled casting surface. It has unexpectedly been found that a combination of carrageenan, especially iota-carrageenan, and at least one modified starch, forms films having characteristics that allow the film to be reversibly stretched during the capsule filling step. These compositions, as wet films, preferably comprise water, 6-12 weight % iota-carrageenan, 12-30 weight % modified starch, 5-30 weight % plasticizers, 0.5-2 weight % buffers and optionally 0-0.2 weight % preservatives.
In another embodiment, the invention provides films comprising water and a solids system. In the films of the present invention, the solids system comprises modified starch and iota-carrageenan. The films of the invention are capable of maintaining their form without being applied to a support; they do not lose their shape through splitting, lengthening, disintegration or otherwise by breakdown of the film when unsupported. However, the films may be stretched when pulled or compressed to a certain extent when an appropriate external force is applied.
As used herein and in the claims, the term “modified starch” includes such starches as hydroxypropylated starches, acid thinned starches and the like. The only native starch determined to be functional with iota-carrageenan in preparing the films according to the invention is potato starch, thereby the term “modified starch” is meant to include native, unmodified potato starch. In general, modified starches are products prepared by chemical treatment of starches, for example, acid treatment starches, enzyme treatment starches, oxidized starches, cross-bonding starches, and other starch derivatives. It is preferred that the modified starches be derivatized wherein side chains are modified with hydrophilic or hydrophobic groups to thereby form a more complicated structure with a strong interaction between side chains.
Through the diligent work of the inventors herein, they have determined that some starches are barely functional in their inventive compositions and include high amylose starches, native starches other than potato starch and cross-linked starches. Hydrogenated starch hydrolysates that have been used to promote the disintegration of the gelatin capsule would likewise not be useful in the present invention.
There are two characteristics that help characterize modified starches that are useful in the present invention and they are 1) hydration temperatures below about 90° C. and 2) film forming capabilities. Through a careful study of numerous starches, it has been determined that the following starches are not useful in the present invention: tapioca dextrin, high amylose non-modified corn starch, modified waxy maize starch, non-granular starch, modified high amylose corn starch and pregelatinized rice flour.
There is further disclosed an edible, soft capsule which comprises:
a) a soft, dry shell which comprises:
(i) about 12-24 weight % iota-carrageenan;
(ii) about 30-60 weight % modified starch;
(iii) about 10-60 weight % plasticizer;
(iv) about 1-4 weight % sodium phosphate dibasic buffer system; and
wherein said shell encloses:
b) a soft capsule fill material.
In a further embodiment of the invention, there is disclosed a capsule wherein the plasticizer is comprised of glycerin or sorbitol or a mixture thereof and the modified starch is selected from modified corn starch, acid modified hydroxypropylated corn starch and hydroxypropylated acid modified tapioca starch.
Carrageenan has been known for decades as a useful food ingredient. While salt and sugar are rather simple food ingredients, technologically, carrageenans are rather complex and there are hundreds of different products available in the market called carrageenan with highly different price levels and functionalities. Carrageenan is obtained by aqueous extraction of natural strains of seaweeds of Gigartinaceae, Solieriaceae, Phyllophoraceae, and Hypneaceae, families of the class Rhodophyceae (red seaweeds). The three major forms of carrageenan are known as iota, kappa and lambda carrageenan. Lambda and kappa carrageenans do not typically occur together in the same plant, however, since the various species are harvested together, extraction yields a typical mixture of kappa and lambda with an average of around 70% kappa and 30% lambda. Euchema Spinosum is the seaweed source for production of iota-carrageenan either as an extract or as a processed Euchema seaweed. During the production of carrageenans, it is common that no sorting takes place before shipment of the seaweed to the carrageenan rendering facilities. Seaweeds are typically sold based on seaweed type and content of sand, salt, stones and humidity and not based on functional specifications. Thus, carrageenan manufacturers need to test each seaweed shipment to determine the quality of the extractable carrageenan in order to see if any processing adjustments are needed for obtaining the desired specifications. Carrageenans are available in the market place as standardized and non-standardized carrageenans. Standardization is done either by blending different pure carrageenan batches (cross-blending) or by blending one or more carrageenan batches with other ingredients such as salts (KCl, NaCl, and CaCl 2 ) and/or sugars (saccharose, dextrose, maltodextrins, lactose) in order to reach the desired specification. As used herein an in the claims, the recited weight percents for iota-carrageenan include the standardizing ingredient.
All carrageenans are water soluble gums having the common structural feature of being linear polysaccharides with a sugar backbone of alternating units consisting of galactose units linked by 1,3-β-D-linkages, as well as 1,4-α-D-linkages. The fundamental properties of iota, kappa and lambda are a function of the number and position of the ester sulfate groups. Iota-carrageenan contains approximately 30% by weight 3,6 anhydro-D-galactose and 32% ester sulfate by weight. In contrast, kappa carrageenan contains more than 36% by weight 3,6 anhydro-D-galactose and 32% ester sulfate by weight. Molecular weight ranges from 100,000 to 500,000 Daltons. The gelling carrageenans (kappa and iota) contain an “internal” ring—the 3,6-anhydro ring. The presence of ester sulfate makes carrageenans negatively charged at all pH values and is responsible for carrageenans being highly reactive molecules. Commercially available carrageenans are typically not well defined chemical compounds. However, through careful quality control, relatively pure materials with specified properties are available commercially.
The gelling carrageenan types (kappa and iota) are biosynthesized by the living seaweed as a non-gelling precursor, which is then turned into the gelling form by the action of the enzyme, dekinkase, which catalyzes the formation of the 3,6-anhydroglacatose ring. As mentioned previously, iota-carrageenan is only produced from Euchema Spinosum and produces the strongest gels with calcium ions (Ca ++ ). The gels are very elastic and completely syneresis free at the normal concentrations for food application (i.e., 0.5 to 2% by weight). Although iota-carrageenan does not gel with Na+, diluted iota-carrageenan solutions will form thixotropic solutions also with Na+ as it acts as a stabilizing agent. In the best mode of the present invention, the Ca ++ content is kept to a minimum.
In iota-carrageenan, the 1,3- and 1,4- linked units are respectively D-galactose-4-sulfate and 3,6-anhydro-D-galactose-2-sulfate. However, some of the 3,6-anhydro-D-galactose-2-sulfate rings may be replaced by D-galactose-6-sulfate, which may reduce considerably the gelling power of the iota-carrageenan.
The iota-carrageenans useful in the composition according to the invention should conform to the specification laid down by the USA and European regulatory authorities. The iota-carrageenan should not be degraded and should conform to minimum viscosity standards, which correspond to a molecular weight of about 100K Daltons.
Syneresis is often measured on carrageenan gels to determine breaking force and characterize the iota from the kappa carrageenan. After breaking force has been measured, the gel is transferred to a petri dish and covered to avoid evaporation from the gels. After typically about four (4) hours, the amount of free water (the syneresis) is measured. A high value indicates a strong gelling kappa, whereas no syneresis indicates iota.
Table II sets out typical analytical patterns and values for iota-carrageenan.
TABLE II
Typical Analytical Parameters and Values for Iota-carrageenan
Parameter
Typical Values (Ca-iota)
Typical Values (Na-iota)
Gel strength
0-100 g/cm 2 (1.5%
0
carrageenan)
pH
7-10 (in 1.5% gel)
7-10
Viscosity
10-30 cP (1.5% at 75° C.)
10-30
Chloride
0-1% (as KCl)
0-1%
Calcium
2-6%
0-0.5%
Sodium
˜1%
3-5%
Potassium
3-5%
4-7%
Through extensive investigative efforts, the inventors have determined that iota-carrageenan alone does not produce an acceptable film and that the modified starches alone do not produce a useable film for encapsulation. Without being bound to any theory or mechanism, it is speculated that the iota-carrageenan and modified starches interact synergistically to provide films of sufficient strength and elasticity to be useful in the encapsulation process.
The films made from the compositions of the invention possess the desirable properties of the films made from gelatin and function as effective replacements for gelatin films in virtually all processes that employ aqueous-gelatin compositions for the production of soft capsules. Among those processes are rotary die encapsulation processes, reciprocating die encapsulation processes, concentric cylinder processes, and processes for film-enrobing tablets. The film-enrobing process is also a rotary die process, as described in U.S. Pat. No. 5,146,730, the disclosure of which is incorporated herein by reference in its entirety. Thus, the compositions of the present invention provide:
i) mechanically strong, elastic films that set on a temperature-controlled casting drum generally within from about 15 to about 60 seconds, preferably less than about 20 seconds;
ii) films that, when brought into contact with one another, fuse together at temperatures of from about 25-80° C. and pressures of from about 207 to about 2070 kPa (30-300 psi);
iii) films that fuse (form seals in the rotary die process) at temperatures significantly below the melting point of the films; and
iv) strong, durable dried films.
Still other advantages of the inventive compositions include:
i) finished capsules are not prone to cross-linking or insolubilization due to interaction with materials such as aldehydes, phenols ketones, that may be present within the capsule fill or shell, or that are formed over time by oxidization; and
ii) finished capsules exhibit greater stability when exposed to elevated humidity and temperature than capsules made using gelatin.
The compositions of the present invention are capable of forming unsupported wet and/or dry films, i.e., the films do not require a support to maintain their shape and structure. Further, they do not disintegrate, tear or fracture unless some significant external force is applied. The compositions of the invention are formed into films by any of a variety of suitable methods. While casting or extruding onto a casting drum is preferred in connection with the rotary die process, other processes for forming films will be apparent to those skilled in the art.
Other components may also be incorporated into the compositions provided they do not alter the melting point/fusion point characteristics of the inventive film. Representative of these additional components include flavoring agents, opacifying agents, preservatives, embrittlement inhibiting agents, colorants and disintegrants. The inventive compositions are typically in the molten state when these components are added. Use of conventional pharmaceutical or food grade ingredients is acceptable.
As used herein and in the claims, the phrase “an amount of modified starch effective to form a structured film” means an amount of a modified starch sufficient to form a film or gel that does not flow, but has dimensional stability. More preferably, the phrase “effective to form a structured film” means an amount of a modified starch sufficient to form a dimensionally stable film having a thickness of at least about 0.01 inches.
The phrase “effective elasticizing amount” means an amount of iota-carrageenan sufficient to provide a starch based composition in the form of film with sufficient strength to be removed from a casting drug during rotary die processing and also sufficient elasticity to be deformed during the rotary die process when a fill material is presented between a pair of films of the composition (blow molded).
The phrase “fusion temperature” means the temperature at which two opposing films, in contact with each other, will blend at their contact interface to become one, indistinguishable and inseparable structure.
The weight ratio of modified starch to iota-carrageenan in this invention is at least 1.5:1, more preferably from about 1.5:1 to about 4:1, most preferably, from about 2:1 to about 3:1. Unexpectedly, the compositions of the invention possess the important characteristic of having a melting point temperature that is substantially higher than the fusion temperature. Preferably, the melting point temperature of a film according to the invention, is from about 3-15° C., and more preferably from about 4 to 9° C., above its fusion temperature.
While not being bound to any theory or mechanism, it is believed that the iota-carrageenan functions as an elasticizing agent. In other words, this elasticizing agent renders an otherwise in-elastic, modified starch film, elastic. Consequently, the films of the invention have a “memory” and are capable of returning substantially to their original size and shape after being subjected to a deforming force. For example, a film made from the starch/carrageenan compositions of the invention that is stretched along its length and/or width will substantially return to its original length over time.
As discussed previously, the modified starches useful in the present invention include those starches that have a hydration temperature below about 90° C. Hydration temperatures for most starches are available in the literature, such as product data for commercially available starches. Where they are not available via the literature, such hydration temperatures may be readily determined employing techniques well know to those skilled in the art. Suitable starches also must be capable of forming an aqueous mixture with water at a concentration of at least from about 20 weight % to give a mixture having a viscosity below about 60,000 to 80,000 centipoise (cps) measured at a 10 sec-1 shear rate at the temperature at which starch hydration occurs.
Representative of the commercially available starches useful in the present invention include Pure Cote™ B760 and B790 (an acid-modified hydroxypropylated corn starch), Pure-Cote™ B793 (a pre-gelatinized modified corn starch), Pure-Cote™ B795 (a pre-gelatinized modified corn starch) and Pure-Set™ B965 (a flash-dried acid modified native corn dent starch), all available from the Grain Processing Corporation of Muscatine, Iowa. Other useful, commercially available, modified starches include C*AraTex™ 75701 (hydroxypropylated acid modified tapioca starch), available from Cerestar, Inc. of Hammond, Ind.; M250 and M180 (maltrins) and Pure-Dent™ B890 (modified corn starch) from Grain Processing Corporation; and Midsol Crisp (modified high amylose corn starch) from Midwest Grain, Inc. of Atkinson, Kans. The only native (unmodified) starch suitable for use herein is potato starch. Such a starch is available from Roquette as Potato Starch Supra Bacter.
The invention may include genetically (recombinantly) modified and hybridized starches. Genetically modified and hybridized starches include those that have been developed to alter the physical properties and/or the amylose/amylopectin ratios. The preferred starch is an acid hydrolyzed corn starch modified with 2-hydroxypropyl ether functional groups. This starch is identified by Chemical Abstracts Service Registry No.68584-86-1. This material is commercially available as PURE-COTE™ B760 and B790 from Grain Processing Corporation.
The iota-carrageenan is present in the inventive compositions in an amount that, in combination with starch, effectively causes the compositions to have the required gelatin-like functional properties. As discussed previously, as those skilled in the art will appreciate, the film has what is known as a wet shell composition and a dry shell composition. This results from the evaporation of water from the film during the manufacturing process of the soft capsule. Preferred amounts of iota-carrageenan range from about 6 to 12% by weight of the wet shell composition. More preferred amounts of iota-carrageenan range from about 7-12% by weight of the wet composition. Particularly preferred compositions contain from about 9-11 weight % of iota-carrageenan, based on the weight of the wet composition. Even more preferred compositions contain about 10 weight % of iota-carrageenan by weight of the wet composition.
As will be demonstrated in the Examples, not all members of the carrageenans family can be used herein. Standardized iota-carrageenans are preferred. A particular preferred standardized iota-carrageenan is commercial available from the FMC Corporation of Princeton, N.J., known as VISCARIN® SD389, standardized with 15% by weight dextrose. Other useful iota-carrageenans include a non-standardized iota-carrageenan from SKW BioSystems of Baupt, France known as XPU-HGI and a non-standardized iota-carrageenan from FMC.
In general, the film forming compositions may consist of the iota-carrageenan, at least one modified starch with the balance of the composition being water. However, preferred compositions of the invention include a plasticizer. Suitable plasticizers include the materials used for the same purpose in the manufacture of mammalian gelatin capsules. Representative plasticizers are any of a variety of polyhydric alcohols such as glycerin, sorbitol, propylene glycol, polyethylene glycol and the like. Other plasticizers include saccharides and polysaccharides. The saccharides and polysaccharides suitable for use herein may be produced by hydrolysis and/or hydrogenation of a simple or complex polysaccharides.
Where plasticizers are employed, they can be used in amounts of up to about 60% by weight of the dry shell composition or 30% of the wet shell composition. More preferred compositions contain from about 10 to 25% by weight, based on the weight of the wet shell composition and 30-50% by weight of the dry shell composition.
Also, the capsule forming composition, i.e., the shell mass composition, may optionally contain an embrittlement inhibiting composition. An example of embrittlement inhibiting compositions is a mixture of sorbitol and one or more sorbitans. See U.S. Pat. No. 4,780,316.
Optionally, the film forming composition may contain preservatives and stabilizers such as mixed parabens, ordinarily methyl or propyl parabens, in about a 4:1 ratio. The parabens may be incorporated in the compositions at levels of 0-0.2 weight % for the wet shell and 0-0.4 weight % for the dry shell. It should be noted that in the following Examples, preservatives were included in the experimental formulation to facilitate un-dried sample retention for later evaluations. Without preservatives, the retained wet ribbons would be spoiled by microbial growth in a day or two. On a commercial scale, preservatives would typically note be added to the film forming composition because the wet ribbon would be quickly processed through the encapsulation machines and then the dryers. The dried film does not support microbial growth.
It has been found by the inventors that the use of a buffer system in the inventive compositions is highly desirable. Any known buffer can be used with phosphate buffers being preferred. Controlling the pH of the melt and film is highly important as carrageenans are rapidly broken down in conditions of high temperature and acidity. As mentioned previously, the presence of Ca ++ ions should be kept to a minimum.
Soft capsules may be manufactured in accordance with conventional techniques as set forth in Ebert, W. R., “Soft elastic gelatin capsules: a unique dosage form”, Pharmaceutical Tech ., October 1977; Stanley, J. P., “Soft Gelatin Capsules”, in The Theory and Practice of Industrial Pharmacy , 359-84 (Lea and Febiger ed. 1970); U.S. Pat. Nos. 1,970,396; 2,288,327; and 2,318,718.
The capsules made using the rotary die process, will typically have wet shell thicknesses varying from about 0.024 to 0.1778, preferably from about 0.0508 to 0.127 and more preferably from about 0.0508 to 0.0762 cm in thickness. The capsules of the invention may be manufactured in any desired shape using the above-mentioned rotary die process.
The fill materials for the soft capsules may be any of a wide variety of materials suitable for encapsulation using the rotary die apparatus. Among the types of materials that are suitable for encapsulation include oils, hydrophilic liquids and emulsions. The active components that may be contained within the oils and emulsions are hydrophobic and hydrophilic actives. Those skilled in the art are familiar with and will recognize suitable fill materials. These fill materials may contain cosmetics, foods including vitamins, liquids, semi-solids, suspensions, flavorings and pharmaceuticals. After filling, the capsules are typically dried according to conventional techniques, e.g., tray drying, using a drum dryer or other suitable drying methods.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following examples demonstrate certain aspects of the present invention. However, it is to be understood that these examples are for illustrative purposes only and do not purport to be wholly definitive as to conditions and the scope of this invention. It also should be appreciated that when typical reaction conditions (e.g., temperature, reaction times) have been given, the conditions which are both above and below these specified ranges can also be used, though generally less conveniently.
A further understanding of the invention may be obtained from the following non-limiting examples. Each of the following compositions is prepared according to the method described below. All temperatures are expressed in degrees Celsius (° C.) and all parts are parts by weight, unless designated otherwise.
EXAMPLE 1
Preparation of the Capsule Shell Material
A mixer, fitted with suitable medium shear mixing blades, and a side sweep assembly was used to prepare a molten mass for forming films. The mixing container may be heated or cooled as needed and optionally may be constructed such that a vacuum can be established inside the vessel.
Appropriate quantities of each component (except starch and carrageenan) for each formulation was added to the mixer and blended. The starch and carrageenan were then added to the mixture and mixed under vacuum. Heat and continuous stirring were applied until the mixture became molten and homogeneous. Samples from each formulation were taken and cast onto a glass plate that was at room temperature. A blade or draw bar with a notch of about 15 cm in width and 0.127 cm in height was used to create the casting. After cooling, the film (about 0.06 cm to 0.08 cm in thickness) was evaluated for stiffness, elasticity, brittleness and film strength. Those films that were characterized by the investigator as having some potential were evaluated for sealing properties. The film was carefully removed from the glass plate and folded in half and placed on a preheated bag sealer from Midwest Pacific Corp. The arm was lowered and contacted the folded film as heat and pressure were applied. This device is also known as an impulse sealer and was used to assess the sealability of wet films in the laboratory. This device provided a good guide as to whether or not an experimental film would form a seal. The fusion of the two films was then observed and rated as a weak seal or a good seal. The molten mass was subsequently charged into a heated, preferably electrically heated holding tank and maintained in its molten state until needed for encapsulation, if the formulation was to be used for encapsulation. Normal rotary die pressures for gelatin films range from 200-300 lbs. (91-136 kg). It was determined from this work that sealing pressure reductions of greater than 50% (34-68 kg) could be realized and still produce a good seal.
The following formulations were prepared as discussed above.
Formulation 1
Wet Film Percent
Dry Film* Percent
Ingredient
by Weight
by Weight
PURE-COTE ® B790
15.0
33.94
VISCARIN ® SD389**
8.0
15.38
Glycerin USP (plasticizer)
20.0
45.25
Sodium phosphate di basic
1.0
2.26
(buffer)
Preservative (parabens)
0.20
0.45
Water USP
55.8
Dextrose
2.71
Formulation 2
Wet Film Percent
Dry Film* Percent
Ingredient
by Weight
by weight
PURE-COTE ® B790
15.0
34.32
VISCARIN ® SD389**
10.0
19.45
Glycerin USP (plasticizer)
17.5
40.05
Sodium phosphate di basic
1.0
2.29
(buffer)
Preservative (parabens)
0.20
0.46
Water USP
56.3
Dextrose
3.43
Formulation 3
Wet Film Percent
Dry Film* Percent
Ingredient
by weight
by weight
PURE-COTE ®
22.0
37.29
VISCARIN ® SD389**
10.0
14.41
Glycerin USP
25.8
43.73
Sodium phosphate di basic
1.0
1.69
Preservative
0.20
0.34
Water USP
41.0
Dextrose
2.54
Formulation 4
Wet Film Percent
Dry Film Percent
Ingredient
by weight
by weight
PURE-COTE ® B760
28.0
49.56
VISCARIN ® SD389**
11.0
16.55
Glycerin USP
15.8
27.96
Sodium phosphate di basic
1.5
2.65
Preservative
0.20
0.35
Water USP
43.5
Dextrose
2.92
Formulation 5
Wet Film Percent
Ingredient
by weight
PURE-COTE B790 ®
27
Genuvisco TPM-1 ®
10
Glycerin USP
20
Water USP
43
Formulation 6
Wet Film Percent
Ingredient
by weight
LYCATAB
27.3
pregelatinized starch
(Roquette)
VISCARIN ® SD389
10.0
Glycerin USP
15.0
Sodium phosphate di
1.0
basic
Preservative
0.20
Water USP
46.5
Formulation 7
Native Potato Starch
Wet Film Percent
Ingredient
by weight
Potato Starch Supra
15.8
Bacter (Roquette)
Iota-carrageenan
8.0
Glycerin USP
15.0
Sodium phosphate di
1.0
basic
Preservative
0.20
Water USP
60.0
Formulation 8
Wet Film Percent
Dry Film Percent
Ingredient
by weight
by weight
PURE-COTE ® B790
23.5
41.96
Iota-carrageenan XPU-HGI
8.5
15.18
(SKW) - (not standardized)
Glycerin USP
23.0
41.07
Sodium phosphate di basic
1.0
1.79
Water
44.0
Formulation 9
Kappa only - no iota
Ingredient
Percent by weight
PURE-COTE ®
20.0
Kappa-carrageenan
6.0
Xanthan gum
2.0
Glycerin USP
20.0
Sodium phosphate di
1.0
basic
Preservative
0.20
Water USP
50.8
Formulation 10
Wet Film
Dry Film
Ingredient
Percent by weight
Percent by weight
PURE-COTE ® B760
23.0
40.03
VISCARIN ® SD389**
10.45
15.46
Glycerin USP
23.0
40.03
Sodium phosphate di basic
1.0
1.74
Water USP
42.55
Dextrose
2.73
*Dry Film Values Calculated
**Standardized with 15% by weight dextrose
Note: In the dry film calculations, the dextrose content, from the iota carrageenan is set out separately.
Formulations 1, 3, 4, 6, 8 and 10 all produced excellent films that displayed excellent elasticity and sealing features. Formulation 2 produced a seal, but of a weak character compared to Formulations 1, 3 and 4. This could be the result of the modified starch to iota-carrageenan ratio of 1.5:1, whereas Formulations 3 and 4 had starch to carrageenan weight ratios in excess of 2.0:1. Formulation 5 yielded a good film, but the sealing characteristics were poorer than Formulations 3 and 4; this could be due to the high, 2.7:1, starch to carrageenan ratio. Formulation 7, the only unmodified starch that was found to work with iota-carrageenan was found to cast an acceptable film that evidenced good sealing properties. In contrast, Formulation 9, kappa carrageenan only—no iota, produced a brittle film that could not be sealed. This experiment evidences that kappa carrageenan is not a substitute for iota in the present invention.
EXAMPLE 2
Rotary Die Process
A standard rotary die machine (see The Theory and Practice of Industrial Pharmacy , Lachman, Lieberman and Kanig, Editors, 3 rd Edition, published by Lea & Febiger, was used to attempt the manufacture of filled capsules using Formulations 1-4, 6, 8 and 10. The fill material was provided to the hopper connected to the rotary die encapsulation machine. The hopper was heated and jacketed. Ribbons of casting material were formed in any of a variety of conventional methods, including extrusion or gravity feed of the liquid Formulations 1-4, 6, 8 and 10 onto a revolving casting drum. The formulations were provided to the drum generally at a temperature 2-5° C. above the melting point of the formulation. This temperature varies according to each specific formulation. Encapsulation of the fill material between two ribbons of the film was carried out according to conventional procedures.
Capsules prepared according to conventional rotary die procedures using Formulations 1, 3, 4 and 10, as set forth in this example, produced durable capsules that, upon drying, are similar in appearance to traditional softgels manufactured from mammalian gelatin.
EXAMPLE 3
Evaluation of Capsule Properties
Capsules produced according to Examples 1 and 2 above were tested for disintegration and resistance to accelerated storage conditions. Samples of dried capsules were tested using a standard USP disintegration apparatus fitted with guided disks. The test medium was 0.1 M HCl maintained at 37° C. Capsules ruptured within 3 minutes and the shell disintegrated within 15 minutes. These results are comparable to those obtained using a conventional soft mammalian gelatin capsule.
Additional samples were stored in open containers for 3 months at 40° C./75% Relative Humidity (“RH”), which is a standard condition used to accelerate stability evaluation of pharmaceutical dosage forms. A mammalian gelatin based softgel filled with mineral oil was also evaluated using the same conditions as a control. The modified starch/iota-carrageenan capsules remained structurally intact and exhibited only softening of the shell. In contrast, the mammalian based soft capsules had fused together and lost much of their structural integrity. Thus, the capsules made according to the invention exhibited superior resistance to humidity and temperature compared to conventional mammalian gelatin-based soft capsules.
EXAMPLE 4
Comparative Analysis
The following is a comparison of capsule shell formulation characteristics and associated rotary die parameters for conventional mammalian gelatin-based materials, a composition wherein the film was formed solely from carrageenan, and a modified starch/iota-carrageenan compositions according to the present invention. The only carrageenan composition was made essentially according to the description set forth in published International Application WO 97/07347, except that 17% carrageenan is used instead of 9% as described in the International Application. Table III sets forth the melting point of each composition in addition to processing conditions specific to each composition for use in the rotary die process.
TABLE III
INVENTION
CONTROL
Starch/
CONTROL
Gelatin
Carrageenan
Carrageenan
Formulation
30-45% gelatin; 10-
15-20% starch;
17% iota-
30% plasticizer;
8-10% iota-
carrageenan
water: q.s
carrageenan
Typical Melt
50-55° C.
80-85° C.
95-98%
Temperature
Operational
60-65° C.
About 90-95° C.
98-100° C.
Casting
Fusion
40-42° C.
53-75° C.
98-100° C.
Temperature for
sealing (Wedge
Temperature)
Pressure
100-300 psi
50-200 psi
Not
determined*
Typical Ribbon
0.28-0.040
0.020-0.025
Not
thickness
determined*
(inches)
Machine speed
2 to 3 rpm
2 to 6 rpm
Not
(optimum)
determined*
*The sealing (wedge) temperature was adjusted to the temperature at which the material fuses, 98-100° C., which is also the melting temperature. No fusion takes place at lower temperatures. Sealing and production of capsules was attempted, but the ribbon melted at the wedge. No capsules were formed.
This Example supports the conclusion that the starch/carrageenan compositions of the present invention possess properties similar to mammalian gelatin and therefore allow for their satisfactory use in the rotary die process. In contrast, the film forming composition taught in WO 97/07347 is not acceptable for forming soft capsules.
Films derived from compositions containing carrageenan as the only film forming material do not possess the desired properties of gelatin films and are therefore unsuitable for use in the rotary die process.
EXAMPLE 5
The following Formulations were prepared as set forth in Example 1, except that they were prepared on a 500 gm scale. The prepared formulations, as set forth in Table IV, were cast onto a glass plate using a draw bar set between 0.10 and 0.127 cm in height (0.040 to 0.050 inches) to form ribbons as described in Example 1. The ribbons of film were evaluated wet and then allowed to set/dry overnight and then revaluated. Ribbon strength, elasticity, clarity, texture and thermal sealing were measured. All values are weight % unless noted otherwise.
TABLE IV
Weight Percent Wet Film
Component
#11
#12
#13
#14
#15
#16
#17
#18
#19
#20
#21
#22
#23
#24
#25
#26
#27
1 Kappa
5.65
5.65
10.0
10.0
5.0
2.5
1.0
10.0
8.0
10.0
10.0
10.0
carrageenan
1 Lambda
5.65
carrageenan
1 Iota-
5.65
5.0
7.5
9.0
carrageenan
2 Pure
15.0
22.0
27.3
27.3
27.3
13.55
20.0
20.0
20.0
23.0
27.3
20.0
15.0
Cote ™
B760
Water
80.2
80.2
56.3
41.0
46.5
46.5
46.5
45.0
45.0
48.3
48.3
42.8
68.8
46.5
74.5
50.0
55.0
Glycerin
8.3
8.3
17.5
25.8
15.0
15.0
15.0
30.0
25.8
20.0
20.0
22.0
20.0
15.0
20.0
20.0
20.0
Preservative
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
Na 2 HPO 4
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
Locust Bean
0.25
0.5
1.0
Gum
Xanthan
0.5
Gum
3 XPU-APK
10.0
10.0
Kappa
carrageenan
3 XPU-CMI
5.5
10.0
10.0
Iota/Kappa
blend
1 Supplied by FMC Corporation of Princeton, New Jersey
2 Hydroxypropylated maize starch
3 Supplied by SKW Biosystems
The formulations containing kappa carrageenan, F11 to F23, all produced a brittle and weak film irrespective of the level of the modified starch (Pure Cote B790). Even the inclusion of lambda carrageenan (F11) or iota-carrageenan (F12, F15-F17) to the kappa did not produce a useable film. Even F17 with 1% kappa, 9% iota and 27.3% modified corn starch (Pure Cote B790) produced a non-brittle film that only formed a weak seal. Thus, the presence of even low levels of kappa carrageenan is detrimental to the production of a useable film.
EXAMPLE 6
Using the procedure set forth in Example 5, additional formulations were prepared and evaluated. The formulations are set forth in Table V.
TABLE V
Component
#28
#29
#30
#31
1 Lambda
10.0
carrageenan
1 Iota-carrageenan
10.0
LC-5 standardized
with sacrose
Pure Cote ™ B790
15.0
27.3
27.3
2 TPH-1
10.0
non-standardized iota
3 XPU-HG1 iota
10.0
Water
56.3
46.5
46.5
68.8
Glycerin
17.5
15.0
20.0
20.0
Na 2 HPO 4
1.0
1.0
1.0
1.0
Preservative
0.2
0.2
0.2
0.2
1 Supplied by FMC Corp.
2 Supplied by Hercules Corp.
3 Supplied by SKW Biosystems
F28 (lambda carrageenan plus modified starch) produced a very weak film that did not seal. In contrast F29 and F30 (iota-carrageenan plus modified starch) produced very strong films that provided excellent seals. F31 (iota only) produced a strong film, but would not seal.
EXAMPLE 7
Using the procedure set forth in Examples 1 and 2, the following formulations were prepared cast onto a rotary encapsulation machine and formed into soft capsules filled with vitamin E.
TABLE VI
#32
#33
Component
Wet film
Dry film
Wet film
Dry film
Viscarin SD-389
10.25
14.97
0
0
Standardized iota
Pure Cote B760
25.75
44.25
24.0
41.96
Glycerin
21.0
36.08
22.5
39.34
Sodium phosphate
1.0
1.72
1.0
1.75
buffer
Parabens
0.2
0.34
0.2
0.35
Water
41.8
42.8
XPU HGI
2.64
9.5
16.61
F32 and F33 were found to be easily processed on the rotary die encapsulation machine. These formulations represent the inventors best mode and produced capsules with very few defects. The capsules were then tested in a simulated gastric fluid and were found to dissolve or disintegrate in about five (5) minutes, which is about the time for commercially available mammalian gelatin capsules.
EXAMPLE 8
In this experiment, hydroxypropylated tapioca starch was used in combination with iota-carrageenan to produce a soft capsule. The tapioca formulation #34, and a comparative maize formulation are set forth in Table VII.
TABLE VII
Weight % In Wet Composition
Component
#34
#35
Iota-carrageenan
10.25
10.25
(Viscarin SD389)
Hydroxypropylated tapioca
25.75
0
starch
Glycerin
21.40
21.40
Disodium phosphate
41.60
41.60
Water
1.0
1.0
Hydroxypropylated maize
0
25.75
starch
Soft capsules were manufactured successfully using a pilot scale encapsulation machine using F34 and F35. Yield is a measure of process effectiveness. It is expressed as the percentage of capsules that did not leak after drying, out of the number of capsules produced. The yield, using the hydroxypropylated maize starch, was slightly better than the modified tapioca starch. Formulation #35 has been used to produce over 100,000 soft capsules filled with vitamin E. The yield for this production run was found to be 99.1%, which is considered excellent.
EXAMPLE 9
Comparative
The formulation set forth in Table VIII investigates the use of kappa carrageenan as the sole elasticizing agent, as it is less expensive than iota-carrageenan.
TABLE VIII
Weight % in Wet Composition
Component
#34
Kappa carrageenan
8.0
Locust Bean Gum
0.5
Xanthan Gum
0.25
Hydroxypropylated maize starch
18.00
Pure Cote B790
Glycerin
30.2
Disodium phosphate
1.0
Water
42.05
Formulation #34 was placed on a pilot scale rotary die encapsulation machine and was not successful in producing any intact soft capsules. The formulation would form films, but due to poor mechanical strength, low elasticity coefficient and inability to form seals, no soft capsules could be produced.
Industrial Applicability
The economic manufacture of soft capsules requires that the ribbons used to form the gels possess certain specific properties. While mammalian gelatin has remained the gelling agent of choice, there are numerous shortcomings that the pharmaceutical industry would like to overcome with new, non-gelatin soft capsules.
The present invention, which is founded in a discovery regarding the synergistic activity between a specific form of carrageenan and certain modified starches, will provide to the pharmaceutical industry an alternative to mammalian gelatin. It was through diligent experimentation and scientific observation that the inventive compositions were realized.
In the foregoing, there has been provided a detailed description of preferred embodiments of the present invention for the purpose of illustration and not limitation. It is to be understood that all other modifications, ramifications and equivalents obvious to those having skill in the art based on this disclosure are intended to be within the scope of the invention as claimed. | Disclosed herein are composition comprising a modified starch and a carrageenan, especially iota-carrageenan, where the compositions are suitable for use in manufacturing soft capsules. | 0 |
TECHNICAL FIELD
[0001] The present invention relates to lighting control networks, and more particularly, to an improved communication port control module (“CPCM”) that acts as a serial interface to a network control computer for a lighting system. The present invention also relates to a system that offloads much of the processing normally required of a microprocessor at the lighting device being controlled, instead performing such processing in hardware contained in an interface device interposed between the lighting device being controlled and the control computer controlling said lighting device.
BACKGROUND OF THE INVENTION
[0002] Centralized lighting control systems are known in the art. Typically, the central computer controls the lighting system throughout a building or other facility, such as is defined by the DALI standard, a well-known lighting control standard. The lighting device being controlled interfaces to the central computer through a serial interface. A microprocessor at the lighting device usually performs parallel to serial conversion of incoming commands and data, error detection, and arbitration control between incoming and outgoing data and commands.
[0003] [0003]FIG. 1 shows typical prior art interface into a DALI control computer. The control computer 107 receives and transmits various data and commands serially over lines 103 and 104 as shown. A microprocessor 101 is employed at the lighting device to receive and process the commands and to control other elements of the lighting device over parallel bus 102 . Functions executed by microprocessor 101 include error detection and correction, parallel to serial conversion, and edge detection, as required by the DALI standard. Control of arbitration of communications into and out of the lighting device is also implemented within microprocessor 101 .
[0004] One problem with prior art systems such as that of FIG. 1 is that for cost reasons, microprocessor 101 is typically a basic low end capability processor such as an 8051 . The tasks required to be performed by microprocessor 101 results in significant loading on the processor's limited capabilities, and decreased performance. The foregoing is true particularly with respect to error detection and correction algorithms, where significant mathematical processing may be required.
[0005] In view of the foregoing, there exists a need in the art for an improved technique of interfacing with a central lighting control computer that controls one or more lighting devices using a standard set of commands and a predetermined protocol.
[0006] There also exists a need in the art for an improved technique of minimizing the processing load presented to the basic capability microprocessors typically employed by a DALI compliant lighting device being controlled by a control computer.
SUMMARY OF THE INVENTION
[0007] The above and other problems of the prior art are overcome in accordance with the present invention, which relates to an improved method and apparatus for interfacing a central lighting control computer to a lighting device. In accordance with the invention, a separate hardware device is interposed between the microprocessor located at the lighting device, and the control computer controlling the device.
[0008] The separate device is implemented in hardware to perform error detection, noise filtering, and optionally other functions previously performed by the microprocessor, such as parallel to serial conversion, serial to parallel conversion, edge detection, arbitration control, and possibly others. The hardware device interposed between the lighting device and the control computer offloads much of the functionality from the microprocessor, providing faster operating speeds and permitting better use of less expensive microprocessors typically employed at such lighting devices. In a preferred embodiment, the parallel to serial conversion is implemented as a preshift register and a shift register, and the error detection is implemented in common hardware with parallel to serial conversion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] [0009]FIG. 1 depicts a prior art lighting device microprocessor interfacing to a control computer;
[0010] [0010]FIG. 2 depicts a block diagram of an exemplary embodiment of the present invention, showing a hardware device interposed between the lighting device microprocessor and the network control computer; and
[0011] [0011]FIG. 3 depicts a more detailed block diagram of an exemplary embodiment of a hardware device of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0012] [0012]FIG. 2 depicts a block diagram of a hardware device CPCM 201 connected to a microprocessor 202 . Not shown in FIG. 2 is the lighting device controlled by microprocessor 202 . FIG. 2 includes a plurality of signals interfacing between CPCM 201 and microprocessor 202 .
[0013] A decoder 219 and address lines 216 serve to permit communications to and from CPCM 201 over a parallel computer bus as is known in the art. More specifically, CPCM 201 is at a particular address known to microprocessor 202 and that address is asserted on the bus when communications with CPCM 201 are desired by the microprocessor. Several of the address lines are used for a chip select signal 218 and the remainder utilized as signal 216 in order to select the appropriate location within CPCM 201 . Typically the most significant bits are utilized to decode as a chip select signal, and any remaining bits of the address are used to identify a location within the CPCM.
[0014] Signals 214 and 215 represent the data bus exchanging data between microprocessor 202 and CPCM 201 . Also in a conventional fashion, read and write signals 213 and 212 , respectively, are utilized, and an interrupt signal 211 advises microprocessor 202 when the CPCM 201 wishes to transfer data. A reset signal and clock signal 221 are also used conventionally. Note that preferably clock signal 221 is the same clock signal utilized for both CPCM 201 and microprocessor 202 in order to synchronize the system.
[0015] Serial interfaces 230 and 231 , to and from the control computer respectively, serve to interface the lighting device to the control computer so that the control computer may be configured as in the prior art. More particularly, the control computer need not have any knowledge that the CPCM hardware device 201 has been interposed between the control computer and the lighting device microprocessor 202 . Thus, the standard commands that control intensity, timing, etc., as set forth in the exemplary DALI standard described below herein, may be used. Such an arrangement permits the control computer to operate with the same software that it uses in conventional systems, not being concerned with the fact that a separate hardware device has been placed between the light being controlled and the control computer.
[0016] Preferably, the arrangement of FIG. 2 implements the exemplary DALI standard interface, which provides for the exchange of commands and data on lines 230 and 231 in a serial fashion. The DALI interface is widely published and available and those who are skilled in the art are typically familiar with the standard.
[0017] [0017]FIG. 3 represents a more detailed hardware diagram to implement the functions of error detection, serial to parallel conversion, edge detection and arbitration control for signals entering and exiting from the CPCM 201 . The host interface 310 transmits and receives parallel data over a PC conventionally.
[0018] In operation, data is received serially from the control computer and entered into a preshift register 301 . The error detection noise filtering and parallel to serial conversion is implemented in conjunction with the pre-shift and shift registers 301 and 302 , respectively. The error detection is a hardware circuit that detects particular bit patterns in the incoming data, which violate rules of parity or other error detection techniques.
[0019] An edge detection circuit 304 helps to further detect certain errors. More specifically, in the exemplary embodiment utilizing the DALI Standard, each bit must have an edge since the data is encoded in a manner that a change of state takes place within each bit. Logical ones have a state transition in a first direction, and logical zeroes in a second direction. The failure to detect such an edge represents an error which should be detected by edge detect circuit 304 . A straight forward arrangement of logic circuitry can detect the absence of such an edge, or latch its presence, to ascertain whether an error has occurred.
[0020] Additionally, the start of data is noted in the DALI Standard by a falling edge which is also detected by an edge detect circuit 304 , and conveyed to an arbitration control logic 306 . The arbitration control logic 306 ensures that data being held in locations 321 through 327 is not overwritten by new data before it is read out by the microprocessor. Conventional logic may be used to implement such a system wherein no new data is rewritten into any register 321 through 327 until the previous data is read out. A clock divider 340 serves to operate the CPCM at a rate sufficient to allow for the parallel to serial conversion.
[0021] Registers 321 through 327 are special function registers. Register 321 is the clocking register and is used to set or adjust the data rate in order to provide for signals being read and written to and from the microprocessor and the control computer at different rates. More specifically, the parallel to serial conversion requires that the serial interface operate at many times the speed of the parallel interface in order to keep up with data being sent in parallel.
[0022] Register 322 - 324 stores DALI known commands such as address signals, standard data and other DALI commands. These commands and data would normally be stored in the microprocessor memory in prior systems, where no hardware CPCM is interposed between the control computer and the lighting device. The MOP register 325 is used to store a value indicative of manual dimming, in the event the manual dimming override is utilized to control the lighting device manually rather than via the control computer. Diagnostic computer 327 stores error codes and operating states in order to diagnose problems in a conventional fashion.
[0023] In operation, serial data arrives by via line 351 and is shifted into preshift register 301 . The data is not shifted into register 302 until it has been verified as correct via the error detection and P/S control block 303 . Since the preshift register 301 is typically smaller that the shift register 302 , the data from the preshift register 301 will be shifted to the shift register 302 plural times for each readout from the shift register 302 . The error detection is performed in the smaller preshift register 301 , and the data is only shifted to shift register 302 after passing the error detection testing in preshift register 301 . Hardware device 303 is an error detection system which will substantially immediately detect signaling errors should such an error occur. The generation of such an error will be signaled back to the control computer, and the DALI protocol provides for the retransmission of such erroneously transmitted signals.
[0024] Additionally, if edge detector 304 detects a violation of the DALI protocol, such an error will also be conveyed to the microprocessor. In the exemplary DALI protocol, for example, a falling edge followed by a predetermined length “low” signal is required to being transmission of data, and an edge is required during each bit time. A violation of this rule indicates an error.
[0025] Note from interface 310 that only parallel data is transmitted to and from the microprocessor interface, and that such parallel data has already been checked for errors, and protocol violations, and is ready for decoding. Accordingly, the microprocessor at the lighting device may perform nothing more than the decoding of DALI commands and data. Such a system provides that the software in the microprocessor only perform a table lookup and basic control functions and does not require any error correction algorithms or arbitration control. This greatly increases speed.
[0026] While the above describes the preferred embodiment of the invention, various other modifications and additions will be apparent to those of skill in the art. Such modifications and additions are intended by the following claims. | An improved technique of interfacing a computer lighting device to a control computer is disclosed, wherein a hardware device is interposed between the control computer and the lighting device. The hardware device handles certain functions in hardware, thereby permitting the microprocessor at the lighting device to incur substantially less processing load. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the recovery of vanadium from fly ash formed in boilers fired by heavy oils or by alternate fuel heavy oil/coal systems, which ashes contain relatively high amounts of vanadium oxides, e.g., 5 to 25% by weight, as compared to ores which may contain only about 2% by weight of vanadium pentoxide. Such ashes provide a very competitive source of valuable high vanadium concentrates, alloys and vanadium metal.
The present invention is also concerned with the removal of vanadium oxides from such ashes so that the residue formed is safe for disposal in refuse sites and landfill areas. Vanadium oxides such as vanadium pentoxide are both water-soluble and toxic to humans. Therefore vanadium-containing ashes cannot be deposited in dump sites or landfill areas because of the likelihood of the vanadium oxide being dissolved from the ashes and leaching into groundwater which may contaminate sources of drinking water.
2. Description of the Prior Art
Numerous processes and apparatuses are known for the recovery of vanadium from ores and from dust waste products produced by furnaces. Reference is made to U.S. Pat. Nos. 1,094,114; 1,359,473 and 1,521,607 for their disclosures of processes for recovering or extracting vanadium from vanadium-containing ores. Reference is also made to U.S. Pat. Nos. 4,731,112; 5,127,943 and 5,186,742 for their disclosure of processes for treating ashes or dust waste to render them safe for disposal. Reference is also made to U.S. Pat. No. 4,731,112 for its disclosure of a process for producing iron alloys from iron fines containing iron, carbon and metal oxides including vanadium oxide, in which the iron fines and slag-formers are added to a melting furnace and the oxides are reduced to form a high ferroalloy melt.
SUMMARY OF THE INVENTION
The present invention relates to a novel smelting process and furnace for the economical recovery of vanadium, in the form of ferrovanadium alloy, from oil ashes and/or coal ashes while producing non-hazardous slag for safe and inexpensive disposal in landfill areas.
In essence, the present process involves the steps of (a) providing a mixture containing waste ashes and a carbon source, such as coal, optionally with a binding material, and such as cement; (b) optionally pelletizing the mixture; (c) feeding the mixture, together with steel scrap, through a vertical preheater shaft furnace into a slag pool; (d) impinging fuel gas jets upon the surface of the slag layer to heat and circulate the slag and to burn carbon present in the ash and any carbon added to the ash mixture, generating additional heat, to produce a layer of molten ferrovanadium alloy at the bottom of the molten pool, covered by a layer of molten slag, (e) withdrawing the valuable molten ferrovanadium alloy for use, for example, as a component of hard tool steel for the production of tools, and (f) withdrawing the molten slag for safe disposal in landfill areas, since it is essentially free of vanadium compounds and of significantly smaller volume and lower leachability than the starting ash materials.
Alternatively, oil or coal ash collected from a power station boiler and/or from the ash storage can be used as a feed without pelletizing. In this even, water content in the ash may be preliminarilly-reduced using the furnace exhaust gas or a separate device for drying. Ash with relatively high residual water content is "sticky" and can be top-charged into the furnace. Completely dry ash preferably is charged by a feeder terminating under the surface of the top slage layer.
THE DRAWING
FIG. 1 of the drawing is a flow sheet illustrating the various components and stations of the system and smelting furnace of the present invention.
DETAILED DESCRIPTION
The present process is a smelting reduction process for reducing the metal oxides present in oil ash and/or coal ash, particularly vanadium oxides present in relatively large amounts in Venezuelan oils, in a smelting furnace fired by natural gas-oxygen, or natural gas --O 2 -- enriched air, while masking the molten metal layer with a thick surface layer of slag to prevent re-oxidation of the metals.
The present smelting furnace incorporates top burners in the freeboard area which direct high velocity flames against the upper surface of the slag layer to produce circulation of the slag layer, high heat transfer thereto and combustion of the carbon present in the pellets to provide a second source of heat and a reducing atmosphere for the metal oxides such as vanadium pentoxide and for the iron scraps added with the pellets or molten iron present in the pool. The molten metals descend through the slag layer and deposit in a molten pool at the bottom of the smelting chamber.
Referring to FIG. 1, the smelting furnace 10 thereof comprises a refractory base 11 having a smelting chamber comprising a lower reservoir section 12 and an upper heating space of freeboard 13 covered by a roof portion 14 having a central opening 15 communicating with the vertical shaft 16 of the furnace. The vertical shaft 16 functions as a preheater and feed inlet conduit for the mix 17 pellets and optional steel scrap introduced through the feeder 18, and as an outlet conduit 19 for hot process off-gases which provide the pellet-preheating energy as they escape up the shaft 16, against the flow of the mixed particles 17, and are withdrawn through vent conduit 19. The off-gases are sprayed with cooling water sprayers 20 at a quench station 21 and particulates are separated in a hot baghouse 22 and may be recirculated to the ash supply for the pelletizer 23 while the gases are released to the stack 32.
The pelletizer 23 is automatically supplied with predetermined proportions of ash, coal or carbon and cement to form pellets which are automatically fed at the desired rate into the feeder 18. Some fine steel scrap or iron ore may also be added to the feeder 18 to produce the desired ferrovanadium composition. The particles 17, comprising the pellets and iron scrap, if any, are gravity fed through the vertical preheating shaft 16 where they are heated by the hot off-gases as they drop through the freeboard space of the smelting chamber into the thick slag layer 24 overlying the molten metal layer 25 in the reservoir section 12 of the furnace 10.
The slag layer 24 comprises conventional fluxing agents such as calcium aluminate, lime, limestone, and silicon dioxide which are added to the smelting chamber at start-up, and thereafter as needed. Also additional slag is formed by glass-forming components of the charge, i.e., the ash and the coal. The smelting chamber preferably is cylindrical and the roof 14 thereof has a plurality of openings 26 extending therethrough, each of which supports a gas burner 27 for extension at an angle into the freeboard space 13 to exert the force of the burning gas jet against the upper surface of the molten slag layer 24, for purposes of superheating the slag layer 24 and imparting thereto a horizontal or swirling flow velocity or circulation, as assisted by the cylindrical shape of the smelting chamber. A plurality of uniformly spaced openings 26 and gas burners 27 preferably are present, each gas jet flow preferably being near sonic gas flow conditions.
Each gas burner 27 has a caloric gas inlet 28 connected to a source of fuel such as oil, natural gas or another caloric gas, and an oxidizer gas inlet 29 connected to a source of an oxidizer gas such as air and oxygen. The gas burner(s) 27 include means for mixing the fuel and gases to form a flammable mixture which is ignited as a burning gas jet emitted from burner 27 at a relatively high force.
Combustion products including mostly water vapors and carbon dioxide, carrying a significant amount of sensible heat, are released upwardly into the vertical shaft 16 to preheat the solid mix 17 of iron scrap particles and ash pellets.
The vertical shaft 16 and/or the side outlet conduit 19 can communicate with the oxygen supply to the burners, or with other heat or steam-recovery systems which utilize the normally-lost heat and/or steam and which thereby reduce the temperature to the stack and reduce the amount of lost energy. For example, the shaft 16 or conduit 19 can comprise a water jacket through which cold water is circulated to extract heat and produce steam for related or unrelated power-generation purposes.
The present process is a high temperature process which uses two sources of energy to heat the ash coal/cement pellets. The main source of energy is the energy delivered by the top-fired burners operating with natural gas or oil and oxidizer gas. The secondary source of energy is derived from the combustion or oxidation of carbon present in the ash component and present in the coal component of the pellets. The oxidized carbon produces hot combustion gases which preheat the particles 17 after heating the slag layer by carbon monoxide bubbles generated in the carbon oxidation process.
Metal oxides, including vanadium pentoxide and iron oxides, are reduced to molten metal by the carbon in the slag layer 24 and by other optional stronger reducing agents such as aluminum, if added. The molten metal gravitates to the molten metal layer 25 and the overlying slag layer 24 shields the layer 25 against oxidation by the oxidizing atmosphere of the freeboard space 13 of the furnace and by the burner jets.
As illustrated, the furnace 10, or the refractory base 11 thereof is supported to be tipped so as to drain or tap molten metal 25, through metal spout 30 for use, and/or to drain molten slag 24, through slag spout 31, for safe disposal in a landfill or other area since the heavy metal compounds such as vanadium pentoxide have been alloyed into the molten ferrovanadium metal.
The burners 27 of FIG. 1 can be supported for adjustment between different extension positions and will all be used in the same retracted or extended positions during operation. The burners 27 receive and mix natural gas or other caloric gas, through inlet 28, and an oxidizer gas such as oxygen, through inlet 29, under sufficient pressure to emit burning gas jets which exit at or impinge upon and penetrate and agitate the surface of the slag layer 24, outwardly or tangentially of the center thereof, and create a continuous movement or circulation of the slag layer at a predetermined slag flow velocity. This causes the slag layer to circulate in a vertically-inclined direction, due to the inclined downward force of the gas jets, so that the slag layer 24 is efficiently superheated by continuous movement through the areas of the melting chamber which are most directly affected by the plurality of gas jets 27. The thickness of the slag layer 24 varies depending upon the size of the furnace. Generally the slag layer is maintained sufficiently thick to prevent exposure of the metal layer 25 under the force of the gas jets and sufficiently thin to provide good circulation and more uniform temperature. A slag layer thickness of about three to five inches produces excellent results.
Each jet serves or affects an area of the slag layer 24 having a diameter about equal to the depth of the layer. Some of the generated gases react with an/or remain trapped within the slag layer, such as some of the nitrogen-oxygen pollutants, thereby reducing the discharge of pollutants to the baghouse 22 and to the stack 32. Some of the pollutants are also trapped and/or deposited on the solid pellets 17 in the vertical shaft 16 and are carried back into the furnace with the pellets 17 for re-entry into the slag layer 24. Some of the pollutants are removed from the furnace within the slag layer portions which are discharged through the slag drain spout 31. Formation of nitrogen oxides is also greatly reduced due to the low nitrogen content of the furnace gas.
In an optional efficient system of the present invention, combustion products including water vapors and carbon dioxide carrying significant amounts of sensible heat are extracted from the furnace through roof outlet 15 and can be conveyed by shaft 16 to a steam generation unit where the steam is used to power a compressor turbine to power an oxygen-producing plant and to circulate the oxygen, and air admitted thereto, through a preheater in which the oxidizer mixture is heated to about 600° C., and conveyed to the oxygen inlet 29 of the burners 27.
The furnace roof 14 preferably includes a slag inlet conduit through which fresh slag composition is introduced to the furnace 10 to replace used slag which is withdrawn and/or to introduce slag chemicals which are consumed in the refining processes, such as desulphurization.
To demonstrate the feasibility of the present invention, four hundred and fifty pounds of mixed (oil and coal) wet ash containing 15 lbs (3.3%) of vanadium pentoxide, 12 lbs (2.7%) of iron oxide, and 75 lbs (17%) carbon (all by weight, wet basis) were charged in the preheated smelter (1000 lb. capacity, 21" chamber) having a few pounds of solidified bottom steel layer 25. One hundred pounds of Ca/Al flux and limestone were added. The charge was melted running three top burners 27 and 600 to 800 kBtu/hr power at fuel-lean conditions. Due to ash-carbon combustion, the combustion products in the freeboard 13 had about 25% CO content. After a surface temperature of about 2900° F. was reached, 30 pounds of aluminum scrap were added to ensure reduction of metals from the slag 24. The melt 25 was poured in a sand mold. After cooling, 25 pounds of compact solid metal were separated from 100 pounds of slag.
EDX/SEM and chemical analysis demonstrated the following composition of the extracted metal, probably, Al 3 Fe intermetallic compound: Vanadium content is 3.6% and iron content is 39%. The major slag components were aluminum, calcium, and silicon (originating from both ash and flux), and less than 0.5% (total) of vanadium and iron not extracted (reduced). Aluminum, silicon, and calcium originate from the scrap and flux.
The ferrovanadium alloy 25 and top slag 24 are tapped by tilting the smelter or, in a continuously-operating furnace, bottom tapped at opposite ends of a channel type furnace. Temperature of the process off-gas is moderated in the shaft by heat exchange with the pellets, and finally by a water quench at station 21. Carry-over particulates are separated in the hot baghouse 22 and recirculated into the pelletizer 23. Additional energy savings can be realized by extracting heat from the hot (granulated) slag, which constitutes up to 90 wt % of molten products, and by in-plant (e.g., power station) utilization of the sensible heat left in the process gas leaving the shaft. The process can be continuous, or time-staged by varying the stoichiometry and ash or pellet charging to optimize the melting rate and then the reduction rate.
While FIG. 1 of the present drawing illustrates a preferred embodiment in which the gas burner tuyeres are fixed or supported for retractable extension through openings 26 in the roof portion 14 of the furnace, the burners 27 can be supported for extension into the heating space 13 through openings in the cylindrical side wall of the furnace. The gas burners in the side wall and/or roof portion of the furnace wall preferably are supported for adjustable extension into the heating space 13 of the furnace so that they can be fixed in positions above the upper surface of the slag layer, and can accommodate metal pools 25 and slag layers 24 of different depths.
It will be apparent to those skilled in the art that the present furnace system enables full utilization of natural gas or other caloric fuels and mixtures thereof with oxygen or oxygen-enriched air for the melting of particles 17 which may include ferrous scrap metals such as steel, with recovery of ash fines from the off-gases and/or optional recovery of a substantial portion of the normally-lost heat and/or steam for purposes related to the economy of the system.
Substituting electric energy conventionally used in ferroalloy furnaces with the combination of two less expensive energy sources (natural gas and coal) substantially reduces the cost of ferrovanadium production. The energy savings can be further increased when sensible heat and latent heat of water vapors in the furnace exhaust are recovered and utilized for feed drying and preheating, and/or for power generating purposes either by hot gas recirculating into the main boiler of the power station or by means of an auxiliary turbogenerator.
It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims. | A novel smelting process and furnace for the economical recovery of vanadium, in the form of ferrovanadium alloy, from oil ashes and/or coal ashes while producing non-hazardous slag for safe and inexpensive disposal in landfill areas. A preferred embodiment of the present process involves the steps of (a) mixing the waste ashes with a contained or added carbon source, such as coal, and a binding material, such as cement; (b) pelletizing the mixture; (c) feeding the pellets, optionally together with steel scrap, through a vertical preheater shaft furnace into a slag pool; (d) impinging fuel gas jets upon the surface of the slag layer to heat and circulate the slag and to burn the carbon added to the pellets, generating additional heat, to produce a layer of molten ferrovanadium alloy at the bottom of the molten pool, covered by a protective layer of molten slag, (e) withdrawing the valuable molten ferrovanadium alloy for use, and (f) withdrawing the molten slag for safe disposal in landfill areas. | 8 |
TECHNICAL FIELD
The present invention relates to a transmission system comprising at least two end devices which are connected by a transmission medium for transmitting between them information signals at a symbol rate according to at least a symbol rate and at least a carrier frequency, which system comprises transmission medium analysis means for analyzing the transmission quality of said medium and to modems suitable for use in such a system.
BACKGROUND OF THE INVENTION
Current transmission tendencies are to utilize ever higher transmission rates. However, these rates are not always ensured, for the transmission mediums are subjected to disturbance degrading this transmission and often lower rates which are less sensitive to disturbance have to be selected.
Therefore, the problem occurs of adapting the transmission rate between two modems (a local modem and a remote modem) as a function of the quality of the line and throughput capacity of the modems. This is described in European Patent Application No. 0 643 507 filed Sep. 6, 1994. Although the known system gives entire satisfaction, it is no longer adapted to the new standards that are applied to the modems; one may recollect specifically V.34 standard of CCITT which proposes for certain rates multiple combinations of carrier frequencies and symbol rates.
SUMMARY OF THE INVENTION
For resolving these problems, a transmission system as described in the opening paragraph is characterized in that it comprises:
rate-defining means for producing a first series of information signals which define for each of the end devices a plurality of rates which are compatible with the transmission quality as a function of a symbol rate and a carrier frequency,
first selection means for selecting the combinations of baud rate and carrier frequency for which the value (dmax) produced by the rate-defining means is maximum,
first exchanging means between the two end devices for exchanging the combinations produced by the first selection means,
second selection means for selecting a baud rate of a certain combination pair from combination pairs formed by the local and exchanged combinations,
third selection means for selecting a first rate and a second rate based upon the first combination pair,
fourth selection means for determining a third rate (dcom) based upon the first and second rates.
These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments described hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 shows a transmission system according to the invention, and
FIG. 2 shows an operational block diagram of a system according to the invention.
DETAILED DESCRIPTION
The system shown in FIG. 1 is formed by two modems 1 and 2 which are connected to a telephone line 3. These modems enable two terminals 5 and 6 to exchange data. Within the scope of the described example, reference be made to said V.34 standard. According to this standard there are various symbol rates with the associated carrier frequencies which are given in the Table I hereinbelow.
TABLE I______________________________________symbol rate low frequency high freguency______________________________________2490 1600 18002743 1646 18292800 1680 18673000 1800 20003200 1829 19203429 1959 1959______________________________________
At various symbol rates there may be a plurality of transmission rates given in TABLE II hereinbelow.
TABLE II______________________________________rate SYMBOL Signaling rates↓ 2400 2743 2800 3000 3200 3429______________________________________ 2400 x 4800 x x x x x x 7200 x x x x x x 9600 x x x x x x12000 x x x x x x14400 x x x x x x16800 x x x x x x19200 x x x x x x21600 x x x x x x24000 x x x x x26400 x x x28800 x x32000 x______________________________________
The crosses in above Table indicate the symbol rates associated with the signaling rates.
There are thus various combinations which yield the same rate. One thus seeks to satisfy the following constraints:
the selected transmission rate must be maximum,
the selected transmission rate must belong to a rate fork imposed by the user,
the transmission rates are identical in the two directions of transmission,
the selected transmission rate must ensure operation with minimum errors.
The means for satisfying these constraints are formed by a process used by a processor 9 for the modem 2 and defined by the control codes of this processor, for example in a read-only memory 10. The modem may have a similar structure to that of modem 2.
Now reference will be made to FIG. 2 which shows the various functions of this process. A distinction is made between the calling modem (C) and the called modem (A).
FIRST STEP
For implementing the invention, the test sequence is used which, based upon the signal sequences L1 and L2 (see V.34 standard) allows a determination of the transfer function of the line that connects the modems 1 and 2 and the signal-to-noise ratios of this line. From this transfer function is determined for each combination of symbol rate/carrier frequency a maximum transmission rate that refers to the line. U.S. Pat. No. 4,633,411 provides all the precise information relating to the analysis of the transmission lines.
At the output of the boxes KC0 and KA0, for each modem that has received the signal sequences L1 and L2, there is a list of maximum transmission rates dmax C and dmax A , as a function of the baud rate (fb i ) and the high or low carrier frequency (fpi h or fpi l ), that is to say, for each of the modems:
______________________________________ dmax.sub.C (fb0, fp0.sub.1) dmax.sub.C (fb0, fp0.sub.h) dmax.sub.C (fb1, fp1.sub.1) dmax.sub.C (fb1, fp1.sub.h) . . . . . . dmax.sub.C (fbn, fpn.sub.h)and dmax.sub.A (fb0, fp0.sub.1) dmax.sub.A (fb0, fp0.sub.h) dmax.sub.A (fb1, fp1.sub.1) dmax.sub.A (fb1, fp1.sub.h) . . . . . . dmax.sub.A (fbn, fpn.sub.h)______________________________________
From this first list of rates are retained those rates whose carrier frequencies are associated to the highest rates by implementing the following method: ##EQU1## The index X represents C or A, depending on whether the calling or called modem is considered. This second list is obtained at the end of boxes KC1 and KA1.
a) Case of the calling modem
The calling modem is to process the information block INFO1c. Then, among the 109 bits of this block INFO1c represented by b0 to b108 and being based on the second list, the following insertions will be made: ##EQU2##
The modem also receives the 70 bits b'0 to b'69 of the block which is formed by information signals INFO1a processed by the called modem and which is transmitted by the latter. The bits b'34 . . . 36 of this block indicate the symbol rate fb, the transmission carrier frequency fpT given by bit b'25 is the receiving frequency fpR A of the called modem. A combination C to be defined hereinafter determines the receiving frequency fpR C of the calling modem and also two maximum rates dmax A →C and dmax C →A for the two directions of transmission.
b) Case of the Called Modem
The various information signals dmax C (fbi, fpi) transmitted in the block INFO1c from the calling modem are combined with those dmax A (fbi,fpi) processed by the called modem. The called modem seeks for each baud rate the minimum of the maximum rates in the two directions (box KA5):
dmax(fbi)=min {dmax C (fbi, fpi C ), dmax A (fbi, fpi A )}
Then, by the operation indicated in box KA6, the baud rate is determined which corresponds to the largest dmax(fbi), that is, dmax C →A. If there are various baud rates that give the same values dmax(fb i ), the highest baud rate is selected, that is, fb times this rate, and the combination C(fb,fpi A ,fpi C ) that produces the value fb for the retained value dmax.
However, there are two restrictions to this processing:
1. If, for all the baud rates, the maximum rate is the minimum rate that can be used for each symbol rate under consideration, the selected baud rate is the lowest with, preferably, the high frequency carrier,
2. If the user selects 2400 bits/s as his single transmission rate, the symbol rate is forced to be 2400 Hz with a high frequency carrier, whatever the result of the other tests.
The receiving carrier frequency fpR A of the called modem is the frequency fpi A of said combination C.
The transmitting carrier frequency fpT A is the frequency fpi C of said combination C.
The rate dmax A →C is given by dmax c (fb,fpi c ).
Block INFO1A is constructed in the following manner:
b'25=fpR A
b'30 . . . 33=dmax C →A
b'34 . . . 36=fb
b'37 . . . 39=dmax A →C
SECOND STEP (fourth phase of the synchronization process)
At the end of the second phase, each modem has the following information signals: ##STR1##
Each of these modems thus has the symbol rate, a suitable carrier and the maximum rate. The users of each of the modems can decide on the rates they wish to use. Let {Dutil C } be the set of rates the user of the calling modem wishes to use and {Dutil A } the set of rates the user of the called modem wishes to use. These rates are transmitted in blocks MP by the bits b"35 . . . 39 of this block formed by 188 bits. The rate dmax C →A is also transmitted by the bits b"20 . . . 23 and the rate dmax A →C by the bits b"24 . . . 27. If these rates dmax C →A and dmax A →C are lower than the minimum rate recommended by the user, the latter value is forced upon these rates: ##STR2## Index X represents A or C depending on whether the calling or called modem is considered. Based on these received blocks, the called and calling modems perform the same calculations.
First the maximum common rate d com is determined:
d.sub.com =min (dmax.sub.C→A,dmax.sub.A→C)!.
If d com is smaller than the minimum rate recommended by the user of the remote modem Y, the latter value is forced upon this rate:
if d.sub.com <min {Dutil.sub.Y }
then dcom=min {Dutil.sub.Y }
Index Y represents the remote modem (C or A).
Then the highest possible rate that can be used between the two modems is determined:
D=d.sub.com ∩{Dutil.sub.C }∩{Dutil.sub.A }
If this intersection is empty, the modems do not connect.
If D=2400 bits/s and this rate is not supported by the selected combination (baud rate/carrier frequency), the modems are resynchronized with forced parameters:
D=2400 bits/s
Baud rate=2400 Hz
Carrier frequency (high frequency)=1800 Hz. | A transmission system for transmission between end devices (1) and (2) is provided for transmitting information signals at a certain common bit rate. This bit rate depends on a symbol rate and a carrier frequency. Via a processing by a processor (9) which cooperates with an instruction memory (10), the largest possible bit rate is determined for exchanging information signals between end devices. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a division of prior U.S. application Ser. No. 13/195,022 filed Aug. 1, 2011, entitled “POLYMERIC POLYAMINES AND METHOD FOR PRODUCING THE SAME” and currently pending. The prior U.S. application is a division of prior U.S. application Ser. No. 12/140,507 filed Jun. 17, 2008, entitled “POLYMERIC POLYAMINES AND METHOD FOR STABILIZING SILVER NANOPARTICLE BY EMPLOYING THE SAME”, which has issued as U.S. Pat. No. 8,013,048 on Sep. 6, 2011. The prior U.S. applications claim priority of Taiwan Patent Application No. 096146929, filed on Dec. 7, 2007, the entirety of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to polymeric polyamines and a method for stabilizing Ag nanoparticles by employing the same. The produced Ag nanoparticles are in the form of silver slurry, silver gel or solid, and suitable for composite material or antimicrobial material. Fields of the present invention include electric industries, for example, conductive silver nanowires, parts and sensors, and biomedicine or medicinal industries. In addition, the Ag nanoparticles have both hydrophilic and hydrophobic properties and therefore can be dissolved in water and organic solvents, and are compatible with many kinds of polymers. Therefore, the product of the present invention is a good polymeric surfactant or dispersant suitable for dispersing nanoscale particles, for example, pigments and silver particles.
[0004] 2. Related Prior Arts
[0005] The application of Ag nanoparticles is one of the most important technologies in this century. The traditional methods for producing water solutions of Ag nanoparticles are primarily to reduce silver nitrate or other silver salts with organic surfactants, dispersants or stabilizers for stabilizing the Ag nanoparticles. To exhibit good effects in antimicrobial, pharmaceutical, biomedicine and electrical applications, the Ag particles have to keep in the nanoscale and large surface areas without aggregation. Therefore, it's very important to control size of the Ag particles in the nanoscale and maintain thermal stability thereof.
[0006] In processes for producing Ag nanoparticles, organic surfactants or stabilizers are an important operation factor. In addition, most silver slats, for example, silver nitrate, is more easily dissolved in water than organic solutions, and therefore the product is usually prepared in water solution. That is, the existing conditions will restrict applications of the Ag nanoparticles.
[0007] The above problems have been discussed in some reports. In J. Phys. Chem. B 1998, 102, 10663-10666, the Ag particles are prepared in water solution and stabilized with molecular chains of sodium polyacrylate or polyacrylamide. In Chem. Mater. 2005, 17, 4630-4635, thioalkylated poly(ethylene glycol) is used as a stabilizer for stabilizing Ag particles in water. In Langmuir 1999, 15, 948-951, 3-aminopropyltrimethoxysilane (APS) is used as a stabilizer and N,N-dimethylformamide is used to reduce silver ions in water. In J. Phys. Chem. B 1999, 103, 9533-9539, sodium citrate is used to prevent the Ag particles from aggregation or agglomeration which results in larger particle size, wider size distribution or multiple-peak distribution. In Langmuir 1996, 12, 3585-3589, some nonionic surfactants (polyethylene oxide or ethoxylated block) are used to stabilize Ag nanoparticles which are in the form of gel-type particles covered with molecular chains of the surfactant, the examples include poly-(10)-oxyethylene oleyl ether and Tween 80 (polyoxyethylene-(20)-sorbitan monooleate) (available from Sigma). In Langmuir 1997, 13, 1481-1485, NaBH 4 is used as a reducing agent, and the reaction equation is:
[0000] 2AgNO 3 +2NaBH 4 +6H 2 O→2Ag+2NaNO 3 +2H 3 BO 3 +7H 2
[0000] In this reaction, the stabilizers are cetyltrimethylammonium bromide (CTAB) as a cationic surfactant, sodium dodecyl sulfate (SDS) as an anionic surfactant and poly(oxyethylene)isooctylphenyl ether-TX-100 as a nonionic surfactant.
[0008] As described in the above, the traditional method for stabilizing Ag particles is to add surfactants or stabilizers. However, the solutions of such Ag particles have solid contents less than 10% and can not be in the form of silver slurry, or have a higher solid content with aggregation.
SUMMARY OF THE INVENTION
[0009] The object of the present invention is to provide a polymeric polyamine and a method for producing the same, wherein polymeric polyamine can be applied to producing Ag nanoparticles for stabilizing and dispersing.
[0010] Another object of the present invention is to provide a method for stabilizing Ag nanoparticles with polymeric polyamine, so that the produced silver slurry, silver gel or solid silver has a high solid content and good stability, even after processing treatment or preservation.
[0011] To achieve the above objects, polymeric polyamine of the present invention includes polyoxyalkylene-amine and a linker linking with an amino end thereof. The polyoxyalkylene-amine is preferably monoamine, diamine or triamine having a molecular weight about 200˜10,000, and the linker can be anhydride, carboxylic acid, epoxy, isocyanate or poly(styrene-co-maleic anhydride) copolymers (polystyrene-maleic anhydride polymers, SMA).
[0012] The proper linker includes: (1) anhydride, for example, maleic anhydride, succinic acid anhydride, trimellitic anhydride (TMA), benzene tetracarboxylic dianhydride (PMDA), phthalic anhydride, tetrahydromethyl-1,3-isobenzofurandione and poly(styrene-co-maleic anhydride) copolymers; (2) carboxylic acid, for example, dicarboxylic acid, adipic acid, succinic acid, p-phthalic, isophthalic acid; (3) glycidyl or epoxide, for example, diglycidyl ether of bisphenol-A (DGEBA), 3,4-epoxycyclohexyl-methyl-3,4-epoxy cyclohexane carboxylate; (4) isocyanate or diisocyanate, for example, toluene diisocyanate, methylen-biphenyldiisocyanate, 1,6-cyclohexamethylene-diisocyanate, methyl isopropyl ketone diisocyanate; and (5) maleic anhydride or maleated polystyrene, for example, SMA. The preferred linker includes benzene tetracarboxylic dianhydride (PMDA), trimellitic anhydride (TMA) and adipic acid.
[0013] The polymeric polyamine can have a structural formula: Linker-HN—R—NH-Linker, H 2 N—R—NH-Linker, H 2 N—R—NH-Linker, H 2 N—R—NH-Linker-NH—R—NH 2 , Linker-(HN—R—NH-Linker)x or H 2 N—R—NH-(Linker-HN—R—NH)x-H; wherein x=1˜5, H 2 N—R—NH and HN—R—NH are polyoxyalkylene-amine, R can be dianhydride, diacid, epoxy, diisocyanate or poly(styrene-co-maleic anhydride) copolymers (SMA).
[0014] The method for producing polymeric polyamine is to react polyoxyalkylene-amine with a linker having a reactive functional group. Segments of polymeric polyamine may chelate silver nanoparticles, and disperse in both water phase and an organic solvent. Accordingly, the Ag nanoparticles can be prepared as a stable concentrated gel, slurry or powders having a concentration more than 10 wt %. The polyoxyalkylene-amine and the linker are defined as the above.
[0015] For the process, molar ratio of the polyamine to the linker can be changed to synthesize Linker-(HN—R—NH-Linker)x or H 2 N—R—NH-(Linker-HN—R—NH)x-H, having different end functional groups.
[0016] After reaction of polyoxyalkylene-amine and the linker, the linker provides additional functional groups to enhance stability of silver in water or the organic solvent by chelating with silver. The solution will be more stable and the nanoparticles will not aggregate together.
[0017] The molar ratio of the linker to polyoxyalkylene-amine is preferably (n+1):n, n=1˜5, the reaction temperature is preferably about 25˜150° C., and the reaction time is preferably about 1˜12 hours.
[0018] In the present invention, the method for stabilizing Ag nanoparticles with polymeric polyamine includes steps of: (a) mixing polymeric polyamine and a water solution of silver salt; (b) reducing the Ag + ions with a reducer to form a solution of Ag nanoparticles. The polymeric polyamine serves as a stabilizer or a dispersant and comprises polyoxyalkylene-amine and a linker linking with an amino end of polyoxyalkylene-amine.
[0019] The polyoxyalkylene-amine has a molecular weight about 200˜10,000, and the linker is selected from the group consisting of anhydride, carboxylic acid, glycidyl, epoxide, isocyanate, diisocyanate, maleic anhydride and maleated polystyrene.
[0020] The reducer can be NaBH 4 , methanol, ethanol, glycerin, ethylene glycol, dodecanol, H 2 N—NH 2 , formaldehyde, PVA or DMF. The weight ratio of polymeric polyamine to the silver salt is preferably about 1:10˜10:1. The silver salt can be AgNO 3 , AgI, AgBr, AgCl or silver pentafluoropropionate.
[0021] The solution of Ag nanoparticles can be further dewatered to increase solid content thereof. An organic solvent can be also added to transfer the particles into the organic solvent.
[0022] The solution of Ag nanoparticles can further comprise sodium hydroxide with a molar ratio to the Ag salt more than 1, so that water solubility of the solution will be increased.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 shows stable distribution of the Ag nanoparticles in the TEM picture;
[0024] FIG. 2 shows the size distribution of the Ag nanoparticles in the AFM picture.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Materials used in the preferred embodiments of the present invention include:
1. Polyoxyalkylene-amine
[0026] product of Huntsman Chemical Co., Jeffamine® Amines series, including:
[0027] a. Jeffamine ED-2001: poly(oxypropylene-oxyethylene-oxypropylene)-bis-amines, polyoxyalkylene-amine with two functional groups, molecular weight=2000 (a.k.a. POE-2000), white color, hydrophilic, wax-like solid, nip. 35° C., amino content=0.95 mequiv./g, average oxyethylene/oxypropylene unit=39.5/5, structural formula:
[0000]
[0028] wherein a+c=6, b=38.7;
[0029] b. Jeffamine M-2070: poly(oxypropylene-oxyethylene)-monoamine, polyoxyalkylene-amine with single functional group, molecular weight=2000 (a.k.a. POP-2000), hydrophobic, structural formula:
[0000]
[0000] wherein a=10, b=31.
2. Trimellitic anhydride (TMA)
[0030] product of Aldrich Chemical Co., purified with sublimation before using, structural formula:
[0000]
[0000] 3. Benzene tetracarboxylic dianhydride (PMDA)
[0031] product of Aldrich Chemical Co. or Sino-Japan chemical Co.
[0000] 4. Poly(styrene-co-maleic anhydride) copolymers (SMA)
[0032] product of Aldrich Chemical Co. or Sino-Japan chemical Co., ratio of styrene/maleic anhydride or maleated polystyrene can be 1/1, 3/1, 6/1 or 11/1, average molecular weight=6,000 (SMA1000), 6,000 (SMA3000), 120,000 (SMA6000) and 140,000 (SMA11000).
[0000] 5. 4,4′-methylenebis(phenyl isocyanate) (MDI)
6. Silver nitrate
[0033] AgNO 3 (99.8%), product of Aldrich.
7. Tetrahydrofuran (THF)
8. NaBH 4
[0034] a reducing agent.
9. NaOH
[0035] In the present invention, the method for producing polymeric polyamine is to polymerize hydrophilic or hydrophobic polyoxyalkylene-amine with the linker. The product could be hydrophilic or hydrophobic.
[0036] The reaction is exemplified with schemes. When the linker is TMA, polyoxyalkylene-amine is hydrophilic POE2000 or hydrophobic POP2000, and sodium hydroxide is added for modifying the ions after the reaction, the reaction equations are as follows:
[0000]
[0037] When the linker is PMDA, polyoxyalkylene-amine is hydrophobic POP2000, and sodium hydroxide is added for modifying the ions after reaction, the reaction equations are as follows:
[0000]
[0038] When the linker is SMA and polyoxyalkylene-amine is various, comb-like polymers can be obtained as follows:
[0000]
SMA
Approx. ratio
Approx. Mw
SMA1000 SMA3000 SMA6000 SMA11000
x/y = 1/1 x/y = 3/1 x/y = 6/1 x/y = 11/1
6000 6000 12000 12000
Comb-Amphilic
Approx. Mw
POP230 POP400 POP2000 POP4000 POE2000
a + c = 2~3 a + c = 5~6 a + c = 33 a + c = 68 a + c = 6
b = 38.7
230 400 2000 4000 2000
SMA-M-series
Approx. Mw
M1000 M2070
a = 3 a = 10
b = 9 b = 32
1000 2000
[0039] When the linker is MDI and polyoxyalkylene-amine is various, the reaction equations are as follows:
[0040] (Step 1)
[0000]
[0041] (Step 2)
[0000]
Example 1
Step (A): Preparing a Stabilizer POE2000-TMA/4COOH
[0042] First, hydrophilic POE2000 (Jeffamine® ED-2001) is purified with sublimation. THF is dewatered with calcium hydride and then preserved with molecular sieves. Next, to a three-necked bottle (500 ml), POE2000 (100 g, 0.05 mol) is added and dissolved in THF (150 ml), and then anhydride linker TMA (19.2 g, 0.10 mol, previously dissolved in THF (50 ml)) is added drop by drop, so that molar ratio of POE2000 to TMA is 1:2. The reactant is mechanically stirred and filled with nitrogen during the whole reaction. The reaction is performed at 30° C. for 2 hours or longer. FT-IR spectrum is used for monitoring progress of the reaction by sampling every period of time until the anhydride functional groups disappear. After the reaction is completed, THF is removed by decompression to obtain creamy glue product, amido acid POE2000-TMA/4COOH.
Step (B): Synthesizing Ag Nanoparticles (AgNP)
[0043] To a three-necked bottle, the stabilizer POE2000/4COOH (0.069 g) is dissolved in water (50 g) which is stirred with a magnetic stirrer. AgNO 3 (0.045 g) is then added later. After 2 hours, a NaBH 4 solution (0.015 g, previously dissolved in water (50 g)) is added incontinuously and vigorously agitated. The solution immediately becomes black. The reactor is filled with nitrogen during whole reaction.
Example 2
Step (A): Preparing a Stabilizer POE2000-TMA/2COOH
[0044] The product POE2000/4COOH of Example 1 is heated at 150° C. for 3 hours. Progress of the reaction is monitored with FT-IR for identifying imido functional groups. The product is imido acid POE2000/2COOH.
Step (B): Synthesizing Ag Nanoparticles (AgNP)
[0045] Repeat Step (B) of Example 1, but the stabilizer is replaced with POE2000/2COOH.
Example 3
Step (A): Preparing Stabilizer POP2000-TMA/4COOH
[0046] Repeat Step (A) of Example 1, but hydrophilic POE2000 is replaced with hydrophobic POP2000 to obtain product imido acid POP2000/4COOH.
Step (B): Synthesizing Ag Nanoparticles (AgNP)
[0047] Repeat Step (B) of Example 1, but the stabilizer is replaced with POE2000/4COOH.
Example 4
Step (A): Preparing Stabilizer POP2000-TMA/2COOH
[0048] The product POP2000/4COOH of Example 3 is heated at 150° C. for 3 hours. Progress of the reaction is monitored with FT-IR for identifying imido functional groups. The product is imido acid POP2000/2COOH.
Step (B): Synthesizing Ag Nanoparticles (AgNP)
[0049] Repeat Step (B) of Example 1, but the stabilizer is replaced with POP2000/2COOH.
Example 5
Step (A): Preparing Stabilizer POP2000-PMDA/8COONa
[0050] To a three-necked bottle (500 ml), POP2000 (40 g, 0.02 mol) is added and dissolved in THF (100 ml), and then the dianhydride linker TMA (6.54 g, 0.03 mol, previously dissolved in THF (100 ml)) is added drop by drop, so that molar ratio of POP2000 to PMDA is 2:3. The reactant is mechanically stirred and filled with nitrogen during the whole reaction. The reaction is performed below 30° C. for 3 hours. FT-IR spectrum is used for monitoring progress of the reaction by sampling every period of time until the anhydride functional groups disappear. After the reaction is completed, THF is removed by decompression to obtain creamy glue product, amido acid POP2000-PMDA/8COOH. Into the product POP2000-PMDA/8COOH (3.2 g, 0.08 mol), NaOH is added to form a water-soluble polymeric sodium compound.
Step (B): Synthesizing Ag Nanoparticles (AgNP)
[0051] Repeat Step (B) of Example 1, but the stabilizer is replaced with POP2000-PMDA/8COOH.
Example 6
Step (A): Preparing Stabilizer POE2000-PMDA/4COOH
[0052] The product POE2000-PMDA/8COOH of Example 5 is heated at 150° C. for 3 hours. Progress of the reaction is monitored with FT-IR for identifying amido functional groups. The product is amido acid POE2000-PMDA/4COOH.
Step (B): Synthesizing Ag Nanoparticles (AgNP)
[0053] Repeat Step (B) of Example 1, but the stabilizer is replaced with POE2000-PMDA/4COOH.
Example 7
Step (A): Preparing Stabilizer POP2000-SMA/COOH
[0054] SMA and POP2000 are previously dewatered in vacuum at 120° C. for 6 hours. SMA3000 (10.0 g, 24.4 mmol of MA) and POP2000 (97.6 g, 48.8 mmol) are respectively dissolved in THF (50 mL) Next, SMA is incontinuously added into POP2000. To prevent cross-linking, the molar ratio of POP2000 to SMA is more than 1. Progress of the reaction is monitored with GPC and IR to confirm no cross-linking between the synthesized comb-like polymers. The excess POP2000 is isolated with a solvent mixture of water (or toluene) and ethanol due to different solubilities of the comb-like polymer and the straight-chain polyoxyalkylene-amine. The unreacted POP2000 can be dissolved in the solvent mixture and POP2000-SMA/COOH precipitates.
Step (B): Synthesizing Ag Nanoparticles (AgNP)
[0055] Repeat Step (B) of Example 1, but the stabilizer is replaced with POP2000-SMA/COOH.
Example 8
Step (A): Preparing Stabilizer POE2000-POP2000-MDI
[0056] Jeffamine® ED-2001 and M2070 are first dewatered in a vacuum oven at 100° C. for 6 hours, and MDI is purified with decompressing distillation. To a three-necked bottle (100 ml), the linker MDI (1.5 g, 6 mmol, previously dissolved in toluene (15 g)) is added, and then ED-2001 (5.99 g, 3 mmol, previously dissolved in toluene (10 g)) is added drop by drop. The solution is continuously mixed with a magnetic stirrer. Next, M2070 (11.99 g, 6 mmol, previously dissolved in toluene (20 g)) is added into the solution. The molar ratio of MDI:ED-2001: M2070 is 2:1:2. The reactor is filled with nitrogen during the whole reaction. Progress of the reaction is monitored with FT-IR until the characteristic functional groups of MDI disappear. The solvent is removed from the solution by heating in a vacuum oven at 80° C. for 12 hours. The product is creamy glue.
Step (B): Synthesizing Ag Nanoparticles (AgNP)
[0057] Repeat Step (B) of Example 1, but the stabilizer is replaced with POE2000-POP2000-MDI.
Comparative Example 1
[0058] Repeat the procedures of Example 1, but the stabilizer POE2000-TMA/4COOH is replaced with POE2000. After the reaction, a lot of silver particles precipitate on the bottom of the bottle, which shows that the stabilizer synthesized by the method of the present invention is required.
Analysis of the Product
[0059] Properties and features of the product of Example 1 are analyzed with instruments and results are as follows:
1. Formation of the Ag Nanoparticles
[0060] The Ag nanoparticles are identified by UV absorbance at wave length 400 nm.
2. Stability of the Ag Nanoparticles
[0061] FIG. 1 shows TEM pictures of the products concentrated with a rotary evaporator or a drier to have concentrations of 0.01 wt. % (picture a), 0.3 wt. % (picture b), 0.01 wt. % (picture c, diluted from the slurry of 0.3 wt. %), and 0.01 wt. % (picture d, diluted after evaporated). As shown in FIG. 1 , the Ag nanoparticles uniformly distribute and have diameters less than 30 nm after heating at 80° C. for 1 hour. That is, the solution containing Ag nanoparticles of the present invention is highly stable.
3. Diameter Distribution
[0062] FIG. 2 shows AFM pictures and distribution of the Ag nanoparticles, in which diameters of the Ag particles range about 33˜25 nm.
Concentrating Process
[0063] The Ag nanoparticles of the present invention can be concentrated to 10 wt % or higher with an evaporator or a drier, for example, decompression at 80° C. or freezing at 0° C. The highly concentrated solution can be also diluted and the dilution also exhibits good dispersibility and thermal stability.
[0064] The traditional silver solution has a concentration limit of 5 wt % and easily forms participate or aggregation. Contractively, by means of the present invention, solid content of the solution containing Ag nanoparticles can be promoted to 10 wt % or even higher. The most important factor is that a novel stabilizer, polymeric polyamine, is provided in the reduction reaction of silver salt into Ag nanoparticles. Molecular weight of the Ag nanoparticles is about 500˜10,000 mol/g, and the functional groups may include anhydride, carboxylic acid, epoxy and isocyanate.
[0065] According to the above, features or advantages of the present invention at least include:
[0066] 1. Different sizes of Ag nanoparticles can be obtained by using a synthesized polymeric dispersant and controlling the ratio of polymeric polyamine to silver.
[0067] 2. The prepared silver dispersion can be concentrated as a silver slurry which can be also diluted as a stable dispersion. The dispersing media can be water or other suitable organic solvents, for example, methanol, ethanol, IPA, acetone, ethylene glycol, dimethylformamide, N,N-dimethylacetamide N-methyl-2-pyrrolidinone, THF, MEK, etc.
[0068] 3. The Ag nanoparticles of the present invention are both hydrophilic and hydrophobic and thus are compatible with polymer in nanoscale. The highly concentrated solution of Ag nanoparticles can be applied to blending with organic polymer (for example, PI, Epoxy, Nylon, PP, ABS, PS, etc.), so as to improve conductivity, antimicrobial (properties) thereof. | Polymeric polyamine is produced by polymerizing polyoxyalkylene-amine and a linker. The polyoxyalkylene-amine has a structural formula H 2 N—R—NH 2 , wherein R is selected from the group consisting of dianhydride, diacid, epoxy, diisocyanate and poly(styrene-co-maleic anhydride) copolymers (SMA). The linker can be anhydride, carboxylic acid, epoxy, isocyanate or poly(styrene-co-maleic anhydride) copolymers (SMA). The polymeric polyamine so produced can be used as a stabilizer or dispersant of the Ag nanoparticles. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation application of application Ser. No. 14/198,230 filed Mar. 5, 2014, which is a continuation application of application Ser. No. 13/121,153 filed Mar. 25, 2011, which is a 371 application of PCT/JP2009/004930 filed Sep. 28, 2009, which is based on Japanese Application No. 2008-250618 filed Sep. 29, 2008, the entire contents of each of which are incorporated by reference herein.
TECHNICAL FIELD
[0002] The present invention relates to a CCE+ number assignment method and a base station apparatus in a mixed system in which an LTE (Long Term Evolution) system and an LTE+ (Long Term Evolution Advanced) system exist together.
BACKGROUND ART
[0003] Mobile communication is performed using the downlink (DL) from a radio communication base station apparatus (hereinafter abbreviated as “base station”) to radio communication mobile stations (hereinafter abbreviated as “mobile stations”), and the uplink (UL) from mobile stations to a base station.
[0004] The uplink and the downlink are associated with one another, and, for example, when ARQ (Automatic Repeat Request) is applied to downlink data, a mobile station feeds a response signal indicating the result of error detection about the downlink data, back to a base station using the uplink. A mobile station performs CRC (cyclic redundancy check) check on the downlink data, and, when CRC=OK (no error), feeds ACK (acknowledgment) back to a base station as a response signal, and, when CRC=NG (error present), feeds NACK (negative acknowledgment) to the base station as a response signal. This response signal is transmitted to a base station using an uplink control channel such as a PUCCH (physical uplink control channel).
[0005] In addition, as shown in Non-Patent Literature 1, a base station transmits control information to report downlink data resource allocation results, to mobile stations. This control information is transmitted to mobile stations using downlink control channels such as PDCCHs (physical downlink control channels). Each PDCCH is allocated to one or more CCEs. When one PDCCH is allocated to a plurality of CCEs (control channel elements), this PDCCH is allocated to a plurality of consecutive CCEs. A base station assigns any of a plurality of PDCCHs to each mobile station, according to the number of CCEs (CCE aggregation size) required to report control information, maps control information to physical resources corresponding to CCEs (control channel elements) to allocate PDCCHs to, and transmits the mapped result.
[0006] In addition, studies are underway to associate CCEs and PUCCHs in order to efficiently use communication resources in the downlink. According to this association, each mobile station can determine PUCCHs used to transmit response signals from the mobile station, based on the CCEs corresponding to the physical resources to which control information directed to the mobile station is mapped.
[0007] In this way, there are associations between the uplink and the downlink, and therefore, when coexistence of a plurality of communication systems is desired, there is a problem that frequency resources run short if the uplink and the downlink are assigned to each of a plurality of communication system. In addition, when a new communication system is added to the band used to operate an old communication system, it is preferable to allow mobile stations in the old communication system to be used as is without change in the new system. As a method of solving the above-described problems, a frequency overlay system is proposed in Patent Literature 1.
[0008] With Patent Literature 1, when an old communication system and a new communication system exist together in order to improve efficiency of use of frequencies, the new system is designed to cover the frequency of the old communication system and performs frequency scheduling including the frequency of the old communication system. In addition, a design approach is adopted where correlation between preamble channels (reference signals) used in an old communication system and preamble channels (reference signals) used in a new communication system is low to improve accuracy of channel estimation. Moreover, different control channels are provided in an old communication system and a new communication system, individually, and transmitted in different frequency bands.
CITATION LIST
Patent Literature
PTL 1
[0000]
Japanese Patent Application Laid-Open No. 2006-304312
Non-Patent Literature
NPL 1
[0000]
Nobuhiko Miki, Yoshihisa Kishiyama, Kenichi Higuchi, and Mamoru Sawahashi, “Investigation on Optimum Coding and Multiplexing Schemes for L1/L2 Control Signals in OFDM Based Evolved UTRA Downlink”, The 18th Annual IEEE International Symposium on Personal, Indoor and Mobile Radio Communications (PIMRC'07)
SUMMARY OF INVENTION
Technical Problem
[0011] However, when a new communication system and an old communication system exist together, if control channels for control signals are provided separately, there is a problem that efficiency of use of frequencies deteriorates. Therefore, a case is possible where control channels for a new communication system and control channels for an old communication system are transmitted using the same frequency. In this case, an old communication system has defined formats of time and frequency allocation of signals, the amount of signals and so forth, so that a new communication system needs to follow the formats of the old communication system.
[0012] For example, a case will be considered where 3GPP LTE which is an old communication system, and LTE+ (also referred to as “IMT Advanced”, “LTE Advanced” and “4G”) which is a new communication system exist together. In this case, when, in an LTE+ system, control information to report a downlink data resource assignment result is transmitted to an LTE+ mobile station using a PDCCH+, if the format of LTE CCEs is used as is, the amount of information that can be transmitted is limited by the format of LTE CCEs.
[0013] On the other hand, in an LTE+ system, if the format of CCEs+ to allocate a PDCCH+ to is newly defined independent of the format of LTE CCEs, when the defined format of LTE+ CCEs+ and the format of LTE CCEs are both used, the CCE+ number to allocate a PDCCH+ to and the CCE number to allocate a PDCCH to, might overlap. This causes a problem that the location of the PUCCH+ associated with a CCE+ number and the location of the PUCCH associated with a CCE number collide in transmission resources, so that an ACK/NACK collision occurs.
[0014] It is therefore an object of the present invention to provide a CCE+ number assignment method and a base station apparatus to prevent ACK/NACK collisions in a mixed system in which an LTE system and an LTE+ system exist together.
Solution to Problem
[0015] The control channel element of LTE+ (CCE+) number assignment method that assigns a CCE+ number to CCE+ to which a first control channel is allocated, the first control channel being a downlink control channel in an Long-Term-Evolution-Advanced (LTE+) system, the CCE+ number assignment method comprising: selecting a number, as the CCE+ number, from CCE numbers of CCEs to which a second control channel is allocated, the second control channel being a downlink control channel in an LTE system and assigned to a resource element region composed of the CCEs+ to which the first control channel is allocated.
[0016] The base station apparatus comprising: a mapping section that selects a number from control channel element (CCE) numbers of CCEs to which a downlink control channel in an Long-Term-Evolution (LTE) system is allocated, the downlink control channel in the LTE being assigned to a resource element region composed of CCEs+ to which a downlink control channel in an LTE Advanced (LTE+) system is allocated, holds a CCE+ number assignment mapping representing assigned as CCE+ numbers, selects a certain CCE+ number from the CCE+ number assignment mapping and assigns a region of the certain CCE+ number to the downlink control channel in the LTE+ system; and a transmission section that transmits the downlink control channel in the LTE+ system assigned to the region of the certain CCE+ number.
Advantageous Effects of Invention
[0017] According to the present invention, it is possible to reduce ACK/NACK collisions in a mixed system in which an LTE system and an LTE+ system exist together.
BRIEF DESCRIPTION OF DRAWINGS
[0018] FIG. 1 shows an example of allocation of CCEs and CCEs+ according to Embodiment 1 of the present invention;
[0019] FIG. 2 shows an allocation example which can be adopted in a case in which a resource element region composed of three CCEs are assigned to two CCEs+;
[0020] FIG. 3 shows an example of allocation of CCEs and CCEs+ according to Embodiment 1;
[0021] FIG. 4 shows another example of allocation of CCEs and CCEs+ according to Embodiment 1;
[0022] FIG. 5 shows primary components in a base station apparatus according to Embodiment 1;
[0023] FIG. 6 shows primary components in a mobile station according to Embodiment 1;
[0024] FIG. 7 shows an example of allocation of CCEs and CCEs+ according to Embodiment 2 of the present invention;
[0025] FIG. 8 shows an example of allocation of CCEs and CCEs+ according to Embodiment 2;
[0026] FIG. 9 shows another example of allocation of CCEs and CCEs+ according to Embodiment 2; and
[0027] FIG. 10 shows an example of allocation of CCEs and CCEs+ according to Embodiment 3 of the present invention;
DESCRIPTION OF EMBODIMENTS
[0028] Now, embodiments of the present invention will be described in detail with reference to the accompanying drawings.
[0029] First, communication systems assumed in the embodiment will be explained before explanation of specific configuration and operation according to the embodiment.
[0030] (1) The following systems are assumed as an old communication system and a new communication system. Old communication system: LTE (Long Term Evolution) New communication system: LTE+ (also referred to as “LTE Advanced”, “IMT Advanced”, or “4G”).
[0031] (2) In an LTE system, CCE numbers for PDCCHs are associated with PUCCHs. A PDCCH is a downlink control channel for an LTE system. Meanwhile, a PUCCH is an uplink control channel for an LTE system, and also is a control channel for feedback of ACK or NACK, and therefore may also be referred to as “ACK/NACK channel.”
[0032] (3) In an LTE system, a CCE (one PDCCH unit) is composed of 36 REs (resource elements).
Embodiment 1
[0033] With the present embodiment, a case will be explained where an LTE+ CCE+ is composed of 54 REs, and three LTE CCEs correspond to two CCEs+. In this case, a number is selected, as a CCE+ number, from the CCE numbers of CCEs to allocate PDCCHs to, which are assigned to a resource element region composed of CCEs+ to allocate PDCCHs+ to. A PDCCH+ is an LTE+ system downlink control channel. By this means, even if an LTE PDCCH and an LTE+ PDCCH+ are transmitted at the same time, the same number is not selected between CCE numbers and CCE+ numbers. As a result of this, it is possible to prevent a collision between the PUCCH+ location associated with the CCE+ number and the PUCCH location associated with the CCE number in transmission resources to reduce the rate of ACK/NACK collisions.
[0034] FIG. 1 shows an example of allocation of CCEs and CCEs+ according to the present embodiment. Here, in FIG. 1 , CCE #i represents that a CCE number is i, and also CCE+ #i represents that a CCE+ number is i.
[0035] In the example shown in FIG. 1 , a resource element region composed of three CCEs, CCE #4, CCE #5 and CCE #6, is divided into two regions. Then, two numbers, to be more specific, the beginning number “4” and the end number “6” are selected from three CCE numbers (4, 5 and 6) assigned to the resource element region composed of three CCEs, and the selected numbers are assigned as CCE+ numbers.
[0036] With LTE+, control information, including for example, uplink information, mobile station IDs, data sizes, modulation schemes, uplink transmission power information and demodulation information are assigned to PDCCHs+ and transmitted. It is anticipated that the amount of control information that should be transmitted with LTE+ is greater than with LTE due to increase in the number of antennas and assigned bands. Therefore, the size of a CCE+ needs to be greater than the size of a CCE. In the allocation example, a CCE+ is composed of 36×3/2=54 REs. In this way, according to the present embodiment, a size greater than the size of a CCE is assured for a CCE+.
[0037] In this case, CCEs and CCEs+ are allocated as shown in FIG. 1 to prevent PDCCHs from being allocated to CCE #4 to #6 in an LTE system when PDCCHs+ are allocated to CCE+ #4 and CCE+ #6 in an LTE+ system. In addition, when PDCCHs are allocated to CCE #4 to #6 in an LTE system, PDCCHs+ are prevented from being allocated to CCEs+ #4 and #6 in an LTE+ system. In this way, PDCCHs and PDCCHs+ are allocated using common rules between LTE and LTE+.
[0038] If ACK/NACK is transmitted using a PDCCH and a PDCCH+ allocated as described above, the same number is not selected between CCE numbers to allocate PDCCHs to and CCE+ numbers to allocate PDCCHs+ to, so that it is possible to prevent ACK/NACK collisions. By this means, an LTE+ mobile station can transmit an ACK/NACK signal in synchronization with an LTE mobile station.
[0039] Here, FIG. 1 shows allocation of CCE numbers and CCE+ numbers, and, at a time of transmission, the order of CCEs and CCEs+ are exchanged by interleaving CCEs and CCEs+ on a per REG (resource element group) basis, where an REG is obtained by dividing CCEs and CCEs+ every four REs.
[0040] FIG. 2 shows an example of allocation that can be adopted in a case in which a resource element region composed of three CCEs is assigned to two CCEs+. Here, pattern 2 in FIG. 2 is the same as the allocation example shown in FIG. 1 .
[0041] In pattern 1 in FIG. 2 , the resource element region composed of CCE #2 to CCE #4 is assigned to two CCEs+. In pattern 2 in FIG. 2 , the resource element region composed of CCE #1 to CCE #3 is assigned to two CCEs+. In pattern 3 in FIG. 2 , the resource element region composed of CCE #3 to CCE #5 is assigned to two CCEs+. In this way, when a resource element region composed of three CCEs is assigned to two CCEs+, it is possible to adopt three patterns as shown in FIG. 2 .
[0042] Candidates for CCE+ beginning positions when these patterns are employed, are shown by arrows in FIG. 2 . As seen from FIG. 2 , if there are sixteen CCEs (CCE #1, CCE #2, CCE #16) to which PDCCHs can be allocated, in an LTE system, the number of candidates for CCE beginning positions is 16. By contrast with this, there are three patterns (pattern 1 , pattern 2 and pattern 3 ) that can be adopted in an LTE+ system, so that the number of candidates for CCE+ beginning positions is 28. In this way, with LTE+, the number of candidates for CCE+ beginning positions is greater than the number of candidates for CCE beginning positions.
[0043] Increase in the number of candidates for beginning positions leads to increase in the number of times of blind detections to detect whether or not there are resources assigned to a mobile station in the receiving side. As a result of this, the amount of processing in a mobile station increases. Therefore, another allocation example will be shown where the number of times of blind detections decreases to reduce the processing load in a mobile station.
Allocation Example A
[0044] FIG. 3 shows an allocation example A that can reduce the number of times of blind detections.
[0045] In allocation example A, CCEs+ are allocated to be stuffed from the beginning of a resource element region composed of CCE #1 to CCE #16. Here, in allocation example A, the number j of CCEs represents that a CCE aggregation size to allocate PDCCHs is j, and the number j of CCEs+ represents that the aggregation size of CCEs+ to allocate PDCCHs+ to, is j.
[0046] The allocation in a case in which a resource element region is divided per CCE+ in allocation example A is the same as pattern 2 in FIG. 2 . That is, candidates for beginning positions in a case in which a resource element region is divided per CCE, are the beginning position of CCE #i (CCE number is i) satisfying CCE #i mod 3=1, and a position obtained by shifting from this beginning position of CCE #i by a resource element region (fifty-four REs) constituting one CCE+. Here, “CCE #i mod m” represents the remainder resulting from dividing CCE #i by m (the same applies hereinafter).
[0047] In this way, an allocation is adopted where the beginning position of a resource element region composed of two consecutive CCEs+ matches the beginning position of CCE #i satisfying CCE #i mod 3=1, so that it is possible to limit candidates for beginning positions to the beginning position of CCE #i and a position obtained by shifting from this beginning position of CCE #i by a resource element region (fifty-four REs) constituting one CCE+, and therefore it is possible to narrow down candidate positions for blind detections in the receiving side.
[0048] In addition, when the number of CCEs+ is K (K is an integer and K≧2), a candidate for a CCE+ beginning position is the beginning position of CCE #i satisfying CCE #i mod (3×K/2)=1.
[0049] As described above, with allocation example A, it is possible to limit CCE+ beginning positions, so that it is possible to reduce the number of times of blind detections and the amount of reception processing in the receiving side.
[0050] In addition, CCEs+ are allocated to be stuffed, leaving no space between them, from the beginning of a resource element region, so that it is possible to secure a continuous remaining resource element region. For example, when a CCE is composed of thirty-six REs, a CCE+ is composed of fifty-four REs and there are sixteen CCEs (CCE #1, CCE #2, . . . , CCE #16) to allocate PDCCHs to, it is possible to allocate only two LTE+ PDCCHs in a case in which a resource element region is divided every four CCEs+, so that there is a remaining resource element region corresponding to 144 REs. In this case, CCEs+ are allocated to be stuffed from the beginning of a resource element region, so that it is possible to secure continuous remaining resource element region. As a result of this, as shown in FIG. 3 , it is possible to allocate four consecutive CCEs (CCE #13, CCE #14, CCE #15, CCE #16) to the remaining resource element region.
[0051] As shown in FIG. 3 , CCE #13 to CCE #16 in a case in which a resource element region is divided per CCE, may be allocated to this remaining resource region and used. In addition, CCE #13, 14 and CCE #15, 16 in a case in which a resource element region is divided every two CCEs, may be allocated and used. Moreover, CCE #13 to #16 in a case in which a resource element region is divided every four CCEs may be allocated and used. Furthermore, CCE+ #13 and CCE+ #15 in a case in which a resource element region is divided per CCE+ may be allocated and used, and CCEs+ #13, 15 in a case in which a resource element region is divided every two CCE+ may be allocated and used.
[0052] In this way, with allocation example A, it is possible to secure a continuous remaining resource element region by allocating CCEs+ to be stuffed, leaving no space, from the beginning of a resource element region, so that it is possible to efficiently use resources by allocating PDCCHs, or PDCCHs+ corresponding to a small number of CCEs+, to the remaining resource element region.
[0053] As described above, with allocation example A, a number is selected, as a CCE+ number, from the CCE numbers of CCEs to allocate PDCCHs to, which are assigned to a resource element region composed of CCEs+ to allocate PDCCHs+ to. By this means, even if PDCCHs and PDCCH+ are transmitted at the same time, the same number is not selected between CCE numbers and CCE+ numbers, so that it is possible to reduce the rate of ACK/NACK collisions associated with CCE numbers and CCE+ numbers.
[0054] In addition, with allocation example A, CCEs+ are allocated to be stuffed from the beginning of a resource element region to which LTE PDCCHs can be allocated. By this means, it is possible to limit CCE+ beginning positions, so that it is possible to reduce the number of times of blind detections and the amount of reception processing in a mobile station in the receiving side. In addition, when the number of CCEs+ is great, it is possible to secure a continuous remaining resource element region, and allocate PDCCHs, or PDCCHs+ corresponding to a small number of CCEs, so that it is possible to efficiently use resources.
Allocation Example B
[0055] FIG. 4 shows allocation example B as another allocation example.
[0056] With LTE, a method of associating CCE numbers with mobile station user IDs, are being studied to reduce the number of times of CCE blind detection. In this case, CCE numbers that can be received by LTE mobile stations are limited.
[0057] For example, with allocation example A, when CCE numbers that can be received by an LTE mobile station are only #1 to #12, if an LTE+ mobile station uses CCE+ #9 in a case in which a resource element region is divided per CCE+, the LTE mobile station cannot use CCE #5 to 8 and also CCE #9 to 12 in a case in which a resource element region is divided every four CCEs. Therefore, candidates for CCE numbers available for an LTE mobile station are only CCE #1 to 4.
[0058] Likewise, with allocation example A, when CCE numbers that can be received by an LTE mobile station are only #1 to #12, if an LTE+ mobile station uses CCE+ #9 in a case in which a resource element region is divided per CCE, the LTE mobile station cannot use CCE #1 to 8 and also CCE #9 to 16 in a case in which a resource element region is divided every eight CCEs. As a result of this, there is no CCE number available for an LTE mobile station.
[0059] With allocation example A, when the number of CCEs and CCEs+ increases, the beginning position of a resource element region composed of j CCEs is shifted from the beginning position of a resource element region composed of j CCEs+. Therefore, when the number of CCEs (or CCEs+) increases, if a certain CCE+ number (or CCE number) is being used, the number of available CCE (or CCE+ number) numbers decreases.
[0060] Therefore, an allocation example B will be presented where, even if the number j of CCEs and the number j of CCE+ are great, the beginning position of a resource element region composed of j CCEs matches the beginning position of a resource element region composed of j CCEs+.
[0061] With an example shown in FIG. 4 in which a resource element region is divided per CCE+, CCE+ #1 and CCE+ #3, CCE #4, and CCE+#5 and CCE+ #7 are allocated in this order from the beginning of the resource element region composed of sixteen CCEs. In this way, by allocating two CCE+ #1 and CCE+ #3, one CCE #4 and two CCE+ #5 and CCE+ #7 are allocated to a resource element region, from the beginning in this order, it is possible to match the beginning position of CCE+ #5 with the beginning position in a case in which a resource element region is divided every four CCEs to satisfy CCE #i mod 4=1.
[0062] Incidentally, it is possible to allocate CCE+ #1 and CCE+ #3 in a case in which a resource element region is divided per CCE+ to match the beginning positions in a case in which a resource element region is divided every two CCEs+. In this case, however, the resource element region between CCE+ #1 and CCE+ #3 has eighteen REs, and therefore cannot be assigned a CCE (thirty-six REs), so that an unnecessary region is generated. Therefore, if a CCE+ is composed of fifty-four REs, it is preferable to allocate CCEs+ in a case in which a resource element region is divided per CCE+, as allocation example B.
[0063] In addition, with allocation example B, if a resource element region is divided every K CCEs+, here K=2, 4 and 8, the beginning position of each CCE+ is the beginning position of CCE #i satisfying CCE #i mod (2×K)=1.
[0064] To be more specific, with allocation example B shown in FIG. 4 , candidates for the beginning positions in a case in which a resource element region is divided every two CCEs+, are the beginning positions of CCE #1, CCE #5, CCE #9 and CCE #13, candidates for the beginning positions in a case in which a resource element region is divided every four CCEs+, are the beginning positions of CCE #1 and CCE #9, and a candidate for the beginning position in a case in which a resource element region is divided every eight CCEs+ is the beginning position of CCE #1.
[0065] In this way, the beginning positions match between the case in which a resource element region is divided every two CCEs+ and the case in which a resource element region is divided every four CCEs, and the beginning positions match between the case in which a resource element region is divided every four CCEs+ and the case in which a resource element region is divided every eight CCEs. As a result of this, as compared to allocation example A, it is possible to reduce cases in which a plurality of CCEs are unavailable when a certain CCE+ is selected.
[0066] Assume that when CCE numbers that can be received by an LTE mobile station are only #1 to #12, an LTE+ mobile station uses CCE+ #9 in a case in which a resource element is divided per CCE. In this case, with allocation example A, the LTE mobile station cannot use CCE #5 to 8 and CCE #9 to 12 in a case in which a resource element region is divided every four CCEs. By contrast with this, with allocation example B, the LTE mobile station cannot use only CCE #5 to 8.
[0067] In addition, assume that CCE numbers that can be received by an LTE mobile station are only #1 to #12, an LTE+ mobile station uses CCE+#9 in a case in which a resource element region is divided per CCE+. In this case, with allocation example A, the LTE mobile station cannot use CCE #1 to 8 and also CCE #9 to 16 in a case in which a resource element region is divided every eight CCEs. By contrast with this, with allocation B, the LTE mobile station cannot use only CCE #1 to 8.
[0068] Here, allocation B may be an allocation example in which a basic number of CCEs is 4. That is, with allocation example B, CCEs+ are allocated based on a resource element region composed of a basic number of CCEs (hereinafter referred to as “basic resource element region”).
[0069] To be more specific, if possible, a plurality of PDCCHs+ are assigned to a basic resource element region, like a case in which a resource element region is divided per CCE+. With allocation example B shown in FIG. 4 , two CCE+ #1 and CCE+ #3 in a case in which a resource element region is divided per CCE+, are allocated to a basic resource element region (CCE #1 to CCE #4).
[0070] Like in a case in which a resource element region is divided every two CCEs+, if it is possible to allocate only one PDCCH+ assigned to two CCEs+ to a basic resource element region, one PDCCH+ assigned to two CCEs+ is allocated, and then, the beginning of a region obtained by multiplying the basic resource element region by an integer is the beginning position of a region in which a PDCCH+ is assigned to the next two CCEs+.
[0071] With allocation example B shown in FIG. 4 , CCE+ #1, 3 in a case in which a resource element region is divided every two CCEs+, are allocated to a basic resource element region (CCE #1 to CCE #4). Then, the end position of the basic resource element region is the beginning position of the next two CCEs+ of CCE+ #5, 7.
[0072] When none of PDCCH+ corresponding to four CCEs+ or eight CCEs+ can be assigned to a basic resource element region, like in a case in which a resource element region is divided every four CCEs+ or eight CCEs+, a PDCCH+ corresponding to four CCEs+ or eight CCEs+ is assigned over a basic resource element region. When only one resource element region composed of four CCEs+ or eight CCEs+ is included in a basic resource element region, each beginning position in a case in which a resource element region is divided every four CCEs+ or eight CCEs+ is the end position of a region twice as large as the basic resource element region. When the number of basic resource elements included in a region divided every four CCEs+ or eight CCEs+ is equal to or more than two and less than four, each beginning position in a case in which a resource element region is divided every four CCEs+ or eight CCEs+ is the end position of a region four times a basic resource element region.
[0073] In this way, with allocation example B, one of the numbers of CCEs to allocate a PDCCH to, is selected as the basic number of CCEs, and the beginning position of a resource element region composed of CCEs+ to allocate a PDCCH+ to, matches the beginning position of a region obtained by multiplying a basic resource element region by an integer. By this means, even if CCEs and CCEs+ exist together, it is possible to increase available CCE numbers or CCE+ numbers, as compared to allocation example A. As described above, allocation B is suitable for a case in which the number of LTE mobile stations is great because the allocation of LTE+ PDCCHs+ little influence the allocation of LTE PDCCHs.
[0074] [Configuration of a Base Station Apparatus]
[0075] FIG. 5 shows primary components in a base station that allocates PDCCHs or PDCCHs+ to CCEs or CCEs+ using CCE+ number assignment mapping for assignment shown in the above-described allocation example A or allocation example B.
[0076] Base station 100 shown in FIG. 5 has radio receiving section 101 , demodulation and decoding section 102 , ACK/NACK receiving section 103 , control section 104 , CCE and CCE+ mapping section 105 , modulation and coding section 106 , RE (resource element) mapping section 107 and radio transmitting section 108 .
[0077] Radio receiving section 101 receives a signal transmitted from a mobile station via an antenna, applies radio processing such as down-conversion on the signal and outputs a received signal after radio processing to demodulation and decoding section 102 and ACK/NACK receiving section 103 .
[0078] Demodulation and decoding section 102 demodulates and decodes the received signal to acquire received data.
[0079] ACK/NACK receiving section 103 receives an ACK/NACK signal from a mobile station, and outputs an ACK/NACK signal to control section 104 .
[0080] Control section 104 generates control signals. Control signals include uplink and downlink assignment information, power control information and so forth. Control section 104 outputs control signals to CCE and CCE+ mapping section 105 .
[0081] CCE and CCE+ mapping section 105 assigns PDCCHs or PDCCHs+ including control signals, to CCEs or CCEs+. Here, CCE and CCE+ mapping section 105 allocates PDCCHs or PDCCHs+ including control signals to CCEs or CCEs+, based on CCE+ number assignment mapping according to the above-described allocation example A or allocation example B. CCE and CCE+ mapping section 105 employs allocation example A or allocation example B, so that it is possible to reduce the number of candidates for beginning positions in blind detection in the receiving side. CCE and CCE+ mapping section 105 outputs PDCCH or PDCCH+ assignment information to RE mapping section 107 .
[0082] Modulation and coding section 106 modulates and encodes transmission data to acquire a modulated signal, and outputs the modulated signal to RE mapping section 107 .
[0083] RE mapping section 107 maps PDCCHs or PDCCHs+ to REs, according to assignment information given by CCE and CCE+ mapping section 105 , maps the modulated signal to REs, and outputs a modulated signal after mapping to radio transmitting section 108 .
[0084] Radio transmitting section 108 applies radio processing such as up-conversion to the modulated signal and transmits the result to a mobile station via an antenna.
[0085] [Configuration of a Mobile Station]
[0086] FIG. 6 shows primary components in a mobile station that receives LTE+ system signals transmitted from base station 100 . Mobile station 200 shown in FIG. 6 has radio receiving section 201 , control signal extracting section 202 , CRC (cyclic redundancy check) section 203 , control section 204 , modulation section 205 , RE mapping section 206 , demodulation and decoding section 207 , error detecting section 208 , modulation and coding section 209 , and radio transmitting section 210 .
[0087] Radio receiving section 201 receives a signal transmitted from a base station via antenna, applies radio processing such as down-conversion to the signal, and outputs a received signal after radio processing to control signal extracting section 202 and demodulation and decoding section 207 .
[0088] Control signal extracting section 202 receives blind detection candidate information, as input, and performs blind detection of CCEs+ directed to mobile station 200 from PDCCHs+. Blind detection candidate information indicates candidates for the beginning position of each CCE+, and control signal extracting section 202 searches for CCEs+ assumed as candidates for beginning positions to extract CCEs+ directed to mobile station 200 . Upon extracting a control signal directed to mobile station 200 , control signal extracting section 202 outputs the control signal to CRC section 203 .
[0089] CRC section 203 performs CRC check on the control signal outputted from control signal extracting section 202 . For example, CRC section 203 demasks CRC bits with the ID number of mobile station 200 , and, when CRC=OK (no error), outputs the control signal to control section 204 and RE mapping section 206 . In addition, CRC section 203 outputs a CRC detection result to control section 204 . Moreover, CRC section 203 determines an ACK/NACK transmission position, based on the CCE+ number from which a control signal directed to mobile station 200 is extracted, and outputs information about the determined transmission position to RE mapping section 206 .
[0090] Control section 204 extracts downlink assignment information and uplink assignment information from control signals, and determines an ACK/NACK transmission position based on CCE+ numbers. Control section 204 outputs downlink assignment information to demodulation and decoding section 207 . In addition, control section 204 outputs uplink assignment information to RE mapping section 206 . Moreover, control section 204 generates ACK/NACK, based on the error detection result from error detecting section 208 , and outputs ACK/NACK to modulation section 205 . Here, if the CRC check result from CRC section 203 represents CRC=NG (error present), it is not possible to generate assignment information, so that output of ACK/NACK is cancelled.
[0091] Modulation section 205 modulates ACK/NACK information and outputs modulated ACK/NACK to RE mapping section 206 .
[0092] RE mapping section 206 maps transmission data and ACK/NACK to REs, based on uplink assignment information and the ACK/NACK transmission position, and outputs the result to radio transmitting section 210 .
[0093] Demodulation and decoding section 207 demodulates and decodes a received signal, based on downlink assignment information outputted from control section 204 , and outputs received data to error detecting section 208 .
[0094] Error detecting section 208 detects whether or not there is an error in received data, and outputs the error detection result to control section 204 . In addition, error detecting section 208 outputs received data to a received data processing section (not shown).
[0095] Modulation and coding section 209 modulates and encodes transmission data and control signals to acquire a modulated signal, and outputs the acquired modulated signal to RE mapping section 206 .
[0096] Radio transmitting section 210 applies radio processing such as up-conversion to the modulated signal, and transmits the result to base station 100 via antenna.
[0097] The CCE+ number assignment method, and the primary components in a base station and an LTE+ mobile station according to the present embodiment have been explained.
[0098] As described above, with the present embodiment, a number is selected, as a CCE+ number, from the CCE numbers of CCEs to allocate PDCCHs to, which are assigned to a resource element region composed of CCEs+ to allocate PDCCHs+ to. By this means, the same number is not selected between the CCE numbers of CCEs to allocate PDCCHs to, and the CCE+ numbers of CCE+ to allocate PDCCHs+ to, so that it is possible to prevent ACK/NACK collisions.
[0099] In addition, CCEs+ are allocated to be stuffed from the beginning of a resource element region to which PDCCHs can be allocated. By this means, it is possible to limit the beginning positions of CCEs+, so that it is possible to reduce the number of times of blind detections and the amount of reception processing in a mobile station in the receiving side. In addition, if the number of CCEs+ is great, it is possible to secure a continuous remaining resource element region, and allocate CCEs corresponding to a small number of CCEs+, or CCEs+, so that it is possible to effectively use resources.
[0100] Moreover, one of the numbers of CCEs to allocate PDCCHs to, is selected as a basic number of CCEs, and the beginning position of a resource element region composed of CCEs+ to allocate PDCCHs+ to, matches the beginning position of a region obtained by multiplying a basic resource element region by an integer. By this means, it is possible to increase available CCE numbers or CCE+ numbers, and allocation of PDCCHs+ little influence allocation of PDCCHs, so that it is possible to improve efficiency of use of frequencies even if the number of LTE mobile stations is great.
Embodiment 2
[0101] With the present embodiment, a case will be explained where a LTE+ CCE+ is composed of forty-eight REs, and four LTE CCEs correspond to three CCEs+. In this case, like in Embodiment 1, a number is selected, as a CCE+ number, from the CCE numbers of CCEs to allocate PDCCHs to, which are assigned to a resource element region composed of CCEs+ to allocate PDCCH+ to. By this means, even if LTE PDCCHs and LTE+ PDCCHs+ are transmitted at the same time, the same number is not selected between CCE numbers and CCE+ numbers, so that it is possible to reduce the rate of collisions of ACK/NACK associated with CCE numbers and CCE+ numbers.
[0102] FIG. 7 shows an allocation example of CCEs and CCEs+ according to the present embodiment.
[0103] In the example shown in FIG. 7 , a resource element region composed of four CCEs of CCE #1 to CCE #4 is divided into three CCEs+. Then, three numbers, to be more specific, “1”, “2”, “3” are selected in this order, from four CCE numbers (1, 2, 3, 4) assigned to the resource element region composed of four CCEs, and the selected numbers are assigned as CCE+ numbers.
[0104] As described above, it is anticipated that the amount of control information that should be transmitted with LTE+ is greater than with LTE, due to increase in the number of antennas and assigned bands. Therefore, the size of a CCE+ needs to be greater than the size of a CCE. With the allocation example, a CCE+ is composed of 36×4/3=48 REs. In this way, with the present embodiment, a size greater than the size of a CCE is assured for a CCE+.
[0105] In this case, when PDCCHs+ are allocated to CCE+ #1, #2 and #3 in a LTE+ system, CCEs and CCEs+ are allocated as shown in FIG. 7 , so that PDCCHs are prevented from being allocated to CCE #1 to #4 in an LTE system. Meanwhile, when PDCCHs are allocated to CCE #1 to #4 in an LTE system, PDCCHs+ are prevented from being allocated to CCE+ #1 to #4.
[0106] In this way, PDCCHs and PDCCHs+ are allocated using common rules between LTE and LTE+. By transmitting ACK/NACK using PDCCHs and PDCCHs+ allocated as described above, the same number is not selected between the CCE numbers of CCEs to allocate PDCCHs to, and the CCE+ numbers of CCEs+ to allocate PDCCHs+ to, so that it is possible to prevent ACK/NACK collisions. By this means, an LTE+ mobile station can transmit an ACK/NACK signal at the same time as an LTE mobile station does so.
[0107] Here, FIG. 7 shows allocation of CCE numbers and CCE+ numbers, and, at a time of transmission, the order of CCEs and CCEs+ are exchanged by interleaving CCEs and CCEs+ on a per REG (resource element group) basis, where an REG is obtained by dividing CCEs and CCEs+ every four REs.
Allocation Example C
[0108] FIG. 8 shows allocation example C in which it is possible to reduce the number of times of blind detections.
[0109] With allocation example C, CCEs+ are allocated to be stuffed from the beginning of a resource element region composed of CCE #1 to CCE #16. That is, candidates for beginning positions in a case in which a resource element region is divided per CCE, are the beginning position of CCE #i (CCE number is i) satisfying CCE #i mod 4=1, a position obtained by shifting from this beginning position of CCE #i by a resource element region composed of one CCE+ (forty-eight REs) and a position obtained by shifting from this beginning position of CCE #i by a region (ninety-six REs) twice as large as a resource element region composed of one CCE+.
[0110] In this way, by adopting an allocation in which the beginning position of a resource element region composed of consecutive three CCEs+ matches the beginning position of a resource element region of CCE #i satisfying CCE #i mod 4=1, it is possible to limit candidates for beginning positions, to the beginning position of CCE #i, a position obtained by shifting from this beginning position of CCE #i by (48×K) REs and a position obtained by shifting from this beginning position of CCE #i by (96×K) REs, so that it is possible to narrow down candidate positions for blind detection in the receiving side.
[0111] In addition, when the number of CCEs+ is K (K is an integer and K≧2), a candidate for the beginning positions of a CCE+ is the beginning position of CCE #i satisfying CCE #i mod (4×K)=1.
[0112] As described above, with allocation example C, it is possible to limit CCE+ beginning positions, so that it is possible to reduce the number of times of blind detections and the amount of reception processing in the receiving side.
[0113] In addition, CCEs+ are stuffed to be allocated, leaving no space, from the beginning of a resource element region, so that it is possible to allocate CCEs+ without a remainder unless the resource element region is divided every more than four CCEs.
Allocation Example D
[0114] FIG. 9 shows allocation example as another allocation example.
[0115] With the above-described allocation example C, like in allocation example A, when CCE numbers that can be received by an LTE mobile station are only #1 to #12, if an LTE+ mobile station uses CCE+ #3, 5 in a case in which a resource element region is divided every two CCEs+, the LTE mobile station cannot use CCE #3 to CCE #6 in a case in which a resource element region is divided per CCE, and cannot use CCE #5 to 8 and CCE #9 to 12 in a case in which a resource element region is divided every four CCEs either.
[0116] As described above, with allocation example C, like in allocation example A, when the number of CCEs and the number of CCEs+ are greater, the beginning position of a resource element region composed of j CCEs is shifted from the beginning position of a resource element region composed of j CCEs+. As a result of this, when the number of CCEs (or CCEs+) is greater, if a certain CCE+ number is being used, the number of available CCE numbers (or CCE+ numbers) decreases.
[0117] Therefore, allocation example D will be presented in which, when the number j of CCEs and the number j of CCEs+ are great, the beginning position of a resource element region composed of j CCEs matches the beginning position of a resource element region composed of j CCEs+.
[0118] With allocation example D shown in FIG. 9 , a case is set to prevent decrease in resources for LTE CCEs when LTE+ CCEs+ are allocated to a resource element region composed of sixteen CCEs, from the beginning.
[0119] With allocation example D shown in FIG. 9 , like in allocation example B, when the number of CCEs+ is K (K=2, 4, 8), the beginning position of CCEs+ is a position satisfying CCE #i mod (2×K)=1.
[0120] Meanwhile, the number of CCEs+ is K (K=1), like allocation example C, candidates for beginning positions in a case in which a resource element region is divided per CCE+, are the beginning position of CCE #i (CCE number is i) satisfying CCE #i mod 4=1, a position obtained by shifting from this beginning position of CCE #i by forty-eight REs and a position obtained by shifting from this beginning position of CCE #i by ninety-six REs.
[0121] By this means, the beginning positions in a case in which a resource element region is divided every two CCEs+ match the beginning positions in a case in which a resource element region is divided every four CCEs, and the beginning positions in a case in which a resource element region is divided every four CCEs+ match the beginning positions in a case in which a resource element region is divided every eight CCEs. In this way, by matching the beginning position in a case in which a resource element region is divided every j CCEs+ with the beginning position in a case in which a resource element region is divided every 2j CCEs, it is possible to reduce cases in which a plurality of CCEs are unavailable if a certain CCE+ is selected.
[0122] For example, when an LTE+ mobile station selects CCE+ #5, 6 in a case in which a resource element region is divided every two CCEs, CCEs+ unavailable for an LTE mobile station are CCE #5, #6 and #7 in a case in which a resource element region is divided per CCE, CCE #5, 6, and CCE #7, 8 in a case in which a resource element region is divided every two CCEs, CCE #5 to 8 in a case in which a resource element region is divided every four CCEs, and CCE #1 to 8 in a case in which a resource element region is divided every eight CCEs. Accordingly, it is possible to reduce the number of CCEs unavailable for an LTE mobile station, as compared to a case in which an LTE+ mobile station selects CCE #3, 5 in a case in which a resource element region is divided every two CCEs+ with allocation example C.
[0123] Here, allocation example D may be an allocation example in which a region composed of four CCEs is a basic resource element region. That is, with allocation example D, CCEs+ are allocated based on this basic resource element region composed of four CCEs.
[0124] To be more specific, like a case in which a resource element region is divided per CCE+, a plurality of PDCCHs+ each corresponding to one CCE+ are assigned to a basic resource element region, a plurality of CCEs are assigned to a basic resource element region. In allocation example D shown in FIG. 9 , three CCEs+ #1, #2 and #3 in a case in which a resource element region is divided per CCE+, are assigned to a basic resource element region (CCE #1 to CCE #4).
[0125] Like in a case in which a resource element region is divided every two CCEs+, when it is possible to allocate only one PDCCH+ corresponding to two CCEs+, to a basic resource element region, one PDCCH+ corresponding to two CCEs+ is allocated, and then the beginning position of a region obtained by multiplying a basic resource element region by an integer is the beginning position of a region in which a PDCCH+ corresponding to the next two CCEs+ is allocated.
[0126] In allocation example D shown in FIG. 9 , CCE+ #1, 2 in a case in which a resource element region is divided every two CCEs+, are allocated to a basic resource element region (CCE #1 to CCE #4). Then, the end position of the basic resource element region is the beginning position of the next two CCEs+ of CCE+ #5, 6.
[0127] Like in a case in which a resource element region is divided every four CCEs or eight CCEs, when it is possible to allocate no PDCCH+ corresponding to four CCEs+ or eight CCEs+, a PDCCH+ corresponding to four CCEs+ or eight CCEs+ are allocated over a basic resource element region. When a basic resource element includes only one region composed of four CCEs+ or eight CCEs+, each beginning position in a case in which a resource element region is divided every four CCEs+ or eight CCEs+ is the end position of a region twice as large as a basic resource element region. When the number of basic resource element regions included in a region composed of four CCEs+ or eight CCEs+, is equal to or more than two and less than four, each beginning position in a case in which a resource element region is divided every four CCEs+ or eight CCEs+, is the end position of an region four times a basic resource element region.
[0128] The CCE+ numbers assignment method has been explained where an LTE+ CCE+ is composed of forty-eight REs, and four CCEs correspond to three CCEs+. Here, the configuration of a base station that assigns PDCCHs or PDCCHs+ to CCEs or CCEs+, using CCE+ numbers assigned as described above, is the same as in Embodiment 1, and also the configuration of a mobile station that receives signals transmitted from the base station is the same as in Embodiment 1.
Embodiment 3
[0129] With Embodiment 2, a case has been explained where a CCEs+ is composed of forty-eight REs, and the number of CCEs+ is 1, 2, 4 and 8. With the present embodiment, a CCE+ is composed of forty-eight REs and the number of CCEs+ is 1, 3 and 6.
Allocation Example E
[0130] FIG. 10 shows allocation example E according to the present embodiment. With allocation example E, when a CCE+ is composed of forty-eight REs, that is, four CCEs correspond to three CCEs+, the number of CCEs+ is 1, 3 and 6. By this means, it is possible to match the beginning positions in a case in which a resource element region is divided every three CCEs+ with the beginning positions in a case in which a resource element region is divided every four CCEs. In addition, it is possible to match the beginning positions in a case in which a resource element region is divided every six CCEs+ with the beginning positions in a case in which a resource element region is divided every eight CCEs.
[0131] In this way, when four CCEs correspond to three CCEs+, the number of CCEs+ is 1, 3 and 6, so that it is possible to match the beginning positions in a case in which a resource element region is divided every 3×q CCEs+ with the beginning positions in a case in which a resource element region is divided every 4×q CCEs (here, q is a natural number). As a result of this, when a certain CCE+ is selected, it is possible to reduce cases in which a plurality of CCEs are unavailable.
[0132] For example, when an LTE+ mobile station selects CCEs+ #5, 6, 7 in which a resource element region is divided every three CCEs+, an LTE mobile station can select CCE #1 to 4 and also CCE #9 to 12 in a case in which a resource element region is divided every four CCEs.
[0133] That is, a resource element region composed of N CCEs is divided into M CCEs+, and, when N CCEs correspond to M CCEs+, the number of CCEs+ is K=1, M×L. Here, L represents the number of CCEs, where, with LTE, L=2q −1 (q is a natural number). When the number of CCEs+ is K=1, M×L, it is possible to match the beginning positions in a case in which a resource element region is divided every Mxq CCEs+ with the beginning positions in a case in which a resource element region is divided every Nxq CCEs (M and N are natural numbers).
[0134] As described above, it is anticipated that the amount of control information that should be transmitted with LTE+ is greater than with LTE, due to increase in the number of antennas and assigned bands. Therefore, the size of a CCE+ needs to be greater than the size of a CCE. Here, when N is a natural number and N>M, it is possible to assure a size greater than the size of a CCE as the size of a CCE+. In addition, a size smaller than twice the size of a CCE may be enough for a required size of a CCE+, so that M and N may be set to satisfy N/M<2. By this means, it is possible to efficiently assign LTE+ control information, to resources.
[0135] In this way, when M (M is a natural number) multiples of a resource element region consisting of one CCE+ is equal to N multiples of a resource element region consisting of one CCE, the number K of CCEs+ is 1, M×L. For example, if N=4 and M=3, the number K of CCEs+ is 1, 3 and 6 . . . , and, this is equivalent to allocation example E.
[0136] Here, with allocation example E, N is equivalent to any of the number L of CCEs. To be more specific, with allocation example E, N=4 and a resource element region composed of four CCEs is assigned to M (=3) CCEs+, so that it is possible to match the beginning positions in a case in which a resource element region is divided every 3×q CCEs+ with the beginning positions in a case in which a resource element region is divided every 4×q CCEs, and allocate CCEs and CCE+ without a remainder.
[0137] As described above, with the present embodiment, M (M is a natural number) multiples of a resource element region consisting of one CCE+ is equal to N (N is a natural number, N>M and N<M<2) multiples of a resource element region consisting of one CCE, and, when N CCEs correspond to M CCEs+, the number K of CCEs+ is 1, M×L. Bt this means, it is possible to match the beginning positions in a case in which a resource element region is divided every Mxq CCEs+ with the beginning positions in a case in which a resource element region is divided every Nxq CCEs (q is a natural number), and therefore, when a certain CCE+ is selected, it is possible to reduce cases in which a plurality of CCEs are unavailable.
[0138] In addition, when N is equal to any of the numbers L of CCEs, it is possible to allocate CCEs and CCEs+ without a remainder.
[0139] Here, the configurations of a base station and a mobile station that assign control signals to CCEs and CCEs+ using CCE+ numbers assigned as described above, are the same as in Embodiment 1.
[0140] Also, although cases have been described with the above embodiment as examples where the present invention is configured by hardware, the present invention can also be realized by software.
[0141] Each function block employed in the description of each of the aforementioned embodiments may typically be implemented as an LSI constituted by an integrated circuit. These may be individual chips or partially or totally contained on a single chip. “LSI” is adopted here but this may also be referred to as “IC,” “system LSI,” “super LSI,” or “ultra LSI” depending on differing extents of integration.
[0142] Further, the method of circuit integration is not limited to LSI's, and implementation using dedicated circuitry or general purpose processors is also possible. After LSI manufacture, utilization of a programmable FPGA (Field Programmable Gate Array) or a reconfigurable processor where connections and settings of circuit cells within an LSI can be reconfigured is also possible.
[0143] Further, if integrated circuit technology comes out to replace LSI's as a result of the advancement of semiconductor technology or a derivative other technology, it is naturally also possible to carry out function block integration using this technology. Application of biotechnology is also possible.
[0144] The disclosure of Japanese Patent Application No. 2008-250618, filed on Sep. 29, 2008, including the specification, drawings and abstract, is incorporated herein by reference in its entirety.
INDUSTRIAL APPLICABILITY
[0145] The CCE+ number assignment method and the base station apparatus according to the present invention are useful as a CCE+ number assignment method and a base station apparatus for an LTE+ system in a mixed system in which a LTE system and the LTE+ system exist together.
REFERENCE SIGNS LIST
[0000]
100 Base station
101 , 201 Radio receiving section
102 , 207 demodulation and decoding section
103 ACK/NACK receiving section
104 Control section
105 CCE and CCE+ mapping section
106 , 209 Modulation and coding section
107 , 206 RE mapping section
108 and 210 Radio transmitting section
200 Mobile station
202 Control signal extracting section
203 CRC section
204 Control section
205 Modulation section
208 Error detecting section | A CCE+ number allocation method reduces the ACK/NACK (Acknowledgment/Negative Acknowledgment) collision probability in a mixed system containing an LTE (Long Term Evolution) system and an LTE+ (Long Term Evolution Advanced) system. A CCE (Control Channel Element)+ number is defined by selecting a number from CCE numbers of the CCE to contain PDCCH (Physical Downlink Control Channel) allocated in a resource element region constituting CCE+ where PDCCH+ is arranged. This can prevent overlapped selection of the CCE number and the CCE+ number even when the PDCCH and the PDCCH+ are simultaneously transmitted, thus making it possible to reduce the collision probability of ACK/NACK correlated to the CCE number and the CCE+ number. | 7 |
FIELD OF THE INVENTION
The present invention relates to a system for determining the pressure exerted on an object passed between two rollers, at least one of which is provided with a relatively hard core having a resilient cladding. The invention further relates to a sensor used in the previously mentioned system and to a method for manufacturing the sensor.
BACKGROUND OF THE INVENTION
Devices in which paper, films or other relatively thin sheet-like materials are conveyed, such as printing presses, copying machines and the like, frequently use combinations of rollers pressed against each other between which the paper, film or the like are passed. In general, at least one of the rollers is provided with a resilient outer layer of material such as, for example, rubber.
In the conveyance of paper by means of such roller combinations, it is important to have a uniform constant pressure distribution in the nip between the rollers parallel to the center lines of the rollers. If the pressure near the shaft ends is, for example, higher than the pressure at the center, then the resilient outer layer of material will be compressed more at the ends than at the center. This results in a local increase in the speed of the resilient material and consequently a local increase in the speed with which the paper is conveyed between the rollers. This may cause the paper to be folded, creased or even start to tear. Further, if the paper is introduced asymmetrically between the rollers, then the nonuniform pressure distribution will result in the paper running askew, which, in most cases, is very undesirable.
Others have attempted to design devices for measuring the pressure between the rolls in a nip. Such devices are shown in U.S. Pat. Nos. 3,418,850 and 4,016,756 and in several foreign patent applications: European Patent Application No. 91,089; German Patent Application No. 26,53,556 and French Patent Application No. 2,351,722. Typically, these devices utilize piezoelectric effects such as described in U.S. Pat. No. 4,499,394; Japanese Patent Abstract No. 59-94028, Vol. 8, No. 211 (Sept. 26, 1984) and an article entitled "Piezo polymer promises low-cost robotic sensors" in Electronic Design, Vol. 31, No. 11 (May 1983).
None of these devices, however, provides a system by which the pressure which is exerted on the paper, film or the like during conveyance through a roller combination can be determined locally to optimize the adjustment of the rollers and thereby avoid the undesirable consequences mentioned above.
SUMMARY OF THE INVENTION
Generally, the present invention provides a system for determining the pressure exerted on an object passed between two rollers, at least one of which is provided with a relatively hard core having a resilient cladding, comprising: (a) a pressure-sensitive sensor consisting of a laminated film comprising in sequence: a first layer of electrically conducting material, a layer of polyvinylidene fluoride, a second layer of electrically conducting material having one or more detector regions which make no electrical contact with the part of the second layer situated around them, a layer of dielectric material and a third layer of electrically conducting material; (b) a transmission/receiving device, for generating an ultrasonic wave in the sensor, provided with a means for presenting a transmission pulse to the detector regions of the sensor via one or more lines connected to the respective detector regions while the first and third electrically conducting layers and the surrounding part of the second layer are grounded; (c) a means for detecting a receiving pulse occurring in the sensor due to the ultrasonic wave reflected against the roller core; and (d) a means for determining the time interval between the transmission pulse and the receiving pulse to determine therefrom the instantaneous thickness of the resilient cladding and, on the basis thereof, the pressure which is exerted on the object.
As will be further discussed in more detail, the layer of polyvinylidene fluoride has piezoelectric properties. By means of the transmission device, an electrical pulse is presented to selected detector regions. Because of the piezoelectric properties of the polyvinylidene fluoride layer, a vibration is generated in the layer resulting in the emission of an ultrasonic energy pulse. This pulse is coupled into the resilient cladding of the roller on the side of the first layer of electrically conducting material. After propagation through the cladding, the pulse is reflected against the relatively hard roller core, passes back through the cladding and reaches the sensor, where an electric field is generated in the polyvinylidene fluoride layer which can be detected by the receiving device. From the time difference between the transmission pulse and the receiving pulse, a conclusion can be drawn regarding the local thickness of the resilient cladding and, consequently, regarding the extent of compression of the cladding, which is related to the pressure which is exerted on the sensor.
A fundamentally important component of the system according to the present invention is the sensor. The invention is, therefore, directed not only to the system as a whole but also to the sensor which can be used in the system. According to the present invention, the sensor is made from pressure-sensitive material consisting of a laminated film. The thickness of the laminated film corresponds at least approximately to the thickness of the objects to be conveyed between the rollers. The length of the laminated film is maximally equal to the length of the nip between the rollers to be examined. The width of the laminated film is sufficient for it to be possible to realize the lines to the transmission/receiving device.
Generally, the film comprises, in sequence: a first layer of electrically conducting material; a layer of polyvinylidene fluoride; a second layer of electrically conducting material having one or more detector regions which make no electrical contact with the part of the second layer situated around them and wherein at least one detector region, and preferably all, consists of an elongated region which is in line at a predetermined mutual distance to the elongated region of another detector region, a conductor region which runs approximately essentially perpendicular to the elongated region and which is connected to a connection region; a layer of dielectrically conducting material; and a third layer of electrically conducting material.
The present invention further relates to methods for manufacturing the laminated film which can be used to form the sensor of the system according to the present invention.
Other advantages of the invention will become apparent from the detailed description and the accompanying drawings of the presently preferred embodiment of the best mode of carrying out the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 represents a partial section through the film material from which the sensor according to the present invention is constructed.
FIG. 2 represents a plane view of the second layer of electrically conducting material in which detector regions are provided.
FIG. 3 shows diagrammatically a combination of rollers in which the system according to the present invention is used for determining the pressure which is exerted by the rollers on an object in the nip between two rollers.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Before preferred embodiments of the system according to the present invention are discussed, the sensor which is used in the system will be described in detail.
FIG. 1 shows a section through a part of a laminated film. As shown in FIG. 1, the film is constructed of a first layer 10 of electrically conducting material that is situated on a layer 11 of polyvinylidene fluoride. Layer 11 is attached via an adhesive layer 15 to a second layer 12 of electrically conducting material. Layer 12 is situated on a layer 13 of dielectric material which in turn is covered by a third layer 14 of electrically conducting material. Finally, a layer 16 of flexible material such as silicone rubber is disposed at the top of the laminated film.
FIG. 2 shows a plan view of second layer 12 of electrically conducting material. This layer is provided with a number of detector regions which each consist of an elongated region 20 and a conductor region 21 adjoining approximately perpendicular to elongated region 20. Conductor region 21 is connected at its other end to a connection region 22. Each of these essentially T-shaped detector regions is separated by a small gap from the remaining part of layer 12. All the elongated regions 20 lie in a line on a strip of layer 12, which strip is gripped between the rollers during the use of the film.
The operation of the sensor is based on the properties of polyvinylidene fluoride layer 11. Polyvinylidene fluoride, abbreviated in the literature to PVDF or PVF 2 , a semi-crystalline polymer. The material is readily manufactured in the forms of a film and has, in addition to crystalline properties, also amorphous properties such as flexibility and unbreakability. The film consists of carbon (C) chains with hydrogen (H) and fluoride (F) branches. The H and F atoms provide a dipole moment. These dipoles can be aligned at elevated temperature (approximately 70° C.) by stretching the film and applying an electric field. If the dipoles are aligned and subsequently "frozen in," then the film exhibits piezoelectric properties. The internal dipoles are compensated for at the surface of the film.
If the film is now compressed as a result of an external pressure in the thickness direction, then the internal dipoles will become less oriented and the dipole moment will decrease because the lattice distances are compressed. The result is that the compensation charge has to be removed and this can be detected externally.
If, on the other hand, the compensation charge is disturbed by the presentation of an external electric field, this will result in a mechanical compression/expansion of the film, which provides the possibility of generating an ultrasonic pulse by means of a high frequency electric field.
In the configuration of FIGS. 1 and 2, the polyvinylidene fluoride layer 11 with the first electrically conducting layer 10 at the top and the second electrically conducting layer 12 at the bottom is, in fact, used for piezoelectric conversion. During use, layer 10 is grounded. The connection regions 22 of the detector regions 20 of layer 12 are connected to suitable measuring instruments and the remaining part of layer 12 is grounded. If a pressure is then exerted on the film causing the film to be deformed in the thickness direction locally and, in particular, at the position of the elongated regions 20 of the detector regions, then this mechanical deformation will bring about an electric charge displacement which can be detected via the measuring instruments connected to the detector regions.
If, on the other hand, a high-frequency electric field is applied across layer 11 via the detector regions, as a reaction thereto, there will be generated in layer 11 an ultrasonic wave which in principle is emitted both upwards and downwards. The ultrasonic vibration emitted towards the bottom in FIG. 1 is damped by the further layers of the film assembly. In layers 12, 13 and 14, the acoustic energy is virtually completely absorbed. If the layers 12 and 14 are manufactured from copper and if layer 13 is manufactured from capton, then only 1% of the signal generated in layer 11 is transmitted. A further consequence of this damping at the bottom of the film assembly is that the mechanical vibration in layer 11 decays very rapidly after termination of the activating electric field so that the sensor can be switched over rapidly from transmission to receiving.
Like the uppermost conducting layer 10, the lowermost, third conducting layer 14 is also grounded when the film is in use and these layers together form a Faraday cage, as a result of which an effective screening against external interfering effects is obtained.
Layer 16 at the top is manufactured from a material with a low acoustic impedance, for example silicone rubber, by which a good transmission and a good coupling of the acoustic vibration onto the resilient cladding of the roller are obtained.
In FIG. 3, an arrangement is shown very diagrammatically of two rollers 31 and 32 with a relatively thin sensor 34 between them. The roller 31 is provided with a hard inflexible core and an outer layer 33 of resilient material such as, for example, rubber. Roller 32 is shown as a hard roller, but the present invention can also be used for two rollers which are both provided with a resilient cladding. Sensor 34 is connected to a measuring apparatus 36 via lines 35. Lines 35 include signal lines to each of the connection regions 22 of sensor 34 and also at least one ground line.
Measuring apparatus 36 is a device known per se, for example the ultrasonic test apparatus USIP 12 made by Krautkramer. By means of the test apparatus, an electric high-frequency pulse is transmitted at a predetermined time instant t 0 to sensor 34, as a result of which, in the manner previously described, an ultrasonic vibration is generated by each of the detector regions in sensor 34. This vibration is emitted at the top to roller 31. As has already been discussed, the ultrasonic vibration at the bottom, in the direction of roller 32, is damped in sensor 34 itself. The emitted ultrasonic vibration passes through the resilient cladding 33, is reflected by the hard core of roller 31 and returns to sensor 34. The returning ultrasonic vibration generates an electric pulse at time instant t 1 in sensor 34 which is fed to measuring apparatus 36. In measuring apparatus 36, the time difference t 1 -t 0 is determined, which time difference is a measure of the thickness of resilient cladding 33 in the nip between rollers 31 and 32.
As is indicated diagrammatically in FIG. 3, the resilient cladding 33 is somewhat deformed by the presence of sensor 34. By means of a suitable number of detector regions in the film, it is now possible to determine over the whole width of the nip whether or not this deformation is uniform.
The sensor illustrated in FIGS. 2 and 3 may be manufactured by fabricating a first part assembly consisting of a dielectric film to which a layer of electrically conducting material is applied on both sides. This first part assembly then comprises the layers 12, 13 and 14. Copper is preferably used for layers 12 and 14, and capton is preferably used for layer 13. However, other conducting materials and other dielectric materials can also be used.
The pattern of the detector regions in the layer 12 can be manufactured by any method suitable therefor. Preferably, however, use is made of an etching process to remove the narrow strips of material between the detector regions and the remaining part of second layer 12.
A second part assembly is manufactured by providing a polyvinylidene fluoride film with an electrically conducting layer on one side. The second part assembly then comprises layers 10 and 11 of FIG. 1. Layer 10 of electrically conducting material is preferably manufactured from aluminum, but may also be manufactured from copper or another electrically conducting material. The two part assemblies are then bonded to each other by means of an adhesive layer 15 such as shown in FIG. 1. The adhesive layer consists, for example, of a solution of 5% Union Carbide 49001. This adhesive is applied at room temperature to the PVDF film by means of a so-called kiss coating. The bonding is then brought about under pressure and temperature (60° C.).
Top layer 16 consists of a material having a low acoustic damping, for example, silicone rubber. It is applied during the manufacture of the second part assembly or is applied after the two part assemblies are bonded to each other. In the case of silicone rubber, a so-called "air brush" method is preferably used to apply the silicone rubber to conducting layer 10.
While presently preferred embodiments of the invention have been shown and described in particularity, the invention may be otherwise embodied within the scope of the appended claims. | A system is provided for determining the pressure exerted on an object passed between two rollers. The system comprises a sensor of pressure-sensitive material and a transmission/receiving device for generating an ultrasonic wave in the sensor and then detecting the reflected pulse received by the sensor. The time difference between the transmission pulse and the pulse received by the sensor is related to the pressure exerted on the object in the nip. Preferably, the sensor consists of a laminated film comprising in sequence: a first layer of electrically conducting material; a layer of polyvinylidene fluoride; a second layer of electrically conducting material having detector regions; a layer of dielectric material; and a third layer of electrically conducting material. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the field of beverages, and more specifically, to beverages contained in bottles with removal caps. The present invention provides a container cap that can be retrofittedly placed upon the bottle after removing its original cap, in a manner that dispenses materials into the bottle. Commercial or other written indicia are carried on the external surfaces of the container cap.
[0003] 2. Description of the Prior Art
[0004] The beverage world today is largely possessed by bottled water contained in plastic bottles having virtually identical removable caps. Such caps are removed by twistable action, leaving a band or collar behind as the cap is removed, while simultaneously providing access for drinking to the top of the bottle. Beverages also comprise pre-mixed drinks with a plurality of different designs, requiring, among other things, refrigeration, dates of expiration and other indicators related to the shelf-life of the beverage.
[0005] Also well known in the art are water-soluble drink mixes that are sold in solid form. The consumer measures quantities of the dry material, adds the quantities in the proper ratio to water, and creates a flavored beverage. In these embodiments, the consumer is required to modulate the quantities, and mistakes result in under- or over-flavored mixtures.
[0006] In addition, it is important to maintain freshness of fluid-based products. This is particularly important when the material to be dispensed is vitamin-based, since it is known that water-miscible vitamins can lose their potency over time when in a fluid environment, through changes in temperature, pressure, and light. In addition, fluid-based products can interact with plastic bottles, causing an unpleasant taste and compromising the health of the user. Glass bottles are thereby required for some applications, which are more expensive and much heavier.
[0007] To address these concerns, efforts have been made to provide a universal cap design that contains dry or concentrated materials (e.g., vitamins, drink mixes and other flavors), such that the cap can be used with any number of fluid containers without the need for modifying the existing, standard, plastic bottle design. In other words, once the pre-existing cap for the bottle is removed, the new cap, containing the materials, can be retrofittedly installed on the top of the bottle, dispensing the materials into the fluid. The bottle can be shaken and the completed beverage created moments before consumption.
[0008] Many of these cap designs are embodied in the form of a simple container that holds the material to be dispensed. The contents of the container cap are often not identified, and the user often has no way of knowing if the materials contained in the particular container cap are intended for his/her consumption, or for someone else's consumption.
[0009] It is thus an object of the present invention to provide a universal, single-use cap containing materials for attachment to pre-existing fluid containers to permit dispensation of materials thereby maintaining the freshness of the beverage.
[0010] It is a further object of the present invention to provide a universal single-use cap that provides a commercial message or indicia on, or associated with, the cap.
SUMMARY OF THE INVENTION
[0011] To accomplish the above objectives, the present invention provides a container cap that is adapted for use with a drinking container, the container cap having a container portion having an interior that holds a material for mixing with the liquid in the drinking container, a first connector fluidly communicating with the interior of the container portion and removably coupled to the open mouth of the drinking container, a second connector fluidly communicating with the interior of the container portion, a cap removably coupled to the second connector, and a commercial message provided on the container portion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is an exploded perspective view showing a container cap according to one embodiment of the present invention in use with a conventional water bottle.
[0013] FIG. 2 is a perspective view of the container cap of FIG. 1 .
[0014] FIG. 3A is an exploded perspective view showing a container cap according to another embodiment of the present invention in use with a conventional water bottle.
[0015] FIG. 3B is a perspective view of the container cap of FIG. 3A shown in use with a conventional water bottle.
[0016] FIG. 4 is an exploded perspective view showing a container cap according to yet another embodiment of the present invention in use with a conventional water bottle.
[0017] FIG. 5A is an exploded perspective view showing a container cap according to yet a further embodiment of the present invention.
[0018] FIG. 5B illustrates the paper support of the container cap of FIG. 5A .
[0019] FIGS. 6-12 illustrate other embodiments of container caps according to the present invention.
[0020] FIG. 13A is an exploded perspective view showing a container cap according to another embodiment of the present invention in use with a conventional water bottle.
[0021] FIG. 13B is a perspective view of the container cap of FIG. 13A shown in use with a conventional water bottle.
[0022] FIG. 14 is an exploded perspective view showing a container cap according to yet a further embodiment of the present invention.
[0023] FIG. 15 is an exploded perspective view showing a container cap according to another embodiment of the present invention in use with a conventional glass beer bottle.
[0024] FIGS. 16A and 16B are exploded perspective views showing a container cap according to another embodiment of the present invention in use with a conventional beer can.
[0025] FIGS. 17 and 18 illustrate other embodiments of container caps according to the present invention that can be used with a conventional beer can.
[0026] FIGS. 19 and 20 illustrate other embodiments of container caps according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] The following detailed description is of the best presently contemplated modes of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating general principles of embodiments of the invention. The scope of the invention is best defined by the appended claims.
[0028] FIGS. 1-2 illustrate a container cap 20 according to one embodiment of the present invention. The container cap 20 can be a plastic container having a container portion 22 that holds a material. The material can be a vitamin, supplement, medication, flavoring, fruit or other concentrate, tea, coffee, energy ingredient, powdered milk, or alcohol, and can be provided in liquid, powder, dissolvable tablet or capsule, real fruit (e.g., slice of lemon, or berry) or any similar form that allows for the material to be quickly and conveniently emptied from the container portion 22 to be mixed or dissolved. The container cap 20 further includes a bottom connector 24 and a top connector 26 . The bottom connector 24 is provided in the form of a female connector, in this case with inner threads 28 that are adapted to threadably engage the outer threads 30 on the neck 32 of a conventional water bottle 34 . The top connector 26 is provided in the form of a male connector, in this case with outer threads 36 that are adapted to threadably engage the inner threads 38 of a cap 40 . The cap 40 can be embodied in the form of a conventional water bottle cap. A peel-off seal 42 can be provided at the mouth of the bottom connector 24 to prevent the material inside the container portion 22 from escaping.
[0029] It is also possible to provide a conventional filter or water purifiying element inside the container portion 22 . The filter can function to filter the water from the water bottle 34 , and the purifying element can function to purify the water from the water bottle 34 . This allows the water bottle 34 to be re-used with different sources of water, even water (e.g., tap water) that may need to be purified and/or filtered before being drinkable. A container cap 20 that contains such a filter and/or purifying element can even be useful for soldiers who often need to refill their drinking containers with non-filtered and non-purified water. A soldier can then carry such a container cap 20 for use in purifying and filtering any water that the soldier might find in a battle environment.
[0030] In use, the user can remove the conventional cap of a water bottle 34 that contains clear water or other beverage, then remove the seal 42 , and empty the material 44 (see FIG. 3 ) from the container portion 22 through the open mouth of the neck 32 into the bottle 34 to allow the material 44 to mix with the liquid inside the bottle 34 . The user can then screw the bottom connector 24 onto the neck 32 , unscrew (open) the cap 40 , and then drink the liquid contents of the bottle 34 through the open mouth of the top connector 26 . The liquid contents would flow from the bottle 34 , through the container portion 22 , and then out via the top connector 26 .
[0031] The present invention provides a commercial message 50 on the outer surfaces of the container portion 22 . The commercial message 50 can be a representation or description of the material contained in the container cap 20 , or it can be an advertisement message for another product or service or entity. FIGS. 1-3 illustrate three different examples of commercial messages 50 .
[0032] In addition to a commercial message 50 , other identification codes 52 (e.g., bar codes, SKUs), or even the name 54 of the user can also be provided on the outer surfaces of the container portion 22 . For example, a blank space 56 can be provided on part of the commercial message 50 where a user can write or otherwise inscribe his/her name, or write or inscribe an identification of the material 44 contained therein (e.g., “vitamins”, “fish oil”, “diabetes medication”). In this regard, the container cap 20 can be a re-useable container cap 20 which the user can use to hold vitamins, medication, flavoring, etc. In addition, the message 50 can be provided on a removable sheet 86 (see FIG. 8 ) so that the sheet 86 can be replaced by other sheets, such as when a different name or identification (e.g., medication) is to be attached to the container cap 20 .
[0033] The commercial message 50 does not need to be placed directly on the outer surface of the container portion 22 . For example, in FIGS. 3A and 3B , a cardboard or paper support 60 can be used to display the message 50 . The support 60 can be comprised of four sides 62 , 64 , 66 , 68 and a top side 70 , with an opening 72 provided in the top side 70 . The top connector 26 of the container cap 20 can be inserted through the opening 72 , with the top side 70 seated on the container portion 22 to be supported on the container cap 20 .
[0034] As another example, FIG. 4 shows a cardboard or paper support 74 that is comprised of two sides 76 , 78 that have opposing ends connected to each other to form a generally elliptical shape, and with an opening (not shown) in a top side (not shown) through which the top connector 26 of the container cap 20 can be inserted.
[0035] As a further example, FIGS. 5A and 5B show a laminated paper support 80 which is laminated or glued directly onto the outer surface of a circular container cap 20 . The support 80 has end portions 82 and 84 that extend beyond the central portion of the support 80 . Messages 50 can be provided on these end portions 82 , 84 , thereby providing more visibility or exposure for the message 50 because these end portions 82 , 84 extend beyond the body of the container cap 20 .
[0036] Although FIGS. 1 and 2 illustrate the container cap 20 as being made from a conventional plastic material, it is also possible to embody the container cap 20 in the form of other structures. For example, FIG. 6 illustrates the container portion 22 a of a container cap 20 a embodied in the form of a pouch, with a bottom connector 24 a and a top connector 26 a that are the same as the bottom connector 24 and top connector 26 described above. The cap 40 a can be embodied in the form of a conventional water bottle cap, and a peel-off seal 42 a can be provided at the mouth of the bottom connector 24 to prevent the material inside the container portion 22 a from escaping. The pouch can be made from a soft and flexible material similar to those used for the pouch-like beverages (e.g., children's drinks) that are available in the market today.
[0037] FIG. 7 illustrates the container portion 22 c made from a paper-like material similar to the material used for milk cartons. The container portion 22 c can be a six-sided container comprising five sides 110 , 112 (and two opposing sides and another side, all not shown in FIG. 7 ), and a sixth side comprised of a plurality of flaps 114 , 116 that can be folded to create the sixth side. The bottom connector 24 c, the top connector 26 c, the cap 40 c, and the seal 42 c can be the same as the bottom connector 24 , top connector 26 , cap 40 and seal 42 , respectively, described above.
[0038] The configuration of the container cap 20 can be varied as well. For example, FIG. 8 shows a container cap 20 b where the container portion 22 b is configured as a stepped circular container having two steps 92 and 94 that transition from one circular section to another circular section. The bottom connector 24 b can be the same as the bottom connector 24 described above, but a pivoting drinking lid 96 can be provided at the top instead of a combined top connector 26 and cap 40 . The pivoting drinking lid 96 can be pivotably coupled to an edge of the top surface 100 of the container portion 22 b, with a raised drinking hole 98 provided in the top surface 100 . A stem 102 protruding from the center of the bottom surface of the drinking lid 96 is adapted to be inserted into the hole 98 . As described above, the message 50 can be provided on a removable layer of material or sheet 86 that can be attached to the surface of the container portion 22 b by glue, heat shrink, stickers, or similar mechanisms.
[0039] Referring to FIG. 9 , the container cap 20 d can be configured like a figure having arms, with the message 50 d extending from the plane or surface of the container portion 22 d. The message 50 d can be molded as part of the container portion 22 d, and extended outwardly to accentuate or highlight the contents of the message 50 d. The bottom connector 24 d, the top connector 26 d and the cap 40 d can be the same as the bottom connector 24 , top connector 26 and cap 40 , respectively, described above. As shown in FIG. 9 , additional messages 50 can be provided on the surface of the container portion 22 d.
[0040] By providing the container cap 20 in different configurations, it is also possible to provide the container cap 20 in the form of a toy or amusement item. For example, FIG. 10 shows the container cap 20 e having its container portion 22 e configured as a toy truck which would itself be a commercial message, or would have a commercial message 50 e carried thereon. The bottom connector 24 e, the top connector 26 e and the cap 40 e can be the same as the bottom connector 24 , top connector 26 and cap 40 , respectively, described above.
[0041] Extending this concept further, FIG. 11 shows the container cap 20 f having its container portion 22 f configured as the body of a robot, with a commercial message 50 f carried thereon. A plurality of detachable moving ligatures 130 can be pivotably coupled to the body (i.e., the container portion 22 f ) of the robot. The bottom connector 24 f and the top connector 26 f can be the same as the bottom connector 24 and top connector 26 , respectively, described above.
[0042] The toy or amusement item can be separate from the container cap 20 and be removable therefrom. For example, FIG. 12 shows a container cap 20 g which can be the same as the container cap 20 described above, and a separate toy 120 that can be removably and threadably coupled to screws 122 provided on the outer surface of the container portion 22 g. The toy 120 can be a miniature skateboard with a threaded opening 124 at the center of its board. Commercial messages 50 g can be provided on the skateboard, and/or on the outer surface of the container portion 22 g.
[0043] The separate sheet 86 from FIG. 8 can be extended to cover more than the container cap 20 , including portions of the water bottle 34 . For example, FIGS. 13A and 13B show a sheet 86 h that contains a commercial message 50 h, with the sheet 86 h being long enough to extend past the container cap 20 b. The user can peel off the sheet 86 h from a backing (not shown) and apply the sheet 86 h to the container cap 20 b and the shoulder portion of the water bottle 34 after the container cap 20 b has been secured to the neck 32 of the water bottle 34 . As shown in FIG. 13B , the container cap 20 b would not be visible and the user can drink from the water bottle 34 via the container cap 20 b.
[0044] Electronic features can even be incorporated into the container cap 20 . FIG. 14 shows the container cap 20 of FIG. 1 being modified to include an external panel 140 that carries a speaker 142 , an on/off switch 144 , and a lighted message 150 . Circuitry 146 can be provided on the housing of the container portion 22 , and a power slot 148 can be provided on the housing of the container portion 22 to receive a battery 152 that is coupled to the circuitry 146 to power the speaker 142 and the lighted message 150 . The user can turn on the speaker 142 and the lighted message 150 by turning on the switch 144 . The message can be illuminated by a flashing or constant light, and the speaker 142 can emit an accompanying verbal or musical message.
[0045] The container cap 20 of the present invention is not limited to use with conventional water bottles. As shown in FIG. 15 , the container cap 20 k can be adapted to be secured to the open mouth 162 of a conventional glass beer bottle 160 . In this embodiment, the bottom connector 24 k can be modified to allow it to be securely screwed on to the mouth 162 . For example, the bottom connector 24 k can be cylindrical in nature with an annular band 166 provided along its outer surface. The connector 24 k can be inserted into the open mouth 162 of the bottle 160 until the band 166 abuts the mouth 162 , thereby securing the container cap 20 k at the mouth 162 .
[0046] Similarly, as shown in FIGS. 16A and 16B , the container cap 20 can be adapted to be secured to the top of a conventional aluminum beer can 170 . In this embodiment, the container portion 22 j can have a bottom wall 176 that has a spout 172 from the bottom wall 176 , with the spout 172 having a bottom opening 174 . A flared annular wall 175 extends from the container portion 22 j at the location of the bottom wall 176 , having a radius at its bottom edge 173 that is greater than the radius of the bottom wall 176 . The flared annular wall 175 is sized and configured to be placed about the flanged annular upper edge 177 of a conventional beer can 170 , and can be twisted to secure the flared annular wall 175 to the upper edge 177 . A seal 42 j can seal the bottom of the flared annular wall 175 . In use, the user can remove the seal 42 j, push the spout 172 through the opening 178 at the top wall 180 of the beer can 170 , and secure the flared annular wall 175 to the upper edge 177 . A message 50 j can be provided on the outer surface of the container portion 22 j.
[0047] It should be noted that the concepts shown in any of the drawings in this disclosure can be applied to any of the embodiments shown and described herein. For example, FIG. 17 shows the concepts of FIGS. 9 , 16 A and 16 B applied to a conventional beer can, and FIG. 18 shows the concepts of FIGS. 6 , 16 A and 16 B applied to a conventional beer can.
[0048] In addition, there are many ways to dissolve, mix or otherwise release the material 44 inside the container cap 20 to the liquid in the water bottle 34 , beer can 170 , or beer bottle 160 . The present invention describes the use of a seal 42 that can be removed to release the material 44 , but other techniques can be used with the present invention as well. For example, the material 44 can be retained inside the container portion 22 intermixed with the liquid as the liquid passes from the water bottle 34 through the container portion 22 . As another example, mechanisms can be provided inside the container cap 20 that break a seal to release the material 44 directly into the water bottle 34 when the user screws or otherwise engages the container cap 20 to the neck 32 of the water bottle 34 . Examples of these techniques and mechanisms are shown and described in U.S. Pat. No. 7,562,782 (Yorita), U.S. Pat. No. 6,527,109 (Schoo et al.), U.S. Pat. No. 7,614,497 (Dvorak et al.), U.S. Pat. No. 7,279,187 (Daniels et al.), U.S. Pat. No. 7,055,684 (Anderson), U.S. Pat. No. 3,156,369 (Bowes et al.), U.S. Pat. No. 7,172,095 (Marshall), U.S. Pat. No. 7,537,112 (Balazik) and U.S. Pat. No. 6,962,254 (Spector), among others, whose disclosures are incorporated by this reference as though set forth fully herein.
[0049] FIG. 19 shows additional modifications that can be made to the container cap 20 of FIG. 1 . The container cap 20 m in FIG. 19 can be the same as the container cap 20 in FIG. 1 , except that a third connector 25 m is provided in a side of the container body 22 m. The connectors 24 m and 26 m can be the same as the connectors 24 and 26 , respectively, and the cap 40 m and flap 42 m can be the same the cap 40 and flap 42 , respectively. The provision of the third connector 25 m allows the user with the option to add an additional material to the material mix inside the container portion 22 m. Specifically, a separate container portion 23 m containing the separate material can be provided, has a connector 27 m that can be removably connected to the connector 25 m to allow the material from the container portion 23 m to mix with the material in the container portion 22 m.
[0050] FIG. 20 illustrates a container cap 20 n that can be same as the container cap 20 m shown in FIG. 19 , so the same elements are provided with the same numeral designations except that an “n” is used in FIG. 20 instead of an “m”. In the container cap 20 n, a fourth connector 29 n is provided in a side wall of the container portion 22 n, and can be used to introduce yet another different material (as described below in connection with FIG. 19 for the connector 25 m ), or it can be used to receive a straw 31 n or other drinking mechanism so that the user can actually secure the cap 40 n to the top connector 26 n, and drink through the fourth connector 29 n.
[0051] While the description above refers to particular embodiments of the present invention, it will be understood that many modifications may be made without departing from the spirit thereof. The accompanying claims are intended to cover such modifications as would fall within the true scope and spirit of the present invention. | A container cap is adapted for use with a drinking container. The container cap has a container portion having an interior that holds a material for mixing with the liquid in the drinking container, a first connector fluidly communicating with the interior of the container portion and removably coupled to the open mouth of the drinking container, a second connector fluidly communicating with the interior of the container portion, a cap removably coupled to the second connector, and a commercial message provided on the container portion | 6 |
RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Patent Application Serial No. 60/288,861, filed on May 5, 2002, and entitled METHOD AND APPARATUS FOR FLUID TREATMENT BY REVERSE OSMOSIS UNDER ACIDIC CONDITIONS, the disclosure of which is incorporated herein by this reference.
TECHNICAL FIELD
[0002] This invention relates to a method for the treatment of acidic waters and wastewaters in membrane based water treatment, purification, and concentration systems, and to apparatus for carrying out the method. More particularly, the invention relates to methods for feedwater pretreatment and for operation of membrane based treatment systems such as reverse osmosis (“RO”) and nanofiltration (“NF”), which achieve increased solute rejection, thereby producing very high purity (low solute containing) product water, while significantly increasing on the on-stream availability of the water treatment equipment.
BACKGROUND
[0003] Naturally occurring acidic waters and acidic wastewaters from industrial processes are found in many geographical areas of the world. Conventional treatment methods commonly employed for treatment of such waters involve neutralization with alkali, to raise the pH, so that the water can be discharged or beneficially utilized. However, such methods are not always desirable, or even feasible in some instances, since such methods can add significant amounts of dissolved solids to the water. And, the cost of the necessary chemicals, and particularly the alkali, can be quite high.
[0004] If the treated water is to be utilized for potable applications, one commonly encountered standard which must be met is a World Health Organization criterion that potable water contain no more than 500 milligrams per liter of dissolved solids, and no more than 250 mg/l each of sulfate ion or chloride ion. However, criteria for reuse of water in most industrial applications are far stricter. Consequently, the common “straight neutralization” treatment process is not an acceptable option in a large number of water treatment applications.
[0005] In industrial applications, treatment/reclamation of acidic waters is most often presently based on ion-exchange or on reverse osmosis (RO) systems. Depending upon factors such as the level of hardness (polyvalent cations), total organic carbon (TOC), and other contaminants present in the water, anion-exchange can be used for treatment of such acidic feedwaters for the reduction/removal of acidity. Further, the addition of a cation exchange step before or after the anion exchange step can indeed produce water that is almost completely demineralized. For this process, a weak base, an intermediate base, or a strong base anion exchange resin is employed, either singularly or in combination.
[0006] The major advantages of such prior art ion exchange treatment methods include the following:
[0007] (1) In industry, the method is considered “passive”, meaning that the process is not sensitive to changes in the influent characteristics.
[0008] (2) Compared to conventional reverse osmosis, the method has lower capital cost.
[0009] The major disadvantages of such prior art ion exchange treatment methods include the following:
[0010] (1) The quality, type (e.g., sodium based), and quantity of alkali needed (for regeneration of the IX resin) are actually higher and/or more restrictive than that required for straight neutralization, so the cost of the necessary chemicals is quite high.
[0011] (2) A very substantial volume of anion exchange resin is necessary; such resin is generally quite expensive. Thus, the initial and replacement cost of ion exchange resin in such systems is quite high compared to a membrane based treatment system.
[0012] (3) Depending upon the specific variety of ion exchange resin utilized, fouling by total organic carbon (TOC) can be quite high. Unfortunately, fouled anion resin can be difficult and expensive to clean. And, non-ioniizable TOC components, such as IPA (iso-propyl alcohol) are not removed. Further, TOC components that are cationic in nature are not removed, either. Typically, removal of TOC, or at least significant reduction of TOC, is often an important requirement in a number of industrial applications where reuse of treated waters is desired.
[0013] In conventional membrane based systems that are used for treatment of acidic waste waters or of naturally acidic waters, the pH of the RO/NF feed is commonly adjusted by addition of alkali. Thus, such conventional RO/NF systems operate at, or reasonably close to, neutral pH conditions. With certain exceptions, conventional RO/NF systems are operated under such pH conditions in order to ensure that the RO/NF membranes are not damaged due to very high or to very low pH conditions. More fundamentally, for many commonly encountered membrane materials, the overall solute rejection across the membrane is typically highest at a pH of approximately 8. Thus, the conventional wisdom in the water treatment industry is to avoid operation of RO/NF membranes at low pH conditions.
[0014] Yet, some of the basic RO/NF process characteristics point to some particular potential advantages, when compared to ion exchange systems. For example:
[0015] (1) RO/NF will simultaneously remove cationic as well as anionic species.
[0016] (2) RO/NF will, in general, remove a larger percentage of the TOC present before fouling of the media or membrane becomes a major concern. For instance, RO is capable of removing about 80 %, or sometimes more, of non-ionizable species, such as IPA.
[0017] (3) The capital, as well as the operating costs of RO/NF systems, unlike those of ion-exchange systems, are not particularly sensitive to the influent water chemistry characteristics.
[0018] Nonetheless, the conventional RO/NF systems known to me for treatment of such acidic waters, whether for wastewaters or for naturally occurring waters, still exhibit major shortcomings. Such deficiencies include:
[0019] (1) The quantity and cost of alkali needed to neutralize the RO feed remain comparable to mere neutralization, alone. Consequently, overall treatment costs are high, since RO system capital and operating costs must be added to the costs of neutralization.
[0020] (2) The combination of pH neutralization followed by RO is fundamentally inefficient, since the total dissolved solids content is first increased by the pH neutralization step, but then the total dissolved solids content is decreased by the RO/NF step.
[0021] (3) RO/NF systems are quite susceptible to biofouling and/or particulate and/or organic fouling when they are operated at neutral or near neutral pH conditions. Unfortunately, however, the commonly utilized thin film composite membranes do not tolerate oxidizing biocides, such as chlorine. Consequently, control of biofouling is problematic, especially for treating waters containing organic contaminants.
[0022] Thus, a continuing demand exists for a simple, efficient and inexpensive process which can reliably treat acidic waters, whether naturally occurring or a wastewater from another process. It would be desirable to provide water of a desired purity, in equipment that requires a minimum of maintenance. In particular, it would be desirable to improve efficiency of feed water usage, and lower both operating costs and capital costs for water treatment systems, as is required in various industries, such as semiconductors, chemical production, mining, pharmaceuticals, biotechnology, and electric power plants.
[0023] Clearly, if a new water treatment process were developed and made available that combines the benefits of both conventional RO/NF membrane treatment and of ion exchange processes, particularly for the treatment of naturally occurring acidic waters as well as industrial waste waters, it would be of significant benefit. Additionally, such a process would be even more attractive if it were immune to the most vexing problems associated with either of reverse osmosis/nanofiltration or of ion exchange. In summary, an economically important new acidic water treatment process would necessarily offer some (if not most) of the benefits of both reverse osmosis and of ion exchange. At the same time, any such new process must be capable of effectively coping with the problems which beset the reverse osmosis/nanofiltration process or the ion exchange process.
OBJECTS, ADVANTAGES, AND NOVEL FEATURES
[0024] From the foregoing, it will be apparent that one important and primary object of the present invention resides in the provision of a novel method for treatment of water to reliably and continuously produce consistently pure water from acidic waters and wastewaters. More specifically, an important object of my invention is to provide a membrane based water treatment method which is capable of avoiding common pre-treatment costs and the operational fouling problems, so as to reliably provide a method of producing reliably pure water when operating at high efficiency. Other important but more specific objects of the invention reside in the provision of a method for water treatment as described in the preceding paragraph which has the following attributes:
[0025] (1) It is an advantage of my new process that on an overall “ownership and operating cost” basis, a process is provided which is cheaper to own and operate than conventional reverse osmosis/nanofiltration or ion exchange systems.
[0026] (2) It is an objective of the new process that it not require “close control”, and accordingly it is easily able to cope with variability of feedwater.
[0027] (3) It is an advantage of the new process that it is reliably capable of producing a consistently high quality product.
[0028] (4) It is an objective of the new process that reverse osmosis/nanofiltration membranes be arranged to as to render them unsusceptible to biological or organic fouling.
[0029] (5) It is an objective of the new process that simultaneous removal of cationic, anionic, and non-ionic contaminants be achieved.
[0030] (6) It is an objective that a very substantial portion of the TOC present be rejected or removed, independent of the ionic characteristics of the TOC components.
[0031] (7) It is an objective of my novel process that the addition of chemicals be minimized, not only as a matter of cost, but also as a matter of good environmental stewardship.
[0032] (8) It is an advantage that my novel process that it can be practiced utilizing easily available components that are routinely manufactured by various companies.
[0033] (9) It is a novel feature of my process for treating acidic waters and wastewaters that available components are integrated synergistically, rather than in a contradictory manner, in order to provide the fullest possible benefit of available process equipment.
[0034] (10) It is an advantage that a high recovery rate, or volumetric efficiency, can be achieved when treating acidic waters and wastewaters.
[0035] (11) It is yet another advantage that a membrane can achieve a much higher productivity (flux) compared to conventional systems, and can do so while minimizing or eliminating membrane fouling; importantly, this also reduces capital and operating costs.
[0036] (12) Simplification and cost reduction in reverse osmosis/nanofiltration pretreatment operations is also an objective which is easily attainable by the practice of my novel acidic water treatment process.
[0037] Other important objects, features, and additional advantages of my invention will become apparent to those skilled in the art from the foregoing, and from the detailed description which follows, and from the appended claims, in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
[0038] In order to enable the reader to attain a more complete appreciation of the invention, and of the novel features and the advantages thereof, attention is directed to the following detailed description when considered in connection with the accompanying drawings, wherein:
[0039] [0039]FIG. 1 illustrates a process flow diagram of the equipment utilized in a field test of my novel process for treating acid waters and wastewaters.
[0040] [0040]FIG. 2 illustrates a generalized process flow diagram for employing my novel water treatment process in a variety of applications and with a variety of feedwaters.
[0041] The foregoing figures, being merely exemplary, contain various process steps or treatment elements that may be present or omitted from actual implementations depending upon the circumstances. An attempt has been made to draw the figures in a way that illustrates at least those elements that are significant for an understanding of the various embodiments and aspects of the invention. However, various other process steps or treatment elements of an exemplary low pH membrane treatment process, especially as applied for different variations of the functional components illustrated, may be utilized in order to provide a complete water or wastewater treatment system suitable for use in a particular set of circumstances.
DETAILED DESCRIPTION
[0042] By means of extensive studies and the evaluation of the weaknesses of the existing processes, I have now developed a new water treatment process for the processing of acidic waters. Importantly, I have now confirmed that certain reverse osmosis/nanofiltration systems can be successfully operated at pH values as low as 2, often without any, or with minimal chemical or physical pretreatment. Currently, the lowest allowable pH limit is determined by the characteristics of commercially available reverse osmosis membranes, which is about a pH of 2.0, for continuous operation. In the future, if better (i.e., lower pH tolerant) membranes become available, my novel process will operate at even lower pH than the current limit of pH 2.0.
[0043] In spite of low pH operations, and contrary to conventional industry guidelines, extremely good rejection of cationic solutes, and of multivalent anionic solutes, is achieved. The rejection of sodium and ammonium ions is extraordinarily high, and this is a very significant and unexpected benefit from my new acidic water treatment process. The rejection of TOC is also very high under the process conditions of this new acidic water treatment process.
[0044] Also, I have found that the addition of a TOC removal step prior to feed of water to a low pH reverse osmosis membrane (or even after it, or even later after the anion exchange step) can produce desired low TOC levels in the final product water. Acceptable TOC removal methods include:
[0045] (1) bubbling, including the use of microbubles of air or an inert gas, in a storage tank or any other suitable column of water;
[0046] (2) mechanical or membrane treatment based degasification;
[0047] (3) ultraviolet radiation with 185 nm wavelength UV light, with or without the addition of oxidants such as hydrogen peroxide and/or ozone;
[0048] (4) addition of ferrous or ferric iron, along with hydrogen peroxide, if needed, for in-situe formation of Fenton's reagent, which is known to be an effective oxidant for removing TOC compounds; or
[0049] (5) addition of ozone to feedwater, or to product water.
[0050] An especially important application is possible when the hydrogen peroxide present from semiconductor manufacturing wastewaters is augmented with ferrous or ferric salts. In such a case, the oxidation products are typically organic acids, and or carbon dioxide, which can be effectively removed by an anion exchange step. In contrast, IPA cannot be removed by the anion exchange step, without prior oxidation, since it does not ionize.
[0051] Turning now to FIG. 1, the test setup for one evaluation of my treatment process for acidic wastewaters is shown. A three-stage reverse osmosis system was utilized. Feedwater having a conductivity of 2700 uS/cm was fed under pressure at 1.45 MPa at the rate of 2 m 3 /hr and at the pH of 2.6 and a temperature of 28 degrees C. to the first stage of the system. Subsequently, first stage reject was sent to the second stage at 1.4 MPa. Reject from the second stage was sent to the third stage at 1.35 MPa. Finally, rejected concentrate from the third stage was discharged at the pressure of 1.25 MPa and a pH of 2.4 at the rate of 0.5 m 3 /hr. The permeate from all three stages together was produced at the rate of 1.5 m 3 /h, a pressure of 0.3 MPa, and a conductivity of 28.5 uS/cm.
[0052] Overall, considering all three product stages, the product was produced at an average flux of 22.1 gallons per square foot per day (0.9 9089 m 3 /m2/day). This provided an overall recovery ratio of about 75%. The RO permeate was then sent to an anion exchanger at a pressure of 0.02 MPa, and produced a final effluent, after anion exchange, having a conductivity of 6.7 uS/cm.
[0053] The exemplary results of such testing, and in particular the very high purity of the RO product, as well as the quality of the final effluent from the anion exchange step, demonstrate the efficacy of this novel process.
[0054] In FIG. 2, a generalized flow schematic is illustrated for use of my novel acidic wastewater treatment process in industry. Raw acidic water 10 is provided, either directly, as shown, to a low pH RO unit 12 , or alternately, is routed through one or more pretreatment system components, as indicated in broken lines. First, the raw water 10 can be sent to a UV unit 20 , in which preferably hydrogen peroxide 22 and/or a source of ferrous or ferric iron 24 is provided. Then, the partially treated water is routed to a degas 30 or other liquid-gas contactor, for further removal of TOC components. Reject from the RO is sent for further treatment or discharge as appropriate. Permeate as indicated by line 32 is sent to an anion ion exchange (“I-X”) unit 34 . Then, the product from the ion exchange treatment is ready for use as makeup to an ultrapure water system 40 , or alternately, can be sent to primary mixed bed I-X units 42 and/or secondary mixed bed I-X units 44 . Then, the high purity water can be used, or further treated as appropriate, such as in a filter unit 50 or a second UV treatment apparatus 52 , before being sent to an ultrapure water (UPW) system 54 .
[0055] The process described herein can be practiced in membrane separation equipment which includes at least one separation unit having a membrane separator, to produce a low solute containing product stream and a high solute containing reject stream. In the process, a feedwater stream containing solutes therein is provided for processing. In some cases, the solutes may include at least one constituent that contributes to membrane fouling when the feedwater does not contain free mineral acidity. Before processing the feedwater in a membrane separator, the pH of the feedwater is adjusted, if necessary, to assure that at least some free mineral acidity is present in the feedwater as input to the membrane separator. The pH adjusted feedwater is fed through the membrane separation equipment, in which the membrane substantially resists passage of at least some dissolved species therethrough, to concentrate the feedwater to a preselected concentration factor, to produce
[0056] (i) a high solute containing reject stream, and (ii) a low solute containing product stream. Often, in this process, the pH of the feedwater is adjusted to a pH of about 4.3 or lower. Importantly, the process can be applied in applications where the membrane separator is a reverse osmosis membrane, or a nanofiltration membrane, or a loose reverse osmosis membrane.
[0057] For many important applications, the feedwater includes a total organic carbon (TOC) constituent, and the total organic carbon (TOC) is effectively removed from the product stream. For many applications, treatment objectives include removal of the TOC so that the TOC present in the product stream is approximately 10 percent or less of the concentration of such constituent in the feedwater. The process can be advantageously utilized when the TOC components include one or more substantially non-ionizable species, such as isopropyl alcohol, and acetone.
[0058] Other constituent removals are also of importance. For example, when the feedwater includes sodium ions, treatment in some applications be can be achieved to the degree where the product stream contains approximately two (2) percent or less of the sodium ion concentration present in the feedwater. And, when the feedwater includes ammonium ions, treatment in some applications can be achieved to the degree where the product stream contains approximately eight (8) percent or less of the ammonium ion concentration present in the feedwater. Where the feedwater includes chloride ions, treatment in some applications can be achieved to the degree that the product stream contains approximately twenty five (25) percent or less of the chloride ion concentration present in the feedwater. Where sulfate ions are present in the feedwater, treatment can be achieved to the degree that the product stream contains approximately one-half of one percent (0.5%) or less of the sulfate ion concentration present in the feedwater. However, with fluoride ions, it is common that the concentration of fluoride ions present in the product stream is approximately the same as the concentration of fluoride ions present in the feedwater stream.
[0059] As an additional step in the process of treatment of a feedwater at low pH in a membrane separation system, the free mineral acidity present in the product stream can be removed, at least to some desirable degree, if not substantially completely, by treatment in an anion exchange system. An appropriate anion exchange system could be (a) a weak base anion exchange system, (b) an intermediate base anion exchange system, or (c) a strong base anion exchange system. If desired, the anion exchange system can be set up to process the product stream to effectively removes all anions contained therein.
[0060] For further treatment effectiveness, particularly for removal of TOC, an additional feedwater treatment step, prior to treatment in the membrane separation unit, can be added. On suitable such treatment step includes the addition of either ferrous or ferric ions to the feedwater. In addition, in such a process, hydrogen peroxide could be further added, for example to create a Fenton's reagent for treatment of TOC. In this manner, total organic carbon constituents can be effectively eliminated the said product stream. Alternately, or additionally, the feedwater stream can be further treated prior to membrane separation by adding the step of irradiation of the feedwater stream with a UV light source, and in such a manner, the total organic carbon constituents can be effectively eliminated from the product stream. For yet further treatment to achieve high purity water effluent from the overall treatment process, the additional step of irradiation of the product water stream with a UV light source, so that the total organic carbon constituent is effectively eliminated from the product stream.
[0061] In yet another embodiment, the process further includes the step of ozonation of the feedwater stream with an ozone containing gas, and wherein the total organic carbon constituents are effectively eliminated from the product stream. Alternately, or additionally, the process can further include the step of ozonation of the product water stream with an ozone containing gas, so that the total organic carbon constituent is effectively eliminated from the product stream.
[0062] In yet another embodiment of the process of treating a feedwater in low pH membrane separation operation, in those cases where the feedwater contains hydrogen peroxide, either from an industrial process or via a prior treatment step, the process can be set up to further include the step of treatment of the feedwater stream in an activated carbon system, so that the hydrogen peroxide is effectively eliminated from the product stream.
[0063] Production of permeate product water at a production rate (flux) of at least 15 gallons per square foot per day is normally easily achievable. Importantly, the recovery is normally at least sufficient so that the ratio of the quantity of the product stream produced to the quantity of the feedwater stream provided is about seventy five (75) percent or more. In other embodiments, the recovery is sufficient so that the ratio of the quantity of the product stream produced to the quantity of the feedwater stream provided is about eighty (80) percent or more. In yet other embodiments, the recovery is sufficient so that the ratio of the quantity of said product stream produced to the quantity of said feedwater stream provided is about eighty five (85) percent or more. In still further embodiments, the recovery is sufficient so that the ratio of the quantity of the product stream produced to the quantity of said feedwater stream provided is about ninety (90) percent or more. In certain applications, it is anticipated that the recovery will be sufficient so that the ratio of the quantity of the product stream produced to the quantity of the feedwater stream provided is about ninety five (95) percent or more.
[0064] For still more treatment in combination with the basic low pH membrane separation process described herein, other pretreatment steps can be provided prior to acidification of the feedwater. Such pretreatment processes can include (a) media filtration, (b) cartridge filtration, (c) ultrafiltration, (d) nanofiltration, (e) oxidant removal, (f) softening, (g) cation exchange, (h) degasification, or (i) oxygen removal. In some embodiments, the pretreatment step of cation exchange is accomplished by weak acid cation exchange. In other embodiments, the pretreatment step of cation exchange is accomplished by the step of strong acid cation exchange. Also, the pretreatment step of oxidant removal can include the addition of sodium meta-bisulfite to said feedwater. More generally, the process provided herein can be fundamentally described as the treatment of a feedwater stream in membrane separation equipment, wherein the membrane separation equipment has at least one unit having a membrane separator, to produce a low solute containing product stream and a high solute containing reject stream. In the process, a feedwater stream containing solutes therein is provided, and the pH of the feedwater stream is adjusted, if necessary, to assure at least some free mineral acidity presence, to produce a pretreated feedwater stream. The pretreated feedwater stream, having a preselected pH, is passed through the membrane separation equipment, wherein the membrane substantially resists the passage of at least some dissolved species therethrough, to concentrate the pretreated feedwater to a preselected concentration factor. A high solute containing reject stream having a pH lower than the pretreated feedwater stream is produced. Also, a low solute containing product stream having a pH higher than the pretreated feedwater stream is produced.
[0065] The unique process disclosed herein can also be advantageously practiced by further including the step of utilizing the reject stream from the membrane separation step in the regeneration of a cation exchange system. For example, such a process could include the step of utilizing the reject stream as an acid source for regeneration of a weak acid cation exchange system. Or, such a process could include the step of utilizing the reject stream as an acid source for regeneration of said strong acid cation exchange system.
[0066] The method and apparatus for processing acidic waters via membrane separation equipment, and in particular, via the combination of reverse osmosis/nanofiltration and ion exchange equipment, by the process design as described herein, provides a revolutionary, paradoxical result, namely, simultaneous decrease in total dissolved solids in the water to be treated, and reliable, high purity in the purified RO permeate. This method of operating membrane separation systems, and in particular, for operating reverse osmosis systems, represents a significant option for treating acidic waters, while simultaneously reducing capital and operating costs of the water treatment system. Further, given the efficiencies, dramatically less usage of chemical reagents, whether for neutralization, or for ion exchange regenerant or for RO cleaning, will be achieved per gallon of product water produced.
[0067] It will thus be seen that the objects set forth above, including those made apparent from the proceeding description, are efficiently attained, and, since certain changes may be made in carrying out the above method and in construction of a suitable apparatus in which to practice the method and in which to produce the desired product as set forth herein, it is to be understood that the invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. For example, while I have set forth an exemplary design for treatment of acidic waters, other embodiments are also feasible to attain the result of the principles of the method disclosed herein. Therefore, it will be understood that the foregoing description of representative embodiments of the invention have been presented only for purposes of illustration and for providing an understanding of the invention, and it is not intended to be exhaustive or restrictive, or to limit the invention to the precise forms disclosed. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as expressed in the appended claims. As such, the claims are intended to cover the methods and structures described therein, and not only the equivalents or structural equivalents thereof, but also equivalent structures or methods. Thus, the scope of the invention, as indicated by the appended claims, is intended to include variations from the embodiments provided which are nevertheless described by the broad meaning and range properly afforded to the language of the claims, or to the equivalents thereof. | A process for treatment of water via membrane separation equipment. A feedwater is maintained or adjusted to a pH of 4.3 or lower, and fed to a membrane separation system. In this manner, species such as TOC become more ionized, and (a) their rejection by the membrane separation process is significantly increased, and (b) their solubility in the reject stream from the membrane process is significantly increased. Passage TOC through the membrane is significantly reduced. A recovery ratio of eighty percent (80%) or higher is achievable with most feedwaters, while simultaneously achieving a substantial reduction in cleaning frequency of the membrane separation equipment. The method is particularly useful for the preparation of high purity water. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to improvements in sewing machines. More particularly, the invention is directed to an improved mount for the needle bar of a sewing machine.
2. Description of the Prior Art
It is common practice in sewing machines to provide cylindrical or spherical type bearings at upper and lower portions of needle bars and to cause these bearings to move in such fashion as to impart zigzagging movements to the needle of a sewing machine while the needle is being moved into and out of work being sewed. One well known construction is that shown in U.S. Pat. No. 2,989,016 of R. E. Johnson for Sewing Machines wherein a needle bar is provided with upper and lower spherical bearings, the upper of which is pivoted about a fixed axis and the lower one of which swivels while a needle affixed to the needle bar is thereby caused to trace an arc conforming to an arc of the rotary loop taker of the machine.
In the prior art needle bar mountings for zigzagging machines, the needle bar bearings had to be accurately machined to reliably establish the path of the needle and its position relative to the hook of the rotary loop taker. It was therefor costly to produce these parts.
It is a prime object of this invention to provide a zigzag sewing machine with a stable inexpensive needle bar mounting effective to accurately maintain motion of the sewing needle along a path conforming to the arc of the rotary loop taker of the machine.
SUMMARY OF THE INVENTION
In a sewing machine according to the invention, a frame supporting a needle bar for reciprocation is mounted at a lower end portion on a leaf spring which is secured to a fixed member in the machine head and flexes about a transverse axis to permit zigzagging movements of the frame and needle bar. A flexible plastic coupling connected to the upper end portion of the needle bar frame and fixed member in the machine head causes the needle bar frame and needle bar, when zigzagging, to follow a curved path conforming to the arc of the rotary loop taker of the machine.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of a sewing machine according to the invention with a portion of the housing broken away to show internal parts;
FIG. 2 is an enlarged fragmentary front elevational view showing the needle bar frame and mounting therefor in the machine;
FIG. 3 is a sectional view taken on the plane of the line 3--3 of FIG. 2;
FIG. 4 is a sectional view taken on the plane of the line 4--4 of FIG. 2;
FIG. 5 is a sectional view taken substantially on the plane of the line 5--5 of FIG. 2;
FIG. 6 is a sectional view taken on the plane of the line 6--6 of FIG. 5;
FIG. 7 is a fragmentary front elevational view showing the spring mounting for the needle bar frame of the machine;
FIG. 8 is a top plan view of the rotary loop taker of the machine;
FIG. 9 is a perspective view on a reduced scale illustrating movement of a sewing machine needle with respect to a rotary loop taker of the machine;
FIG. 10 is an exploded perspective view of the needle bar frame and mounting therefor.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, reference character 10 designates a sewing machine housing including a base 12, an upright standard 14, and a bracket-arm 16 terminating in a head 18. A main driving shaft 20 is journaled at spaced locations in the frame in bearings including a bearing 23 located in a member 22 which is affixed to the head 18 by screws 24 and 26. The shaft drives a crank 28, and the crank acting through a link 30 imparts vertical reciprocating motion to a needle bar 32 which is slidably mounted in bearings 34 and 36 in a frame 38. As shown, the link 30 is pivotally mounted at one end on a boss 40 which is integral with the crank 28, and the other end is pivotally mounted on a stub shaft 42 which is integral with a sleeve 44 that is affixed to the needle bar 32.
Crank 28 imparts reciprocating movements in a conventional fashion to a needle thread take-up arm 46 which is integral with a link 47 having one end pivoted on boss 40 and the other end pivotally connected to one end of another link 48, the other end of the link 48 being pivotally mounted on a fixed stub shaft 50.
In accordance with the invention, a lower end portion 52 of the frame 38 is supported on a leaf spring 54 and an upper end portion 56 is connected to the member 22 through a flexible plastic coupling 58.
One part of the spring 54 is sandwiched between overlying and underlying members 60 and 62 respectively, and another part of the spring extends therefrom into a sandwiched relationship with an overlying member 64 and underlying member 66. Members 60 and 62 and the spring portion between them are mounted on a pin 68 affixed to an arm 70 of frame 38, and are secured to the arm 70 by a screw 72 and threaded fastener 74. Member 64 is an integral part of fixed member 22, and such member 64 with that portion of spring 54 which extends between members 64 and 66 are secured to the member 66 by screws 76 and 78 and a plate 80 that receives the screws in threaded holes 82 and 84 respectively.
Needle bar 32 extends through a hole 86 in a spring 54 and a finger 88 on the member 60 extends on one side of the needle bar to a point slightly (such as 1/32 inches) beyond the center line of the needle bar. Member 66 extends partially around the needle bar and terminates at 90 and 92 very slightly (as about 1/64 inches) beyond the center line of the needle bar. Member 62 terminates at 93 under finger 88 of member 60 slightly short (as about 1/32 inches) of the needle bar center line.
The plastic coupling 58 connecting the upper end portion 56 of frame 38 to member 22 includes a semispherical projection 94 which rides in a socket 96 located in the frame 38, and includes another semispherical projection 97 which rides in a socket 100 located in a flanged portion 102 of member 22. The coupling 58 is held in an assembled relationship with the frame 38 and flanged portion 102 of member 22 by springs 104 and 106 which bear against protuberances 108 and 110 respectively on the coupling. As shown, the springs are integral parts of a bracket 108 which is secured to member 22 by a screw 110 and threaded fastener 112.
Needle bar 32 is vertically reciprocated as noted, that is, by the crank 28, and a needle 112 at the lower end of the bar is moved to perform a sewing operation. At the same time, an oscillating motion is imparted to the frame 38, and therefor also to needle 112 by a link 114 which is connected to the frame at 116 and is longitudinally reciprocated by the driving mechanism of the machine in customary fashion. The leaf spring 54 and plastic coupling 58 determine the particular manner in which the frame and needle move. The frame pivots while the spring flexes about a transverse axis in the spring substantially in the plane of the center line of the needle bar. In addition, the upper portion of the frame is caused to follow a curved path 117 in a more or less horizontal plane by the coupling 58, and the leaf spring twists slightly to accommodate this motion. The center-line distance between the sockets 96 and 100 wherein the semi-spherical projections 94 and 97 of the plastic coupling ride is such as to provide, between the extreme points of travel 118 and 120 of the needle, a path 122 concentric with the curvature of the rotary loop taker 124 of the machine.
Although the invention has been described in its presently preferred form, it is to be understood that the present disclosure is by way of example only and that numerous changes in construction and in the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention. | A sewing machine needle bar frame is pivotally supported at a lower end portion on a leaf spring which can bend to permit zigzagging, and the frame is made to follow a curved path, when zigzagging, through the use of a plastic coupling disposed between the upper portion of the needle bar frame and a fixed member in the machine head. | 3 |
REFERENCE TO PENDING PRIOR PATENT APPLICATION
[0001] The present application is a Divisional of U.S. patent application Ser. No. 13/623,895, filed Sep. 21, 2012, which claims the benefit under 35 U.S.C. 119 (e) of U.S. Provisional Patent Application No. 61/537,568, filed Sep. 21, 2012, by Hany A. Al-Ansary, et al., for “CERAMIC FOAM SOLAR SOLID PARTICLE RECEIVER,” which patent application is hereby incorporated herein by reference.
BACKGROUND
[0002] The general concept of a cavity receiver 5 for a solar central receiver system 10 can be described as follows. Sunlight is reflected from many mirrors (heliostats), such that most of the reflected sunlight is focused on one small area 15 at the top of a tower 20 . At that location, the concentrated sunlight is allowed to pass through the aperture of a cavity. The intense solar radiation entering the cavity is then used to heat a material, usually a fluid. The heat absorbed by the fluid can then be used to generate power in a variety of ways.
[0003] A different design, called the solid particle receiver, was first conceived in the 1980s. In this design, the material being heated within the cavity is solid particles 25 rather than a fluid. In the tests conducted on this concept, the solid particles were released from a long narrow slot located at the top of the cavity and were allowed to fall freely, forming what may be called a “curtain”. The concentrated sunlight passing through the aperture was captured directly by the solid particle curtain. As a result, the temperature of the solid particles rose significantly. See, for example, FIG. 1 .
SUMMARY
[0004] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key aspects or essential aspects of the claimed subject matter. Moreover, this Summary is not intended for use as an aid in determining the scope of the claimed subject matter.
[0005] In an embodiment, there is provided a receiver panel, configured to receive a curtain of particles in a solar central receiver system, the panel comprising a porous structure having a top end and a bottom end, the porous structure disposed between the top end and the bottom end, and the porous structure having a size to impede movement of the particles during downward travel from the top end to the bottom end.
[0006] In another embodiment, there is provided a solar central receiver system, comprising a plurality of receiver panels, an individual receiver panel configured to receive a curtain of particles, the panel comprising a porous structure having a top end and a bottom end, the porous structure disposed between the top end and the bottom end, and the porous structure having a size to impede movement of the particles during downward travel from the top end to the bottom end; a tower having an upper portion and a lower portion, the upper portion supporting the plurality of receiver panels in a configuration to receive solar irradiation; and a hopper positioned at a height above the plurality of receiver panels, the hopper forming a slot configured to dispose the particles at a given location on to the porous structure.
[0007] In yet another embodiment, there is provided a pipe configured to receive particles in a solar central receiver system, the pipe comprising an inlet portion not necessarily circular in cross section having a first cross section area, the inlet portion forming a passageway sized to transmit at least one of a fluid (such as a molten slat or other fluid) and a stream of solid particles; an outlet portion having a second shape and cross section area, the outlet portion forming a passageway sized to transmit the at least one of the fluid and the stream of solid particles; and a porous structure disposed between the inlet portion and the outlet portion, the porous structure having a size to impede movement of the at least one of the fluid and the stream of solid particles during downward travel from the inlet portion to the outlet portion.
[0008] In still another embodiment, there is provided a method of capturing solar energy with a solar central receiver system, the method comprising releasing a curtain of particles into a cavity configured to receive solar irradiation; and increasing a resident time of the curtain of particles falling through the cavity with a porous structure impeding the fall of the particles.
[0009] Other embodiments are also disclosed.
[0010] Additional objects, advantages and novel features of the technology will be set forth in part in the description which follows, and in part will become more apparent to those skilled in the art upon examination of the following, or may be learned from practice of the technology.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Non-limiting and non-exhaustive embodiments of the present invention, including the preferred embodiment, are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified. Illustrative embodiments of the invention are illustrated in the drawings, in which:
[0012] FIG. 1 illustrates prior art experiments on the solid particle receiver concept at Sandia National Laboratories;
[0013] FIG. 2 illustrates a general description of the cavity receiver, (a) illustrates a general layout of the receiver inside the tower, and (b) illustrates a composition of a single receiver panel;
[0014] FIG. 3 illustrates side view of the panel, showing one structural exemplary embodiment;
[0015] FIG. 4 illustrates an exemplary embodiment of solid particle flow within the porous structure;
[0016] FIG. 5 illustrates an exemplary embodiment of a staggered series having a staggered block formation;
[0017] FIG. 6 illustrates an exemplary embodiment of staggered series embodiment having a zig-zag pattern;
[0018] FIG. 7 illustrates an exemplary embodiment of a porous foam block with indented holes;
[0019] FIG. 8 illustrates an exemplary embodiment of a finned pipe;
[0020] FIG. 9 illustrates an exemplary embodiment of opaque surface;
[0021] FIG. 10 illustrates an exemplary embodiment of transmissive cover;
[0022] FIG. 11 illustrates an exemplary embodiment of mesh surface; and
[0023] FIG. 12 illustrates an exemplary embodiment of a simple cavity.
DETAILED DESCRIPTION
Overview
[0024] Embodiments are described more fully below in sufficient detail to enable those skilled in the art to practice the system and method. However, embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. The following detailed description is, therefore, not to be taken in a limiting sense.
[0025] The actual conversion efficiency of the system shown in FIG. 1 was relatively low for two main reasons:
1) Due to their free-fall from the long narrow slot, the solid particles 25 quickly attain high velocities such that there is not enough residence time for the particles to attain very high temperatures. 2) The presence of voids between the falling solid particles allows some of the incoming concentrated sunlight to penetrate the solid particle curtain 25 and hit the back wall of the cavity, instead of being directly utilized to heat the solid particles.
[0028] Embodiments described herein overcome issues with other solid particle receivers, and also add other enhancing features. FIG. 2 shows a general layout of a new receiver design 200 , which constitutes a core embodiment.
[0029] In one embodiment, the receiver consists of multiple panels 205 that are installed inside a cavity 210 having an aperture 215 and arranged in a general curved shape. The backsides 220 of all panels 205 may be fixed to a structure that can be easily assembled of disassembled for maintenance purposes. Cavity 210 is disposed at a top portion of a tower 225 .
[0030] In an embodiment, each panel may include three components: a porous structure (e.g., a foam block); a back plate; and an insulation block. However, the exact composition of the each panel may vary depending on design and operating conditions.
[0031] FIG. 3 is illustrative of an embodiment of a receiver panel 205 having different layers and is a side view. These layers may include a porous block 305 (or other porous structure 305 ). A back plate 310 may be provided together with an insulation block 315 .
[0032] The following is a description for a working procedure of an exemplary embodiment (see FIG. 4 ):
Solid particles 25 are released from one or more hoppers through a long slender slot and allowed to flow by virtue of gravity. The hoppers are made of appropriate size and flow regulation capabilities. Right after the point of release, the solid particles 25 are immediately allowed to go through the porous block 305 . The presence of numerous ligaments 405 within the porous structure 305 causes the solid particles 25 to collide with those ligaments 405 , thereby impeding their movement and reducing their speed. As the solid particles 25 trickle down the porous block 305 , the originally narrow “curtain” of solid particles 25 may spread. This depends on a number of parameters. The “curtain” spreads in the direction transverse to the general downward direction of solid particle movement due to the aforementioned collisions with the ligaments of the porous structure. As the concentrated sunlight irradiates the porous block 305 , the solar radiation may be partially absorbed by the slow-moving solid particles. Furthermore, any radiation that penetrates through the voids between solid particles 25 may mostly be absorbed by the ligaments 405 of the porous material 305 which, in turn, will transfer the heat to the solid particles 25 .
[0037] As FIG. 4 shows, it is preferable to have the point of release of solid particles 25 retarded or recessed from the front face of the porous foam block 25 . This minimizes radiation reflected by the solid particles 25 , which may not have optimal absorption.
[0038] Since solid particles 25 do not flow through a portion of the porous block 405 , referred to as foam buffer 410 , the buffer 410 is expected to be somewhat hotter than the solid particles. However, the particles 25 flow just behind the buffer 410 induce air flow through the buffer 410 to cause cooling.
[0039] The depth of the foam buffer 410 depends on the dispersion of solid particles 25 during trickle down through the porous foam block. This dispersion depends on a number of parameters, including grain size, initial and terminal velocity, particle sheet thickness, and the porosity and density of the porous foam.
[0040] Another feature that could be employed is preheating of solid particles prior to reaching one or more of the hoppers 415 . This can be done by taking advantage of the hot air that is expected to accumulate at the top of the cavity. The ramp that leads to the one or more hoppers can be designed in a way such that it will be in contact with the hot air. On the other side of the ramp, solid particles can slide down at relatively high speed, getting heated in the process, and making use of the expected high heat transfer coefficient.
[0041] This embodiment overcomes the issues encountered in earlier solid particle receiver designs in a number of ways:
[0042] By employing a cavity receiver 205 , radiation losses are minimized.
[0043] Collision of the solid particles 25 with the numerous ligaments 405 inside the porous block causes the flow of solid particles 25 to be impeded and its velocity to be reduced, thereby providing the solid particles 21 with longer residence time to absorb more energy.
[0044] The reduced velocity of solid particles 25 also reduces the voids between the particles 25 . Furthermore, even if some of the sunlight penetrates the voids between the solid particles 25 , it will be absorbed by ligaments 405 within the porous block 305 , which in turn, indirectly contributes to heating the solid particles 25 . Therefore, the solar energy conversion efficiency may be rather high.
[0045] Since most of the flowing solid particles 25 will be contained within the porous block 305 , solid particle drift due to wind is expected to be very small compared to other designs.
[0046] Finally, instead of porous blocks 305 , an embodiment can also be realized by the use of mesh screens, including metallic mesh screens or mesh screens made of other materials.
Staggered Series
[0047] In this embodiment, the velocity of solid particles is reduced intermittently by the use of obstacles of various forms.
[0048] Staggered Blocks or Meshes
[0049] FIG. 5 illustrates an embodiment of a staggered series of porous foam blocks 305 (or meshes 305 ) arranged vertically to temporarily arrest the free fall of particles 25 and form a panel 505 configured to be irradiated by concentrated sunlight 515 . The spacing 510 of the blocks/meshes 305 is set to control the overall residence time of the particles 25 from their point of release to their point of collection. In this variation, solid particles 25 are irradiated directly during their travel between blocks 305 .
[0050] FIG. 6 illustrates an embodiment of slanted porous foam blocks 305 (or meshes 305 or solid plates 305 ) arranged in a zig-zag pattern 605 to temporarily arrest the free fall of particles 25 and form a panel 610 to be irradiated by concentrated sunlight 615 . The spacing and angle of the blocks/meshes/plates 305 are set to control the overall residence time of the particles 25 and heat the particles passing through the irradiated panel 610 .
[0051] Surface with Front Holes
[0052] In this embodiment, and referring to FIG. 7 , a porous foam block 305 (or mesh screens 305 ) similar to those described above have indented holes 705 in the front surface 710 of the block 305 and arranged in a manner so as to influence the flow of particles 25 and form a panel configured to be irradiated by concentrated sunlight 715 . In this embodiment, more solid particles are allowed to absorb direct sunlight. The spacing of the holes 705 is set to control the overall residence time of the particles 25 and heat the particles passing through the irradiated panel.
[0053] Finned Pipe
[0054] In this embodiment, and referring to FIG. 8 , a porous foam block 305 or mesh screens 305 encase a pipe to form a panel 810 to be irradiated by concentrated sunlight 815 . A fluid 25 (or solid particles 25 ) may move through the pipe 805 and become heated as it passes though the irradiated panel 810 . In this embodiment, the porous foam block 305 (or mesh screen) 305 acts as fins that enhance the heat transfer to the pipe 805 due to the large internal surface area. In various embodiments, the pipe may be configured to receive particles in a solar central receiver system. The pipe may include an inlet portion, which may be circular or other shapes (i.e., the pipe is not necessarily circular in cross section.) The pipe may have a first cross section area. The inlet portion may form a passageway sized to transmit at least one of a fluid (such as a molten salt or other fluid), a stream of solid particles, or both the fluid and stream of solid particles. An outlet portion may be provided having a second shape and cross section area. The outlet portion may form a passageway sized to transmit one or both of the fluid or the stream of solid particles. A porous structure may be disposed between the inlet portion and the outlet portion. The porous structure may have a size to impede movement of the fluid, the stream of solid particles, or both, during downward travel from the inlet portion to the outlet portion.
[0055] In addition to the basic embodiments described earlier, there are a number of other considerations regarding materials used in building the receiver, working materials, surface treatment, as well as receiver location and arrangement.
[0056] Receiver Materials
[0057] The receiver panel may be made of any material that possesses high thermal conductivity and high-temperature durability. However materials of particular interest are silicon carbide, zirconia, titanium oxide, tungsten, and high-temperature steel alloys.
[0058] Working Materials
[0059] It is preferable that particulate materials used in conjunction with the embodiments discussed above possess have high absorptivity, small grain size, high melting point, and high cycling durability. Of particular interest are silica sand, fracking said, and fracking alumina beads. In an embodiment, a stream of particles may include a combination of a first set of particles and a second set of particles. The first set of particles may include natural particles having a given solar absorptivity. The second set of particles may include artificially created particles having a solar absorptivity greater than the first set of particles. In one embodiment, the higher absorptivity particles may be captured and recirculated through the receiver.
[0060] Surface Treatment
[0061] The surface which receives the incoming concentrated sunlight may be treated in many different ways. The following are exemplary surface treatments:
[0062] Natural Open Face
[0063] This is the surface type described in embodiments discussed above. However, the surface may have a coating to increase absorptivity to solar irradiation.
[0064] Opaque Surface
[0065] This is a surface that is sealed to prevent particles from escaping (see, for example, FIG. 9 ). As in the previous case, the surface may be treated with a coating 905 to increase absorptivity to solar irradiation.
[0066] Transmissive Cover
[0067] This is a clear layer 1005 over the front face to prevent particles from escaping and allow direct transmission of solar irradiation (see, for example, FIG. 10 ). A potential material for this layer is quartz.
[0068] Mesh Surface
[0069] This is a mesh layer 1105 over the front face to partially prevent particulates from escaping and partially allow direct transmission of solar irradiation (see, for example, FIG. 11 ). The mesh may be made of a high-temperature material such as tungsten.
[0070] Receiver Location and Arrangement
[0071] The receiver may be located inside a cavity, with a number of panels, and may be arranged in a generally curved shape. However, there are other possibilities for location of the receiver and its arrangement.
[0072] Simple Cavity
[0073] FIG. 12 illustrates a cavity 1205 with a general cubic shape, and the receiver is made of multiple panels 305 lining the sides of the cavity.
[0074] Flat Receiver
[0075] In its simplest form, the receiver can be flat, consisting of one or more panels. In this case, the receiver is not enclosed within a cavity.
[0076] Although the above embodiments have been described in language that is specific to certain structures, elements, compositions, and methodological steps, it is to be understood that the technology defined in the appended claims is not necessarily limited to the specific structures, elements, compositions and/or steps described. Rather, the specific aspects and steps are described as forms of implementing the claimed technology. Since many embodiments of the technology can be practiced without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended. | There is disclosed a receiver panel. In an embodiment, the panel is configured to receive a curtain of particles in a solar central receiver system. A porous structure of the panel has a top end and a bottom end. The porous structure is disposed between the top end and the bottom end. The porous structure has a size to impede movement of the particles during downward travel from the top end to the bottom end. There is disclosed a solar central receiver system. In an embodiment, the receiver system includes a plurality of receiver panels, a tower supporting the plurality of receiver panels in a configuration to receive solar irradiation, and a hopper forming a slot configured to dispose the particles at a given location on to the porous structure. Other embodiments are also disclosed. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This nonprovisional application is a continuation of currently pending PCT Application PCT/US2013/067046 filed Oct. 28, 2013, which claims priority to provisional application No. 61/718,945, entitled “Semiconducting Oxytelluride Single Crystal BA2TEO,” filed on Oct. 26, 2012 by the same inventors, and is incorporated by reference in its entirety.
STATEMENT OF GOVERNMENT SUPPORT
This invention was made with government support under C & E funds from the National High Magnetic Field Laboratory. The government has certain rights in the invention.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to novel semiconductor materials. More specifically, the invention relates to oxychalcogenide crystal compositions.
2. Brief Description of the Prior Art
There exists many more reported crystal structures of tellurates/tellurites containing cationic Te3+/4+, than for oxytellurides containing anionic Te2−. Yet, semiconducting oxytelluride systems may have promise in the field of commercialized optoelectronic applications like transparent semiconductors. The complex orbital hybridizations in anion-ordered multinary crystals like oxytellurides can give rise to unique physical properties. These systems are the cutting edge of applied semiconductor technology research, but further exploration for better suited materials could result in more efficient and/or more effective functional materials. in such a raw materials intensive market, though, a semiconductor that is comprised of the most abundant and/or inexpensive elements may be of the greatest commercial interest and have the most potential for large scale applications.
The copper-based oxychalcogenides (Liu 2007, Zakutayev 2010; Ueda, et al., Thin Solid Films 496 (2006) 8-15; Ohta, et al., Solid-State Electronics 47 (2003) 2261-2267), such as LaCuOX (X═S, Se) and La2O2CdSe2, are classes of materials which may have commercial applications. (Ueda, et al., Applied Physics Letters 77 (2000) 2701-2703; Huang, et al., Journal of Solid State Chemistry 155 (2000) 366-371; Kamioka, et al., Journal of Luminescence 112 (2005) 66-70; Ramasubramanian, et al., Journal of Applied Physics 106 (2009) 6). Transition metal oxysulfides like Sm2Ti2S2O5 have also been identified as stable catalysts for photo-oxidation and reduction of water. (Ishikawa, et al., Journal of the American Chemical Society 124 (2002) 13547-13553; Meignen, et al., Journal of Solid State Chemistry 178 (2005) 1637-1643).
BRIEF SUMMARY OF THE INVENTION
The long-standing but heretofore unfulfilled need for oxychalcogenides compounds containing both anionic chalcogenides and oxygen, and methods for manufacturing these compounds, is now met by a new, useful, and nonobvious invention.
The oxychalcogenide compounds may comprise a tetragonal crystal of repeating units of RX and RO where R is an alkaline earth metal cation, X is an anionic chalcogens, and O is oxygen. The anionic chalcogens may be tellurium, selenium or sulfur, and the alkaline earth metal cation is beryllium, magnesium, calcium, strontium, barium, radium or mixtures thereof, with the alkaline earth metal cation of RO is integrated into a crystalline structure with the unit of RX. Additionally, the molar ratio of the alkaline earth meal cation and the anionic chalcogens is 2:1.
These and other important objects, advantages, and features of the invention will become clear as this disclosure proceeds.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the invention reference should be made to the following detailed description, taken in connection with the accompanying drawings, in which:
FIG. 1 is a general flow chart of an exemplary method for producing oxychalcogenide crystals.
FIG. 2 is a general blow chart of an exemplary method for producing oxychalcogenide crystals.
FIG. 3 is a general flow chart of an exemplary method tier producing oxychalcogenide crystals.
FIG. 4 is an illustration of a crystalline structure.
FIG. 5 is an illustration of a crystalline structure having tetragonal symmetry.
FIG. 6 is an illustration of a single unit of a crystalline structure having tetragonal symmetry.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As used herein, “about” means approximately or nearly and in the context of a numerical value or range set forth means about ±15 percent of the numerical.
Oxytellurides (OR2Te) may be better suited as transparent conductors due to their high hole mobilities. Doping of the 5p orbitals of Te increases hole mobility and conduction in LnCuOTe (Ln=La, Ce, Nd) phases more than doping of the 3p/4p orbitals of S/Se in the corresponding LaCuO (S/Se) phases.
Using metal fluxes to grow oxide single crystals may generate an advantageous chemical growth environment since oxygen is a minority constituent of the system, with the metal flux acting as a reducing agent. Good oxygen solubility in the metal flux may therefore be beneficial, and preliminary synthesis experiments have indicated high oxygen solubility in alkaline earth fluxes. In addition, low growth temperatures are desirable for discovery activities, especially coupled with low cost crucible materials. The molten alkaline flux reactions create a unique single crystal oxide growth environment and may further allow control of dopant substitution, electron transfer, and phase selectivity. Since alkaline earth metals readily form solid solutions with lanthanide metals as well as group IIIB and IVB metals, complex intermetallic phases have been grown (Stojanovic, M. and Latturner, S. E. Growth of new ternary intermetallic phases from Ca/Zn eutectic flux. J. Solid State Chem. 180, 907-914 (2007); Latturner, S. E., Bilc, D., Mahanti, S. D. and Kanatzidis, M. G. R3Au6+xAl26T (R═Ca,Sr,Eu,Yb; T=Early Transition Metal): a Large Family of Compounds with a Stuffed BaHg11 Structure Type Grown from Aluminum Flux. Inorg. Chem. 48, 1346-1355 (2009); Latturner, S. E. and Kanatzidis, M. G. RE(AuAl2)nAl2(AuxSil-x)2: A New Homologous Series of Quaternary Intermetallics Grown from Aluminum Flux. Inorg. Chem. 47, 2089-2097 (2008)). The alkaline earth flux can be further modified to include transition element, expanding the possibilities of discovery of new phases.
Investigating the oxygen solubility in alkaline earth fluxes showed, surprisingly, that single crystal oxide growth is possible in this unique environment, and may allow for control of dopant substitution, electron transfer, and phase selectivity.
Slow cooling of the alkaline earth metal flux from about 1000° C. may kinetically force oxygen anion-metal cation organization that is high in cation concentration due to the presence of the flux. This bonding in the liquid flux may be relatively weak compared to more oxygen-rich combinations of the same ion pairs, which may allow for crystal growth. The use of eutectic mixtures therefore may allow for a temperature reduction well below the critical precipitation temperature for most oxide phases, effectively pitting thermal kinetic energy losses in competition with increased crystal lattice energies. This balance of equilibrium factors, combined with quick removal of the liquid solvent environment (quench), may lead to exclusive stabilization and isolation of metastable phases not formed at ambient temperatures and pressures.
FIG. 1 illustrates an exemplary method 100 for producing oxychalcogenide crystals according to various embodiments. At step 105 , a mixture may be provided that may have a molar ratio of about 20 R:1 RO:1 X, where R is an alkaline earth metal cation and X is an elemental chalcogen. In various embodiments, the alkaline earth metal cation may comprise barium (Ba), supplied as chunks or rods (99+ percent, Acros Organics), and the RO may comprise barium oxide (BaO), supplied in powder form (99+ percent, Cerac). The elemental chalcogen may be provided, for example, as tellurium powder (99.999 percent, Puratronic, AlfaAesar). The mixture may then be heated until the mixture melts (step 110 ), forming a molten barium flux. At step 115 , the mixture may be fluxed for about 10 hours while holding the mixture at a temperature of at least the melting point of the mixture. The mixture may then be allowed to cool (step 120 ), at which point one or more oxychalcogenide crystals may be removed from the mixture (step 125 ).
In various embodiments, doping may occur during the fluxing step in which a portion of the chalcogen anions in the crystal phase are replaced with a different anion. For example, a Group 15 pnictogen may be used to dope the material. In various embodiments, the pnictogen may be bismuth. The doping concentration may be on the order of Ba2OTe0.8Bi0.2. The doping anion may substitute up to about 20 atomic percent of the chalcogen anions. Experimentation has indicated that doping with bismuth may change the electronic conductivity of the material making the material more conductive, which may be useful for transparent semiconductor applications. In addition, the doped material may absorb light in the ultraviolet range, and may be suitable for an ultraviolet light emitting device.
FIG. 2 illustrates an exemplary method 200 for producing oxychalcogenide crystals according to various embodiments. Similar to method 100 , a mixture may be provided that may have a molar ratio of about 20 R:1 RO:1 X, were R is an alkaline earth metal cation and X is an elemental chalcogen (step 205 ). At step 210 , the mixture may be placed in a crucible under an inert atmosphere at elevated pressure, then the crucible may be welded shut. The crucible may also be sealed in quartz tubing under vacuum. The inert atmosphere may comprise argon gas at a pressure of about 1.5 atm. One Skilled in the art will readily recognize that other gas environments (comprising a single gas or mixture of gases) may be used in place of argon, and that other pressures may be used that are higher or lower than 1.5 atm. The mixture may then be heated to about 1000° C., and the mixture allowed to melt (step 215 ). The mixture may then be allowed to flux at about 1000° C. (or at least the melting point of the mixture) for about 10 hours (step 220 ). The mixture may then be allowed to cool to about 820° C. over a period of time ranging from about 24 hours to about 150 hours (step 225 ). The crucible may be opened in an inert atmosphere glovebox, and then one or more oxychalcogenide crystals may be removed from the mixture (step 230 ).
FIG. 3 illustrates a further exemplary method 300 for producing oxychalcogenide crystals in the form of R2XO according to various embodiments. Similar to method 100 , a mixture may be provided that may have a molar ratio of about 20 R:1 RO:1 X, where R is an alkaline earth metal cation and X is an elemental chalcogen (step 305 ). At step 310 , the mixture may be placed in a crucible under an inert atmosphere at elevated pressure, then the crucible may be welded shut. The crucible may also be sealed in quartz tubing under vacuum. The inert atmosphere may comprise argon gas at a pressure of about 1.5 atm. One skilled in the art will readily recognize that other gas environments (comprising a single gas or mixture of gases) may be used in place of argon, and that other pressures may be used that are higher or lower than 1.5 atm. The mixture may then be heated to about 1000° C., and the mixture allowed to melt (step 315 ). The mixture may then be allowed to flux at about 1000° C. (or at least the melting point of the mixture) for about 10 hours (step 320 ). The mixture may then be allowed to cool to about 820° C. over a period of time ranging from about 24 hours to about 150 hours (step 325 ). The crucible may be opened in an inert atmosphere glovebox, and then one or more crystals of R2XO may be removed from the mixture (step 330 ).
Elemental analysis using EDS in a JEOL 5900 scanning electron microscope indicated the stoichiometry of an exemplary oxychalcogenide with the formula Ba2TeO having a molar Ba:Te ratio of 2:1 to within about 5 atomic percent as shown in Table 1. The crystals had a platelet morphology and micacious cleavage.
TABLE 1
Result of Elemental Analysis
Intensity
Error
Element
Line
(c/s)
2-sig
Atomic %
O
Ka
0.00
0.000
0.000 †
Cu
Ka
3.13
1.119
0.334
Te
La
286.76
10.707
31.859
Ba
La
553.93
14.882
67.807
100.000
Total
† Element not detected because the atomic electron values were below the detection limits for the device.
The crystals were structurally characterized by single crystal x-ray diffraction using an Oxford-Diffraction Xcalibur2 CCD system. The as-grown crystals were transferred. from the glovebox under Paratone-N oil on a glass slide. The crystals were cleaved in the oil and shards of appropriate size were selected and mounted in cryoloops then aligned in a nitrogen stream for data collections at 200 K. Reflections were recorded, indexed and corrected for absorption using the Oxford-Diffraction CrysAlis software. Subsequent structure determination and refinement was carried out using SHELXTL. (Sheldrick, 2000).
A Quantum Design PPMS system was used to measure the zero-field heat capacity between 2 K and room temperature, with crystals embedded in grease. Electrical resistance was tested using 4-point contacts at room temperature. The optical reflectivity spectra of the crystals were collected with a 0.75 m focal length spectrometer and back-illuminated CCD configured to provide a spectral resolution of 1.2 nm, with a polished aluminum surface serving as a reference.
Atomic Structure and Chemical Stability
Ba2TeO is structurally comprised of one BaTe unit combined with one BaO unit. The normal structure type for both BaTe and BaO is the cubic “NaCl” structure type (Fm-3 m, #225). Single crystalline Ba2TeO was obtained in platelet form and had a metallic color. The crystals averaged about 4 mm×4 mm×0.5 mm and were mildly air sensitive, showing signs of decomposition within a few hours on the benchtop.
The atomic structure of Ba2TeO is tetragonal symmetry as illustrated in FIG. 4 . FIG. 5 shows an exploded view of the Ba2TeO crystal structure to better illustrate the tetragonal symmetry and the placement of the oxygen atoms within the structure. FIG. 6 illustrates a single unit of tetragonal symmetry for the Ba2TeO structure. The structure may have puckered square layers of BaO and 2D BaTe layers alternating in the a-b plane. There may be a shorter than expected bond between the Ba and O atom at 2.44 Å, which may be the result of the linking bond between the BaO and BaTe layers.
The disclosures of all publications cited above are expressly incorporated herein by reference, each in its entirety, to the same extent as if each were incorporated by reference individually.
Glossary Of Claims Terms
a-b plane: An atomic plane in a crystal lattice.
Alkaline earth metal: Metallic elements found in the second group (also known as Group IIA) of the periodic table, comprising beryllium (Be), magnesium (Mg), calcium (Ca), strontium (Sr), barium (Ba), and radium (Ra). Generally, very reactive metals that do not occur freely in nature.
Anionic: Having a negative electrical charge, such as an ion with more electrons than protons.
Ba2TeO: A semiconducting oxytelluride compound containing barium.
Barium: Chemical element (Ba) with atomic number 56. Barium is an alkaline earth metal.
Cation: An ion having fewer electrons than protons, thus having a positive charge.
Chalcogen: The elements sulfur (S), selenium (Se), and tellurium (Te).
Chalcogenide: A compound containing a chalcogen.
Crucible: A container that can withstand very high temperatures and is used for metal, glass, and pigment production as well as various other modern laboratory processes.
Crystal: Solid material whose constituent atoms, molecules, or ions are arranged in an orderly, repeating pattern extending in all three spatial dimensions.
Doping: The process of intentionally introducing impurities into a semiconductor to change the electrical properties of the semiconductor.
Fluxing: A process by which molten metals are brought into contact with one another to form an alloy. The flux may act as a reducing agent.
Oxychalcogenide: A compound containing a chalcogen ion and oxygen.
Oxygen: Chemical element (O) with atomic number 8.
Oxytelluride: A compound containing a telluride ion (Te2−) and oxygen.
Pnictogen: Elements found in the fifteenth group (also known as Group VA) of the periodic table, comprising nitrogen (N), phosphorus (P), arsenic (As), antimony (Sb), and bismuth (Bi).
Selenium: Chemical element (Se) with atomic number 34.
Sulfur: Chemical element (S) with atomic number 16.
Tellurium: Chemical element (Te) with atomic number 52.
Tetragonal structure: A crystalline structure with a four-fold symmetry axis.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall there between. | Single crystals of the new semiconducting oxychalcogenide phase were synthesized using a novel crystal growth method. The crystals had low defects and homogeneous composition as characterized by single crystal X-ray diffraction and scanning electron microscopy, respectively. Heat capacity and resistivity measurements were in agreement with the calculated band structure calculations indicating semiconductivity, with a band gap of about 3 eV. | 2 |
FIELD OF THE INVENTION
The present invention relates to facial imaging generally and more particularly to facial imaging in utero.
BACKGROUND OF THE INVENTION
Various techniques are known for facial imaging in utero using ultrasonic technology. The quality and completeness of such images is generally rather non-uniform and depends inter alia on the position of the face of a fetus relative to ultra-sound imaging apparatus. Conventional systems which provide facial imaging in utero are known inter alia from the following publications:
U.S. Pat. No. 5,239,591;
InViVo-ScanNT of the Fraunhofer Institut fuer Graphische Datenverarbeitung IGD in Darmstadt, Germany, commercially available;
3-D Ultrasound—Acquisition Methods Details, of Life Imaging Systems, Inc. of London, Ontario
UCSD radiologists are working on a new ultrasound technology that's guaranteed to produce much clearer images in three dimensions. by Kate Deely, UCSD Perspectives, Spring 1999;
Product literature relating to the following products:
Imaging software available from A 1 Alpha Space, Inc, of Laguna Hills, Calif., U.S.A. and from Echotech 3-D of Hallbergmoos, Germany;
HDI1500 commercially available from ATL—Advanced Technology Laboratories, Bothell, Wash., U.S.A.;
Voluson 530 D commercially available from Kretztechnik AG of Zipf, Austria and from Medison America of Pleasanton, Calif., U.S.A. This ultrasound system includes a scalpel feature which enables manual removal of occlusions blocking full visualization of a fetal face.
L 3 -Di commercially available from Life Imaging Systems Inc. of London, Ontario, Canada;
Echo-Scan, Echo-View and Compact3-D commercially available from TomTec Imaging Systems GmbH of Unterschleissheim, Germany;
NetralVUS, commercially available from ScImage, Inc. of Los Altos, Calif. 94022, U.S.A.;
3-Scape commercially available from Siemens AG of Erlangen, Germany;
Vitrea, commercially available from Vital Images, Inc of Minneapolis, Minn., U.S.A.;
VoxarLib, commercially available from Voxar Ltd. of Edinburgh, UK;
LOGIC 700 MR commercially available from GE Ultrasound.
SUMMARY OF THE INVENTION
The present invention seeks to provide an improved system for fetal face imaging in utero.
There is thus provided in accordance with a preferred embodiment of the present invention a system for providing an image of at least a portion of a fetus in utero including an imager providing image data for a volume including at least a portion of a fetus in utero, an at least partially computer controlled image processing algorithm based segmenter for defining geometrical boundaries of various objects in the volume including at least a portion of a fetus in utero, and a sculpting tool, utilizing the geometrical boundaries of at least some of the various objects defined by the segmenter, for selectably removing at least portions of the objects in order to provide a desired non-occluded image of at least a portion of the fetus in utero, based on the image data.
Further in accordance with a preferred embodiment of the present invention the imager is an ultrasound imager.
Still further in accordance with a preferred embodiment of the present invention the image data contains speckles.
Preferably the segmenter is fully automatic. Alternatively the segmenter is semi-automatic.
Additionally in accordance with a preferred embodiment of the present invention the segmenter operates substantially in real time.
Further in accordance with a preferred embodiment of the present invention the segmenter defines geometrical boundaries in at least one slice of the volume by employing previously acquired information relating to at least another slice of the volume.
Preferably the segmenter operates in a slice-by-slice manner.
There is also provided in accordance with a preferred embodiment of the present invention a method for providing an image of at least a portion of a fetus in utero, the method including providing image data for a volume including at least a portion of a fetus in utero, utilizing an at least partially computer controlled image processing algorithm based segmenter to define geometrical boundaries of various objects in the volume including at least a portion of a fetus in utero, and utilizing the geometrical boundaries of at least some of said various objects defined by the segmenter to selectably remove image data relating to at least portions of the objects in order to provide a desired non-occluded image of at least a portion of the fetus in utero, based on the image data.
Further in accordance with a preferred embedment of the present invention the method employs ultrasound.
Additionally in accordance with a preferred embodiment of the present invention, the image data contains speckles.
Still further in accordance with a preferred embodiment of the present invention the segmenter operates fully automatically. Alternatively the segmenter operates semi-automatically.
Moreover in accordance with a preferred embodiment of the present invention the segmenter operates substantially in real time.
Additionally in accordance with a preferred embodiment of the present invention the segmenter defines geometrical boundaries in at least one slice of the volume by employing previously acquired information relating to at least another slice of the volume.
Still further in accordance with a preferred embodiment of the present invention the segmenter operates in a slice-by-slice manner.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be understood and appreciated more fully from the following detailed description, taken in conjunction with the drawings in which:
FIG. 1 is a simplified block diagram illustration of a fetal face imaging system constructed and operative in accordance with a preferred embodiment of the present invention and employing a volume imager and a volume segmenter followed by sculpting and visualization tools;
FIG. 2 is a simplified block diagram illustration of a fetal face imaging system constructed and operative in accordance with another preferred embodiment of the present invention employing a volume imager and a slice-by-slice volume segmenter followed by sculpting and visualization tools;
FIG. 3 is a simplified block diagram illustration of a fetal face imaging system constructed and operative in accordance with yet another preferred embodiment of the present invention it employing a 2-D imager, a 2-D slice-by-slice segmenter and a 2-D sculpting tool followed by a volume constructor and a visualization subsystem;
FIG. 4 is a simplified block diagram illustration of a fetal face imaging system constructed and operative in accordance with still another preferred embodiment of the present invention employing a 2-D imager and a 2-D slice-by-slice segmenter followed immediately by a volume constructor, followed by 3-D sculpting and visualization tools;
FIG. 5A is a flow chart illustrating operation of the system of FIG. 1 in accordance with a preferred embodiment of the present invention;
FIG. 5B is a flow chart illustrating operation of the system of FIG. 2 in accordance with a preferred embodiment of the present invention;
FIG. 5C is a flow chart illustrating operation of the system of FIG. 3 in accordance with a preferred embodiment of the present invention;
FIG. 5D is a flow chart illustrating operation of the system of FIG. 4 in accordance with a preferred embodiment of the present invention;
FIG. 6 is a flow chart illustrating 3-D image segmentation step of the operation of FIG. 5A in accordance with a preferred embodiment of the present invention;
FIG. 7 is a flow chart illustrating a surface edge enhancement step of the operation of FIG. 6 in accordance with a preferred embodiment of the present invention;
FIGS. 8A, 8 B, 8 C and 8 D are pictorial illustrations showing the progressive shrinking of an imaging balloon about an image of the head of a fetus;
FIGS. 9A and 9B together are a flowchart illustrating a three-dimensional filtering operation performed in accordance with a preferred embodiment of the present invention on an original volume image;
FIG. 10 is an illustration useful in understanding the filtering operation illustrated in FIGS. 9A and 9B;
FIG. 11 is a flow chart illustrating 3-D image segmentation step of the operation of FIG. 5B in accordance with a preferred embodiment of the present invention;
FIG. 12 is a flow chart illustrating a region of interest defining step of the operation of FIG. 11 in accordance with a preferred embodiment of the present invention;
FIGS. 13A and 13B together are a flowchart illustrating a two-dimensional filtering operation performed in accordance with a preferred embodiment of the present invention on an original volume image;
FIGS. 14A and 14B together are a flow chart illustrating one part of an optimal boundary defining step of the operation of FIG. 11 in accordance with a preferred embodiment of the present invention;
FIG. 15 is a flow chart illustrating another part of the optimal boundary defining step of the operation of FIG. 11 in accordance with a preferred embodiment of the present invention;
FIG. 16 is an illustration useful in understanding the flowchart of FIG. 12;
FIG. 17 is an illustration useful in understanding the flowchart of FIGS. 13A and 13B;
FIGS. 18A and 18B are illustrations useful in understanding the flowchart of FIGS. 14A and 14B;
FIG. 19 is an illustration useful in understanding the flowchart of FIG. 15;
FIGS. 20A and 20B are simplified illustrations showing operation of a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Reference is now made to FIG. 1, which is a simplified block diagram illustration of a fetal face imaging system constructed and operative in. accordance with a preferred embodiment of the present invention.
As seen in FIG. 1, the fetal face imaging system of one embodiment of the present invention preferably comprises a volume imager 10 . Volume imager 10 may be of any suitable type and may employ any suitable technology, such as, for example, ultrasound imaging. It is also possible that magnetic resonance imaging (MRI) could be employed. Currently available ultrasound volume imagers and imaging software include:
Imaging software available from A 1 Alpha Space, Inc, of Laguna Hills, Calif., U.S.A. and from Echotech 3-D of Hallbergmoos, Germany;
HDI1500 commercially available from ATL—Advanced Technology Laboratories, Bothell, Wash., U.S.A.;
Voluson 530 D commercially available from Kretztechnik AG of Zipf, Austria and from Medison America of Pleasanton, Calif., U.S.A.
L 3 -Di commercially available from Life Imaging Systems Inc. of London, Ontario, Canada;
Echo-Scan, Echo-View and Compact3-D commercially available from TomTec Imaging Systems GmbH of Unterschleissheim, Germany;
NetralVUS, commercially available from ScImage, Inc. of Los Altos, Calif. 94022, U.S.A.;
3-Scape commercially available from Siemens AG of Erlangen, Germany;
Vitrea, commercially available from Vital Images, Inc of Minneapolis, Minn., U.S.A.;
VoxarLib, commercially available from Voxar Ltd. of Edinburgh, UK;
Conventional 2-D ultrasound images are also available from the following sources: ATL—Advanced Technology Laboratories, Bothell, Wash., U.S.A., Siemens AG, Acuson Corporation of Mountain View, Calif., U.S.A., GE Medical Systems of Milwaukee, Wis., U.S.A., Toshiba America Medical Systems of Tustin, Calif., U.S.A. and Hewlett-Packard Medical Group of Palo Alto, Calif.
It is appreciated that most currently available volume imagers operate on a slice-by-slice basis. It is anticipated, however, that volume imagers which do not operate on a slice-by-slice basis will become available in the future and will also be useful in the present invention.
In accordance with a preferred embodiment of the present invention, image data from volume imager 10 is supplied to a sculpting subsystem 12 preferably embodied in a workstation 13 including a computer controlled image processing algorithm based volume segmenter, preferably a computer controlled 3-D edge detection algorithm based volume segmenter 14 . The volume imager 10 provides a volume image which may be acquired directly or by acquiring a series of 2-D images and construction a volume image therefrom. Typically segmenter 14 receives the output of volume imager 10 in 3-D form and enables a workstation operator 17 using that output, to readily locate and isolate a fetal face image and, as necessary to remove parts of the image which occlude a full view of the fetal face from a desired perspective.
Segmenter 14 , as will be described hereinbelow in detail, is operative in a computer-assisted manner, preferably under the control of the operator 17 , to differentiate between various body parts and to distinguish the fetus or the fetal face from its environment, such as for example, from the amniotic fluid in which it resides and the surrounding placenta and uterus.
Preferably modified or annotated image data from segmenter 14 is employed by a 3-D sculpting tool 15 . It is appreciated that sculpting tool 15 may be used not only to remove occlusions but also to otherwise enhance the fetal face image. It is additionally appreciated that there may be cases where operator input in the operation of sculpting tool 15 may be unnecessary. In such a case, the sculpting tool 15 may be entirely computer controlled and operated.
It is appreciated that sculpting subsystem 12 may be integrated in the same computer platform which serves to control the operation of volume imager 10 .
The output of sculpting subsystem 12 , typically in the form of modified or annotated image data, is preferably supplied to a visualization subsystem 16 , which may comprise, for example, a video display, a video recorder or transmitter, or a printer or even a three dimensional model generator. It is appreciated that the visualization subsystem may include image processing circuitry and software for desired image enhancement or modification.
Reference is now made to FIG. 2, which is a simplified block diagram illustration of a fetal face imaging system constructed and operative in accordance with another preferred embodiment of the present invention.
As seen in FIG. 2, the fetal face imaging system of another embodiment of the present invention preferably comprises a volume imager 20 . Volume imager 20 may be of any suitable type and may employ any suitable technology, such as, for example, ultrasound and magnetic resonance imaging (MRI). Currently available volume imagers include products listed hereinabove with reference to FIG. 1 .
In accordance with a preferred embodiment of the present invention, image data from volume imager 20 is supplied to a sculpting subsystem 22 preferably embodied in a workstation 23 including a computer controlled image processing algorithm based slice-by-slice segmenter, preferably a computer controlled slice-by-slice segmenter based on 2-D or 3-D edge detection 24 . Typically segmenter 24 receives the output of volume imager 20 in either 2-D or 3-D form and enables a workstation operator 27 , using that output, to readily locate and isolate a fetal face image and, as necessary to remove parts of the image which occlude a full view of the fetal face from a desired perspective.
Segmenter 24 , as will be described hereinbelow in detail, is operative slice-by-slice in a computer-assisted manner, preferably under the control of the operator 27 , to differentiate between various body parts and to distinguish the fetus or the fetal face from its environment, such as for example, from the amniotic fluid in which it resides and the surrounding placenta and uterus.
Preferably modified or annotated image data from segmenter 24 is employed by a 3-D sculpting tool 25 . It is appreciated that sculpting tool 25 may be used not only to remove occlusions but also to otherwise enhance the fetal face image. It is additionally appreciated that there may be cases where operator input in the operation of sculpting tool 25 may be unnecessary. In such a case, the sculpting tool 25 may be entirely computer controlled and operated.
It is appreciated that sculpting subsystem 22 may be integrated in the same computer platform which serves to control the operation of volume imager 20 .
The output of sculpting subsystem 22 , typically in the form of modified or annotated image data, is preferably supplied to a visualization subsystem 26 , which may comprise, for example, a video display, a video recorder or transmitter, or a printer or even a three dimensional model generator. It is appreciated that the visualization subsystem may include image processing circuitry and software for desired image enhancement or modification.
Reference is now made to FIG. 3, which is a simplified block diagram illustration of a fetal face imaging system constructed and operative in accordance with yet another preferred embodiment of the present invention.
As seen in FIG. 3, the fetal face imaging system preferably comprises a two-dimensional (2-D) imager 30 . Two-dimensional imager 30 may be of any suitable type and may employ any suitable technology, such as, for example, ultrasound. Currently available 2-D imagers are listed hereinabove with reference to FIG. 1 .
In accordance with a preferred embodiment of the present invention, image data from 2-D imager 30 is supplied to a 2-D sculpting subsystem 32 preferably embodied in a workstation 33 including a computer controlled 2-D image processing algorithm based segmenter, preferably a computer controlled slice-by-slice segmenter based on a 2-D edge detection algorithm 34 . Typically segmenter 34 receives the output of 2-D imager 30 in 2-D form and makes it possible, with or without operator ( 37 ) intervention, to readily locate and isolate a fetal face image and, as necessary, to remove parts of the image which occlude a full view of the fetal face from a desired perspective.
Segmenter 34 , as will be described hereinbelow in detail, is operative slice-by-slice in a computer-assisted manner, preferably under the control of an operator 37 , to differentiate between various body parts and to distinguish the fetus or the fetal face from its environment, such as for example, from the amniotic fluid in which it resides and the surrounding placenta and uterus.
Preferably modified or annotated image data from segmenter 34 is employed by a 2-D sculpting tool 35 . It is appreciated that sculpting tool 35 may be used not only to remove occlusions but also to otherwise enhance the fetal face image. It is additionally appreciated that there may be cases where operator input in the operation of sculpting tool 35 may be unnecessary. In such a case, the sculpting tool 35 may be entirely computer controlled and operated.
The output of sculpting tool 35 is preferably supplied to a volume constructor 36 which is operative to construct a volume image from a plurality of individual slices of two-dimensional image data, while preserving the segmentation and sculpting thereof.
It is appreciated that sculpting subsystem 32 may be integrated in the same computer platform which serves to control the operation of 2-D imager 30 .
The output of sculpting subsystem 32 , typically in the form of modified or annotated image data, is preferably supplied to a visualization subsystem 38 , which may comprise, for example, a video display, a video recorder or transmitter, or a printer or even a three dimensional model generator. It is appreciated that the visualization subsystem may include image processing circuitry and software for desired image enhancement or modification.
Reference is now made to FIG. 4, which is a simplified block diagram illustration of a fetal face imaging system constructed and operative in accordance with yet another preferred embodiment of the present invention.
As seen in FIG. 4, the fetal face imaging system of yet another embodiment of the present invention preferably comprises a two-dimensional (2-D) imager 40 . Two-dimensional imager 40 may be of any suitable type and may employ any suitable technology, such as, for example, ultrasound. Currently available 2-D imagers are listed hereinabove, with reference to FIG. 1 .
In accordance with a preferred embodiment of the present invention, image data from 2-D imager 40 is supplied to a sculpting subsystem 42 preferably embodied in a workstation 43 including a computer controlled 2-D image processing algorithm based segmenter, preferably a computer controlled slice-by-slice segmenter based on a 2-D edge detection algorithm 44 . Typically segmenter 44 receives the output of 2-D imager 40 in 2-D form and makes it possible to readily locate and isolate a fetal face image and, as necessary, to remove parts of the image which occlude a full view of the fetal face from a desired perspective.
Segmenter 44 , as will be described hereinbelow in detail, is operative slice-by-slice in a computer-assisted manner, preferably under the control of an operator 47 , to differentiate between various body parts and to distinguish the fetus or the fetal face from its environment, such as for example, from the amniotic fluid in which it resides and the surrounding placenta and uterus.
Preferably modified or annotated image data from segmenter 44 supplied to a volume constructor 45 , which is operative to construct a volume image from a plurality of individual slices of two-dimensional image data, while preserving the segmentation thereof.
The output of volume constructor 45 is preferably supplied to a 3-D sculpting tool 46 . It is appreciated that 3-D sculpting tool 46 may be used not only to remove occlusions but also to otherwise enhance the fetal face image. It is additionally appreciated that there may be cases where operator input in the sculpting tool 46 may be unnecessary or obviated by operation of the segmenter 44 . In such a case, the sculpting tool 46 may be entirely computer controlled and operated.
It is appreciated that sculpting subsystem 42 may be integrated in the same computer platform which serves to control the operation of 2-D imager 40 .
The output of sculpting subsystem 42 , typically in the form of modified or annotated image data, is preferably supplied to a visualization subsystem 48 , which may comprise, for example, a video display, a video recorder or transmitter, or a printer or even a three dimensional model generator. It is appreciated that the visualization subsystem may include image processing circuitry and software for desired image enhancement or modification.
Reference is now made to FIG. 5A, which is a flow chart illustrating operation of the system of FIG. 1 in accordance with a preferred embodiment of the present invention. As seen in FIG. 5A, a series of 2-D ultrasound images or a 3-D ultrasound image may be acquired by volume imager 10 (FIG. 1 ). The relationship of the 2-D ultrasound images is preferably one of adjacent slices of a volume image, such that a volume image is constructed therefrom. Alternatively, where possible, a 3-D volume image may be acquired directly.
The operation of segmenter 14 of sculpting subsystem 12 (FIG. 1) is to apply computer-assisted or computer-controlled 3-D image segmentation with a view towards isolating an image of a fetal face from the volume image data received from the volume imager 10 (FIG. 1 ).
Following 3-D image segmentation, sculpting tool 15 (FIG. 1) is operative, normally, but not necessarily, without operator intervention, to eliminate portions of the isolated image which occlude a desired image of a fetal face. Following operation of sculpting subsystem 12 , a generally unoccluded image of the fetal face, with or without further image enhancement, is produced.
Reference is now made to FIG. 5B, which is a flow chart illustrating operation of the system of FIG. 2 in accordance with another preferred embodiment of the present invention. As seen in FIG. 5B, a series of 2-D ultrasound images may be acquired by volume imager 20 (FIG. 2 ). The relationship of the 2-D ultrasound images is preferably one of adjacent slices of a volume image, such that a volume image is constructed therefrom. Alternatively, where possible, a 3-D volume image may be acquired directly.
In this embodiment, the volume image may be converted into a series of 2-D image slices. These slices may correspond to the 2-D image slices originally acquired or alternatively may be sliced in different planes.
The operation of segmenter 24 of sculpting subsystem 22 (FIG. 2) in this embodiment is to apply computer-assisted or computer-controlled image segmentation on a slice-by-slice basis with a view towards isolating an image of a fetal face from the volume image data received from the volume imager 20 (FIG. 2 ).
Following image segmentation, 3-D sculpting tool 25 (FIG. 2) is operative normally, but not necessarily, without operator intervention, to eliminate portions of the isolated image which occlude a desired image of a fetal face. Following operation of sculpting subsystem 22 , a generally unoccluded image of the fetal face, with or without further image enhancement, is produced.
Reference is now made to FIG. 5C, which is a flow chart illustrating operation of the system of FIG. 3 in accordance with another preferred embodiment of the present invention. As seen in FIG. 5C, a series of 2-D ultrasound images may be acquired by 2-D imager 30 (FIG. 3 ). The relationship of the 2-D ultrasound images is preferably one of adjacent slices of a volume image, such that a volume image is constructed therefrom.
The operation of segmenter 34 of sculpting subsystem 32 (FIG. 3) in this embodiment is to apply computer-assisted or computer-controlled image segmentation on a slice-by-slice basis with a view towards isolating an image of a fetal face from the volume image data received from the 2-D imager 30 (FIG. 3 ).
Following image segmentation, 2-D sculpting tool 35 (FIG. 3) is operative normally, but not necessarily, without operator intervention, to eliminate portions of the isolated image which occlude a desired image of a fetal face. Following operation of sculpting subsystem 32 and volume constructor 36 (FIG. 3) a generally unoccluded image of the fetal face, with or without further image enhancement, is produced.
Reference is now made to FIG. 5D, which is a flow chart illustrating operation of the system of FIG. 4 in accordance with another preferred embodiment of the present invention. As seen in FIG. 5D, a series of 2-D ultrasound images may be acquired by 2-D imager 40 (FIG. 4 ). The relationship of the 2-D ultrasound images is preferably one of adjacent slices of a volume image, such that a volume image is constructed therefrom.
The operation of segmenter 44 of sculpting subsystem 42 (FIG. 4) in this embodiment is to apply computer-assisted or computer-controlled image segmentation on a slice-by-slice basis with a view towards isolating an image of a fetal face from the volume image data received from the 2-D imager 40 (FIG. 4 ).
Following image segmentation, a volume image is constructed by volume constructor 45 (FIG. 4) and supplied to a 3-D sculpting tool 46 (FIG. 4 ), which is operative normally, but not necessarily, without operator intervention, to eliminate portions of the isolated image which occlude a desired image of a fetal face. Following operation of sculpting subsystem 42 , a generally unoccluded image of the fetal face, with or without further image enhancement, is produced.
Reference is now made to FIG. 6, which is a flow chart illustrating the 3-D image segmentation step of the operation of FIG. 5A in accordance with a preferred embodiment of the present invention.
As seen in FIG. 6, a 3-D image which may have associated therewith initial markings distinguishing between portions of the image which are of interest and portions of the image which it is desired to discard, is supplied to surface edge detection based segmentation circuitry 60 which preferably initially performs surface edge enhancement on the received 3-D image.
Following surface edge enhancement, a balloon is defined which is centered on a region of the image which is of interest. The balloon may be defined with the assistance of operator generated markings on the 3-D image, but does not require such markings.
The balloon may be subsequently automatically expanded or shrunk until its boundaries lie on or near enhanced edges of the 3-D image or on operator input markings, which may be supplied in the course of 3-D segmentation and not only prior thereto. The final balloon configuration defines one or more surface boundaries. An example of progressive shrinkage of the balloon about a fetal face is illustrated in FIGS. 8A, 8 B, 8 C and 8 D. Shrinkage of the balloon is known from the following prior art publications, the disclosures of which are hereby incorporated by reference:
On Active Contour Models and Balloons, Laurent D. Cohen, CVGIP: IMAGE UNDERSTANDING, Vol. 53, No. 2, March, pp 211-218, 1991;
Finite-Element Methods for Active Contour Models and Balloons for 2-D and 3-D Images, Laurent D. Cohen and Isaac Cohen, IEEE TRANSACTIONS ON PATTERN ANALYSIS AND MACHINE INTELLIGENCE, Vol. 1 5 , No. 11, November, 1993, pp 1131-1147;
Snakes, Active Contours, and Deformable Models http://www.wpi.edu/ 18 dima/ummed/presentation/index.html.
The resultant one or more surface boundaries are superimposed on the 3-D image. An operator may carry out a visual confirmation check to satisfy himself that the indicated boundaries are indeed correct. If so, a closed surface boundary superimposed on the 3-D image is output.
Should the operator not be satisfied with the indicated surface boundary or boundaries he can carry out a manual correction or may additionally or alternatively have the boundaries recalculated by edge detection based segmentation circuitry 60 . Whichever method is chosen, the corrected boundaries are superimposed on the 3-D image and a further visual check is conducted repeatedly until the operator is satisfied with the indicated boundaries.
Reference is now made to FIG. 7, which is a flow chart illustrating a surface edge enhancement step of the operation of FIG. 6 in accordance with a preferred embodiment of the present invention. As seen in FIG. 7, following input of the volume image from volume imager 10 , the volume image is preferably blurred using a 3-D filter, such as a 3-D Gaussian filter. Thereafter, a 3-D median filter is preferably applied to the blurred volume image. The preceding two steps are examples of noise suppression techniques useful in edge enhancement pre-processing.
Following the noise suppression steps described above, a plane enhancement filter is applied to the pre-processed image, thus producing a surface edge enhanced volume image output.
Reference is now made to FIGS. 9A and 9B, which together are a flowchart illustrating a three-dimensional filtering operation performed in accordance with a preferred embodiment of the present invention on an original volume image. Such a filtering operation is preferably employed as part of the step of performing surface edge enhancement of a 3-D image forming part of edge detection based segmentation 60 , as shown in FIG. 6, and corresponds to the step in FIG. 7 identified as “APPLY PLANE ENHANCEMENT FILTER”. Reference is also made in this context to FIG. 10, which is an illustration useful in understanding the filtering operation illustrated in FIGS. 9A and 9B;
FIGS. 9A and 9B taken together with FIG. 10, describe steps of a filtering operation which is performed on the volume image received from volume imager 10 in accordance with a preferred embodiment of the present invention. The detailed flowchart of FIGS. 9A and 9B describes a plane enhancement operator. The plane enhancement operator is an extension to three dimensions of edge or ridge enhancement operators in 2 dimensions described hereinbelow with reference to FIGS. 13A & 13B as well as FIG. 17 .
The plane enhancement operator operates upon a volumetric image and provides a grey-level volumetric image output in which the edges or ridges appear as enhanced surfaces in three dimensions. Stated more generally, the operator provides a volumetric image representation of the intensity of the surface edge property at each image voxel. FIG. 10 is an illustration of the plane enhancement operator whose functionality is detailed in FIGS. 9A & 9B. For the sake of conciseness, in view of the detailed nature of the steps of the operation indicated in FIGS. 9A and 9B with reference to FIG. 10, a further textual explanation of these steps is believed to be unnecessary and thus is not provided.
Reference is now made to FIG. 11, which is a flow chart illustrating a 3-D image segmentation step of the operation of FIG. 5B in accordance with a preferred embodiment of the present invention. FIG. 11 presents details of slice by slice segmentation in the operation of FIG. 5 B. As seen in FIG. 11, a 2-D image, which may be sliced from a volume image, is selected by the system or by an operator and is initially operated on by the segmenter using an operator input which applies initial markings, such as boundary markings, to various portions of the 2-D image to distinguish between portions of the image which are of interest and portions of the image which it is desired to discard.
Thereafter, fully or partially computerized 2-D segmentation is carried out using edge detection techniques in accordance with an algorithm which is described hereinbelow. The segmenter provides an output which may be stored while additional 2-D image slices are segmented as described hereinabove.
For each subsequent 2-D image, the output and/or other characteristics of at least one preceding 2-D image are used as initial markings or in any other suitable manner for determining or partially determining the boundary. It is appreciated that the image may include more than one boundary. Once all of the required 2-D images have been segmented, a segmentation output is provided to the sculpting tool.
The segmentation output defines a closed boundary or boundaries distinguishing portions of the image which are of interest and portions of the image which it is desired to discard.
The 2-D segmentation step shown in FIG. 11 preferably incorporates the following steps:
Initial markings or the preceding boundary are superimposed on the image and a visual check of the boundary may then be carried out. If the boundary appears to need correction and a manual correction is called for, a manual correction is carried out. If, however the boundary does not appear to need correction, it is preferably stored. If the slice being segmented is the last 2-D image slice to be segmented in the 3-D image, the volume having the output boundary or boundaries superimposed thereover is output. If the slice being segmented is not the last 2-D slice to be segmented in the 3-D image, a further 2-D slice is selected. The previous boundary is preferably defined as an initial boundary for the further slice.
If, however, the boundary or boundaries are found to need correction and manual correction is selected, a manual correction module applies a manual correction to the boundary or boundaries superimposed on the image. If manual correction is not called for, computerized correction is typically effected by edge detection based segmentation circuitry 90 .
The operation of edge detection based segmentation circuitry 90 may be summarized as follows: The boundary or boundaries initially superimposed on the image are supplied to circuitry 90 separately from the image and are broadened in order to define a strip-shaped region or regions of interest (ROI). Edge enhancement is performed on the image, preferably, but not necessarily, within the ROI. As seen in FIGS. 18A & 18B, referred to hereinbelow, a multiple vertex geometrical construction is provided within the region of interest and includes a multiplicity of vertices interconnected by line segments, wherein each line segment is assigned a weight. As described in greater detail hereinbelow, an optimal boundary is constructed from the line segments. The optimal boundary is then superimposed onto the image.
The foregoing segmentation method continues until it is decided that the boundary on the last 2-D image of the volume does not require correction.
Reference is now made to FIG. 12, which is a flow chart illustrating a strip-shaped region of interest defining step of the operation of FIG. 11 in accordance with a preferred embodiment of the present invention and to FIG. 16 which shows such a region of interest.
As seen in FIG. 12, the initial marking or boundary is received and any closed loops, as illustrated in FIG. 16, along the initial marking or boundary are deleted. A strip-shaped region of interest is defined about each initial marking or boundary, for example by employing a convolution having filled circles of constant pixel value as a convolution kernel. The circles need not all have the same diameter. A thresholding function is then applied to discard pixels located exteriorly to the region of interest. The thus-corrected initial marking or boundary is then output together with the strip-shaped region of interest.
Reference is now made to FIGS. 13A and 13B, which together are a flowchart illustrating a two-dimensional edge enhancement filtering operation performed in accordance with a preferred embodiment of the present invention on a slice of the original volume image and to FIG. 17, which is an illustration useful in understanding the flowchart of FIGS. 13A and 13B. It is appreciated that the operation of FIGS. 13A and 13B provides a grey level edge enhanced image. Stated more generally, the operation provides an image representation of the intensity of the edge property at each image pixel.
The operation illustrated in FIGS. 13A, 13 B and 17 is carried out at each pixel location in each slice of the volume image and searches for a candidate edge segment at every such pixel location, preferably by searching for the direction of a candidate edge segment. For the sake of conciseness, in view of the detailed nature of the steps of the operation indicated in FIGS. 13A and 13B with reference to FIG. 17, a further textual explanation of these steps is believed to be unnecessary and thus is not provided.
Reference is now made to FIGS. 14A and 14B, which together are a flow chart illustrating one part of an optimal boundary defining step of the operation of FIG. 11 in accordance with a preferred embodiment of the present invention which includes providing a multiple vertex geometrical construction within the region of interest having a multiplicity of vertices interconnected by line segments, wherein each line segment is assigned a weight.
Reference is also made to FIGS. 18A and 18B, which are useful in the understanding of the flow chart of FIGS. 14A & 14B. The functionality of FIGS. 14A & 14B provides information for use in defining a closed boundary within the region of interest. The closed boundary is determined at each point therealong inter alia based on the following characteristics: proximity to an initial marking or a boundary already determined for an adjacent or other slice, the degree of similarity in direction to the initial marking or previously determined boundary and the degree of overlap with the initial marking or previously determined boundary.
Optionally, not only the configuration of the previously determined boundary for another slice or other slices, but also some or all of the above-listed characteristics of the said slice or slices, may be employed in subsequently determining the boundary for the current slice.
For the sake of conciseness, in view of the detailed nature of the steps of the operation indicated in FIGS. 14A and 14B with reference to FIGS. 18A and 18B, a further textual explanation of these steps is believed to be unnecessary and thus is not provided.
Reference is now made to FIG. 15, which is a flow chart illustrating a further part of the optimal boundary defining step of the operation of FIG. 11 in accordance with a preferred embodiment of the present invention which provides an optimal boundary by employing dynamic programming based on the operations described hereinabove with reference to FIGS. 14A, 14 B, 18 A and 18 B. Reference is also made to FIG. 19, which is an illustration useful in understanding the flowchart of FIG. 15 .
The overall operation of the present invention may be understood from a consideration of FIGS. 20A and 20B. FIG. 20A schematically depicts the head of a fetus partially occluded by the uterus and placenta. The operation of the present invention provides an image of the head of the fetus without such occlusions (FIG. 20 B).
It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described hereinabove. Rather the scope of the present invention includes both combinations and subcombinations of various elements described hereinabove as well as modifications and variations thereof which would occur to a person skilled in the art upon reading the foregoing description and which are not in the prior art. | This invention discloses a system for providing an image of at least a portion of a fetus in utero including an imager providing image data for a volume including at least a portion of a fetus in utero, an at least partially computer controlled image processing algorithm based segmenter for defining geometrical boundaries of various objects in the volume including at least a portion of a fetus in utero, and a sculpting tool, utilizing the geometrical boundaries of at least some of the various objects defined by the segmenter, for selectably removing image data relating to at least portions of the objects in order to provide a desired non-occluded image of at least a portion of the fetus in utero based on the image data.
A method for providing an image of at least a portion of a fetus in utero is also disclosed. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to magnetic data recording and more particularly to an improved magnetic hard bias structure for use with a scissor type magnetoresistive sensor.
BACKGROUND OF THE INVENTION
[0002] The heart of a computer is an assembly that is referred to as a magnetic disk drive. The magnetic disk drive includes a rotating magnetic disk, write and read heads that are suspended by a suspension arm adjacent to a surface of the rotating magnetic disk and an actuator that swings the suspension arm to place the read and write heads over selected circular tracks on the rotating disk. The read and write heads are directly located on a slider that has an air bearing surface (ABS). The suspension arm biases the slider into contact with the surface of the disk when the disk is not rotating, but when the disk rotates air is swirled by the rotating disk. When the slider rides on the air bearing, the write and read heads are employed for writing magnetic impressions to and reading magnetic impressions from the rotating disk. The read and write heads are connected to processing circuitry that operates according to a computer program to implement the writing and reading functions.
[0003] The write head includes at least one coil, a write pole and one or more return poles. Whet a current flows through the coil, a resulting magnetic field causes a magnetic flux to flow through the write pole, which results in a magnetic write field emitting from the tip of the write pole. This magnetic field is sufficiently strong that it locally magnetizes a portion of the adjacent magnetic disk, thereby recording a bit of data. The write field, then, travels through a magnetically soft under-layer of the magnetic medium to return to the return pole of the write head.
[0004] A magnetoresistive sensor such as a Giant Magnetoresistive (GMR) sensor, or a Tunnel Junction Magnetoresisive (TMR) sensor can be employed to read a magnetic signal from the magnetic media. The sensor includes a nonmagnetic conductive layer (if the sensor is a GMR sensor) or a thin nonmagnetic, electrically insulating barrier layer (if the sensor is a TMR sensor) sandwiched between first and second ferromagnetic layers, hereinafter referred to as a pinned layer and a free layer. Magnetic shields are positioned above and below the sensor stack and can also serve as first and second electrical leads so that the electrical current travels perpendicularly to the plane of the free layer, spacer layer and pinned layer (current perpendicular to the plane (CPP) mode of operation). The magnetization direction of the pinned layer is pinned perpendicular to the air bearing surface (ABS) and the magnetization direction of the free layer is located parallel to the ABS, but free to rotate in response to external magnetic fields. The magnetization of the pinned layer is typically pinned by exchange coupling with an antiferromagnetic layer.
[0005] When the magnetizations of the pinned and free layers are parallel with respect to one another, scattering of the conduction electrons is minimized and when the magnetizations of the pinned and free layer are antiparallel, scattering is maximized. In a read mode the resistance of the spin valve sensor changes about linearly with the magnitudes of the magnetic fields from the rotating disk. When a sense current is conducted through the spin valve sensor, resistance changes cause potential changes that are detected and processed as playback signals.
[0006] With the need to ever increase data density various novel sensor structures have been investigated. One way to increase data density is to reduce the sensor gap thickness which defines the bit length. Standard GMR or TMR sensors use an antiferromagnetic layer to pin the pinned layer structure of the sensor. In order to function as an antiferromagnetic layer, these layers must be very thick relative to the other sensor layers. This of course increases the gap thickness, which increases the bit length, which decreases data density.
[0007] A sensor that has been investigated to overcome this challenge is a sensor that is known as a scissor sensor. Such a sensor has two free magnetic layers with magnetizations that move in a scissor fashion relative to each other. Such a sensor shows promise because it does not require a thick antiferromagnetic layer. However, such a sensor presents challenges with regard to magnetic biasing of the two free layers. Therefore, there remains a need for a sensor that can reduce gap thickness such as by eliminating an AFM layer, while providing robust, reliable and workable biasing of the magnetic layers.
SUMMARY OF THE INVENTION
[0008] The present invention provides a magnetic sensor comprising, a sensor stack including first and second magnetic layers and a non magnetic layer sandwiched between the first and second magnetic layers, the sensor stack having a front edge located at an air bearing surface a back edge located opposite the front edge and first and second laterally opposed sides each extending from the front edge to the back edge. The sensor also includes a magnetic bias structure located adjacent to the back edge of the sensor stack for providing a magnetic bias field to the sensor stack, the magnetic bias structure including a neck portion near the sensor stack that has first and second sides that are aligned with the first and second sides of the sensor stack and having a flared portion.
[0009] The magnetic sensor can be constructed by a method that includes forming a magnetic shield and depositing a series of sensor layers over the magnetic shield. A first mask is formed over the series of sensor layers, the first mask being configured to define front and back edges of a sensor structure. A first ion milling is performed to remove portions of the series of sensor layers that are not protected by the first mask, thereby defining front and back edge of the sensor structure. A magnetic hard bias material is deposited, and the first mask is removed. A second mask is then formed, the second mask including a portion configured to define a sensor width and having another portion configured to define a shape of a magnetic hard bias structure extending from the back edge of the sensor. A second ion milling is performed to remove portions of the sensor material and magnetic hard bias material that are not protected by the second mask.
[0010] The novel hard bias structure having a neck portion that is aligned with the first and second sides of the sensor stack and having a tapered or wedged portion extending backwards from the neck portion provides a strong robust magnetic bias field for biasing the magnetic layers of the sensor stack. This bias field can be optimized by forming the tapered or wedged portion with side edges that define an angle of 25-50 degrees with respect to the air bearing surface.
[0011] These and other features and advantages of the invention will be apparent upon reading of the following detailed description of preferred embodiments taken in conjunction with the Figures in which like reference numerals indicate like elements throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] For a fuller understanding of the nature and advantages of this invention, as well as the preferred mode of use, reference should be made to the following detailed description read in conjunction with the accompanying drawings which are not to scale.
[0013] FIG. 1 is a schematic illustration of a disk drive system in which the invention might be embodied;
[0014] FIG. 2 is an ABS view of a slider illustrating the location of a magnetic head thereon;
[0015] FIG. 3 is an enlarged ABS view of a magnetoresistive sensor according to an embodiment of the invention;
[0016] FIG. 4 is an exploded, top-down, schematic view of layers of the magnetoresistive sensor of FIG. 3 ;
[0017] FIG. 5 is a top down view of a magnetoresistive sensor and magnetic bias structure;
[0018] FIG. 6 is a table illustrating bias fields for various hard bias structure configurations;
[0019] FIGS. 7-17 are views of a magnetic sensor in various intermediate stages of manufacture, illustrating a method for manufacturing a magnetic sensor and hard bias structure according to an embodiment of the invention; and
[0020] FIG. 18 is a top down view of a top down view of a magnetoresistive sensor and hard bias structure according to an alternate embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] The following description is of the best embodiments presently contemplated for carrying out this invention. This description is made for the purpose of illustrating the general principles of this invention and is not meant to limit the inventive concepts claimed herein.
[0022] Referring now to FIG. 1 , there is shown a disk drive 100 embodying this invention. As shown in FIG. 1 , at least one rotatable magnetic disk 112 is supported on a spindle 114 and rotated by a disk drive motor 118 . The magnetic recording on each disk is in the form of annular patterns of concentric data tracks (not shown) on the magnetic disk 112 .
[0023] At least one slider 113 is positioned near the magnetic disk 112 , each slider 113 supporting one or more magnetic head assemblies 121 . As the magnetic disk rotates, slider 113 moves radially in and out over the disk surface 122 so that the magnetic head assembly 121 can access different tracks of the magnetic disk where desired data are written. Each slider 113 is attached to an actuator arm 119 by way of a suspension 115 . The suspension 115 provides a slight spring force which biases slider 113 against the disk surface 122 . Each actuator arm 119 is attached to an actuator means 127 . The actuator means 127 as shown in FIG. 1 may be a voice cod motor (VCM). The VCM comprises a coil movable within a fixed magnetic field, the direction and speed of the coil movements being controlled by the motor current signals supplied by controller 129 .
[0024] During operation of the disk storage system, the rotation of the magnetic disk 112 generates an air bearing between the slider 113 and the disk surface 122 which exerts an upward force or lift on the slider. The air bearing thus counter-balances the slight spring force of suspension 115 and supports slider 113 off and slightly above the disk surface by a small, substantially constant spacing during normal operation.
[0025] The various components of the disk storage system are controlled in operation by control signals generated by control unit 129 , such as access control signals and internal dock signals. Typically, the control unit 129 comprises logic control circuits, storage means and a microprocessor. The control unit 129 generates control signals to control various system operations such as drive motor control signals on line 123 and head position and seek control signals on line 128 . The control signals on line 128 provide the desired current profiles to optimally move and position slider 113 to the desired data track on disk 112 . Write and read signals are communicated to and from write and read heads 121 by way of recording channel 125 .
[0026] With reference to FIG. 2 , the orientation of the magnetic head 121 in a slider 113 can be seen in more detail. FIG. 2 is an ABS view of the slider 113 , and as can be seen the magnetic head including an inductive write head and a read sensor, is located at a trailing edge of the slider. The above description of a typical magnetic disk storage system and the accompanying illustration of FIG. 1 are for representation purposes only. It should be apparent that disk storage systems may contain a large number of disks and actuators, and each actuator may support a number of sliders.
[0027] FIG. 3 shows an air bearing surface (ABS) view of a magnetic sensor 300 according to an embodiment of the invention. The sensor 300 includes a sensor stack 302 that is sandwiched between first and second magnetic shields 304 , 306 that cal be formed of an electrically conductive magnetic material so that they can function as electrical leads for supplying a sense current to the sensor stack 302 as well as functioning as magnetic shields.
[0028] The sensor stack 302 includes first and second magnetic layers 308 , 310 with a thin non-magnetic layer 312 sandwiched between the magnetic layers 308 , 310 . The sensor 300 is preferably a tunnel junction sensor, wherein the layer 312 is a non-magnetic, electrically insulating layer such as MgO. However, the sensor 300 could also be a giant magnetoresistive sensor (GMR sensor), in which case the layer 312 would be a non-magnetic, electrically conductive layer such as Cu, Ag, AgSn. The sensor stack 302 can also include a seed layer 314 , provided at the bottom of the sensor stack 300 to initiate a desired grain formation in the above formed layers. The sensor stack 300 can also include a capping lay 316 such as Ru/Ta/Ru or Ru to protect the under-lying sensor layers during manufacture. The space to either side of the sensor stack 302 , between the magnetic shields 306 , 304 is filled with a non-magnetic, electrically insulating material 318 , 320 such as alumina as well as other non-magnetic, electrically insulating materials, as will be seen.
[0029] The magnetic layers 308 , 310 have a magnetic anisotropy that tends to align magnetizations 322 , 324 of the magnetic layers in anti-parallel directions parallel with the air bearing surface (ABS) as shown. However, the magnetizations 322 , 324 are canted away from being perfectly parallel with the ABS by a magnetic bias structure that will be described in greater detail herein below.
[0030] FIG. 4 shows a top down, exploded, schematic view of the magnetic layers 308 , 310 and magnetizations 322 , 324 , The magnetization 322 is shown in dashed line to indicate that it is the magnetization of the layer 308 , which is hidden behind the magnetic layer 310 . A magnetic bias structure 402 located behind the air bearing surface (ABS), which applies a magnetic bias field that pulls the magnetizations 322 , 324 away from being parallel with the ABS and away from being perfectly anti-parallel with one another. In the presence of an external magnetic field, such as from a magnetic medium, the magnetizations 322 , 324 will deflect so that they are either more or less anti-parallel or parallel with one another. This change in the relative orientations 322 , 324 of the magnetic layers 308 , 310 changes the electrical resistance through the sensor stack 302 ( FIG. 3 ) based on the spin dependent tunneling effect of electrons passing through the thin barrier layer 312 .
[0031] Because the relative movement of the magnetizations 322 , 324 resembles the motion of a scissor during operation, such a sensor can be referred to as a scissor sensor or scissor TMR sensor. In order for such as scissor sensor to operate effectively and reliably, the magnetic bias field provided by the bias layer 402 must be sufficiently strong to overcome the magnetic anisotropy of the magnetic layers 308 , 310 to keep the magnetizations 322 , 324 generally perpendicular to one another in the absence of an external magnetic field. Keeping the magnetizations 322 , 324 oriented in this manner, so that the pivot about a perpendicular orientation, ensures that a signal processed from such as sensor is within the linear region of the signal curve. Therefore, in order to provide excellent sensor performance it is necessary to provide a hard bias structure 402 that provides robust biasing.
[0032] FIG. 5 shows an expanded view of a sensor stack 302 and hard bias structure 402 according to an embodiment of the invention. Areas outside of the sensor stack 302 and hard bias structure can be filled with a non-magnetic, electrically insulating material such as alumina and may include the fill layers 318 , 320 described above with reference to FIG. 3 . Also, the sensor 302 is separated from the hard bias structure 402 by a thin, non-magnetic, electrically insulating layer 505 , which can be a material such as alumina and which preferably also covers the bottom shield 304 in order to prevent shunting of sense current through the hard bias layer 402 .
[0033] As can be seen, the hard bias structure includes a neck portion 504 that has sides 506 , 508 that are generally parallel with and aligned width first and second sides 510 , 512 of the sensor stack 302 . The hard bias structure 402 also includes a flared portion having flared sides 510 , 512 . These flared sides 510 , 512 , preferably define an angle □ of 25-50 degrees relative to a plane that is parallel with the air bearing surface (ABS). The inventors have found that this range of angles, along with the neck portion 504 , provide and an optimal magnetic bias field for use with a scissor type sensor.
[0034] The benefit of the above described hard bias structure 402 can be better understood with reference to FIG. 6 which shows the hard bias field for various hard bias layer shapes. For purposes of the table of FIG. 6 , the hard bias field (HBF) is the field as measured at the center of the sensor 302 ( FIG. 5 ). In the table of FIG. 6 , a basic hard bias structure that extends straight back from the sensor is shown in column I and is used as a reference for the other hard bias shapes. Because this is the reference shape, the HBF for this structure in column I is denoted as being zero for purposes of comparison with the other shapes. Column II shows that a bias structure that is significantly wider than the sensor, but extends straight outward from the sensor has a 50 % increase in bias field compared with the structure of column I. Column III shows that the bias field for a bias structure having a wedge shape (i.e. shallow tapered front edge) with the taper initiating right at the back edge of the sensor (e.g. no neck portion) provides an 84% increase in bias field. Column IV shows a structure similar to that of column III, but with a sharper taper, and shows that this structure provides a 99% increase in bias field. In column III, the taper angle is 25-50 degrees relative to a plane that is parallel with the air bearing surface. Column V shows a bias structure having a shallow taper and also having a neck portion at the back edge of the sensor. As can be seen, this structure provides a 109% increase in bias field. Finally, column VI shows the bias field from a bias structure that has both a neck and a steep tapered wedge (forming an angle of 25-50 degrees relative to the air bearing surface). This structure provides a bias field that has a 117% increase compared with the structure of column I. As can be seen, this structure of column VI provides the highest bias field of all of the structures shown in FIG. 6 .
[0035] FIG. 18 shows a top down view of a magnetoresistive sensor 302 having a hard bias structure 1800 according Lo an alternate embodiment of the invention. Like the embodiment described above with regard to FIG. 5 , the hard bias structure 1800 extends from the back edge of the sensor 302 and is separated from the sensor by a thin insulation layer 505 . The hard bias structure includes a neck portion 504 . The bias structure also includes a flared portion having a front edge portion 1702 (nearest to the neck 504 ) that defines an angle θ of 25-50 degrees with respect to the ABS. The hard bias structure 1800 also includes a second tapered edge portion 1704 that is further from the neck portion 504 than the first edge portion 1702 , the edge 1704 defining an angle with respect to the ABS that is greater than θ, but which is less than 90 degrees.
[0036] FIGS. 7 through 17 , illustrate a method for manufacturing a scissor style magnetic sensor having a magnetic bias structure according to an embodiment of the invention. With particular reference to FIG. 7 , a substrate 702 is provided, which can be a layer of a non-magnetic, electrically insulating material such as alumina. An electrically conductive, magnetic shield 704 , constructed of a material such as NiFe is formed on or into the substrate 702 . The shield 704 is preferably constructed such that the shield is embedded into the substrate 702 and has an upper surface that is coplanar with the surface of the substrate. 702 . A series of sensor layers 706 is deposited over the magnetic shield 704 and the substrate 702 . The series of sensor layers can include layers of the sensor stack 302 described above with reference to FIG. 3 , but also includes layers of sensors having various other structures as well. The series of sensor layers 706 preferably includes a layer of material that is resistant to chemical mechanical polishing (CMP resistant material) such as diamond like carbon (DLC) or amorphous carbon a its top.
[0037] Then, with reference to FIG. 8 , a mask structure 802 is formed. This mask structure can include various layers. These various mask layers can include, for example, a bottom hard mask layer 804 preferably constructed of a material that is resistant to chemical mechanical polishing, an image transfer layer, such as DURIMIDE® 806 , an optional top hard mask/bottom antireflective coating layer 808 , and a photoresist layer 810 . The photoresist layer 810 can be patterned as desired by a photolithographic patterning and developing process, and the pattern of this image transfer layer can be transferred onto the underlying layers 804 , 806 , 808 by one or more reactive ion etching processes and/or ion milling. The patterned mask 802 has a central covered portion 804 (which will define a sensor area and first and second openings at either end of the central portion. The dashed line denoted (ABS) indicates the location of the air bearing surface plane. Therefore, the openings in the mask are in front of and behind the sensor area. The pattern of the mask 802 can be better understood with reference to FIG. 9 which shows a top down view of the mask 802 and openings through which the sensor layers 706 are exposed.
[0038] With the mask thus formed, an ion milling process is performed to remove portions of the sensor layers 706 that are not protected by the mask (e.g. parts that are exposed through the openings in the mask 802 ), leaving a structure as shown in FIG. 10 . Then, as show in FIG. 11 , a thin insulation layer 1102 is deposited followed by a layer of magnetic material having a high coercivity, (hard magnetic material) 1104 . The insulation layer can be SiN and is preferably deposited by a conformal deposition process such as ion beam deposition to a thickness of about 30 Angstroms. The hard magnetic material 1104 can be constructed of a material such as CoPt or CoPtCr and is preferably deposited to at thickness that is about as high as the height of the sensor layers 706 . The hard bias layer 1104 is preferably deposited to a thickness that is about 4 times the thickness of the insulation layer or about 120 Angstroms.
[0039] Then, another layer of material that is resistant to chemical mechanical polishing (CMP resistant material) such as diamond like carbon (not shown) is deposited. A wrinkle bake process is then performed, followed by a chemical liftoff process to remove the mask 802 . This is followed by a chemical mechanical polishing process, which is then followed by a reactive ion etching to remove the CMP resistant material. These processes leave a planarized structure as shown in FIG. 12 , having a smooth planar surface 1202 across the hard bias layers 1104 and the sensor material 706 .
[0040] With reference now to FIG. 13 , another mask structure 1302 is formed. Like the previously formed mask 802 , the mask 1302 can include a CMP resistant hard mask 1304 such as DLC, an image transfer layer 1306 such as DURIMIDE®, an optional top hard mask/bottom antireflective coating layer 1308 and a photoresist mask 1310 . The photoresist mask 1310 is photolithographically patterned to the desired mask shape, and the shape of the photoresist mask 1310 can be transferred onto the underlying layers 1304 , 1306 , 1308 by one or more reactive ion etching processes.
[0041] The pattern of the mask 1302 can be better seen with reference to FIG. 14 which shows a top down view. As can be seen, the mask 1302 has a narrow, constant width, throat portion 1402 that extends over the portion of the sensor material layer 506 that is between the two portions of hard bias material 1104 . Preferably, however, the throat portion 1402 also extends slightly over the hard bias material 1104 as well. This throat portion 1402 has a width that defines the width of the sensor 302 and that also defines the neck portion 504 of the hard bias structure 402 (as described above with reference to FIG. 5 ). The mask 1302 also has a flared portion 1404 that is formed over the hard bias material 1104 . This flared portion will define the wedged or tapered portion of the hard bias layer structure as will be seen.
[0042] With the second mask 1302 in place, a second ion milling can be performed to remove sensor material 706 and hard bias material 1302 that is not protected by the mask 1302 . Then, with reference to FIG. 15 , a fill layer is deposited. Most preferably, this includes depositing an anti-diffusion layer such as 30 Angstroms of SiN 1502 , followed by a non-magnetic, dielectric fill layer such as alumina 1504 followed by a CMP resistant layer such as about 2 Angstroms of diamond like carbon (DLC).
[0043] This can then be followed by a wrinkle bake process and a chemical liftoff process to remove all or a portion of the mask 1302 , followed by a chemical mechanical polishing process to remove any remaining mask materials and to polarize the structure. A reactive ion etching RIE can then be performed to remove any of the remaining CMP resistant material 1506 , 1304 . This leaves a structure as show in FIG. 16 , with all of the mask 1302 and CMP resistant material removed and with a smooth planar surface across the sensor material 706 hard bias 1104 and fill layer 1504 .
[0044] A magnetic material can then be electroplated over this structure to form an upper shield (not shown in FIG. 16 , but shown as shield 306 in FIG. 3 . FIG. 17 shows a top down view of the structure of FIG. 16 . After the sensor and any other necessary structures have been formed (such as a write head, not shown), a dicing and lapping operation can be performed to define the air bearing surface. The lapping operation removes material from the direction indicated by arrows 1702 and is terminated when the air bearing surface plan (dashed line ABS) has been reached.
[0045] While various embodiments have been described above, it should be understood that they have been presented by way of example only and not limitation. Other embodiments falling within the scope of the invention may also become apparent to those skilled in the art. Thus, the breadth and scope of the 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 scissor style magnetic sensor having a novel hard bias structure for improved magnetic biasing robustness. The sensor includes a sensor stack that includes first and second magnetic layers separated by a non-magnetic layer such as an electrically insulating barrier layer or an electrically conductive spacer layer. The first and second magnetic layers have magnetizations that are antiparallel coupled, but that are canted in a direction that is neither parallel with nor perpendicular to the air bearing surface by a magnetic bias stricture. The magnetic bias structure includes a neck portion extending from the back edge of the sensor stack and having first and second sides that are aligned with first and second sides of the sensor stack. The bias structure also includes a tapered or wedged portion extending backward from the neck portion. | 6 |
BACKGROUND OF THE INVENTION
This invention resulted from an experimental program to develop an extremely cheap yet lightweight solar collector. Although many types of solar collectors have been covered by patents, most of these are the so-called flat-plate collector which by its very nature has many disadvantages. It is the purpose of this invention to overcome these disadvantages and at the same time develop a collector which will be relatively low-cost in materials and construction.
PRIOR ART
In general, the flat-plate solar collectors, which are by far the most common in commercial application at this time, utilize the same technical principles. The flat plate, usually of metal, typically copper or aluminum, is coated with a heat-absorbing material which converts the energy in solar radiation into heat within the thin surface coating. This heat in turn is conducted through the plate and transferred to the heat-collecting fluid which can be either a liquid or gas. By the very nature of heat transfer, it is obvious that the temperature of the collector surface must be somewhat greater than the temperature attained by the heat-collecting fluid, typically in the range of 160°-240° F. Although the wave lengths of the energy in the solar radiation striking the collector surface are largely within the limits of the visible spectrum (0.4-0.7 microns), the hot surface of the collector itself becomes a radiator of infra-red energy which in turn is reradiated back towards the source of the solar radiation. In order to contain this infra-red energy within the collector, it is necessary to include as part of the collector solar windows, typically soda-lime glass, which are transparent to the visible spectrum but tend to absorb the energy in the infrared range. This is the well-known so-called "greenhouse effect". Since the reradiated infra-red energy is actually absorbed by the window glass, this glass must necessarily increase in temperature, reradiating or reflecting a portion of the acquired infra-red heat back into the collector, although some of this absorbed energy is transferred by conduction through the glass and is lost by convection and radiation on the outer side. For this reason, it has been common practice in the construction of flat-plate solar collectors to use two panes of glass separated by a confined air space, which serves as an insulating layer to minimize the loss of the infra-red energy which has been absorbed and converted to heat by the inner pane of glass.
The necessity to use glasses which are not transparent to infra-red energy is in itself a disadvantage, since the entire available energy of the incident solar radiation includes a substantial amount in the infra-red range (wave lengths greater than 0.7 microns) which is then shielded from passing through the glass to the collector surface. Thus, when glass is used as the "greenhouse" protection against reradiation, a portion of the solar energy which is available for conversion to useful heat is not allowed to enter the collector and is thus not available for conversion to thermal energy.
An additional disadvantage of the conventional solar collectors is the weight and cost of the unit. The collector plates must be of some suitable metal which will allow transfer of the heat from converted solar energy to the collecting fluid utilized in the system. In addition, the one or two panes of glass required to establish the "greenhouse" protection for the recovered heat must be of sufficient thickness, usually at least one-quarter of an inch, to give the structural strength required to protect the collector system from breakage. This adds considerable weight to the collector as well as a substantial increase in cost.
Another disadvantage of the flat-plate collector system involves the various heat-absorbing coatings which must be carefully applied to the metal plate. These coatings in turn may deteriorate with use, requiring disassembly of the unit for the necessary repair procedures. It is thus obvious that the typical solar collectors available today are heavy, relatively costly, and subject to breakage.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the passage of lights rays 1-6 through a random fiber in the glass wool matt; while
FIG. 2 illustrates one embodiment of the solar collector including a first layer of glass fiber (5), whose chemical composition permits only minor attenuation of the solar energy rays that pass through these fibers, a second layer of glass fibers (6), whose chemical composition permits absorption and greater attenuation of solar energy into heat than the first layer, and openings for admitting air into and out of the layers of glass fibers.
FIG. 3 illustrates one embodiment of the solar collector including a first layer of glass fiber (5), whose chemical composition permits only minor attentuation of the solar energy rays that pass through these fibers, a second layer of glass fibers (6), whose chemical composition permits absorption and greater attentuation of solar energy into heat than the first layer, and pipe (7) embedded within the second layer of glass fibers (6), which pipe is made up of a heat-conducting material, through which a heat-transfer medium (heating-medium) passes for collection of heat.
DESCRIPTION OF THE INVENTION
It is the purpose of this invention to overcome the disadvantages described previously for the common flat-plate solar collector available in the market-place today. In order to accomplish this, advantage is taken of the physical and optical properties of fiberglass, typical of that currently in use for insulation purposes. An extremely low-cost lightweight collector system is thus possible. Considering first the optical properties of glass, and fiberglass in particular, reference is made to FIG. 1. In this case a single fiber of glass is depicted which is a part of a bundle of glass wool or batt. Since this particular fiber is located somewhere below the surface of the wool matt, it is assumed that rays of solar light are striking the fiber at many random angles, since they have previously been reflected, refracted and otherwise bent in their travel through the overlying layers of glass fiber. In the case of Ray 1, which strikes the fiber at a steep angle approaching 90°, some of the ray will be reflected back, as is indicated by Ray 2. Some of the light energy will pass directly through the fiber and be emitted through the far side as Ray 3. Because of the random angles at which the rays of sunlight are striking at various fibers, it is assumed that some rays, such as Ray 4 will strike the fiber at a sufficiently low angle that the proportion not reflected (Ray 5) will, upon entering the fiber, be trapped within it (Ray 6) because of the critical refractive angle phenomenon, and will continue to pass down the length of the fiber. It is this very phenomenon that is currently being utilized in the development of fiber optics for the transmission of telephonic and other electronic signals which have been modulated upon a ray of light and directed into a glass fiber. In the case of fiber optics, however, it is desired that the chemical composition of the glass be of such high purity that there is a minimum tendency for attenuation of the energy in the light beam in order that it will pass through a substantial length of the fiber before being reduced to a negligible energy state. In contrast, in this invention it is desired that the purity of the glass be such, particularly in reference to the presence of multivalent metallic ions, such as iron, chromium, nickel, cobalt, manganese and the like, that in a very short length of fiber the solar energy contained in the trapped beam of light will be absorbed and converted to heat energy by the attenuation of the light beam resulting from the presence of the metallic ions. For example, in a typical type of amber glass conventionally used for malt beverage containers, a ray of light in the visible spectrum will lose 99% of its energy, that is, 99% of the light energy will be converted to thermal energy by raising the temperature of the fiber, after passing through a total path length of the amber glass of about 3 centimeters. In short, it is the purpose of this invention to utilize glass fibers of such chemical composition that solar energy contained in the rays of sunlight will be converted to heat energy after passing through a predetermined length of fiber.
The second important principle embodied in this application of glass fibers for the collection and conversion of solar energy is illustrated in FIG. 2. As the figure illustrates, the uppermost layers of glass fibers (5) exposed to the direct incidence of the rays of solar energy, are intended to be of glass of chemical composition such that only minor attenuation of the solar energy occurs as this light passes through the upper layers of the glass matt. As the figure indicates, the layer of glass wool or other similar fibrous material designated as 6, is intended to be of such chemical composition that the absorption and conversion of solar energy to heat occurs fairly rapidly. The purpose of the relatively transparent overlay layer (5) is to serve as an insulating layer which will not particularly rise in temperature above the ambient or temperature of the incoming heat-transfer fluid, be it air or liquid. By this technique then, the layer of glass wool which "sees" the incoming source of solar energy is at a relatively low temperature, and thus the tendency to reradiate infra-red energy as generated by the higher temperatures in the bed will be greatly reduced compared with flat-plate collectors. Thus the uppermost layer of wool isolates (and insulates) the layers of glass in which the major portion of the heat is being generated, and, consequently, the need for the "greenhouse effect" as is required with the conventional flat-plate collector is much less important. This has several advantages. First, it is not necessary to use thick and/or double layers of heavy, expensive window glass to create the "greenhouse" protection, but rather it is possible to use cheaper and lighter-weight plastic material. In addition it is desirable that these plastic materials be of the variety that will transmit as much as possible of the infra-red portion of the solar spectrum, since this too, is available for conversion to heat when the protection from reradiation is not required.
In terms of heat transfer from the heated collector medium to the heat transfer fluid, the use of fiberglass wool also has the advantages over the flat-plate collector. Because of the small fiber diameter and loose packing in glass wool, a tremendous surface area is exposed. For example, in the case of typical glass wool-type insulation, there is over 72 square feet of fiber surface area per inch of wool in one square foot of cross-section. Thus, when a fluid passes through the wool, the contact between the wool and the fluid is extremely intimate and heat transfer occurs very rapidly. In addition, because of the loose packing in glass wool, which often runs no more than 0.5 lbs per cubic foot in bulk density, the energy required to force the fluid (pressure drop) through the wool is extremely low. Again in the general case, with air passing through three inches of typical glass wool insulation, the pressure drop for a gas rate of 1 cu ft/min/sq ft is approximately 0.01 inches of water.
In terms of cost, glass wool is considerably cheaper than the materials and production costs required to manufacture typical flat-plate collectors. Current costs for fiberglass insulation amount to only a few cents per square foot for insulation 3 inches in thickness. In addition because of the lower cost for the plastic glazing which would be satisfactory in this application, the total cost per module for solar collectors embodying the teachings of this invention would be relatively low compared with the conventional flat-plate units now currently in use. In order to maintain both the low cost and lightweight advantages of this invention, it is further recommended that the housings which make up the module and furnish the needed structural support be fabricated from fiberglass reinforced plastic (FRP) construction. The additional external insulation required to minimize heat losses from the heat transfer fluid would presumably be essentially the same regardless of the type of collector module utilized.
It is not to be construed by this discussion that existing fiberglass types of insulation are satisfactory for this application. In general they are not, and it would be necessary to produce glasses meeting the special heat absorption requirements for each layer of the solar collector in order to maximize the advantages possible by the use of the glass fibers. Depending upon the particular applications required for the various types of solar collectors utilizing the teachings of this invention, the composition of the glass fibers in terms of the multi-valent metallic ions which cause the attenuation of solar light and its conversion to heat, various types of glass fibers would need to be produced to meet these various requirements. This is, however, no problem since these various compositions are common knowledge to glass technologists and could be easily manufactured. The components required are readily available and, in fact, are commonly used in the production of other types of glass. For the outside layer of wool which is primarily for the purpose of transmitting most of the solar energy through to the inner layers of heat-absorbing fibers, glass compositions more or less typical of that currently used in flint glass for containers would be satisfactory. For example, using iron as the multivalent metallic additive, in general terms the iron contents would be of the order of 0.03-0.06% expressed as Fe 2 O 3 . The glass wools prepared for the function of converting the solar energy to heat would vary over ranges, for example of iron from 0.07 to 1.0% or higher. In addition, the state of oxidation of the iron is also involved in the absorptivity of the glass for solar radiation and this too would be regulated by the addition of typical reducing agents now used in the preparation of all types of glass, to establish the optimum conditions for the specific applications. Although the other metallic ions mentioned previously could and would be useful in this application, the concentrations required would be in the same limits (0.05-1.0%, calculated as the highest oxide state of the metal) and the state of oxidation to develop the optimum solar conversion properties of the glass would be controlled as is now the case in glass manufacture by the addition of various oxidizing agents (sodium sulfate, sodium nitrate, arsenic oxides, etc.) and reducing agents (sulphur, carbon, iron pyrite, and the like). Each specific application of this proposed collector would require its own optimum compositions and thicknesses of the various glass wools involved, but it is to be understood that the production of these is simple and in effect is possible based upon present-day glass manufacturing procedures.
A similar principle of solar heat retention, although in another medium is practiced in Israel. In these a basin is filled progressively with brines of differing salt concentrations, thus establishing concentration layers along a vertical profile. Consequently, convection currents cannot circulate through the entire depth of the pond. Rather, heat transfer between layers can occur only by conduction. Sunlight incident on the pond for the most part passes through the upper brine layers to a blackened bottom. The heat absorbed there conducts to the lowest brine layer where it is effectively trapped by the slow rate of heat transfer between layers. Temperatures near the boiling point of water can thus be obtained. At the same time, the high temperature zones in the solar collector are well-protected from infra-red reradiation back into space by the various layers of brine which are transparent to the solar energy contained in the visible wave lengths, but are opaque to the wave lengths in the infra-red region.
It should also be noted that the use of packed-bed collectors has been reported in the literature (Swartman and Ogunlade, Solar Energy, 10, 1966, pp 106-110). In this case, the packed beds were composed of such materials as copper screens, glass marbles, stones, and hollow celluloid spheres. Although interesting results were reported from the various tests performed in accordance with this study, commercialization of the idea has not materialized, since the collection efficiencies were not particularly superior to those obtained with flat-plate collectors, and because the cost and weight of the collectors containing such packings as stones and glass marbles were of no advantage as far as making possible collectors lighter in weight and cheaper than those of the normal flat-plate variety.
The use of permeable collector media has also been reported (Chiou, El-Wakil and Duffie, Solar Energy, 9, 1965, pp 73-80). In this case packings are made from such materials as slit-and-expanded aluminum foil blackened on one side, which was turned toward the sun. The solar collector was built up from several layers of the specially-prepared foils and the performance of them as solar collectors was found to be reasonably efficient. However, because of the costs involved in preparing the special packings and the necessity for a blackened heat-absorbing layer on the collectors, these too have not proved to be competitive with the flat-bed collector.
It should also be recorded that the use of glass wool has also been suggested and employed in various types of solar collectors. It should be pointed out, however, that in all cases of record the glass fibers serve merely as a substrate for a blackened coating, and in fact the use of other fibrous materials such as steel wool, excelsior (wood), and the like, all coated with a black heat-absorbing layer are similarly described. In no case has the glass wool been suggested as a solar collector based upon the optical properties of the glass itself as a transducer of solar energy to thermal energy as is the subject of this invention.
EXPERIMENTAL
In order to establish the validity of the principles covered by this invention, samples of commercially-available glass wool insulation have been subjected to test procedures. In these, wool batts several inches in thickness were exposed to direct sunlight with indicating thermometers located at various known positions below the top surface of the wool. The temperatures were recorded as a function of the time of exposure. Results typical of those which were obtained are presented in the table below.
______________________________________ Glass Wool Temperatures - °F.Sun Exposure Distance Below Top Wool Surface - InchesTime - Min. 1" 2" 3" 4"______________________________________0 Min. 75° F. 75° F. 75° F. 75° F.2 97 88 78 754 120 104 83 756 140 120 89 7710 168 146 103 8615 189 167 115 9525 205 188 129 10640 213 198 139 116______________________________________
It is apparent that temperatures in excess of 200° F. were readily obtained. When this wool was incorporated in a solar collector module similar to that illustrated in FIG. 2, and ambient air at a rate of about 1 cu ft/min/sq ft of exposed area was passed over and down through the wool, an average exit temperature of the heated air of 160° F. was obtained.
As an example of a glass wool which is relatively transparent to solar radiation, tests were made of a thin felt-like material commonly referred to in the trade as "veil". This product is about 0.31 mm in thickness and has a bulk density of approximately 2.7 lbs/cu ft. In order to establish the efficiency of this wool for absorbing solar radiation a Dodge Solar Meter (Model 776) was employed to measure the incident solar energy level. Meter readings were taken with increasing numbers of layers of the wool. The following results were obtained:
______________________________________ Meter ReadingsWool Btu/hr/sq ftThickness Input Outputcm I.sub.o I.sub.t I.sub.t /I.sub.o______________________________________O 312 312 10.062 312 250 0.8010.124 312 190 0.6090.186 310 150 0.04840.248 310 128 0.4130.31 310 102 0.3290.372 310 82 0.2650.434 302 68 0.2250.496 298 57 0.1911.12 305 7 0.023______________________________________
In order to interpret these data the absorption properties of this wool were characterized by calculating the absorption coefficient as is defined by the well-kown Lambert equation.
I.sub.t =I.sub.o (e.sup.-at)
where I o =the intensity of the incident radiation
I t =the intensity of the radiation after passing through the absorbing medium
t=thickness or length of path through the absorbing medium, cm
a=absorption coefficient
In this case the absorption coefficient, a, is a definite property of the material and its value depends upon the chemical and physical properties of the wool. When log (I t /I o ) is plotted against the wool thickness, t, a straight line is obtained which has a slope equivalent to the absorption coefficient, a. In this case the absorption coefficient was found to have a numerical value of 3.35 cm -1 .
Thus, it is apparent that the Lambert relationship can be used to establish an equivalent absorption coefficient for a fibrous wool material. Once this value has been established for any given wool, the equation can then be used to calculate the thickness of wool needed to obtain any desired degree of attenuation in the intensity of the incident radiation.
As has been explained previously, the types of glass wool currently available for insulation purposes are not necessarily those with the optimum optical properties for converting solar energy to thermal energy according to the teachings of this invention. Glass wools much more suitable for this application must be prepared specifically in terms of the amount and valence state of the multivalent metallic ions contained therein. In particular, a wool low in heat-absorbing components, such as iron, must be available which can serve as the top layer as is indicated in FIG. 2, in which only a small portion of the incident solar energy is converted to heat, but which will by its relative transparency allow the major portion of the solar energy to be transferred to the lower layers of wool where this conversion does take place. In this manner the higher temperature zones in the wool are shielded from reradiation by the more light-transparent and thus cooler upper layer. It is this principle that is a key factor in this invention.
Although glass wools containing various contents of the suitable multivalent metallic compounds as indicated are suitable and desirable, it is not to be construed that these are the only combinations which will satisfy the principles of this invention. It should also be understood that any suitable heat transfer fluid is applicable in the pursuit of this invention. This includes air, water, and other liquids which are common in current solar collector technology. The purpose of the glass wool is to convert the solar energy to thermal energy in a manner in which reradiation is minimized and the thermal energy is then transferred to a working fluid for the normal purposes intended. Auxilliary additions to these systems, such as heat storage units and other mechanical and physical devices to control the flow of the heat transfer fluids commonly used with other solar collectors, are certainly equally applicable in use with this invention. It should also be understood that suitable coils of pipe can be imbedded at appropriate locations in the fiber glass, preferrably at the zones of maximum temperature development, through which heat transfer fluids can be passed to extract the available heat. In addition, although glass fibers have been described as the basis for this invention, it is also obvious that fibers of other materials, such as plastics, slags, mineral wools, etc., which have similar optical properties for trapping and converting solar energy rays and converting this energy to heat, would be equally applicable in the practice of this invention.
While certain advantages have been described which illustrate the merits of this invention, it is to be understood that various changes and modifications can be made by those skilled in the art without departing from the scope and intent of the invention as defined in the appended claims. | Solar energy absorbing means in solar collectors are provided by matts of a fibrous material which by its chemical composition absorbs solar radiation, converting this energy to thermal energy within the fiber itself. The solar energy absorbing properties of the fibers are controlled by the state of oxidation and amounts of various multivalent chemical components contained within the material composing the fibers. The thermal energy thus collected is transferred to a heat transfer medium by either passing the fluid directly through the matt of fibers or through pipes or coils imbedded in the matt. | 5 |
FIELD OF THE INVENTION
[0001] This invention relates generally to a pair of pants in which the seat is modified to allow insertion of cushioning means positioned to provide cushioned comfort for the seated derriere of a wearer of the slacks. The term “pants” is used to define a pair of trousers, whether “long” trousers or “shorts”, such as is commonly used as an outer garment by either men or women in everyday usage.
THE PROBLEM
[0002] In the particular instance where the pants are to be worn to a sporting event such as a game or race, or other event such as a concert or festive rally, to be held in an arena such as a stadium in which the wearer is to sit on a hard seat, whether a bench or chair, for an extended period, there is a need for a pair of pants, usually worn as an outer garment, which can be worn, as if they were merely fashionably patched, but not modified for any other purpose than being worn as patched pants. Thus, the wearer may wear the pants, as he would any other pair of patched pants, then, modify the pants and go to an arena to watch an event. The pants may be modified while being worn. After having been modified, the wearer will be seated comfortably on a hard surface because the area under the wearer's hip bone is protected with cushioning means.
BACKGROUND OF INVENTION
[0003] Pants of all kinds have been modified to provide their wearer with protection. Protection of various parts of the lower body is afforded in specialty pants used for sports such as ice hockey, American football, ice fishing, and the like. Such clothing, and such pants in particular, would attract undue attention if worn in every day use. The invention disclosed herein is narrowly directed to a dual purpose pair of pants which can be worn during the course of a wearer's day or night, as routinely worn by the wearer, then modified by him/her to watch an event, whether a festive celebration, a game or a race, in comfort.
[0004] It is found that the weight of a seated human body is supported mainly by the hip bone, and more particularly by the lower tuberosities of the left and right ischiums of the hip bone. Since the pants are narrowly directed to providing a modicum of comfort when seated on a hard surface there is no reason to provide cushioning for more area under a wearer's derriere than the area under the left and right ischiums which typically support at least 75% if not essentially the weight of the wearer.
[0005] It is well known (and documented in U.S. Pat. No. 5,365,610) that if a protective pad is merely inserted into a pocket having a configuration similar to that of the pocket without the pad being sewn or otherwise attached to the pocket or the garment, the pad often has a tendency to wad and fold up within the pocket as the pocket and pad are subjected to movement and stresses imposed upon the garment during sporting activities.
[0006] There can be little argument about the effectiveness of pants padded as disclosed in U.S. Pat. No. 6,874,168, to provide seated comfort, but the padding extends partially through the thigh area, being deliberately oversized. In contrast, the pads in the invention disclosed herein, are most preferably deliberately minimally sized so as to protect only the limited area under the ischiums of the wearer, are not placed in use until required, and when so placed attract no undue attention with respect to the pants being in any way different, except for a pair of vertical lines, from conventional pants.
[0007] Though the prior art discloses pouches in which a protective pad may be inserted, a panel forming a non-pleated pouch, as shown in U.S. Pat. No. 5,365,610, is clearly visible and noticeable as it loosely overlies the pants when the pad is not inserted. Moreover, prior art padded pants have been modified in such a manner that they are obviously designed and constructed for the specified purpose. They cannot be used for everyday wear without attracting undue attention.
SUMMARY OF THE INVENTION
[0008] A pair of pants is provided with generally rectangular panels mimicking a fashionably patched pants' seat, except for a vertical line centrally disposed in each panel evidencing the presence of a hidden box pleat. Each panel is symmetrically disposed in spaced-apart mirror-image relationship with the centerline of the pants' seat and secured thereto to form expansible pouches with defined openings, each opening distally disposed relative to the vertical center line of its pouch so as to be openable and closeable in those locations only. Maximum expansibility at the center of a pouch is no more than 5.08 cm (2″).
[0009] The pants are uniquely adapted to accommodate a pair of removably insertable cushioning means in pouches provided in the seat of the pants.
[0010] The pouches are provided with the specific purpose of not altering or interfering with the normal or usual shape of the user's buttocks or rear end in any manner whatsoever, until the user is about to be seated on a hard seating surface to watch an event. Except for a pair of oppositely disposed spaced apart vertical lines, each left by a disappearing box pleat, the pants appear to be a conventional pair of pants. A box pleat in the panel is found unexpectedly to hide the underlying pouch, at the same time providing an expandable panel without which a pouch could not accommodate a protective pad.
[0011] A pair of pants is provided with a single pair of critically positioned pleated pouches, each disposed in mirror image relationship about the center seam (or centerline) of the pants, and in laterally spaced apart relationship with the center seam. The positioning of each pouch is most preferably determined by the location of each ischium of the wearer, and more specifically, the lower tuberosity of each ischium which is the lower posterior portion of the hip bone on which the body rests when sitting.
[0012] Each pouch is formed with a panel of non-stretchable fabric which is visually matched to the fabric of the pants so as to be unobtrusive. By “non-stretchable” is meant that the fabric is not stretched noticeably when pulled upon by human hands. The choice of non-stretchable fabric is based on the finding that a stretchable fabric is unsuited for ready insertion and removal of a pad while the wearer is wearing the pants. Moreover, stretchable pants are not typically fashionably patched in the seat.
[0013] Each panel is uniquely shaped for its intended purpose, and secured along its edges by being sewn or stitched to the fabric to form a pouch in a particular manner so as not to be visually obtrusive when the wearer does not have pads inserted; and yet sewn to accommodate a pad snugly though it may be readily inserted and removed.
[0014] It is critical that each panel be provided with at least one box pleat, preferably only one, so that the pouch formed between the seat fabric and the overlying panel, may have an ischium-cushioning means removably inserted into it. The ischium-cushioning means, may be an elastomeric synthetic resinous foam, a bubble-wrap or an inflated pillow, each of which, singly or collectively, for ease and convenience, are referred to hereinafter as a “pad”. Each pad is removably insertable into each pouch, by lifting its overlying panel which is openable and closeable, most preferably along a portion of each of two adjacent edges of a panel, so that, when open, only the outer upper corner of the panel is raised to open the pouch sufficiently to allow insertion and removal of the pad while the pants are being worn.
[0015] A vertical box pleat in the midportion of each panel is a critical feature of the pouch because it provides the panel of the pouch with requisite expansibility to accommodate a pad snugly and immovably after the pad is inserted in the pouch. The vertical line formed by adjacent edges of the two back-to-back knife-edge pleats which form the box pleat, effectively negates any visually discernible effect on shaping the contour of the wearer's derriere, yet unexpectedly and effectively hides the presence of each pouch under an unobtrusive vertical line on the seat of the pants.
[0016] A pouch is critically dimensioned so as to hold a pad in the range from about 12.7 mm (0.5″) to 5.08 cm (2″) thick, and an area in the range from about 103.23 cm 2 (16 in 2 ) to 709.7 cm 2 (110 in 2 ), depending upon the size of the pants. The dimensions of the pouch are determined by those of the pad it is to hold, the location and dimensions of which pad are determined by the size of the wearer for whom the pants are made.
[0017] It is essential that each of the two pouches be openable and closeable in such a manner as to enable the wearer readily to open and close them, to insert and remove a pad, while the wearer is wearing the pants.
BRIEF DESCRIPTION OF THE DRAWING
[0018] The foregoing and additional objects and advantages of the invention will best be understood by reference to the following detailed description, accompanied with schematic illustrations of preferred embodiments of the invention, in which illustrations like reference numerals refer to like elements, and in which:
[0019] FIG. 1 is a perspective view illustrating the pads placed in pouches on the seat of the trousers, which pouches will lie directly beneath the left and right ischiums of the wearer when he/she is seated, without protecting any other portion of the wearer's derriere, and so as to fail to support the wearer's thighs and lower back;
[0020] FIG. 2 is a plan view of the right seat portion of the pants which have been pulled apart from both sides to allow the pants to be spread flat so as to show a pouch positioned to protect only that portion of the derriere which will directly overlie the pouch when the wearer is seated, and protect no other portion of the derriere or thigh. The upper outer corner of the pouch is openable for insertion of a pad, and the corner is closeable with mating hook and loop fasteners.
[0021] FIG. 3 is a cross-sectional view, along the line 3 - 3 , of the box pleat.
[0022] FIG. 4 is a detail of a pouch in a view analogous to that shown in FIG. 3 above, except that the pouch is secured along the entire length of the upper, lower and interior edges, leaving only an outer edge which may be raised to insert a pad. A small portion, in the range from 1% to 10% of the length of the outer edge, near its upper and lower portions, is sewn to the fabric of the seat to provide strength at each corner.
[0023] FIG. 5 is a perspective view of a rectangular parallelepiped of synthetic resinous foam having a thickness of from about 2.54 cm (1″) but no more than 5.08 cm (1″).
[0024] FIG. 6 is a perspective view of a pad which has angulated sides, each having a short vertical height then being inclined to meet the pad's upper surface.
[0025] FIG. 7 is a perspective view of a pad which is a frustum of a pyramid, also referred to as a truncated pyramid.
[0026] FIG. 8 is a perspective view of a pad which is a frustum of a cone.
[0027] FIG. 9 is a perspective view of a pad which is an inflatable valved pad formed from ribbed laminar sheets less than 50.8 μm (2 mils or 0.002″) thick, of a synthetic resin which is essentially impermeable to air.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0028] The problem referred to above is best addressed by scaling a pair of pouches adapted to snugly accommodate pads scaled to the derriere of the wearer. The larger the pants, the larger the pouches and the pads. It will be recognized that pants for a relatively small wearer may be provided with pouches which are far too large snugly to accommodate small pads sufficient to cushion the relatively small derriere of the wearer, but the resulting effect would be visually displeasing.
[0029] It will also be recognized that a pouch dimensioned to hold a contoured pad of relatively soft, that is, readily compressible foam, having a maximum thickness of 5.08 cm at its center, will also readily hold a rectangular parallelepiped of firmer plastic foam or bubble wrap no thicker than 2.54 cm and still provide adequate seating comfort, because the foam or bubble-wrap is less compressible than the softer foam.
[0030] The term “foam” is used in its broader sense to refer to a compressible material of synthetic resin (“plastic”), or of natural rubber or other material such as a sponge, whether open cell with interconnected pores, or closed cell with air trapped in cells which are not interconnected. Since “bubble wrap” is air trapped in bubbles, it is also broadly referred to herein as a “foam”.
[0031] By “contoured pad” is meant a pad, symmetric or asymmetric about one or more axial planes, shaped generally to be readily insertable into a pouch. Such a shape is conveniently a truncated pyramid or cone which provides an upper surface having an area smaller than its lower surface, and each (pyramid or cone) may have a base portion with vertical walls extending a short distance before inclining to form the sides, the base portion providing the edges of the pad with requisite durability while they are inserted and removed from a pouch. The sides of the pyramid may be different in area, one from another, and the cone may be asymmetrical, having one portion thinner than the other, the thinner portion being inserted into the pouch first.
[0032] Referring to FIGS. 1 and 2 there is illustrated a perspective view of a pair of pants, referred to generally by reference numeral 10 , which are provided with a pair of pouches formed by panels 20 and 20 ′ symmetrically disposed about the rear centerline C and rear center seam (only the upper portion is visible) of the seat of the pants. Each panel, preferably formed of the same fabric as the pants' so as to visually blend therewith, is provided with a vertical box pleat 30 and 30 ′ respectively which allows the pouch to be expanded to accommodate a protective pad. Though an additional vertical box pleat may be provided in the panel of each pouch, so as to more easily accommodate the pad, the cost of providing an additional box pleat cannot be justified as it does not produce a benefit corresponding to the cost. A single vertical box pleat in each panel functions as well as two parallel vertical box pleats for the maximum thickness of the pad held in the pouch.
[0033] Each upper, lower and outer edge of the panel is generally linear and the three edges are approximately rectangularly disposed relative to each other.
[0034] For the least obtrusive visual effect, and to mimic a pair of conventionally patched pants, a panel 20 is sewn, with suitable thread 35 , to the fabric of the seat along the entire length of the panel's lower edge 22 ; and also along the entire length of inner vertical edge 23 adjacent the rear center line C of the pants. Most preferably, the line of the edge 23 corresponds to line of the center seam of the seat of the pants, so as to provide visual compatibility of edge and seam. In addition to the sewn inner 23 and lower 22 edges , either the entire length of the upper edge 21 , or, the entire length of the outer vertical edge 24 of the panel, but not both, may be sewn to the fabric of the seat so that the side of the pouch not sewn shut, is left open for insertion of a pad.
[0035] Each panel 20 and 20 ′ of each pouch is thus positioned so that its upper edge 21 and 21 ′ respectively, are essentially parallel to the upper edges of hip pockets 29 and 29 ′ so as to present a pleasing visual effect. Lower edges 22 and 22 ′ are likewise essentially parallel to the upper edges 21 and 21 ′ respectively, and to the upper edges of hip pockets 29 and 29 ′ so that each pouch is positioned on each cheek of the derriere but fails to extend over the upper portion of each thigh.
[0036] In this configuration of a pouch, a pad may be inserted from above, or from the side, depending which edge 21 or 24 is sewn shut, or partially shut, while a wearer is wearing the pants.
[0037] Preferably, a portion, most preferably, a minor portion of the length of the upper edge 21 of the panel, and, a minor portion of the adjacent length of the outer vertical edge 24 , are both left open so as to form a pouch with an openable and closeable corner 26 . The dimensions of each panel are scaled to the size of the pants. The dimensions of each pad are necessarily deliberately restricted so as to correspond to an area not more than about 50% larger than the area of the derriere directly beneath the lower surfaces of the tuberosity of the respective left or right ischium, so that neither pad provides padded protection for any portion of the wearer's thigh, and no protection for the area of the derriere between the pouches.
[0038] The area under the ischiums of a seated wearer is best measured by noting the laterally spaced apart distance between indentations on a compressible foam pad, and the area of each indentation. A pad for the area of the indentation is then at least 10% but no more than 50% larger than the area of the indentation; preferably the pad is in the range from 10% to 25% larger than the area of the indentation.
[0039] Referring particularly to FIG. 2 there is shown a portion of the seat of the pants in which a pouch is formed by a panel 20 having a box pleat 30 . The shape of the panel is generally rectangular, but is preferably provided with its inner edge 23 corresponding in curvature to the adjacent center seam C of the seat of the pants, so that the edge may be arcuate, or the edge may be angulated to present a shape which is approximately trapezoidal. The panel 20 is sewn with thread 35 to the fabric of the seat along the entire length of the panel's lower and inner edges 22 and 23 respectively. Though inner edge 23 may appear angulated, so as to provide an obtuse angle greater than 135° formed by intersecting upper and lower lines, edge 23 is preferably an arcuate edge, as shown by smoothly arcuate dotted line 23 ′. Whatever the precise geometry of the center seam C, for a pleasing visual appearance, the curve of inner vertical edge 23 preferably corresponds to and is in parallel spaced-apart relationship with, the rear center seam of the seat of the pants.
[0040] In addition, the upper edge 21 is sewn to a location just past the vertical line of the box pleat 30 so that the upper end of the box pleat is anchored to the fabric of the seat; and, outer edge 24 is sewn for a portion of its vertical length, preferably a major portion of its vertical length, to a location just past the horizontal center line H of the panel 20 . Thus, most preferably, a minor portion of the length of the upper edge 21 of the panel 20 , and, a minor portion of the adjacent length of the outer vertical edge 24 , are not sewn to the fabric of the seat, leaving the upper corner 26 to be opened for insertion of a pad.
[0041] For easy opening and closing of the pouch formed by panel 20 , at least a portion of the unsewn, that is, unsecured to the fabric of the seat, portion of the upper edge 21 , and at least a portion of the unsewn portion of the outer vertical edge 24 are each provided with one mating part 27 of a Velcro mating hook and loop fastener, the other mating part 27 ′ (not shown) being secured to the fabric of the seat.
[0042] Referring to FIG. 3 , there is shown a cross-section of the box pleat formed by two back-to-back knife-edge pleats 31 and 32 with a common base 33 . A box pleat with a base of 5.08 cm (2″), the pleat formed in a panel of a pair of pants for a large adult male, allows insertion and removal of a pad up to 5.08 cm (2″) thick at its center. In a pouch having maximum dimensions for a relatively large human, the width of the base of the box pleat is no more than about 5.08 cm (2″), and the minimum width for a child or relatively small adult human is about 1.9 cm (0.75″).
[0043] Referring to FIG. 4 there is shown a detail of a portion of the seat of the pants in which a pouch is formed by a panel 40 having a box pleat 30 . The panel is sewn with thread 35 to the fabric of the seat at the panel's upper, lower and inner edges 41 , 42 and 43 respectively, and as before, inner edge 43 may be arcuate to correspond to the center seam C. A small portion, in the range from 1% to 10% of the length of the outer vertical edge 44 , near its upper portion, is also sewn, with thread 35 , to the fabric of the seat; and, analogously, a small portion, in the range from 1% to 10% of the length of the outer vertical edge 44 , near its lower portion, is sewn to the fabric of the seat, so that the opening of the pouch formed, is provided with strength at both, the upper outer, and the lower outer corners of the pouch. Thus, the opening formed, and left open for insertion and removal of a pad, is at least 80% of the vertical length of the outer edge 44 .
[0044] For easy opening and closing of the pouch formed by panel 40 , at least a portion of the unsewn portion of the outer vertical edge 44 is provided with one mating part 28 of a Velcro mating hook and loop fastener, the other mating part 28 ′ (not shown) being secured to the fabric of the seat.
[0045] As shown in FIGS. 1 , 2 and 4 each panel is generally rectangular in which the inner edge is generally arcuate, whether smoothly arcuate or obtusely angulated, and generally parallel to the rear center seam of the pants, while the other three sides are the sides of a rectangle. The panel most preferably has a single vertical box pleat to minimize the obtrusiveness of a vertical line through the mimicked patch.
[0046] Referring to FIG. 5 there is shown a rectangular parallelepiped of synthetic resinous, relatively difficultly compressible foam 50 having a thickness of from about 1.27 cm (0.5″) but no more than 5.08 cm (1″). A suitable foam for the purpose, preferably of a homogeneous closed cell or open cell foam of an elastomer is commonly referred to as a “foam rubber pad”. It is exemplified by a synthetic resinous material having a hardness in the range from about Shore OO 15-95 (ASTM D-2240), and having a resilience measured as compressive pressure required to make an indentation 25% of the thickness of the pad, the pressure being in the range from 6.89-344.5 KPa (1-50 psi). Particularly suitable foams are exemplified by those having a negative Poisson's ratio and used for seat cushion material. Such foams are disclosed in “Negative Poisson's Ratio Foam as Seat Cushion Material” by A. Lowe and R. S. Lake, Cellular Polymers, 19, 157-167, July 2000, which is incorporated herein by reference. Another suitable foam is Evalite ethylene vinyl acetate foam having a density of 32 Kg/cu meter (2 lb/cu ft) and requiring 34.5 KPa (5 psi) for 25% deflection. Other suitable pads may be made from “Ultimate” rebound polyurethane foam (from Leggett & Platt Inc.); Poron cellular polyurethane foam (from Rogers Corporation); and, white melamine foam having a density of 11.2 kg/cu meter (0.7 lb/cu ft) having a resilience measured as requiring 12 KPa (1.74 psi) to provide compression of 25% (also referred to as a 25% deflection).
[0047] Referring to FIG. 6 there is shown a contoured pad 60 the lower portion 61 of which is rectangular, providing short vertical distances in the range from 1.59 mm (0.0625″) to 6.35 mm (0.25″), while the upper portion 62 has angulated sides so that the upper portion is the frustum of a pyramid. The short vertical distance of the lower portion 61 is less than 50%, preferably less than 20% of the overall thickness of the pad which is typically in the range from 12.5 mm (0.5″) to 3.2 cm (1.25″). Each short vertical distance, at its top, is upwardly inclined at an angle in the range from about 10°-80°, to meet the pad's upper surface, the inclination, preferably in the range from about 40°-65°, depending upon the compressibility of the foam and the thickness of the desired pad. A suitable foam for a pad 60 having what is commonly referred to as “graded compressibility” is of the type used in seats of automobiles and sofas and in pillows and mattresses. A preferred such foam in a pad is initially more readily compressible than after it is compressed to make an indentation 25% of the thickness of the pad. Such a foam is exemplified by foam supplied by Carpenter Foam Products of Elkart Ind. and is similar to Tempur® foam used in Tempur-Pedic® pressure relieving Swedish mattresses and pillows.
[0048] If desired, in lieu of the contoured pad of FIG. 6 of suitable foam, one may use a combination of separate pads, one a rectangular parallelepiped pad, the other a truncated pyramid positioned on the rectangular pad.
[0049] FIG. 7 is a perspective view of a pad 70 which is a frustum of a pyramid made of relatively compressible foam such as is used in the embodiment shown in FIG. 6 .
[0050] FIG. 8 is a perspective view of a readily insertable pad 80 which shaped as a frustum of a cone made of relatively compressible foam such as is used in the embodiment shown in FIG. 6 . The sides of the frustoconical pad are inclined at an angle in the range from about 10°-80°, preferably in the range from about 40°-65°, to meet the pad's upper surface 81 , the inclination, depending upon the compressibility of the foam and the thickness of the desired pad. The lower surface 82 is sized to be slidably inserted and removed from a pouch.
[0051] FIG. 9 is a perspective view of an inflatable pad 90 which may be inserted in a deflated condition, into the pouch formed by a panel 20 or 40 . The pad is provided with a conventional self-sealing air valve 91 such as is disclosed in U.S. Pat. No. 4,080,751 and well-known in numerous inflatable articles. After the pad 90 is inserted in the pouch, and prior to the wearer of the pants being seated, the pad 90 is inflated by attaching one end 92 of a tube over the valve 91 , the other end (not shown) being placed in the wearer's mouth to inflate the pad. The pad is shown, only slightly inflated, to illustrate that it is preferably formed from an extruded envelope 93 with at least one of its opposed sides 94 , 95 , preferably both, provided with one or more ribs 96 . The ribs 96 allow the pad to form, when inflated to the pressure desired, a generally rectangular pad (instead of an ellipsoid) to support the derriere of the wearer of the pants. | A pair of pants is modified to mimic a pair of fashionably patched pants except that the “patches” are panels which forms pouches on the seat of the pants. Each panel is provided with a vertical box pleat which allows the pouch, formed by securing the panel to the fabric of the seat, to be expanded sufficiently to hold a cushioning means located directly beneath the lower tuberosity of each ischium of the wearer. The cushioning means is typically a pad of chosen compressibility which can be inserted and removed from its pouch by the wearer while the pants are being worn. The protective pads are effective to provide cushioning for only the area under each ischium and not for any portion of the thighs or lower back. | 0 |
[0001] This is a continuation of U.S. application Ser. No. 08/979,867, filed Nov. 26, 1997, entitled SYSTEM AND METHOD FOR PROVIDING CALL SUBJECT INFORMATION TO A CALLED PARTY.
BACKGROUND OF THE INVENTION
[0002] The field of the invention is providing information received from a calling party to a called party, and in particular providing call subject information received from a calling party to a called party.
[0003] When a calling party desires to communicate with a called party, the called party must often decide whether to communicate with the calling party based upon insufficient information. For example, one known system only provides the called party with a ring when the calling party desires to communicate with the called party. The ring reveals nothing about the identity of the calling party; nothing about the purpose of the communication desired by the calling party; and nothing about the urgency of the communication.
[0004] Another known system provides some additional information about a calling party by identifying the name and/or telephone number of the calling party on a display visible to the called party (e.g., “caller ID”). Although this provides more information than only a ring, it still fails to inform the called party as to the purpose of the calling party's intended communication or its urgency. Further, the added information provided by caller ID is worthless in practice when the called party is unfamiliar with the calling party's telephone number and/or name.
[0005] With such limited information about the calling party and virtually no information about the topic, contents or urgency of the calling party's communication, a called party may have to communicate with a calling party with which it would rather not. For example, when the calling party is a telemarketer desiring to communicate the advantages of a product it wishes to sell to a called party at the called party's dinner time, the called party may prefer not to communicate with the telemarketer. On the other hand, if the calling party is a hospital official desiring to communicate information pertaining to the medical condition of a member of the called party's family, then the called party may desire to communicate with the official, even at a time that would otherwise be considered inconvenient.
[0006] If the called party is only provided with a simple ring as in one known system, the called party does not know whether the calling party is a telemarketer or a hospital official. Thus, the called party feels compelled to communicate with the calling party at least until the calling party can be identified and/or the subject of the call can be ascertained by the called party. If the called party is apprised of the calling party's telephone number and/or name as in another known system, the called party may not be able to distinguish the number or name of the telemarketer from that of the hospital official, and thus may still feel compelled to communicate with the calling party.
[0007] A called party needs more information than that provided by known systems to make an informed decision as to whether to communicate with the calling party.
SUMMARY OF THE INVENTION
[0008] In one embodiment of the present invention, a system and method provide call subject information from a calling party to a called party. A call subject platform receives a call from a calling party. The call subject platform prompts the calling party to provide call subject information. If call subject information is received at the call subject platform from the calling party, then the call subject platform sends at least part of the call subject information to the called party. The call subject platform then determines if the called party desires to communicate with the calling party.
[0009] The present invention advantageously provides more information to a called party about a prospective communication than do known systems. This advantageously provides a more substantial basis upon which the called party can make an informed decision as to whether to communicate with the calling party. In accordance with the present invention, the called party advantageously need not communicate with a calling party to determine if communication with the calling party is desirable. The present invention thus allows the called party to advantageously avoid an unwanted communication with a calling party.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 shows a system-level embodiment of the present invention.
[0011] [0011]FIG. 2 shows an embodiment of an apparatus in accordance with the present invention.
[0012] [0012]FIG. 3 shows another embodiment of an apparatus in accordance with the present invention.
[0013] [0013]FIG. 4 is a flow chart showing an embodiment of the method of the present invention.
DETAILED DESCRIPTION
[0014] [0014]FIG. 1 shows a system-level embodiment of the present invention. Calling party 101 , called party 102 , and call subject platform 104 are connected to a network 103 . In one embodiment, of the present invention, network 103 is the public switched telephone network (PSTN). In another embodiment, network 103 is the Internet. In other embodiments of the present invention, network 103 includes a packet-switched, circuit switched, connectionless, or connection oriented network or interconnected networks, or any combination thereof.
[0015] As used herein, the term “computer” is an apparatus that comprises a processor, a memory that stores instructions adapted to be executed by the processor, and a port adapted to be connected to a network. The memory and port are coupled to the processor. Embodiments of memory include a hard disk drive, random access memory (RAM), read only memory (ROM), flash memory, or any combination thereof.
[0016] In one embodiment of the present invention, calling party 101 is a telephone. In another embodiment, a calling party 101 is a calling party computer whose memory stores instructions adapted to be executed by the processor to communicate through a network, and to provide call subject information. As used herein, “call subject information” includes any information from the calling party 101 beyond the calling party's 101 identity or telephone number. Examples of call subject information include: information pertaining to the purpose of the telephone call from the calling party 101 ; information pertaining to the urgency of the telephone call; etc. For example, call subject information can include a reference to a previous call from the called party 102 to the calling party 101 : “I'm returning your telephone call of earlier today” from the calling party 101 is an example of call subject information. Call subject information can be advantageously combined with other information (e.g., caller identification information) to contribute to the process of determining how the called party 102 desires to handle the telephone call (e.g., communicate with the calling party 101 , forward the call, send the call to a Messaging service, not accept the call, etc.)
[0017] In one embodiment, called party 102 is a telephone. In another embodiment, called party 102 is a called party computer. In one embodiment, a called party computer is a computer whose memory stores instructions adapted to be executed by the processor to communicate through a network; to receive call subject information; and to provide an indication as to whether communications are desired with a calling party.
[0018] An embodiment of call subject platform 104 is shown in FIG. 2. Call subject platform 104 comprises a processor 301 , a memory 302 that stores call subject instructions 303 adapted to be executed by processor 301 to receive call subject information from calling party 101 and send at least a part of the call subject information to called party 102 . Instructions 303 are further adapted to be executed by the processor 301 to determine if called party 102 desires to communicate with calling party 101 . In another embodiment, instructions 303 are further adapted to be executed by the processor 301 to establish communications between the calling party 101 and the called party 102 if it is determined that the called party 102 desires to communicate with the calling party 101 .
[0019] Embodiments of memory 302 include a hard disk drive, random access memory (RAM), read only memory (ROM), flash memory, or any combination thereof. Call subject platform 104 further comprises a port 304 adapted to be connected to a network 103 . Port 304 and memory 302 are coupled to processor 301 .
[0020] Another embodiment of the call subject platform 104 is shown in FIG. 3. Call subject platform 104 comprises an application specific integrated circuit (ASIC) 401 that embodies call subject instructions 402 that ASIC 401 executes to receive a call from a calling party, prompt the calling party for call subject information, receive call subject information from the calling party, and determine if the called party desires to communicate with the calling party. In yet another embodiment, instructions 402 are further adapted to be executed by ASIC 401 to establish communications between the calling party 101 and the called party 102 .
[0021] ASIC 401 further comprises memory 403 and a port 404 . Embodiments of memory 403 include a hard disk drive, random access memory (RAM), read only memory (ROM), flash memory, or any combination thereof. Memory 403 and port 404 are coupled to ASIC 401 . In one embodiment, memory 403 stores call subject information.
[0022] [0022]FIG. 4 is a flow chart showing an embodiment of the present invention. The call subject platform receives a call from a calling party, step 501 . The call subject platform prompts the calling party for call subject information, step 502 . If the call subject platform received call subject information from the calling party, the call subject platform sends at least a part of the call subject information to the called party, step 503 . In one embodiment of the present invention, at least part of the call subject information is received from the calling party in a first format (e.g., text) and at least part of the call subject information received in that first format is translated by the call subject platform into a second format (e.g., audio) adapted to be played or displayed to the called party. Techniques known in the art can be used to perform such a translation. Examples of such known techniques include voice recognition, voice-to-text translation, text-to-audio translation, dual tone modulated frequency signal to audio message translation, and so on.
[0023] The call subject platform then determines if the called party desires to communicate with the calling party, step 504 . In one embodiment, if it is determined that the called party desires to communicate with the calling party, then the call subject platform establishes communications between the calling party and the called party, step 505 . In another embodiment, if it is determined that the called party desires to communicate with the calling party, but that the called party is presently unavailable, then the call from the calling party is forwarded to a Messaging Service. In yet another embodiment, if it is determined that the called party desires to communicate with a calling party, then the call is forwarded to another telephone number.
[0024] In one embodiment, if the call subject platform does not receive call subject information from the calling party, the call subject platform provides an indication to the called party that no call subject information was received from the calling party, step 506 . The call subject platform then determines if the called party desires to communicate with the called party, step 504 .
[0025] In another embodiment of the present invention, if no call subject information is received from the calling party, then this lack of information automatically results in the determination that the called party does not desire to communicate with the calling party and the call is terminated or forwarded to another telephone number or forwarded to a Messaging Service, etc.
[0026] In one embodiment of the present invention, if it is determined that the called party desires to communicate with the calling party, the call subject platform sends a message to a switch. In response, the switch establishes communications between the calling party and the called party.
[0027] In one embodiment of the present invention, call subject information is obtained by the call subject platform from the calling party by requesting the calling party to select an item of call subject information from a plurality of items of call subject information. This can be carried out using an interactive voice response system in known fashion. For example, the calling party can be asked to press “one” if the caller is a relative of the called party, “two” if the calling party is the family physician, and “three” if the call is urgent. In response, the calling party generates a dual tone modulated frequency (DTMF) signal using a telephone touchpad, in one embodiment. In another embodiment, the calling party generates a DTMF signal using a computer.
[0028] In another embodiment, the calling party is prompted for voice responses to questions. For example, the calling party can be asked to speak the word “one” if the calling party is a relative. In another embodiment, the calling party can be asked to speak a message to be sent to the called party pertaining to the calling party's intended communication. The call subject platform records this message. Voice responses can be digitized and/or translated into text using voice recognition techniques known in the art. Call subject information can include multimedia information. As used herein, the term “multimedia call subject information” includes call subject information that is text, audio, video, graphics, animation, or DTMF, or any combination thereof. Multimedia call subject data can include digital data, analog information, or any combination thereof.
[0029] In one embodiment, the DTMF signals are translated by the call subject platform into an audio message. If the DTMF signal for “one” is received alone, then the call subject platform processes the DTMF signal and sends an audio message to the called party that states “A call from a relative is waiting.” If the DTMF signal for “two” is received alone, then the call subject platform sends an audio message to the called party that states, “A call from Dr. PHYSICIAN_NAME is waiting,” where PHYSICIAN_NAME is a variable whose value is the name of the family physician.
[0030] In another embodiment, voice response messages are played by the call subject platform to the called party. In another embodiment, voice response messages are translated into text and sent to the called party by the call subject platform.
[0031] In one embodiment of the present invention, call subject information is processed before being sent to the called party. For example, information provided in an audio voice format by the calling party is translated into text and summarized by the call subject platform before being sent to the called party. In one embodiment, the information is summarized by selecting key words from the call subject data. In another embodiment, the information is summarized by truncating the call subject data received from the calling party.
[0032] In another embodiment, at least a part of the call subject information is forwarded to the called party intact, just as it was received from the calling party (e.g., a short voice or video message).
[0033] The present invention thus advantageously provides multimedia information to the called party from the calling party to help the called party to decide if the called party desires to communicate with the calling party. This advantageously allows the called party to avoid unwanted communication with a calling party.
[0034] Although several embodiments are specifically illustrated and described herein, it will be appreciated that modifications and variations of the present invention are covered by the above teachings and are within the purview of the appended claims without departing from the spirit and intended scope of the invention. | A system and method is provided for providing call subject information to a destination device. A call subject platform provides a selection menu to an originating device to receive call subject information. If call subject information is received at the call subject platform from the originating device, then the call subject platform sends a summary of the call subject information to the destination device. | 7 |
BACKGROUND OF THE INVENTION
The patent literature contains significant precedent in the use of addition type polymers for use as stain resistant coatings on fibrous materials (eg. U.S. Pat. No. 4,695,497). There is not, however, precedent on the use of polymeric materials based largely on difunctional monomers, eg. itaconic acid, as stain resistant coatings for fibrous materials. The compositions of this invention are particularly advantitious in that they are comprised mainly of low toxicity monomers derived from a renewable resource, eg. itaconic acid.
SUMMARY OF INVENTION
The non-fluorine containing polymeric compositions of the present invention consist essentially of pure polymers or mixtures of
(1) an addition polymer of a least one monomer having the formula (A) ##STR1## where
R 1 =H, C5-C22 alkyl, ##STR2## cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl;
m=0-12;
n=0, 1, 2, 3;
X=CH 2 , 0 when m>1,
R 2 is chosen from the list above and may or may not be the same as R 1 , R 1 and R 2 cannot both be H, and
(2) an addition copolymer of
(a) at least one monomer having the formula described as (A) above,
(b) and may include one or more of the monomers (B) ##STR3##
(c) and may include one or more of the monomers of the formula ##STR4## where
R 3 is H or CH 3
R 4 is C1-C22 alkyl, ##STR5## cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl;
m=0-12;
n=0, 1, 2, 3;
X=CH 2 , 0 (when m>1).
The fluorine-containing compositions of the present invention consist essentially of copolymers of
(1) at least one monomer having the formula (A) as above
(2) at least one monomer having the formula
(D) CF 3 CF 2 (CF 2 )X(CH 2 )YOC(O)C(R 3 )=CH 2
wherein
X is an integer from 2-18
Y is an integer from 1-15, R 3 is H or CH 3 and
(3) optionally monomer having the formula ##STR6## where R 5 and R 6 may be H, CF 3 CF 2 (CF 2 )X(CH 2 )Y, but R 5 and R 6 cannot both be H
wherein
X is an integer from 2-18
Y is an integer from 1-15
For the non-fluorinated hydrocarbon polymers, the preferred polymeric composition should be as follows: Based upon the total weight of the composition, monomer A would constitute between 20 and 100 percent by weight; monomer B would constitute between 0 and 20 percent by weight; monomer C would constitute 0 to 80 percent by weight. More preferably, monomer A would constitute between 70 and 100 weight percent; monomer B would constitute between 1 and 10 weight percent and monomer C would constitute between 0 and 30 percent by weight. The total number of carboxylic acid end groups should not exceed, on the average, one per two monomer units.
The polymeric non-fluorinated hydrocarbon polymers of the present invention are useful in imparting durable stain resistance to a wide range of fibrous materials.
For the fluorine containing copolymers, the preferred polymeric composition should be as follows: based upon the total weight of the composition, monomer A would constitute between 20 and 90 percent by weight and monomer D would constitute between 10 and 80 percent by weight and monomer E would constitute between 0 and 80 percent be weight. More preferably, the fluorinated monomers would constitute between 40 and 60 weight percent and monomer A would constitute 40 to 60 weight percent.
The polymeric fluorinated compositions of the 25 present invention are useful in imparting stain resistance to fibrous materials as well.
The polymeric compositions of the present invention can be prepared by using well known polymerization techniques and conditions. They can be prepared using bulk, solution, suspension or emulsion technologies. Preferably, the polymerization process of this invention is run using an emulsion technique. In the most preferred technique, the monomers are combined with nonionic and anionic surfactants and water to form a dispersion. Initiator, preferably 0.5 to 2 mole percent based on monomers, is then added. The reaction is then carried out at a temperature sufficient to promote efficient initiation. In bulk polymerization, the temperature will be sufficient to keep the monomers in the carried out a temperature sufficient to promote efficient initiation. In bulk polymerization, the temperature will be sufficient to keep the monomers in the molten state.
The fluorinated monomers most preferred for the present invention are (meth) acrylate mixtures such that their perfluoroalkyl groups consist mainly of A=2, 4, 6, 8, 10, 12 and B=2. Such materials are described in U.S. Pat. Nos. 3,282,905, 4,147,852 and 3,645,989.
Conventional free radical initiators such as peroxy compounds and azo compounds may be used. Examples are benzoyl peroxide, 2,2'-azo-bis(2-methylpropionitrile), hereinafter AIBM, potassium persulfate and the like. Initiator concentration should be between 0.5 and 2.0 percent based on the total moles of the monomers. Likewise, conventional chain transfer agents, such as carbon tetrachloride and dodecyl mercaptan in amounts sufficient to control the molecular weight, may be used but are not always necessary.
DETAILED DESCRIPTION OF THE INVENTION
The following tests were used to evaluate the end use properties of the polymeric compositions of the invention on woven nylon sleeve.
EXAMPLE 1
A 3-liter polymerization vessel charged with bis(cyclohexylmethyl) itaconate (1500 g, 4.65 mol), AIBN (15.3 g, 2 mol %) and toluene (300 ml). The flask was flushed with argon and cooled in a dry ice/acetone bath. The contents of the flask were degassed via 4 cycles of argon purge followed by evacuation to 0.5 torr. The vessel was then flushed with argon, protected from the atmosphere with an oil bubbler and placed in a 60° C. water bath. After two days the vessel was cooled and the viscous mixture was diluted with tetrahydrofuran (2000 ml). The polymer solution was then slowly added to vigorously stirred methanol (8000 ml). The precipitated product was then collected via filtration and dried under vacuum at 50° C. White glassy product was obtained in 78% yield. An aliquot of the polymer (0.1 g) was dissolved in dichloromethane (15 ml). White nylon sleeve (5.0 g) was dipped in the solution with agitation and squeezing to ensure penetration of the liquid into the fiber bundles. The sample was then air dried followed by annealing at 105° C. for 15 minutes. The samples were stained, washed and rated as described below. The stain repellancy is set forth in Table 1 and wash durability is in Table II.
EXAMPLE 2
A polymerization vessel was charged with bis(docosyl)itaconate (17.5 g, 0.023 mol), bis(octyl)itaconate (8.3 g, 0.023 mol) and AIBN (0.15 g, 2 mol percent). The flask was sealed and degassed under argon via four vacuum/purge cycles. The sealed flask was then placed in a 75° C. bath for 24 hours. The molten mass solidified upon cooling. An aliquot of the polymer was coated onto nylon and treated as above.
EXAMPLE 3
A polymerization vessel was charged with bis(cyclohexylmethyl)itaconate (3.0 g, 9.3 mmol), DuPont Fluoroacrylate Telomer B (2.0 g, 3.8 mmol) - α; α, α, trifluorotoluene (1.0 ml) and AIBN (0.043 g, 2 mol %). The flask was flushed with argon and cooled in a dry ice /acetone bath. The contents of the flask were degassed via 4 cycles of argon purge followed by evacuation to 0.5 torr. The vessel was then flushed with argon, sealed, and placed in a 60° C. water bath. After two days the vessel was cooled, and the viscous mixture was diluted with tetrahydrofuran (100ml). The polymer solution was then slowly added to vigorously stirred methanol (800 ml). The precipitated product was then collected via filtration and dried under vacuum at 50 C White glassy product was obtained in 88% yield. An aliquot of the polymer was coated onto nylon and treated as above.
EXAMPLE 4
A polymerization vessel was charged with bis(cyclohexylmethyl)itaconate (5.0 g), Makon 8 surfactant (0.5 g) deionized water (9.0 ml) and potassium persulfate (0.07 g). Vigorous stirring was started and thee vessel was purged with argon for one hour. The sealed vessel was then placed in a 50° C. bath with continued stirring. After 8 hours, the mixture was cooled and treated with methanol (200ml). The white solid product (4.5g, 90%) was collected via filtration and dried under vacuum at 50 C An aliquot of the polymer was coated onto nylon and treated as above.
STAIN TESTING AND WASH DURABILITY
EXPERIMENTAL
Coating Procedure: White nylon-6 sleeve (˜5 g) was dipped into a CH 2 C 12 solution (15 ml) containing the polymer (0.1 g) to be tested. All of the solution was absorbed and worked into the fiber. The sleeve was then air dried followed by annealing at 105° C. for 15 minutes.
Kool Aid Staining
The nylon swatch to be tested was placed in a large petrie dish. Unsweetened Cherry Kool Aid (30 ml) was poured, from a height of two inches, onto the sleeve. After standing for 5 minutes, the swatch was cleaned with cold tap water and paper towels. The samples were allowed to air dry before stain ranking.
Coffee Staining
The nylon swatch to be tested was placed in a large petrie dish. Coffee, prepared in a drip coffee maker using 100 ml solid grounds (Maxwell House ADC) per liter of water, was poured 30 ml, 71° C. from a height of 2 inches, onto the sleeve. After standing for 5 minutes, the sample was cleaned and ranked.
Mustard Staining
The nylon swatch to be tested was placed in a large petrie dish. Mustard (2 grams) was dropped onto the fiber from a height of 2 inches. After standing for 5 minutes, the sleeve was cleaned and ranked.
Stain Ranking
The dry sample was sandwiched between a white background and a standard stain scale. Numerical rankings were obtained by matching the stain to the scale. A rating of 0 indicates no visible stain and 8 represents a severe stain.
Durability Testing
A nylon sleeve coated and annealed as above was subjected to a standard soap solution at 25° C. (cold wash) or 60° C. (hot wash) for 5 minutes with agitation. The sample was rinsed well with cold tap water, dried by blotting followed by air drying. The dry sample was then stained and ranked as above.
TABLE 1______________________________________Itaconate Homo and Co-polymer Stain Rankings1A 2A 2D KoolR.sub.1 & R.sub.2 R.sub.1 & R.sub.2 R.sub.6 R.sub.5 Aid ™ Coffee Mustard______________________________________2-pentyl -- -- -- 3.0 4.0 1.51-octyl -- -- -- 3.0 4.5 1.51-dodecyl -- -- -- 5.0 5.0 3.01-octadecyl -- -- -- 2.0 6.5 2.01-docosyl -- -- -- 5.0 3.0 3.0cyclohexyl -- -- -- 6.0 5.0 3.0methyl1-docosyl 2-pentyl -- -- 1.5 5.0 1.51-docosyl 1-octyl -- -- 1.0 2.0 0.51-octadecyl 1-octyl -- -- 3.0 3.0 1.0cyclohexyl- 2-pentyl -- -- 6.0 4.0 1.0methyl1-octadecyl 1-docosyl -- -- 5.0 4.0 1.0cyclohexyl- per- H 3.0 0.5 0.5methyl fluoro- alkyluntreated -- -- 8.0 8.0 6.0sleeve______________________________________
The column Headings 1A, 2A and 2D refer to the compounds so designated in the summary of Invention above. In 2D, Y is 2 and X is various values from 3 to b. The perfluoroalkyl precursor is DuPont Telomer B acrylate.
TABLE II______________________________________WASH DURABILITY Wash Num- Kool1A 2A 2D Con- ber Aid ™R.sub.1 & R.sub.2 R.sub.1 & R.sub.2 R.sub.6 R.sub.5 ditions washes Stain______________________________________Cyclohexyl- -- -- -- Cold 1 7.0methylCyclohexyl- -- -- -- Cold 2 7.5methylCyclohexyl- -- -- -- Hot 1 3.0methyl1-octyl 1-docosyl -- -- Cold 1 2.01-octyl 1-docosyl -- -- Cold 2 3.51-octyl 1-docosyl -- -- Hot 1 3.0Cyclohexyl- -- per- H Cold 1 3.0methyl fluoro- alkylUntreated -- -- -- Cold 1 8.0SleeveUntreated -- -- -- Hot 1 7.5Sleeve______________________________________ | The present invention relates to non-halogenated hydrocarbon polymeric compositions which impart durable stain resistance to fibrous substrates, particularly nylon containing articles. In addition, it relates to fluorine containing polymeric compositions which impart durable stain resistance to fibrous substrates as above. It relates also to processes in which such substrates are treated so as to impart durable stain resistance to them. It relates further to a manufacturing process for preparing the compositions of the invention. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO AN APPENDIX
[0003] Not applicable.
BACKGROUND
TECHNICAL FIELD
[0004] The technology described herein is generally related to the field of integrated circuits (“IC”) and, more particularly to operational amplifier circuits.
DESCRIPTION OF RELATED ART
[0005] Two-stage complementary-metal-oxide-silicon (“CMOS”) operational amplifier (“op-amp”) circuits are ubiquitous in electronic circuit design, providing relatively high voltage gain, very high input impedance, very low output impedance, and good rejection of common-mode signals (two signal voltages of the same phase, frequency and amplitude on the inputs). One class of CMOS op-amp circuits has a differential input and a single output. FIG. 1A (Prior Art) illustrates a basic, two-stage, differential op-amp. In CMOS IC implementations, two or more differential amplifier stages are used where the gain of each stage is frequency dependent; the response of a multistage op-amp is a composite of the individual responses of the internal stages.
[0006] One problem with two-stage CMOS op-amp circuits is an inability to both source and sink a large current to the output. For example, consider a CMOS op-amp where the first stage, input, devices are p-channel metal-oxide-silicon field-effect-transistors (“MOSFET”) and the second stage consists of a p-channel pull-up device that provides a constant bias current and an n-channel pull-down device in a common-source gain configuration. As such, the current that can be sourced from the positive power supply to the output is limited to the bias current in the p-channel device. The current that can be sunk from the output to the negative power supply (or ground) is greater, due to the gain of the common-source configuration. Conversely, an op-amp with n-channel inputs can source large currents but can only sink up to the bias current in the output stage. In general it is undesirable to increase the output current capability by increasing the bias currents as that would lead to large standby mode power dissipation.
[0007] Common-mode feedback has been used in an operational amplifier having differential inputs and differential outputs wherein a predetermined common-mode output voltage independent of common-mode input voltage and input voltage variation is provided. U.S. Pat. No. 4,573,020, Feb. 25, 1886, by Whatley, for a FULLY DIFFERENTIAL OPERATIONAL AMPLIFIER WITH D.C. COMMON-MODE FEEDBACK, uses D.C. common-mode feedback to provide a common-mode output voltage of the differential operational amplifier.
BRIEF SUMMARY
[0008] The present invention generally provides for an improved, common-mode feedback circuit.
[0009] The foregoing summary is not intended to be inclusive of all aspects, objects, advantages and features of the present invention nor should any limitation on the scope of the invention be implied therefrom. This Brief Summary is provided in accordance with the mandate of 37 C.F.R. 1.73 and M.P.E.P. 608.01(d) merely to apprise the public, and more especially those interested in the particular art to which the invention relates, of the nature of the invention in order to be of assistance in aiding ready understanding of the patent in future searches.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1A (PRIOR ART) is a schematic block diagram of a two-stage differential amplifier.
[0011] FIG. 1B is an electrical circuit diagram of an exemplary implementation of a two-stage differential amplifier employing the present invention.
[0012] FIG. 2 is an exemplary embodiment of a common-mode feedback device in accordance with the present invention as may be employed in a two-stage differential amplifier as shown in FIG. 1B .
[0013] Like reference designations represent like features throughout the drawings. The drawings in this specification should be understood as not being drawn to scale unless specifically annotated as such.
DETAILED DESCRIPTION
[0014] The op-amp in its basic form typically consists of two or more differential amplifier stages. Using conventional symbols, FIG. 1A (Prior Art) shows a two-stage op-amp. The first stage, “STAGE 1 ,” is a fully-differential amplifier OP-AMP 1 , having two inputs, a non-inverting input “+Vin 1 ,” an inverting input “−Vin 1 ,” and respective outputs “+Vout 1 ,” “−Vout 1 ,” and a common-mode feedback device “CMFBD.” The second stage, “STAGE 2 ,” OP-AMP 2 , has inputs “+Vin 2 ,” “−Vin 2 ” connected respectively to the outputs +Vout 1 , −Vout 1 of STAGE 1 and a single output “Vout.”
[0015] FIG. 1B is a schematic diagram of an exemplary BiCMOS embodiment for a circuit implementing a two-stage op-amp device incorporating a common-mode feedback device to be described in depth with respect to FIG. 2 hereinafter. This is a type of exemplary two-stage differential amplifier that is able to both source and sink a large current at its output OUT 102 . This exemplary circuit 100 is a folded-cascode, fully-differential input stage class op-amp followed by a push-pull, single-ended output stage class op-amp. It will be noted by those skilled in the art that a pair of bipolar input transistors Q 1 , Q 2 form the differential pair input stage. Four MOSFETs M 1 , M 2 , M 3 , and M 8 establish bias currents. Resistors R 5 and R 6 provide a load for the input transistors Q 1 , Q 2 . A pair of MOSFETs M 9 , M 10 are cascode devices. A pair of MOSFETs M 5 , M 6 provide an active load for the output. The differential output signals V 1 (+), V 2 (−) of the differential input stage are at the drain terminals of the active load MOSFETs M 5 , M 6 respectively. The push-pull single-ended output stage comprises a first pair of MOSFETs M 7 , M 12 . A second pair of MOSFETs M 4 , M 11 mirror the output signal at the drain of MOSFET M 5 around to the gate of MOSFET M 12 .
[0016] As the first stage is a fully-differential op-amp in that both the input and output signals are differential, a CMFB device HB 1 is required on the first stage output to set the DC level of the outputs to be at a reference voltage potential between the two power supply rails 201 , 203 potentials, e.g., a VDD potential and ground, GND, (or other secondary supply potential depending on the implementation) when a differential voltage is applied to the inputs of STAGE 1 .
[0017] An improved common-mode feedback circuit HB 1 which may be employed with the circuit 100 of FIG. 1B is shown in FIG. 2 . FIG. 2 illustrates an exemplary implementation of a common-mode feedback circuit device, CMFC/HB 1 200 , in accordance with the present invention that has significant advantages over known manner CMFBD circuits such as shown by Whatley, supra. Reference to both FIGURES is made in the following detailed description of an exemplary structure of the present invention.
[0018] In the CMFC/HB 1 200 , first pair of n-channel MOSFETs M 21 , M 23 receives the differential output voltages V 1 , V 2 (see also FIG. 1A , “+Vout 1 ,” “−Vout 2 ”) from the first stage of the amplifier 100 at respective CMFC input terminal ports 202 , 204 . MOSFET M 21 has a gate region 21 G connected to the CMFC input terminal port 202 for receiving the first output voltage V 1 of the amplifier 100 first stage, FIG. 1B . MOSFET M 21 has a drain region 21 D connected by a CMFC input terminal port 201 ′ to one power supply rail 201 , GND, of the amplifier 100 . The source 21 S of MOSFET M 21 is connected to the source 23 S of the second MOSFET M 23 . The gate 23 G of MOSFET M 23 is connected to the CMFC input terminal port 204 and thus to the second output voltage V 2 of the first stage of the amplifier 100 . The drain 23 D of MOSFET M 23 is connected to the power supply rail 201 , GND.
[0019] A third input terminal port 203 ′ to the CMFB 200 supplies power supply voltage VDD from power supply rail 203 to the CMFB through a second pair of n-channel MOSFETs M 25 , M 26 by being connected to and thereby biasing the respective source regions 25 S, 26 S. The gate regions 25 G, 26 G are connected to each other and to the drain region 26 D of MOSFET M 26 . The drain region 25 D of MOSFET M 25 is connected to the source regions 21 S, 23 S of the V 1 -V 2 receiving MOSFETs M 21 , M 23 , respectively.
[0020] A third pair of MOSFETs M 22 , M 24 provide a CMFB output level “Vcmo” as DC common-mode feedback to the amplifier 100 via its first stage MOSFET M 6 . A n-channel MOSFET M 22 has its source region 22 S connected to the source regions 21 S, 23 S of the V 1 /V 2 input MOSFETs M 21 , M 23 , respectively. MOSFET M 22 has a body region connected to the body regions of MOSFETs M 21 and M 23 . Note that in this particular implementation, the substrate is p-type and p-channel FETs are formed in an n-well body region. While the exemplary embodiment(s) described herein is illustrative of using semiconductor devices having a specific transistor polarity implementation, it will be recognized by those skilled in the art that an implementation of reverse polarity devices can be made. No limitation on the scope of the invention is intended by the exemplary embodiment(s) and none should be implied therefrom. The drain region 22 D of MOSFET M 22 is gate coupled. The drain region 22 D of MOSFET M 22 is also connected to the drain region 24 D and gate 24 G of a p-channel 24 S of MOSFET M 24 is connected to the GND rail 201 . The gate region 24 G is connected to the drain region 24 D and Vcmo output.
[0021] Compared to devices such as taught by Whatley, this exemplary common-mode feedback device of the present invention eliminates several devices, combines others, and reduces the total power supply current required for operation while still providing a DC common-mode output voltage Vcmo for the over all op-amp ( FIG. 1B ) functionality at the necessary level for operation of its push-pull output stage.
[0022] Referring again to both FIGS. 1B and 2 , operation of the present invention will be described. Assume initially that the amplifier 100 is in a steady-state condition with no differential signal applied. In this case, a CMFC/HB 1 200 will also be in a steady-state condition; currents through transistors M 21 , M 22 and M 23 are matched according to their geometric size ratios.
[0023] For example, when transistors M 21 , M 22 and M 23 are substantially identical in size, if the drain current of transistor M 21 is “I,” then the drain current of transistor M 22 , which is geometrically equal to two transistors identical to M 21 , would be twice “I” or “2I.” The drain current of transistor M 23 would be “I,” the same as the current in transistor M 21 . Because of the well-known characteristics of FETs, this will cause the gate-to-source voltage of the three FET devices M 21 , M 22 and M 23 to be equal. With their source terminals 21 S, 22 S, 23 S all connect to the same node N 20 , the gate voltage of each FET M 21 , M 22 and M 23 will be equal. FET M 22 therefore sets a reference voltage established by the gate-to-source voltage of FET M 24 , and the CMFC HB 1 input terminal ports 202 , 204 , voltages “V 1 ” and “V 2 ,” respectively, will be forced to a voltage equal to this reference.
[0024] In a first stage of the CMFC HB 1 200 , the FET M 26 is “diode-connected.” A common current source circuit—not shown, but represented here as an ideal current by symbol “I 1 ”—is connected to the drain 26 D and gate 26 G of FET M 26 . The current source circuit is effectively a bias current which would be known in the art to be established by any number of circuits such as a band gap reference circuit. Current I 1 pulls down on the gate 26 G and drain 26 D, establishing a voltage on the gate that is a function of the current. FET M 25 is a “mirror FET” with the same connects of its gate 25 G and source 25 S as FET M 26 . Therefore, the current out of the drain 25 D of FET M 25 will tend to be equal to the current in FET M 26 which is I 1 . Thus, a current I 1 ′ out of the drain 25 D of FET M 25 flows into the node 207 connected to source regions M 21 S, M 23 of HB 1 second stage and source region M 22 of the HB 1 third stage of the CMFC/HB 1 200 . Thus, the output of the first stage is at a level such that it drives a common-source second stage. The third stage FETs M 22 , M 24 coupled to the second as described above thus provide the proper aforementioned Vcmo output.
[0025] Now assume that this equilibrium state is disturbed by a differential input signal +Vin 1 , −Vin 2 to the amplifier 100 . The voltage at CMFC/HB 1 200 input 202 “V 1 ” will, for example, decrease while the voltage at CMFC/HB 1 200 input 204 “V 2 ” will, for example, increase. As a result of these changes, the drain current in FET M 21 will increase and the drain current in FET M 22 will decrease, but the equilibrium point of the CMFC/HB 1 200 is not affected. The circuit is still balanced as long as the total current through FET M 21 and FET M 23 , determined by summing the individual drain current of each device, is equal to the drain current of FET M 22 . In this case the common-mode feedback circuit does not affect the overall operation of the amplifier 100 .
[0026] Note that when a differential signal of the opposite polarity—such that the voltage at CMFC/HB 1 200 input 202 “V 1 ” increases and the voltage at CMFC/HB 1 200 input 204 “V 2 ” decreases—would also produce the same result.
[0027] If the equilibrium state is disturbed by a common-mode change such that the voltage at CMFC/HB 1 200 input 202 “V 1 ” and the voltage at CMFC/HB 1 200 input 204 “V 2 ” both change in the same direction, then the feedback circuit will operate to restore the amplifier 100 to equilibrium. For example, suppose that both CMFC inputs 202 , 204 “V 1 ” and “V 2 ,” respectively, decrease in voltage. Transistors M 21 and M 23 will attempt to increase the amount of current flowing through them. Since the current available to the three FETs M 21 , M 22 and M 23 is fixed at “I 1 ” by the bias device M 25 , the increase in current through FETs M 21 and M 23 causes a corresponding decrease in the current flowing through FET M 22 . This reduced current causes the reference voltage “Vcmo” formed by the gate-to-source voltage of device M 24 to also decrease. The reference voltage “Vcmo” is then supplied to the amplifier circuit 100 first stage through CMFC/HB 1 200 output terminal port 206 .
[0028] It can now be recognized that externally to the common-mode feedback circuit 200 , the amplifier 100 will respond in a known manner to the output “Vcmo” to increase the voltages at input terminals 202 and 203 “V 1 ” and “V 2 ” respectively. The CMFC/HB 1 200 circuitry is brought back into equilibrium, where the current through M 21 and M 23 is equal, and the current through M 22 is twice that value.
[0029] The above analysis can be extended to the case where the common-mode imbalance is caused by both CMFC inputs 202 , 204 wherein “V 1 ” and “V 2 ” are increasing in voltage.
[0030] It will be understood that while a two-stage amplifier has been used as an exemplary embodiment, the concept can be readily adapted to implementations having more stages.
[0031] Moreover, it will be understood by those skilled in the art that the concept of the present invention can be readily adapted to implementations using bipolar technology, BiCMOS technology, and the like integrated circuit design and fabrication processes.
[0032] The foregoing Detailed Description of exemplary and preferred embodiments is presented for purposes of illustration and disclosure in accordance with the requirements of the law. It is not intended to be exhaustive nor to limit the invention to the precise form(s) described, but only to enable others skilled in the art to understand how the invention may be suited for a particular use or implementation. The possibility of modifications and variations will be apparent to practitioners skilled in the art. For example, while the exemplary embodiment(s) described herein is illustrative of using semiconductor devices having a specific transistor polarity implementation, it will be recognized by those skilled in the art that an implementation of reverse polarity devices can be made. No limitation on the scope of the invention is intended by the exemplary embodiment(s) and none should be implied therefrom. No limitation is intended by the description of exemplary embodiments which may have included tolerances, feature dimensions, specific operating conditions, engineering specifications, or the like, and which may vary between implementations or with changes to the state of the art, and no limitation should be implied therefrom. Applicant has made this disclosure with respect to the current state of the art, but also contemplates advancements and that adaptations in the future may take into consideration of those advancements, namely in accordance with the then current state of the art. It is intended that the scope of the invention be defined by the Claims as written and equivalents as applicable. Reference to a claim element in the singular is not intended to mean “one and only one” unless explicitly so stated. Moreover, no element, component, nor method or process step in this disclosure is intended to be dedicated to the public regardless of whether the element, component, or step is explicitly recited in the Claims. No claim element herein is to be construed under the provisions of 35 U.S.C. Sec. 112, sixth paragraph, unless the element is expressly recited using the phrase “means for . . . ” and no method or process step herein is to be construed under those provisions unless the step, or steps, are expressly recited using the phrase “comprising the step(s) of . . . ” | A common-mode feedback circuit is provided for fully-differential operational amplifier stages of a multistage amplifier. A first stage of the circuit establishes a substantially constant current output level for a feedback generating stage of the circuit. An exemplary embodiment using MOSFET devices illustrates using a diode-connected MOSFET and mirror MOSFET first stage and a generating the current for a common-source connected MOSFET second stage connected to the respective outputs for said fully-differential operational amplifier. An output stage of the circuit provides feedback voltage at a first level when inputs to said fully-differential operational amplifier are in equilibrium and at a second level for balancing said fully-differential operational amplifier when inputs to said fully-differential operational amplifier are not in equilibrium. | 7 |
BACKGROUND AND SUMMARY OF THE INVENTION
This invention relates to a torque limiting clutch. More particularly, this invention relates to a clutch coupling a driven member and a driving member for rotation in unison while transmitting torque therebetween up to a predetermined torque limit of the clutch. When the torque limit of the clutch is reached, the clutch slips to allow relative rotation of the driving and driven members while transmitting the predetermined torque therebetween.
Clutches of this nature find wide application in a variety of mechanical arts. For example, power driven assembly tools which are used to drive threaded fasteners usually incorporate a torque limiting clutch to prevent over tightening of the fasteners. Such clutches also find application in aircraft where they are used in servo systems. Servo systems are used in aircraft to perform a variety of functions. For example, servo systems may be employed to extend and retract the aircraft landing gear or move engine thrust reversing devices between stowed and deployed positions. Further, an aircraft may have servo systems which moves aerodynamic surfaces of the aircraft between selected positions. In all of these illustrative servo systems, and others, torque limiting clutches may be used to prevent damage to the aircraft structure and to the servo system drive train in the event that a jam prevents movement of the system.
In view of the wide application of torque limiting clutches, a number of desirable characteristics for such clutches have been recognized. Among these desirable characteristics are a smooth transition from driving to slipping torque transmission, a repeatable torque limit so that the clutch begins to slip at substantially the same torque time after time, and a mechanically simple and physically rugged clutch structure which is relatively inexpensive to manufacture. Further, a torque limiting clutch should be easily calibrated during manufacture so that compensation may be made for tolerance stack up of its component parts which effect the torque limit of the clutch. Finally, the clutch should be such that wear occurring during the life of the clutch has only an acceptably small effect upon the torque limit of the clutch.
Because of the many desirable characteristics for a torque limiting clutch, conventional clutches of this type have been deficient in one or more respects. Accordingly, it is a primary object for this invention to provide a torque limiting clutch which avoids or ameliorates one or more of the deficiencies of conventional torque limiting clutches.
Another object for this invention is to provide a torque limiting clutch having a driven member and driving member coupled by a multitude of friction elements the number of which may be changed to calibrate the torque limit of the clutch.
Still another object is to provide a method of calibrating a torque limiting clutch according to this invention.
Yet another object is to provide a torque limiting clutch which effects a smooth transition from driving to slipping torque transmission.
Another object for this invention is to provide a torque limiting clutch which has a substantially constant torque limit throughout its service life.
Still another object is to provide a torque limiting clutch which is mechanically simple in construction and physically rugged.
In summary, this invention provides a torque limiting clutch having a number of axially stacked resilient friction elements interposed between a driven member and a driving member. The friction elements are dislorted to resiliently and frictionally engage one of the members and mechanically interlock with the other member. When torque is applied to either one of the members, the resilient elements transmit the torque to the one member. The nature of the interlocking fit of the resilient elements with the other member is such that the transmitted torque urges the resilient elements away from engagement with the one member. So long as the transmitted torque is less than a predetermined value the preload of the resilient elements prevails and relative rotation of the members is prevented. When the transmitted torque reaches the predetermined value, the torque prevails over the preload of the resilient elements so that they slip relative to the one member. Thus, relative rotation of the driving and driven members is permitted while the predetermined torque is transmitted therebetween.
One preferred embodiment of the invention is described in detail below with reference to drawing figures which illustrate only this one preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an axial cross sectional view of a torque limiting clutch according to the invention;
FIG. 2 is a fragmentary transverse cross sectional view taken along line 2--2 of FIG. 1; and
FIG. 3 is an enlarged fragmentary view of an encircled portion of FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a torque limiting clutch 10 according to a preferred embodiment of the invention. Clutch 10 includes a housing 12 composed of first and second cylindrical parts 14 and 16, respectively, which threadably interconnect at 18. The parts 14 and 16 cooperate to define a stepped bore 20 extending axially through the housing 12. The housing 1 also defines threaded bores 22 by which the clutch 10 may be mounted to driving and driven apparatus (not shown) as by bolts engaging the bores 22. The housing 12 carries a pair of bearings 24, 26 between respective steps 28, 30 on the bore 20. A number of annular shims 32 are interposed between the step 30 and bearing 26 so that the axial preload on bearings 24 and 26 may be adjusted. A clutch assembly 34 is rotatably carried by the bearings 24 and 26.
The clutch assembly 34 includes a cylindrical member 36 having a circumferentially extending wall 38 defining a bore 40. In order to drivingly connect with one of the driving or driven apparatus (not shown), the member 36 includes a hollow stem 42 extending axially to the opening of bore 20 at the right end of clutch 10, viewing FIG. 1. The stem 42 defines a recess 44 which is square in transverse cross section. A shaft of one of the driving or driven apparatus is receivable into the recess 44 to couple with the member 36. The clutch assembly 34 also includes a member 46 having a hollow stem 48 defining a recess 50 which is square in cross section. The stem 48 extends to the opening of the bore 20 at the left end of the clutch 10 to couple with the other of the driving or driven apparatus.
A second stem 52 defined by the member 46 extends rightwardly into the bore 40 of the member 36. The stem 52 carries a spool member 54 defining a bore 56. An externally splined portion 58 of the stem 52 drivingly engages with a matching splined portion 60 of the bore 56. A bearing 62 is captured between a shoulder 64 on the member 46 and a shoulder 66 on the spool member 54. A similar bearing 68 is captured between a shoulder 70 on the spool member 54 and a washer 72 carried by the stem 52. A nut 74 threadably engages the stem 52 and bears against the washer 72 to trap the spool member 54, bearings 62, 68, and washer 72 on the stem 52. The bearings 62, 68 engage the wall 38 of member 36. In view of the above, it is easily understood that the clutch assembly 34 is rotatable within the housing 12 and that the members 36 and 46 of the clutch assembly are relatively rotatable.
Viewing FIGS. 2 and 3, it will be seen that the spool member 54 defines an axially extending groove 76. An elongate channel member 78 is secured in the groove 76, as by welding. The channel member 78 defines a pair of radially and axially extending walls 80 and 82 which are substantially parallel. The walls 80 and 82 cooperate to define a predetermined dimension "D" therebetween.
In order to drivingly couple the members 36 and 46, the clutch assembly 34 includes an axially stacked multitude of relatively thin resilient elements 84. The elements 84 are received in a coannualar chamber 86 which is substantially defined in the bore 40 by the cooperation of wall 38 and spool member 54. The resilient elements 84 are substantially C-shaped and each one defines a pair of confronting ends 88 and 90, viewing FIG. 3. Each of the resilient elements 84 is radially distorted from its unrestrained or free shape in the bore 40. As a result, an outer circumferential surface 92 of each of the elements 84 frictionally engages the wall 38. In other words, the resilient elements 84 in their free shape define an outer diameter which is greater than the inner diameter of the bore 40. As a result, the resilient elements 84 within the bore 40 are yieldably preloaded into frictional engagement with the wall 38 by their own inherent resilience (illustrated by arrows R and R 1 , viewing FIG. 3).
Further examination of FIGS. 2 and 3 will reveal that the radial dimension of the resilient elements 84 varies circumferentially. The resilient elements 84 define their smallest radial dimension adjacent the ends 88, 90 and circumferentially increase in radial dimension with increasing distance from the ends 88, 90. At a point 91 substantially diametrically opposite the ends 88, 90, viewing FIG. 2, the resilient elements 84 define their maximum radial dimension. Because of the circumferential variation in radial dimension of the resilient elements 84, the radial pressure between the surface 92 of each of the elements 84 and the wall 38 is substantially uniform circumferentially. Additionally, stresses in the resilient elements 84 caused by their distortion in the bore 40 are substantially uniform circumferentially. Thus, it will be understood that the resilient elements 84 engage the member 36 to function as friction elements.
A pair of projections 94, 96 extend radially inwardly from the pair of ends 88, 90, respectively, of each resilient element 84. The projections 94, 96 are received between the walls, 80, 82, of the channel member 78. A pair of radially extending and circumferentially oppositely disposed abutment surfaces 98, 100 are defined by the pair of projections 94, 96, respectively. The abutment surfaces 98, 100 cooperate to define a dimension "d" therebetween, which is less than the dimension "D". The abutment surfaces 98, 100 are engageable with the walls 80, 82, respectively, of the channel member 78. Thus, the resilient elements drivingly interengage with the channel member 78 to couple the elements 84 with the member 46. Regardless of the sense of torque prevailing between the members 36 and 46, after a small possible relative rotation determined by the difference between the dimension "D" and "d", one of the projections 94, 96 engages one of the walls 80, 82 to transmit torque between the members 36 and 46.
Upon examination of the drawing figures it will be seen that the resilient elements 84 bear a strong resemblance to commercially available snap rings of the internal type. In fact, the elements 84 are substantially similar to snap rings. In some applications snap rings may be used in the clutch 10 as the friction elements 84 so that the manufacturing costs of the clutch are significantly reduced. Even in those applications where commercially available snap rings are not appropriate for use in the clutch 10, the similarity of the friction elements 84 to snap rings, for which low-cost manufacturing methods are well established, reduces the cost of the elements 84.
Having observed the structure of clutch 10, attention may now be directed to its operation. When a torque prevails between the two members 36, 46 (as is illustrated by arrows T and T 1 ; viewing FIG. 3) one of the projections 94, 96 of each element 84 engages one of the walls 80, 82 of channel member 78 to couple the member 46 to the elements 84. Thus, one of the driving and driven apparatus (not shown) is coupled with the elements 84 for rotation in unison therewith. The resilient friction elements 84 in turn frictionally couple with the member 36 and with the other of the driving and driven apparatus. As a result, the driving and driven apparatus are coupled for rotation in unison while the clutch 10 transmits torque therebetween.
Viewing FIG. 3, it will be seen that as a result of the torque T-T 1 the wall 82 applies a force (represented by arrow F) to the projection 96 of each of the elements 84 in order to transmit torque to the latter. The force F is transmitted circumferentially within the elements 84 and transmitted therefrom to the wall 38 by the frictional engagement therebetween. The end 88 of each friction element is unrestrained; being spaced from the wall 80 by a gap equal to the difference between the dimensions "D" and "d" and also being spaced from the end 90. The force F opposes the resilience R of each element 84 at the end 90 while the torque T 1 opposes the resilience R 1 of the elements 84 at the end 88. Thus, the torque T-T 1 is transmitted between the elements 36, 46 while opposing the inherent resilience of the members 84. (It will be understood that the torque T-T 1 and the resilience R-R 1 are actually distributed circumferentially rather than localized at the ends 88-90.) Nonetheless, as long as the prevailing torque between the members 36 and 46 is less than a predetermined torque limit of the clutch 10, the resilience of the elements 84 predominates and the members 36, 46 are frictionally coupled for rotation in unision. When the prevailing torque reaches the predetermined torque limit, the torque predominates over the resilience of the elements 84 to urge the latter away from frictional engagement with the wall 38 so that slippage occurs therebetween and results in relative rotation of the members 36, 46.
It will be noted that the torque limit of the clutch 10 is believed to be substantially independent of the friction coefficient between the elements 84 and wall 38 as long as this friction coefficient is above a limiting minimum valve. The torque limit of the clutch is believed to be dependent upon the resilient preload of the elements 84 urging the surface 92 into engagement with the wall 38. Thus, the elements 84 are shaped so that wear occuring during the service life of the clutch 10 has only a small effect upon the preload of the elements against the wall 38 and a small effect upon the torque limit of the clutch.
In view of the above, it is easily perceived that each one of the multitude of elements 84 transmits its prorata share of torque between the members 36, 46. In order to calibrate the torque limit of the clutch 10 lo bring the torque limit thereof within a preselected range, the number of elements 84 in the clutch may be increased or decreased. During manufacture of the clutch 10, the clutch may be assembled with a determined number of elements 84 therein and tested to ascertain its torque limit. If the torque limit of the clutch is outside of the preselected range, the number of elements 84 in the clutch may be increased or decreased according to the deviation of the torque limit from the preselected torque range. If desired, the clutch may again be tested to assure that the torque limit has been brought within the preselected range. Moreover, during serial production of clutches according to this invention the determined number of elements 84 initially placed in each clutch may be adjusted in view of an iteration as described above so that few of the clutches will require further addition or removal of resilient elements in order for their torque limit to fall within the preselected range.
Additionally, it is easily perceived that the clutch 10 is bidirectional. That is, the elements 36, 46 may be driven in either direction with the wall 80 or 82 of channel member 78 engaging the appropriate projection 94 or 96 of the resilient elements 84 so that the torque limit of the clutch is substantially uneffected by the direction of rotation. Further, either of the members 36, 46 may connect to the driving apparatus with the other of the members 36, 46 connecting to the driven apparatus. In other words, the torque limit of the clutch 10 is substantially uneffected by which of the members 36, 46 is driving and which is driven.
While this invention has been described with reference to a preferred embodiment thereof, no limitation upon the invention should be implied because of such reference. Many modifications, changes, and alterations to the preferred embodiment of the invention will suggest themselves to those skilled in the pertinent art. Such equivalents of the invention are intended to fall within the scope and spirit of the appended claims which alone define and limit the invention. | A torque limiting clutch having a torque limit which is easily calibrated and relatively constant throughout the service life of the clutch. The clutch includes a pair of rotatable members which are rotatably coupled by resilient friction members yieldably engaging one of the pair of members and securing to the other of the pair of members. The friction elements are configured to achieve substantially uniform friction force and wear along their friction surfaces. According to one embodiment of the invention standard commercial snap rings may be employed as the friction elements. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to solar energy heating systems.
Significant technological progress has been made in solar heating systems in recent years, following the realization of limits on fossil fuels and the rapidly increasing cost thereof. Solar heating is becoming a practical reality in some geographical areas, particularly in the southern and southwestern parts of the United States, sometimes designated the "Sun Belt". In the more northern regions, as in the northwestern, midwestern, and northeastern parts of the United States, where the number of sunny days is less, there is difficulty justifying the installation cost of solar equipment because of the considerably lower efficiency thereof. There are many cloudy or partly cloudy days when the collector cannot generate sufficient heat to meet requirements, particularly during cool mornings and evenings. Hence, any solar system of the presently known type is typically inactivated at such times, with the heat then being generated by fossil fuel combustion. Unfortunately, these same regions of cooler climate are more in need of whatever solar energy there is available, even if insufficient to meet the total heat requirements.
SUMMARY OF THE INVENTION
This invention provides a solar heating system particularly suited for use in the cooler, less sunny, northern climates, by enabling efficient usage of whatever heat there is available from the solar collector and in the storage unit, even when the solar collector is not generating adequate heat to supply the requirements for the space being heated. A unique air flow system is capable of selectively retrieving heat simultaneously from both the solar collector and the heat storage, mixing the two fluids and subsequently propelling the mixture to the space to be heated.
The novel air handler and mixer enables the lesser amount of heat which the solar collector is able to generate to be salvaged and combined with previously stored heat for maximizing the output. Yet, the additional apparatus required to achieve this, over that solar equipment which is conventionally employed, is relatively small, and relatively inexpensive, with installation thereof being readily made.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of the heating and air flow system of this invention, depicted in mode 1, that is, in the mode of heating the controlled environment or space directly from the solar collector;
FIG. 1a is an electrical diagram of the control system for mode 1;
FIG. 2 is a schematic diagram of the novel system in mode 2, with the space being specially heated by a portion of the air being circulated through the solar collector and a portion through the heat storage, with subsequent mixing of these air portions;
FIG 2a is an electrical diagram of the control system for mode 2;
FIG. 3 is a schematic diagram of the system in mode 3, with heated air flow from only storage to the space;
FIG. 3a is an electrical diagram of the control system for mode 3;
FIG. 4 is a schematic diagram of the system in mode 4, with air flowing from the solar collector to storage;
FIG. 4a is an electrical diagram of the control system for mode 4;
FIG. 5 is a schematic diagram of the system in mode 5, with heat being supplied from the auxiliary heating unit to the space;
FIG. 5a is an electrical diagram of the control system for mode 5;
FIG. 6 is a schematic diagram of the system at rest.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now specifically to the drawings, in FIG. 6 is disclosed a schematic of the components of this system. Specifically, the system or assembly 10 includes a solar collector 12, a heat storage unit 14, an enclosure for the space or protected environment 16 to be heated, a unique air flow handling and mixing assembly 18, preferably an auxiliary heating unit 20, and interconnecting ducts, namely duct 22 from collector 12 to assembly 18, duct 24 between assembly 18 and space 16, duct 28 between space 16 and storage 14 also having a portion 28' extending from storage 14 to collector 12, and duct 29 between assembly 18 and storage unit 14.
The particular construction of the solar heat collector 12 can vary widely, there being many known in the art. Basically, the collector is positioned at a selected angle to the vertical to maximize absorption of solar radiation for conversion to thermal energy. It is constructed to allow air flow through channels in engagement with the heat absorbing surfaces, usually black, e.g. 12a and 12b, from an inlet typically at the lower end of the collector, to an outlet at the upper end thereof.
The storage unit 14 likewise can vary in nature and specifics, there being several conventional designs which can be employed. A typical storage unit, for example, would be a three dimensional enclosure containing "heat sink" material such as rocks or the equivalent which are spaced to allow air flow therethrough for absorption of heat from heated air to the rocks, or subsequent discharge of stored heat from the rocks to cooler air flowing therethrough.
The environmental space to be heated will vary with the circumstances, typical examples being a home, an office space, a work space, or any other environmental area encountered in normal living patterns.
Auxiliary heater 20 may assume a variety of forms, typically being a fossil burning unit such as a gas, oil, or coal burning furnace, but may alternatively be another source of heat such as an electrical energy heat exchanger or a heat pump.
The ducts 22, 24, 26, 28, 28' and 29 are formed in the shape and dimension necessary to conduct air in the several recirculatory paths set forth for the different operating modes of this system to be described.
The mixing assembly 18 includes a first, powered, air propulsion means or two-speed blower A having its inlet communicant with duct 22 and its outlet communicant with a special air mixing or blending chamber 32. A damper I in duct 22 adjacent the inlet to blower A is pressure responsive, allowing flow from the duct to the blower, but preventing reverse flow by being responsive to positive pressure at the blower. Assembly 18 also includes a second air propulsion means or blower B having an inlet communicant with duct 22, an inlet communicant with duct 29 and an outlet communicant with mixing chamber 32. Duct 29 is communicant with storage unit 14, as well as with the inlet of blower B or alternately with mixing chamber 32. A motor operated damper C is between duct 29 and mixing chamber 32 to allow, when open, air flow from mixing chamber 32 to duct 29 and hence to storage unit 14. A back pressure responsive, normally closed damper F is at outlet duct 23 of auxiliary heat source 20. Inlet 21 communicates with duct 28 and outlet 23 with duct 24.
With this novel system, particularly using the novel assembly 18, solar engery can more effectively be employed in geographical areas where sunlight is not as plentiful as in other areas, e.g. there being shorter days during cold weather, the sun being partially blocked by clouds so as to lessen the amount of solar radiation usable, and there being cooler mornings and evenings when the solar collector cannot always generate sufficient heat to accommodate the space to be heated. Thus, with the novel assembly, not only can air be heated and circulated directly between the solar collector 12 and the space 16 (mode 1, FIG. 1), or circulated directly between the solar collector 12 and the storage unit 14, (FIG. 4, mode 4), or circulated between storage unit 14 and the environmental space 16 (FIG. 3, mode 3), but also, especially in the morning or evening when there is some sunlight available or during an overcast day when there is partial solar radiation available but not in sufficient amount to totally accommodate the environmental space requirements, a blend of some air partially heated by passage through storage unit 14 with other air partially heated by passage through solar collector 12 is prepared in the mixing chamber 32 by the two blowers and circulated to the environmental space (FIG. 2, mode 2). This controlled operation of the two separately activated blowers plus controlled activation of the dampers combines air from the two different heat sources in the mixing chamber and propels such to the environmental space. The air propulsion unit A for handling air from the solar collector has different air output capacities and settings so that in mixing mode 2, its output is substantially lessened from that in modes 1 and 4, preferably to about one-half. This can be achieved by having, for example, a two speed motor 31 operating this blower A, with one set of windings for high motor speed and greater air output and another set of windings for low motor speed and lesser air output. The low speed is used when the combined output from blowers A and B is mixed and circulate.
The blowers, motor operated dampers, and auxiliary heating unit are operated in response to temperature sensors or thermostats at strategic locations in the system. In the embodiment depicted, there are four basic locations for such sensors. One location is in the environmental space to be heated where space thermostat sensor T4 is located. Another location is at the lowest energy (i.e. lowest temperature) point of the storage unit, in this case the opening 15 at the bottom where thermostat sensor T2 is located. Another location is at the highest energy, (i.e. highest temparature) point of the storage chamber, in this case at the opening adjacent duct 29, where thermostat sensor T3 is located. The fourth location is at the highest energy, (i.e. highest temperature) point in the solar collector, in this case near the top outlet where thermostat sensors T1, T1', and T1" are located. Sensor T1 is part of a differential thermostat in combination with sensor T2. It operates relay CR1 which shifts switch 42 between two positions to complete a circuit for low speed blower windings or a circuit for high speed blower windings for motor A of blower A. Differential thermostates are conventional items marketed for example under the trademarks "Honeywell" and "Rho Sigma", the operation of which is explained hereinafter.
In FIGS. 1a, 2a, 3a, 4a and 5a is set forth an electrical diagram depicting a control circuit, each figure showing the control circuit in a different mode of operation. The circuit is powered from bus lines L1 and L2 and includes relays CR1, CR2, CR3, CR4, CR5, CR6, CR6a, CR6b and CR7 as well as temperature sensors T1, T1', T1", T2, T3 and T4. It includes an electrical motor A for blower A and an electrical motor B for blower B, a motor operated damper C and a motor operated damper E. A differential thermostat 40 employs temperature sensor T1 in the solar collector and temperature sensor T2 in the low energy part of the storage unit. The sensor T1 is adjusted to activate at a temperature of above about 140° F., while sensor T2 is adjusted to activate at a temperature of above about 80° F. and below 140° F. A thermostat T4 in the enviromental space to be heated, when closed, operates the coils for relays CR6A and CR6B. Thermostat T1 controls the relay CR5 and thermostat T1" controls relay CR7. Thermostat T3 controls relay CR3.
In operation, in mode 1, the environmental space is heated by the solar collector. Specifically, when the space calls for heat by closing of the space thermostat contacts, relays CR6A and CR6B are energized. In this mode, blower A is energized by either (1) the differential thermostat or (2) by relay CR2 (which is closed when damper E is open) plus relay CR5 which is activated when temperature sensor T1' indicates solar heat availability in the collector, plus relay CR6 closed by the space thermostat T4. When sensor T1 energizes relay CR5, and relay CR6 is energized, such energizes relay CR4, which in turn operates motorized dampers C and E. These dampers are always in opposite positions relative to each other. In this mode 1, damper E opens and damper C closes. Positive back pressure against damper F keeps it closed to maintain isolation of the auxiliary unit. Back pressure responsive damper I is held open by air flow pressure differential thereacross.
In this condition, mode 1, the system operates as indicated by the arrows in FIG. 1, i.e. heated air in the solar collector is advanced through duct 22 and through open damper I by blower A operated by its motor 31, into chamber 32 and through damper E into duct 24 to the space to be heated, the return air being drawn through duct 28 and 28' to the collector.
Mode 2 is the special mixing mode which is described hereinafter.
In mode 3, see FIG. 3 and FIG. 3a, heat is obtained from the storage unit and circulated to the space and returned. Specifically, the temperature in the solar collector is not sufficient, as detected by sensor T1', to activate relay CR5. Sensor T3 in the high temperature end of the storage unit however, energizes relay CR3 such that, with relay CR2 being activated by one the dampers E and C being open, and with relays CR6A and CR6B being activated by the space thermostat, blower B is energized. The activation of relays CR3 and CR6 also energizes relay CR4, opening motorized damper E and closing damper C. The pressure differential holds damper I closed. It acts as a check valve to prevent air flow back through the collector. Blower A cannot be energized in this mode 3 because, for sensor T3 to be satisfied and not temperature sensor T1, the temperature at sensor T1 must equal or be less than the temperature at sensor T2 which excludes relay CR1, relay CR5, and relay CR7, to prevent air flow through the other paths. Thus, the air is recirculated by blower B drawing air from storage unit 14 through duct 29, through blower B into mixing chamber 32, through open damper E into duct 24 to the space at 16, being returned through the return duct 28 to the storage inlet 15. Heat is thus drawn from the storage unit and transferred via heated air to the environmental space.
In the special mixing mode 2, see FIG. 2 and FIG. 2a, the temperature of the solar collector 12 is sufficient to activate sensor T1 i.e. above about 80° F., although not sufficient to supply all of the heat requirements to the environmental space i.e. below about 140° F. This preset temperature value of about 80° F. can be varied, although a solar collector temperature of 80° F. is sufficiently above a comfort temperature range of 65°-75° F. to supply some energy to the space to be heated. The preset temperature value of about 140° F. will be varied to suit the size of the space to be heated, the size of the collector unit or units, heat losses in the ducts, air blower capacity and the like. The specific setting is chosen to be that at which the energy level in the collector is sufficient to heat the space without added supplemental energy. The T1 activation temperature, e.g. 80° F., is the minimum temperature to activate the system for air mixing operation according to mode 2. The blower A is then on low speed. The T2 activation temperature, e.g. 140° F., is the minimum temperature to activate the system for mode 1 operation wherein the collector supplies all of the required heat.
Thus, in mode 2, the air flow path described above relative to mode 3 is active and in addition, since the temperature of the solar collector is above the minimum mixing temperature but not above the minimum temperature for supplying all of the heat requirements for the space, and with the space calling for heat thereby having its thermostat activating relays CR6A and CR6B, blower A is energized at low speed by differential thermostat 40 causing relay CR1 to shift switch 42 for the low speed windings of the motor for blower A. With blower A energized at low speed, and blower B also being energized as explained previously, relative to mode 3, some air is drawn from the collector 12 through duct 22 and through damper I and through blower A operating at low speed into mixing chamber 32, while simultaneously, heated air is drawn from the storage unit 14 through duct 29 and blower B into mixing chamber 32, where both portions of air are mixed and blended before being propelled through damper E and duct 24 to the space within enclosure 16. The return air through duct 28 from the space is partially transferred into storage chamber 14 at 15 and partially conveyed through branch duct 28' to collector 12, for recirculation. Thus, any heat that is available in the collector 12 is salvaged, while supplemental heat is drawn from storage unit 14, by the cooperative action of the two blowers and the mixing chamber in the system.
In mode 4, FIG. 4 and 4a, the space to be heated does not call for heat but the solar collector has sufficient heat to be added to storage for further use. Thus, the temperature sensor T1 senses a temperature greater than the temperature sensed by sensor T2 so that the differential thermostat energizes relay CR1 and, if either motorized damper E or C is open, blower A will have power applied to the high speed windings thereof. The motorized damper C will open, allowing transfer of heated air to the storage from the solar collector. Because the space is not calling for heat, relays CR6A and CR6B are not energized and relay CR4 is in its rest position. The relays in the schematic are in fact all at rest in this mode. Also, in this mode, temperature sensors T1 and T3 are not necessarily satisfied and are shown as such. Back pressure responsive damper I is held open by pressure upstream greater than downstream thereof. (In the schematic, double contacts are shown used for relay CR2, for increased amperage although this is purely optional.)
Thus, in mode 4, air from the collector 12 is circulated through duct 22 and blower A operating at high speed, into chamber 32 and back through motorized damper C to storage unit 14 where it discharges heat by passage through the heat sink, and then is recirculated back through duct portion 28' to the solar collector to again be heated.
Assuming that the solar system is being employed where an auxiliary heating unit 20 is necessary, the illustrative version of the system depicted is shown to include such. Mode 5 (FIG. 5 and FIG. 5a) is set forth to depict supply heat from such a source when there is inadequate heat in the storage unit and in the collector. This optional arrangement need not be employed in some climatic conditions. If such is employed, with the temperature at sensors T1, T1' and T1" in the solar collector equal to or less than the temperature at sensor T2, and sensor T3 not being satisfied, energizing of relays CR6A and CR6B by the space thermostat does not activate the blowers. In such a condition, the space thermostat can energize an additional relay (not shown) to activate the auxiliary heating unit with its own independent air propulsion means. This would open damper F to allow heated air flow directly from the auxiliary unit to the environmental space, and return in recirculatory fashion as depicted in FIG. 5.
It will be readily apparent to those in the art and to those skilled in control circuitry that many variations in the type and arrangement of components, and in the type of circuitry and circuitry components employed, could be made. The particular embodiment shown has the advantage of being readily assembled and operated by those with ordinary training in the field of heating, using standard available components such as relays, motors, dampers, and thermostats that are readily and widely available. The use of solid state circuitry for part or all of the electrical system would enable a more compact arrangement capable of mass production, of course, and might be desirable in some instances. These and other variations are intended to be within the scope of the invention taught. | There is disclosed herein a forced air solar heating system which causes selectively operated multiple air blowers in combination with multiple ducts and control dampers to operate in response to heat sensors in the space to be heated, and in a solar collector, and in a storage chamber, to transfer heat from the collector to storage, or to controllably transfer heat to said space from the collector or from the storage, but also alternatively as mixed heated air from both the collector and the storage, to a mixing chamber and then to said space. The air propelling blowers, the flow control dampers, and the mixing chamber are preferably all part of a unitary air handler. | 8 |
FIELD OF THE INVENTION
This invention generally relates to image sensor devices and more particularly to charge coupled devices.
BACKGROUND OF THE INVENTION
Without limiting the scope of the invention, its background is described in connection with virtual phase charge coupled device (CCD) image sensors and bulk charge modulated device (BCMD) image sensors, as an example.
Heretofore, in this field, the virtual phase CCD was developed to provide a single phase CCD comparable in performance to multiphase CCD's while retaining all the advantages of single level structure. See Hynecek, J., "Virtual Phase Charge Transfer Device", U.S. Pat. No. 4,229,752, issued Oct. 21, 1980; and Hynecek, J., "Virtual Phase Technology: A new Approach to Fabrication of Large-Area CCD's", IEEE Transactions on Electron Devices, Vol. ED-28, No. 5, May 1981, which are incorporated herein by reference. The bulk charge modulated device (BCMD) device was developed to achieve optimal imaging performance in all aspects of image sensing. See Hynecek, J., "Bulk Charge Modulated Transistor Threshold Image Sensor Elements and Method of Making", U.S. Pat. No. 4,901,129, issued Feb. 13, 1990; and Hynecek, J., "BCMD-An Improved Structure for High-density Image Sensors", IEEE Transactions on Electron Devices, Vol. 38, No. 5, May 1991, which are incorporated herein by reference.
Charge coupled devices (CCDs) are well known monolithic semiconductor devices and are used in various applications such as shift registers, imagers, infrared detectors, and memories. A virtual phase CCD device contains a single set of gates and a single clocking bias. The virtual phase CCD device operates on the principle of selectively doping different regions of each cell so that clocking the gate affects only the energy bands in a portion of each cell and drives them from below to above the fixed energy bands in the remainder of each cell. The doped region that shields this remainder of a cell from the effect of the clock bias of the gate voltage is normally called the "virtual gate". The virtual gate is a doped region that is built directly into the silicon surface and is biased at the substrate potential. The virtual phase CCD minimizes the possibility for gate-to-gate shorts encountered in previous CCD technologies, and provides high quantum efficiency, excellent uniformity, low dark current, and blemish free imagery.
The BCMD sensor consists of a buried-channel MOS transistor with a specially designed storage well located under the transistor channel in the silicon bulk. When the device is illuminated, charge accumulates in the well and changes the potential profile of the entire structure. This in turn affects the potential of the MOS transistor channel that carries the current. The resulting new level of the channel potential is then simply sensed as a voltage of the source junction of the transistor when the device is connected as a source follower. The well is then easily emptied by applying a large negative pulse to the gate of the transistor. The BCMD well is emptied in the vertical direction to the substrate, whereas charge is emptied from CCD wells in a lateral direction. The resulting BCMD is an X-Y addressable MOS image sensor that has a high-sensitivity low-noise high-blooming overload capability, no detectable smear, and no image lag.
It is well known that image sensors based on the CCD concept provide high performance imaging with minimum fixed pattern noise. On the other hand X-Y addressed sensors such as charge injection devices (CID) and BCMD devices which sense charge in each photosite without any charge transfer have an advantage that they can be read out nondestructively. The nondestructive readout is necessary in devices which are used in still photography or in auto focussing elements or in exposure control elements where the correct integration time is not known before hand. The nondestructive readout can be used to interrogate the sensing element several times to determine in "real time" if enough charge has accumulated for a "good signal" before the element is read out and reset.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-section of a virtual phase CCD element with an active transistor pixel;
FIG. 2 is a diagram of the potential wells created by the device of FIG. 1;
FIG. 3 is a perspective view of the device of FIG. 1;
FIG. 4 is a side view cross-section of the device of FIG. 1;
FIG. 5 is a side view cross-section of the device of FIG. 1 showing an antiblooming, drain;
FIGS. 6-8 show the device of FIG. 1 at three stages of fabrication;
FIG. 9 is a diagram of a CCD array with a CCD sensor array having vertical and horizontal registers and a CCD memory array;
FIG. 10 is a timing diagram showing the various inputs to the device of FIG. 9;
FIG. 11 is a circuit diagram of an array using the CCD element of FIG. 1;
FIG. 12 is a diagram of a CCD array with a CCD sensor array having vertical and horizontal decoders and a CCD memory array having vertical and horizontal decoders.
Corresponding numerals and symbols in the different figures refer to corresponding parts unless otherwise indicated.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 is a cross-section of a preferred embodiment of a virtual phase CCD element with an active transistor pixel. The structure of FIG. 1 includes a P type silicon substrate 20, an N type layer 22 in the substrate 20, P+ virtual phase regions 24, 26, 28, and 30 formed in the upper portion of N type layer 22, P+ source 32 formed in the upper portion of N type layer 22, gate insulator layer 34, transfer gates and 38, transistor gate 40, donor implants 42 in the N type layer 22, transfer gate input (φ TG ), transistor gate input (φ PG ), and source voltage (V PD ).
The operation of the device of FIG. 1 will be described below and is illustrated by the potential profile shown in FIG. 2, directly below the corresponding regions of the device of FIG. 1. These regions are given the following names: P+ regions 24, 26, 28, and 30 are called virtual gates (or virtual electrodes) and also serve as a drain for the active transistor, the regions below the virtual gates 26 and 30 are called virtual barriers, the regions below virtual gates 24 and 28 are called virtual wells, the regions below the transfer gates 36 and 38 and below donor implants 42 are called the clocked wells, the regions below the transfer gates 36 and 38 and not below the donor implants 42 are called the clocked barriers, the region below the transistor gate 40 is the transistor gate well, and the region below P+ region 32 is the source.
FIG. 3 is a perspective view of the device of FIG. 1. FIG. 3 shows the top of the device which includes the transfer gates 36 and 38, the transistor gate 40, P+virtual phase regions 26 and 28, and P+ trench 44. The donor impurities 43 extend under the entire virtual phase region 28. Since the P+ virtual phase regions 26 and 28 are in contact with the P+ trench 44 and the P+ trench 44 is in contact with the substrate 20, the virtual phase regions 26 and 28 are maintained at the substrate potential. Virtual phase regions 24 and 30 are maintained at the substrate potential in the same way as regions 26 and 28. The P+ trench 44 also provides isolation between the CCD columns.
FIG. 4 is a side view of the device of FIG. 3 crossing through the plane A-A' as shown in FIG. 3. FIG. 4 shows the P+ trenches 44 and 48 which connect the virtual phase regions (P+ regions) 24, 26, 28, and 30 to the substrate 20. The structure of FIG. 4 extends further in the A' direction than does the structure in FIG. 3 in order to show the trench 48.
Also, an antiblooming drain can be formed in the trench area, as shown in FIG. 5. The antiblooming drain is an alternative embodiment formed in place of the trench 48 in FIG. 4. The antiblooming drain consists of a small N+ region 49, shown in FIG. 5, instead of the larger P+ region 48, shown in FIG. 4. The donor impurities in the area 45 are less than in area 43 to form the potential profile which serves as a charge overflow barrier. When the charge level in the virtual well goes above this overflow barrier, the charge flows over this barrier and into the drain. The antiblooming drain allows excess charge to flow out of the virtual well to prevent the excess charge from spreading to other cells. Other types of antiblooming structures can be formed as well. For example, a structure with a gate controlled antiblooming barrier in place of the implant 45 can be formed.
FIGS. 6-8 illustrate successive steps in a process for fabricating an active transistor pixel CCD element, as shown in FIG. 1. Referring first to FIG. 6, an N type layer 22 is implanted in P type semiconductor substrate 20. A dopant such as phosphorus may be used as the implant dopant. Then a gate insulator layer 34 is grown over the surface of the device. The gate insulator layer 34 is preferably formed of oxide and may be grown from the substrate. Next, a photoresist layer is used to pattern an implant into N type layer 22 to form the donor implants 42 shown in FIG. 6. This implant is done with an N type dopant such as phosphorous.
After the photoresist layer is stripped, the transistor gate 40 and the transfer gates 36 and 38 are deposited, doped to be conductive, patterned, and etched as shown in FIG. 7. The transistor gate 40 and the transfer gates 36 and 38 can be polysilicon, in which case they may be doped in place by a dopant such as phosphoric oxytrichloride (POCl 3 ). Next, the transistor gate 40 and the transfer gates 36 and 38 are used for a self-aligned implantation step to form P+ source 32 and P+ drain regions (virtual phase regions) 24, 26, 28, and 30, as shown in FIG. 8. This implant is done with a P type dopant such as boron. Then a photoresist layer is used to pattern an implant to form the donor implants 43 shown in FIG. 1. This implant is done with an N type dopant such as phosphorous.
The operation of the device shown in FIGS. 1, 3, and 4 consists of two steps. In the first step, the device integrates the charge signal generated by incident light into the device while the level of charge is being nondestructively interrogated. After the signal reaches a satisfactory level, charge is transferred out from the device of FIG. 1 into a CCD memory and is read out destructively with a high accuracy and uniformity.
During charge integration the transfer gates 36 and 38 are biased negative which separates individual active transistors. The transistor is a P-channel MOS device with enclosed source 32 and drain common to virtual phase regions 26 and 28. If the source 32 is biased by a constant current source from a power supply, the potential of the source 32 will adjust itself to a level which will be sensitive to charge in the transistor region. This is similar to BCMD operation. The P-channel transistor operates in a source follower mode with the gate-source threshold determined by the doping profiles of the structure and by the amount of electrons under the transfer gates 36 and 38.
During nondestructive readout, the transistor gate 40 and the transfer gates 36 and 38 are biased as follows: the transfer gates 36 and 38 are negative to separate the pixels and the transistor gate 40 is addressed either high or mid level. If the transistor gate 40 is biased mid level, the cell is selected. If the transistor gate 40 is biased high, it is not selected.
During nondestructive readout the fixed pattern noise caused by transistor threshold variations is not important since the array is used only to find a suitable integration time and to make a rough measurement of the charge level. However, various fixed pattern noise subtraction schemes can be used to subtract fixed pattern noise if necessary. After the integration is completed, the charge signal is read out more accurately by the CCD action.
During charge transfer, the transistor gate 40 and the transfer gates 36 and 38 are clocked out of phase to accomplish a CCD charge transfer. During this phase the device functions as a standard CCD device. Several types of CCD architectures can be used such as frame transfer, interline transfer, frame-interline transfer, full frame, charge sweep device, and line addressable device.
The operation of the device of FIG. 1 during charge transfer is explained by referring to the potential profile shown in FIG. 2. The energy levels for an electron in the buried channel (conduction band minimum) are shown for the various regions of the device and for different bias levels of the transfer gates 36 and 38, and different bias levels of the transistor gate 40. Starting with an electron in the clocked barrier 60 at level 61 below transfer gate 36 with the transfer gate bias approximately equal to substrate bias, the operation is as follows. First the electron falls into the clocked well 64 at level 65. The electron will remain in the clocked well 64 as long as the transfer gate bias is approximately equal to substrate bias because the potential wells of both adjacent regions are higher. When the transfer gate 36 is switched to a negative bias with respect to the substrate 20, the potential level of the clocked well 64 moves up to level 67 and the potential level of clocked barrier 60 moves up to level 63. Then the electron passes from the clocked well 64 to the virtual barrier 68. The electron then moves from the virtual barrier 68 into the transistor gate well 70 at level 73.
When the transistor gate bias returns to a more negative voltage, the electron passes from the transistor gate well 70 to the virtual well 74 as the transistor gate well moves from potential level 73 to level 71. The electron remains in the virtual well 74 until the transfer gate bias moves to a more positive value which lowers the potential of clocked barrier 76 from level 77 to level 79 which is below the potential of the virtual well 74, and also lowers the potential of the clocked well 80 from potential level 81 to level 83. When the transfer gate bias is switched to this more positive value, the electron passes through the clocked barrier 76 and into the clocked well 80 at level 83. Movement of the electron to further cells is just a repeat of the same steps and clocking of the transfer gates 36 and 38, and the transistor gate 40 as described above.
A schematic block diagram representation of a first preferred embodiment of a basic sensor system architecture for an active transistor pixel CCD is depicted in FIG. 9 and incorporates the structure of FIGS. 1, 3, and 4. The system includes image sensing area 100, dual field CCD memory area 102, horizontal shift register 104, vertical shift register 106, horizontal switches 108, vertical switches 110, serial CCD register 112, clearing gate 113, charge clearing drain 114, and charge detection amplifiers 116 and 118.
FIG. 11 is a detailed circuit diagram of the image sensing area 100 along with the horizontal shift register 104, horizontal switches 108, vertical shift register 106, and the vertical switches 110, shown in FIG. 9. The circuit includes vertical shift register 106, horizontal shift register 104, photosites 120 (the device of FIG. 1), array columns 122 (X-address), array lines 124 (Y-address), vertical switches 110, horizontal switches 108, transfer gate voltage (φ TG ), charge transfer input (φ PG ) to transistor gates, transistor mode input (V ML ) to transistor gates, and output circuit 132 with output transistor 134.
In the circuit of FIG. 11, the vertical shift register 106 is used to select an array line for nondestructive readout of the active transistor in the photosites. The vertical shift register 106 selects the vertical switches in sequential order. Each vertical switch is connected to all of the transistor gates in the corresponding line of the array. The horizontal shift register 104 selects an array column for nondestructive readout. The horizontal shift register 104 selects the horizontal switches in sequential order. Each horizontal switch is connected to all of the transistor sources in the corresponding column of the array. The nondestructive output is taken from line 136 of the output circuit 132.
One purpose of the nondestructive readout is to determine the optimum charge integration time. As incident light causes charge to build up in the device, the active transistor element can be sensed to measure the level of charge building up in the device. The charge level is sensed from the source of the transistor. The use of the transistor to detect the charge level will have minimal effect on the charge that has already built up. Once the charge has reached the desired level, the charge can then be transferred in CCD mode to the memory array. This process will allow the charge integration time to be optimized before the charge is transferred from the image sensing array to the memory array.
In the CCD array shown in FIG. 9, the dual field CCD memory area 102 is constructed such that it can accept charge from one channel and direct it either to the memory "A" or "B". This dual feature allows for field signal subtraction. If one field is with signal and the other without (just the background), the subtraction is easily accomplished during the readout. Two consecutive charge signals are subtracted. The time domain sequential subtraction reduces problems with amplifier mismatch and balance if two channels and a dual amplifier system is used.
FIG. 10 is a timing diagram showing the various inputs to the device of FIG. 9. φ Vi is the input which starts the vertical shift register. φ Vs is the input to the vertical clock. φ Vr is the input to the vertical reset clock. φ Pg is the photogate pulse to bias the gate for readout. φ Tg is the charge transfer pulse. φ MA/B is the memory A and B pulses. φ Hi is the input for the horizontal scan start. φ Hs is the horizontal scan pulses. φ Hr is the horizontal reset pulses. Horizontal CCD register pulses are not included in this timing diagram.
The timing cycle starts with a charge clearing period from the image sensing area 100 and the memory areas 102. Charge is dumped into the charge clearing drain 114 located below the serial register 112. In this interval clocking pulses are similar to the charge transfer to memory cycle.
After the charge clearing period, the charge integration and nondestructive readout period 150 follows. This interval is as long as necessary to integrate a sufficient amount of charge in the pixels. The sufficient amount is determined in the external circuitry by supplying the nondestructive signal to it. External circuits determine when to stop the integration and proceed with the next cycle.
Next is charge transfer to memory 152. During this interval the device operates in a standard CCD mode. This interval can be followed by another integration period 154 and transfer cycle of identical length but with the light source turned off to load memory "B" with the background information for subtraction.
After both memories "A" and "B" are loaded with the corresponding signals, the data is transferred into the serial register 112 and read out. This is performed in a serial fashion with pixel by pixel analog subtraction. The serial register 112 shifts the charge serially into the charge detection amplifier 116. Serial readout is common to all CCD devices. This is not shown on the timing diagram in FIG. 10.
Vertical as well as horizontal switches and shift registers are typically built using CMOS devices. It is therefore beneficial to integrate CMOS and CCD architectures into a single process.
A schematic block diagram representation of a second preferred embodiment of a basic sensor system architecture for an active transistor pixel CCD is depicted in FIG. 12 and incorporates the structure of FIG. 1. The system includes image sensing area 200, field memory area 202, horizontal decoder 204 to the image sensing area 200, vertical decoder 206 to the image sensing area 200, horizontal switches 208 for the image sensing area 200, vertical switches 210 for the image sensing area 200, horizontal decoder 212 to the memory area 202, vertical decoder 214 to the memory area 202, logic input 205 to horizontal decoder 204, logic input 207 to vertical decoder 206, logic input 213 to horizontal decoder 212, logic input 215 to vertical decoder 214, horizontal switches 216 for the memory area 202, vertical switches 218 for the memory area 202, serial register 220, clearing gate 230, charge clearing drain 222, and charge detection amplifiers 224, 226, and 228.
The difference between the system of FIG. 12 and the system of FIG. 9 is that the shift registers of the system in FIG. 9 have been replaced by decoders in the system of FIG. 12. Also, the active transistor pixel (ATP) CCD is used in the field memory area 202 as well as in the image sensing area 200. The decoders 212 and 214 in the memory area 202 are used for the ATP CCD in the memory area.
The use of decoders in the system of FIG. 12 instead of shift registers, as in the system of FIG. 10, allows the cells in the array to be non-destructively read out in any order. With the decoders each cell can be selected directly without having to scan through the other cells as with the shift registers. This provides more flexibility in the operation of the system. For example, the decoders allow a coarse readout of the array by reading out only selected cells in the array.
For a coarse readout, the array can be divided into several regions with each region consisting of more than one ATP CCD cell. Then each region can be coarsely monitored by reading only one cell in that region. The output from the selected cell will be compared to a threshold level. Then only those regions of the array having a selected cell with an output above the threshold will be read out in CCD mode. The contents of the other regions of the array will be discarded. This process will save time in the readout of the device because only those parts of the memory with significant information will be read out.
This coarse readout process can be used in either the image sensor array area 200 or the memory area 202. If used in the image sensor area 200, only the regions of the image sensor array above the threshold will be transferred to the memory array 202, then only that data will be transferred out of the memory array 202. If this coarse readout process is done only in the memory array 202, then all of the data in the image sensor array cells will be transferred to the memory array 202. Then the memory array 202 will be coarsely scanned to determine which cells to read out in CCD mode.
In another technique for a coarse readout, the array can be divided into regions and the transistors in each region can all be connected together to determine the charge level in each region. For each cell in a region to be weighted evenly with the other cells in that region, all the transistors in a region can be shorted together. In this way, the signals from all the cells in a region will be treated equally. For situations where some cells need to be weighted more heavily than others, the transistors can be connected together through resistive networks that provide the desired weighting between the cells.
The image sensor array 200 of FIG. 10 can also be scanned to determine optimum charge integration time as described above for the device of FIG. 9. With the decoders, there is more flexibility in selecting array cells for determining optimum charge integration time. The cells in the array can be selected in any order and in any area of the array. Also, any number of the cells in the array can be selected for determining charge integration time. For a coarse determination, only a small number of cells can be measured in selected areas of the array. For a fine determination, more cells can be measured.
This invention incorporates both the CCD transfer as well as nondestructive X-Y addressable capability into a single pixel of an imaging device. This provides several advantages. One advantage of the invention is that the nondestructive X-Y addressable capability can be used to interrogate the sensing element several times to determine in real time if enough charge has accumulated for a good signal before the element is read out and reset. Another advantage of the invention is provided by the ability to scan the image sensing array to determine which elements in the array have sufficient charge levels so that only those elements with sufficient charge levels will be read out. This advantage reduces read out time of the device. Another advantage of the invention is the ability to have the nondestructive read out capability in the memory array as well as in the image sensing array. The memory array can be scanned to determine which elements in the memory array have sufficient charge levels so that only those elements with sufficient charge levels will be read out. This advantage also reduces read out time of the device.
The nondestructive X-Y addressable capability also allows the array to be coarsely scanned by measuring only selected elements located at strategic positions in the array. In this manner, the array can be quickly scanned to determine which regions of the array have sufficient charge levels for read out. Then, in order to reduce read out time, only those regions of the array with sufficient charge levels will be read out. This coarse scanning technique can be accomplished in either the image sensing array or the memory array.
A few preferred embodiments have been described in detail hereinabove. It is to be understood that the scope of the invention also comprehends embodiments different from those described, yet within the scope of the claims.
For example, the cells can be connected through logic networks that perform arithmetic operations such as the sum, difference, and division. The signals from the transistors in the array can also be input into a processor for performing arithmetic operations on the signals to determine the status of the signal levels in the array.
While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is therefore intended that the appended claims encompass any such modifications or embodiments. | An image sensor element having at least one charge storage well 70 and 80, charge transfer structures for transferring charge from one charge storage well 70 to another charge storage well 80, and a charge sensor for sensing charge levels in a charge storage well 70 without removing the charge from the well.
Other devices, systems and methods are also disclosed. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a recording apparatus, and more particularly to a recording apparatus in which the number of parts is reduced and which is compact.
2. Description of the Prior Art
Heretofore, recording apparatuses such as printing apparatuses have been made compact and adopted in electronic desk top type calculators and widely utilized as recording type desk top calculators.
In the conventional printing apparatuses, however, movement of the printing head and paper transfer have been accomplished by discrete drive sources and this has prevented the apparatuses from being made as compact as is desirable.
Therefore, printing apparatuses have been proposed which utilize a single drive motor to effect the head feeding and paper transfer, and this has led to further compactness.
However, use must be made of discrete anti-slippage members to accomplish anti-slippage of the rotary shaft of the pinch roller urged against the paper transfer roller and the resilient member such as a plate spring for obtaining the printing pressure and the pinch roller pressure. This has led to an increased number of parts which in turn has led to difficulties in assembly of as well as higher cost and bulkiness of the apparatus.
SUMMARY OF THE INVENTION
It is an object of the present invention to simplify the structure of the recording apparatus.
It is another object of the present invention to make the recording apparatus easier to assemble and to reduce the number of parts used therein, thereby making the apparatus compact.
Other objects of the present invention, will become apparent from the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the present invention is illustrated in the drawings, wherein:
FIG. 1 is a plan view;
FIG. 2 is a front view;
FIG. 2a is a perspective view showing an embodiment of the present invention, useful in describing operation of the invention.
FIG. 3 is a right side view;
FIG. 4 is a cross-sectional view along line A--A of FIG. 2;
FIG. 5 is a cross-sectional view along line B--B of FIG. 4; and
FIG. 6 is a perspective view showing the structure of the connection between a drive motor and a lead screw.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Throughout the drawings which illustrate an embodiment of the present invention, identical parts are designated by identical reference numerals.
In the drawings, reference numeral 1 designates a frame which is a first holding member of the apparatus. The frame 1 has a pair of side plates 2 and 3. A motor 5 is fixed to the outer side of the side plate 3 through a mounting plate 4 which is a second holding member. The output shaft 6 of the motor 5 is formed with a D-shape as shown in FIG. 6, and a lead screw 7 is mounted coupled to the shaft at its D-shaped portion 6a. In the end portion of the lead screw 7, which is adjacent to the motor 5, there is formed a bore 7a of D-shaped cross-section with which the D-shaped portion 6a of the output shaft 6 mates, and a spiral guide groove 7b is formed on the peripheral surface of the lead screw 7. The pin of a carriage which will be described later is fitted in the guide groove 7b.
The lead screw 7, as shown in FIG. 2, has its other end rotatably journalled in the side plate 2 through a small-diameter shaft 7C.
A carriage 8 is fitted to the lead screw 7, and a pin 9 provided on the carriage 8 is fitted in the guide groove 7b as shown in FIGS. 2 and 4. Accordingly, when the motor 5 is rotated in a forward direction and a reverse direction, the lead screw 7 follows the rotation of the motor and the carriage 8 is freely moved forwardly and backwardly. A printing head 10 is attached to the carriage 8.
As shown in greater detail in FIG. 2a, the lead screw 7 having the spiral guide groove formed on the peripheral surface thereof is fitted to a through-hole portion 31 of a carriage 8 having the printing head 10 attached thereto. When the lead screw 7 is rotated by the motor 5, the pin 9 projecting inwardly in the through-hole portion 31 of the carriage 8 is received in the guide groove 7b. Accordingly, the carriage may be moved forwardly and backwardly as described above.
A holder 11 extends horizontally in opposed relationship with the carriage 8. A ridge 12 is formed on that side of the holder 11 which is adjacent to the carriage 8, over the full length thereof. This ridge 12 is fitted in an elongated groove 14 formed in the back side of a platen 13. Since the amount of projection of the ridge 12 is greater than the depth of the groove 14, the platen 13 can pivot with the ridge 12 as the fulcrum. On the opposite side to the platen 13 with respect to the carriage 8, a horizontally extending guide 15 is provided integrally within the side plates 2 and 3, and the carriage 8 is guided between the guide 15 and the platen 13.
The holder 11, as shown in FIG. 5, has a protrusion 11a in the lower portion thereof. The protrusion 11a is rotatably journalled to a shaft 16 extending horizontally between the side plates 2 and 3. Pinch rollers 17 and 17 are rotatably supported on the shaft 16 at the opposite sides of the protrusion 11a. The shaft 16, as shown in FIGS. 3 and 4, is fitted in slots 18 formed horizontally in the side plates 2 and 3 so that it is movable in the slots 18. An anti-slippage stepped portion 19 is provided on that end portion of the shaft 16 which is adjacent to the side plate 2, and anti-slippage of the other end of the shaft is accomplished by knocking it against the mounting plate 4 of the motor 5.
On the other hand, projections 20 are provided on the back side of the holder 11 at a predetermined interval in the direction of the length thereof. A plate spring 23 which is a resilient member having its opposite ends fitted in holes 21 and 22 formed in the inner sides of the projections 20 and 20.
As shown in FIG. 5, an anti-slippage stepped portion 23a is formed on one end of the plate spring 23, and anti-slippage of the other end is accomplished by bringing it into contact with the mounting plate 4 of the motor. By the pressure force of the plate spring 23, the holder 11 is pushed toward the carriage 8. The shaft 16 is urged against the ends of the slots 18 and 18 which are adjacent to the carriage, through the protrusion 11a in the lower portion of the holder 11, and toward the pinch rollers 24 and 24.
The rubber pinch rollers 24 and 24 are fixed to a shaft 26 having its opposite ends rotatably fitted in substantially L-shaped guide holes 25 and 25 formed in the side plates 2 and 3.
A cam 27 is mounted between the rubber rollers 24 and 24 for rotation and sliding movement relative to the shaft 26. A spiral ridge 28 is provided on the outer peripheral surface of the cam 27. The cam 27 is biased toward the rubber roller 24 adjacent to the motor 5 by a coil spring 29 loosely fitted on the shaft 26.
As shown in FIG. 2a, tooth profiles in mesh engagement with each other are formed on the surfaces of contact between the cam 27 and the rubber roller 24 adjacent to the motor 5 to constitute a one-way clutch or ratchet mechanism 32 which is capable of transmitting only one-way rotation of the cam 27 to the rubber roller 24 adjacent to the motor 5.
On the other hand, the lower portion of the carriage 8 is formed with a guide groove 30 in which is fitted the ridge 28 of the cam 27. Accordingly, as the carriage 8 is moved along the lead screw 7, the cam 27 rotates about the rubber roller shaft 26 through the ridge 28. As a result, the rubber roller 24 adjacent the motor effects rotation for paper feeding due to one-way sliding movement of the carriage 8, or more specifically, the sliding movement of the carriage during its return. That is, the ratchet mechanism 32 provided between the rubber roller 24 adjacent the motor 5 and the cam 27 transmits rotation of the cam 27, developed during sliding movement of the carriage, to the rubber rollers 24 and 24 only during return of the carriage 8. Recording paper P nipped between the rubber rollers 24, 24 and pinch rollers 17, 17 is then fed during the rotation of rollers 24.
On the other hand, the pressure force of the plate spring 23 imparts to the holder 11 a counterclockwise rotational force about the pinch roller shaft 16 as viewed in FIG. 4 and therefore, the platen 13 is urged against the carriage 8 on which the printing head 10, with the guide 15, is mounted, with a predetermined pressure. Thus, the pressure force of the printing head, namely, the printing pressure, against recording paper P is obtained. The platen 13, as previously described, is designed to be pivotable about the ridge 12 relative to the holder 11 and thus follows the movement of the surface of the printing head 10 to thereby ensure that a proper surface of contact is obtained. Also, the holder 11 is urged against the plate spring 23 at two locations through horizontally spaced apart projections 20 and 20 and receives the pressure force of the plate spring, so that any horizontal back-lash of the holder 11 is prevented and the surface of the platen 13 and the surface of the guide 15 are kept in a good degree of parallelism.
Description will hereinafter be made of the operation of the printing apparatus according to the present invention constructed as described above.
During printing operation, the lead screw 7 is rotated in a clockwise direction as viewed in FIG. 2a with rotation of the motor 5 and therefore, the carriage 8 is moved along the lead screw 7 in the leftward direction as viewed in FIGS. 1 and 2a, namely, in the printing direction.
Since the pressure force of the platen 13 is always exerted on the printing head 10 by the plate spring 23, the printing head 10 effects its printing operation while being in contact with the recording paper P. The cam 27 is rotated in the counter-clockwise direction as viewed in FIG. 2a with the movement of the carriage 8 during the printing operation, but the rotation of the cam 27 is not transmitted to the rubber roller 24 adjacent to the motor 5 by the one-way clutch or ratchet mechanism 32, in the portion of contact between the cam 27 and the rubber roller 24 and thus, paper feeding is not effected.
On the other hand, in the case of carriage return, the carriage 8 is moved to the right as viewed in FIGS. 1 and 2a, but in this case the cam 27 is rotated in the clockwise direction as viewed in FIG. 2a and therefore, the one-way clutch or ratchet mechanism 32 between the cam 27 and the rubber roller 24 adjacent to the motor 5 mesh-engage each other and the rubber roller 24 is rotated, so that the recording paper P nipped between the rubber rollers 24, 24 and the pinch rollers 17, 17 by the plate spring 23 is fed.
In this manner, printing operation and paper feeding operation are effected.
As is apparent from the foregoing description, according to the present embodiment, there can be provided an inexpensive, super-compact printing apparatus in which the mounting plate of the driving motor is utilized to provide anti-slippage of one end of the lead screw, pinch roller shaft and plate spring, whereby special anti-slippage structure need not be provided and simple assemblage is possible with the number of parts reduced.
The present invention is not limited to the above-described embodiment, but is also applicable to apparatuses for recording figures and any other recording apparatus. | A recording apparatus comprises a recording head for effecting recording on recording paper, a unit for generating a rotational force, a feed unit for shifting the relative position of the recording head and the recording paper by the rotational force from the rotational force generating unit so that the recording head can record a series of records on the recording paper, a first holding unit for holding the feed unit for rotation and sliding movement in the direction of the axis thereof, and a second holding unit for holding the rotational force generating unit, the second holding unit being fixed to the first holding unit to control the movement of the feed unit in the axial direction. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable
FEDERALLY SPONSORED RESEARCH
[0002] Not applicable
SEQUENCE LISTING OF PROGRAM
[0003] Not applicable
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] This invention relates to an improved guide system for hand held power tools, particularly circular saws and routers.
[0006] 2. Prior Art
[0007] Woodworking has long needed an affordable, simple way to accurately work with large materials like 4′×8′ sheet goods. As more and more material comes in sheet sizes, it has become one of the biggest problems faced by woodworkers today.
[0008] There are dedicated tools, like panel saws and panel routers and large sliding table saws, for this application, but they are large, definitely not portable and well out of the price range of an average woodworker, many of whom must nonetheless deal with the aggravation of working with 4′×8′ sheets. Professionals working on job sites face the same problem—trying to work with 4′×8′ sheet goods with tools that don't do it at all well.
[0009] Many people, professionals included, lacking the large expensive equipment designed to do this work, fall back on the basic method of laying the sheet on some 2×4's on the floor or sawhorses, clamping on something as simple as a relatively straight board, and cutting the material with a circular saw. The results are predictably crude, but the reason so many still do this is that the circular saw is portable, light, and easy to work with, and the material itself doesn't have to be moved. With sheet goods like MDF and particle board weighing up to 100 lb. per sheet, not moving the material is something definitely to be preferred. So in many ways the ideal solution to this problem of trying to work 4′×8′ sheets and indeed any large awkward material, would be a circular saw guide that was portable, very accurate, required no or little adjustment to the saw itself, and was quick and easy to use.
[0010] There are no lack of circular saw (and router) guides on the market and in the patent database. They generally fall into two categories:
[0011] 1. Clamp on straight edges—examples of these are U.S. Pat. Nos. 2,677,399, 3,586,077, and 2,708,465. These have the advantage of attaching to the material itself and being of sufficient rigidity and length to handle the 4′ and 8′ cuts required in sheet goods. These have limitations—a) they work to one side of the power tool only, requiring that either the tool be kept against the straight edge by the operator (with the potential for error if this isn't done properly), or b) they require that a secondary plate or other devise be attached to the power tool, and the secondary devise then tracks in a controlled way along the straight edge. Neither of these is a satisfying solution—the first is far to open to human error and the second requires that you have an awkward devise attached to something like your circular saw, which must be either attached and removed constantly, or left on and in practice often limit the use of the power tool to working with the straight edge and nothing else. Further, the additional plate must have a form of bearing connecting it to the straight edge, and this bearing is prone to play and wear. All long clamp on straight edges also have the usually ignored disadvantage of limiting the straightens of the cut to the inherent straightness of the straight edge itself. Most long clamp on straight edges also give no reference to where the power tool will cut.
[0012] 2. Rail systems that attach to a substructure—examples of these are U.S. Pat. Nos. 3,368,594, 3,741,063 and 4,050,340. These systems are generally designed to allow both angle and straight cuts. These systems solve the problem of supporting the saw or router without an additional plate by using two rails, one on each side of the tools. However, they all require a substructure to attach the rails themselves to, which creates it own set of problems—the size and weight of a substructure large enough to handle 4′×8′ sheets is substantial, and the rigidity and accuracy of the rails themselves for these size of cuts brings you right back to the cost and size of a panel saw. The substructure, by nature, lies beneath the material and the tool cannot therefore work on top of the material alone, as many everyday applications require. In practice, these dual rail systems are limited in range—they are fine for doing crosscuts up to around 2′, but beyond this become too large and awkward. These designs in practical use have been generally supplanted by power mitre saws.
[0013] For example in U.S. Pat. No. 4,050,340 to Flanders, the drawings and summary clearly show that even though the track is designed to support both sides of the power tool, it is designed to guide only one side. Secondly, the first sentence of the first claim says that it requires a substructure. Thirdly, its straightness is limited to the straightness of its guide rails.
OBJECTS AND ADVANTAGES
[0014] This invention approaches the problem of cutting large material from a unique direction. The ideal solution to working with large material has four basic needs:
1. there must be nothing attached to the power tool itself, so that the tool can be quickly dropped into the guide, used, and then taken off to do whatever other work is required 2. there must be no required substructure for the guide to attach to—it simply lies on the material itself, and, equally important, for cutting a hole in, for example, an existing floor, not require anything to necessarily extend below the material for the guide to work in most applications 3. in the preferred embodiment it can adjust and adapt to any number of tools, primarily circular saws and routers. 4. it must be very accurate, and make the power tools conform to that accuracy
[0019] The proposed power tool guide rail system is extremely simple. In the preferred embodiment, it would be composed of lightweight material, like aluminum extrusion, that would be quite thin in the vertical cross-section, for example ¼″-⅜″, and quite wide in the horizontal cross-section, for example 11″-12″, and long enough to accommodate large material like 4′×8′ sheets. The guide lies directly on the material being cut, and thus the material itself is providing the necessary vertical support—the guide is only required to provide lateral support. In the preferred embodiment, this lateral support would be provided mainly by the rigidity of the aluminum, but could also be aided by grip pads running lengthways along the bottom of the guide rail. These grip pads, in addition to aiding the lateral support for the guide would, for a great many applications (like ripping and crosscutting ¾″ thick sheet goods), provide all the necessary force to secure the guide in place during the cut, eliminating the need to lock it by another means.
[0020] The guide itself has a base component the bottom of which rests on the material and the top of which the power tools ride on, with a narrow, more or less central, through slot along the length of the base component for the blade or bit of the power tool to operate in. A left and right side rail, in the preferred embodiment, adjustably attach to the base component at several points along their lengths. The sides rails allow the guide to adapt to the different base plates of various power tools and keep them tracking straight along the length of the guide. The base component of the guide is designed so that it extends beyond the material at each end. It will, in the preferred embodiment, extend far enough that a circular saw, with the blade set to its maximum depth, can be sitting on the guide with the blade clear of the material at the start of the cut, and the base component will extend further than the blade and have enough width there to secure both sides of the base component that lie to the left and right of the central through slot. It will do essentially the same thing at the other end as well, although this requires less overhang because only the front teeth of the circular saw blade need to finish the cut.
[0021] To use the tool, one would first adjust the side rails to the power tool being used. In the case of a circular saw, by a simple process of measuring from the saw blade to the edge of the saw plate, one of the side rails on the guide can be adjusted to this measurement so that the blade will run near the center of the through slot in the base guide component. In the preferred embodiment, this side rail will be less substantial than the base component beneath it, and can therefore, with a known straight edge or string line, be further adjusted to true straight. The base plate of the power tool itself can then be tracked along and against the side rail just fixed and used to determine where to secure the second side rail so the tool slides easily but is well controlled.
[0022] In the preferred embodiment, the base guide will have a replaceable strip attached under the entire length of the through slot of the base component, that could be made out of something like neoprene or rubber. The first cut by the power tool will cut both the replaceable strip and the material being cut. For all subsequent cuts, the replaceable strip gives an exact read for, in the case of a circular saw, where both sides of the blade will cut. It will also provide a replaceable chip guard to reduce surface chipping on both sides of the material being cut.
[0023] The process of actually using the tool then becomes extremely simple. Mark the cut to be made on the material at two locations with a pencil and tape measure, lay the guide on the material so that the two pencil marks are aligned with either the left or right exposed edge of the replaceable strip that show where the blade cuts, and so there is enough clearance at the start of the cut for the saw blade to be free of the material, drop the saw into the guide so it is clear of the start of the cut, and proceed to do the cut. In the preferred embodiment, there could be a fixed or removable attachment for the side of the base guide component that provides a means for accurate repeat cuts.
SUMMARY OF THE INVENTION
[0024] The proposed guide rail system is therefore a unique and powerful combination of these simple things—nothing attaches to the power tool itself, the guide guides both sides of the power tool, the guide requires no substructure, the guide adapts to a large variety of tools, the guide can be adjusted to true straight, and the guide is extremely lightweight and portable. Further objects and advantages will become apparent from a consideration of the ensuing description and drawings
DETAILED DESCRIPTION OF THE INVENTION
[0025] FIG. 1 shows the top view of the guide rail system
[0026] FIG. 2 shows the end plan view of the guide rail system
[0027] FIG. 3 shows the guide rail system in cross section
[0028] FIG. 4 shows the guide rail system in another embodiment, with side extensions providing means for referencing repeat cuts
[0029] A preferred embodiment of the guide rail system is shown in FIG. 1 (top view) and FIG. 2 (end view). In FIG. 1 we have a comprehensive view of the full tool from above. The dashed lines h represent the edges of the material to be cut, and the angled lines represent the material itself that lies between the dotted lines as seen from above. In FIG. 1, 1 is the base component of the rail system, and in the preferred embodiment is substantially flat when viewed from the end or side plan views. This base component is shown drawn at about 48″ long×about 11″ wide, although these dimensions are not critical and may be varied, but in general the length would be significantly greater than the width. This base component is designed, in the preferred embodiment, so that there are no moving or adjustable parts. This could be made out of a lightweight, strong material like aluminum. As shown in the drawing, in normal use the ends of the guide rail c 1 and c 2 will overhang the edges of the material h to allow the power tools room to enter and exit the cuts without cutting the guide rail itself. There is a through slot, a, either cut into the base component 1 or created by assembling the several pieces that could compose the base component 1 . This slot is contained within the perimeter 1 b of the base component 1 , and runs longitudinally along it, more or less centrally located across the width. c 1 and c 2 represent the areas of the base component 1 that extends beyond the ends of the slot a. These areas support the base component to both sides of the slot and allows the base component 1 to function, in the preferred embodiment, essentially as a single unit. There are two guide components 2 a and 2 b attached to the base component 1 . These guide components 2 a and 2 b in the preferred embodiment, will be less substantial than the base component 1 that they are attached to, and there are means, such as slots, b to adjust the guide components 2 a and 2 b laterally relative to the base component 1 , allowing the guide components 2 a and 2 b to adjust to different tools and to true straight.
[0030] FIG. 2 . is the end plan view of the invention. The dotted lines i are the material top and bottom seen from the end. This view would essentially be a mirror image at the other end. Note that nothing extends down from the guide rail below the surface of the material. Parts 3 and 4 are the only parts of the guide system, in the preferred embodiment, that sit lower than the bottom of the base component 1 . In the preferred embodiment there are several grip strips 3 that attach to the bottom of the base component k 2 . These strips could be made out of foam or light rubber and because they sit slightly lower than the bottom of the base component k 2 , supply a surface friction with the material below it, giving the tool additional lateral rigidity and in many cases eliminating the need to lock the guide rail. Strip 4 , in the preferred embodiment, would be replaceable and sit directly under slot a (not visible in this view but seen in FIG. 1 and FIG. 3 ), and could be made out of something cuttable but fairly stiff like neoprene of rubber, providing, when it is cut by a saw blade for example, a reference slot m ( FIG. 1 and FIG. 3 ) to both sides of the saw blade's cutting width and also, because of its slight down pressure on the surface of the material, help prevent chipping of the material by the saw blade. The top of the base component k 1 is what the power tools rest on and slide along and the vertical edges of the guide components 2 a and 2 b , marked e 1 and e 2 , provide the necessary height to guide and contain the base of the power tools along the length of the guide components 2 a and 2 b . Slot j shows one embodiment of a means to connect an optional locking mechanism to the underside of the base component 1 .
[0031] FIG. 3 shows the guide rail system in cross section. This view is similar to the view in FIG. 2 but slot m in strip 4 and slot a in base component 1 and where they locate are visible.
[0032] FIG. 4 shows the guide rail system form the top in a different embodiment, with two side extensions g, that sit on essentially the same horizontal plane as base component 1 and connect to base component 1 providing means to reference to the edge of the material f to allow the guide rail to do repeat identical cuts.
OPERATION OF INVENTION
[0033] Before use, the two guide components 2 a and 2 b of the guide rail will be adjusted to the power tool being used. By measuring from the location of the power tool blade relative to the power tool base, the first guide rail 2 a can be adjusted and locked to the base component 1 by using slots b so that the blade of the power tool will run at the center of slot a. The guide component 2 a can be further adjusted with slots b to true straight if desired using a known straight edge or string line and locked there as well. The power tool itself is then rested on the top of the base component k 1 and slid against e 1 of the guide component 2 a that is already attached. The vertical edge e 2 of the second guide component 2 b is then adjusted against the power tool base so that it is snugly controlled in longitudinal movement but slides easily. The guide rail is now ready to use.
[0034] The guide rail in its entirety is laid on the material to be cut, as shown in FIG. 1 . The grip strips 3 on the bottom of the base component rest directly on the surface of the material providing friction for lateral support and locking. The first cut can be done in scrap material to establish the groove m in strip 4 that indicates the power tool's blade location. The location of subsequent cuts is determined by lining up one side or the other of groove m with measured marks on the material itself, or by using the side repeater referencing arms g shown in FIG. 4 . The guide rail will extend over the material at the start end of the cut so that the power tool can be resting on the top of the base component k 1 , between the vertical edges of the two guide components e with its blade or bit in slot m ready to cut, and its blade or bit will be clear of the material and clear of c 1 on the guide rail base component.
[0035] The power tool in use is then simply slid along between the two guide components 2 a and 2 b on top of base component 1 —the guide rail will now automatically make the cut exactly straight.
CONCLUSIONS, RAMIFICATIONS AND SCOPE
[0036] The reader will see that the proposed power tool guide system offers real advantages over existing tools: it allows precision beyond even its own inherent straightness, it requires no attachment to the power tool itself, making it very quick and easy to use, it can be aligned to work with many different tools, it gives a repeatable reference to future cuts and even offers means to do repeatable cuts, and it sits directly on the material, requiring no substructure of any kind.
[0037] While the above description contains many specificities, these should not be construed as limitations on the scope of the invention, but rather as an exemplification of one preferred embodiment thereof. Many other variations are possible, for example, a guide with fixed or integral side rails for a predetermined tool.
[0038] Accordingly, the scope of the invention should be determined not by the embodiment(s) illustrated, but by the appended claims and their legal equivalents. | A guide rail system for hand held power tools like circular saws and routers comprising a rigid base component and adjustable guide components designed to lay directly on the material being worked and requiring no substructure of any kind, while accurately guiding and providing support to both sides of the power tool and reference to both sides of its cutting path. | 8 |
FIELD OF THE INVENTION
The present invention pertains to transportation and temperature regulation of consumables. In particular, the present invention pertains to the transportation and temperature regulation of packaged fluids, such as soft drinks.
BACKGROUND OF THE INVENTION
Insulated coolers for transporting canned drinks and food are a fixture of American culture and are practically required equipment for picnics, sporting events and other outdoor activities. Insulated coolers are also utilized in industrial applications. For example, coolers are used to transport medical supplies and samples for scientific analysis, such as soil samples for environmental testing.
The myriad of potential uses for coolers fueled an almost endless variation in their design. Coolers act as armrests in vehicles. Coolers are designed to wrap around the torso like a hiker's “fanny pack”. There are very large coolers and very small coolers. The majority of these coolers, however, all share one thing in common: they contain a cavity, usually rectangular, that holds both the material to be cooled (i.e., can drinks) and the refrigerant (i.e., ice or a frozen insert). These coolers also share the common design feature of some type of lid that completely encloses the material to be cooled and the refrigerant. The lid is intended to extend to life of the refrigerant by reducing heat transfer between the ambient temperature and the refrigerant.
Unfortunately, the lid, along with the body of the cooler, hides the contents of the cooler. This limitation of known coolers is often bothersome when coolers are used at sporting events or other areas with entrance restrictions. For example, many sporting events will allow spectators to carry coolers with soft drinks but not alcoholic beverages. Enclosed coolers are therefore often the subject of a time consuming search by security personnel.
Additionally, the ice that is usually the refrigerant of choice for most coolers eventually melts resulting in cold wet hands or wet food. If frozen inserts are used instead of ice, care must be taken to ensure that the contents of the cooler remain in contact with the inserts otherwise insufficient cooling will take place.
Accordingly, a need exists for a cooler that does not possess the limitations stated above. In particular, a need exists for a cooler that allows its contents to be visible at all times, if desired. Additionally, this cooler should provide close contact between the material to be cooled and the refrigerant while avoiding the problems associated with close contact refrigerants such as crushed ice.
OBJECT AND SUMMARY OF THE INVENTION
Therefore, an object of the present invention is to provide a cooler that effectively maintains a desired temperature for articles transported therein while avoiding the problems associated with known coolers, namely the concealment of the articles.
A further object of the invention is to provide a cooler that maintains close contact between the material to be cooled and the refrigerant.
These and other objects and advantages of the present invention are provided by a unique cooler for carrying packaged beverages. In one embodiment, the cooler comprises a hollow polygon having at least six faces, an enclosed interior, and an opening in at least one face of the hollow polygon. The opening provides fluid communication with the interior of the hollow polygon. In other words, the opening (i.e., drain/fill cap) allows the hollow polygon to be filled with a liquid and subsequently drained. The cooler also comprises at least one cavity extending from one of the polygon's faces into the interior of the polygon. The cavity is not in fluid communication with the interior of the polygon or the above mentioned opening. For example, water poured into the cavity will not enter the interior of the polygon and flow out the opening and water entering the opening will not flow into the cavity. In many applications, the cavity will be of a size and shape to receive a standard drink can.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one embodiment of the cooler according to the invention;
FIG. 2 is a cross-section of the cooler of FIG. 1 taken along line 2 — 2 of FIG. 1;
FIG. 3 is a cross-section of the cooler of FIG. 1 in conjunction with a mating receptacle; and
FIG. 4 is a schematic of a cooler according to the invention that holds twelve drink cans.
DETAILED DESCRIPTION
The invention provides a cooler for transporting articles while maintaining those articles at a desired temperature. In particular and referring now to FIGS. 1 and 2, the invention provides a cooler 10 for carrying packaged beverages, for example, soft drink cans. The embodiment of the invention shown in FIG. 1 comprises a hollow polygon 12 , preferably having at least six faces. It will be understood that solid polygons can comprise as few as four faces (e.g., tetrahedral and pyramids) and coolers according to the invention can include such shapes. The invention also includes other hollow geometrical shapes such as hollow spheres, ovals (e.g., egg shaped) etc, that may not fit the precise definition of a polygon. Such shapes may possess one, two, or three surfaces or faces. Nevertheless, the term polygon as used herein should be interpreted to include such geometrical shapes. The rectangular polygon illustrated in the drawings, however, is presently preferred for a number of reasons.
The hollow polygon 12 acts as a container for a temperature controlling substance 13 ; the easiest and most convenient of which is ice. In a preferred embodiment, the hollow polygon 12 is formed of a polymer or polymer composite, is generally rectangular and is of a length and width sufficient to encompass the space needed to enclose at least six beverage cans. As used herein, the term polymer includes composites comprising polymers. It is to be understood, however, that the size and shape of the hollow polygon 12 may vary depending upon the requirements of the user. For example, FIG. 4 illustrates an embodiment of the invention that holds twelve cans.
Likewise, the polymer employed in the practice of the invention may be any polymer utilized in production of coolers or molded articles. Polymers such as polyethylene, polypropylene, and polyethylene terephthalate and composites thereof are representative candidates.
The cooler according to the invention also comprises an opening 14 in at least one face of the hollow polygon 12 that provides fluid communication with the interior 15 of the hollow polygon 12 . The purpose of the opening 14 is to provide a means to fill and drain the hollow polygon 12 with a temperature controlling substance. The functional aspect of the opening 14 is illustrated in FIG. 1 where a common water faucet can be used to fill the interior 15 of the polygon with water. The opening 14 is closed by a simple screw cap 17 as shown in FIG. 2 or any other suitable means for controlling fluid flow. In the embodiment shown in FIGS. 1 and 2, the opening 14 is located on the upper or top face 18 of the hollow rectangular polygon 12 . Although this is a convenient location for the opening 14 , the opening or additional openings may be located at any point on the surface of the hollow polygon 12 . A fill level 16 along the outer perimeter of the hollow polygon 10 indicates an appropriate quantity of temperature controlling substance to use.
In most instances the temperature controlling substance 13 will be a coolant such as cold water or ice or a liquid or gel refrigerant such as those currently used in reuseable cold packs. The invention, however, also contemplates the use of high temperature substances such as hot water or oil, provided that the hollow polygon 12 is made of a material resistant to high temperatures. Thus, it will be understood that the term “cooler” is used in an exemplary rather than limiting fashion.
In an alternative embodiment, the cooler according to the invention need not possess an opening 14 that provides fluid communication with the interior 15 of the hollow polygon 12 . In this embodiment, the temperature controlling substance, most likely a non-water or gel refrigerant, is sealed inside the interior 15 of the hollow polygon, thus eliminating filling and emptying the interior 15 on a periodic basis.
Referring now to FIG. 2, the apparatus according to the invention is further defined by at least one cavity 20 that extends from one of the polygon faces 18 into the hollow polygon 12 but is not in fluid communication with the opening 14 (or the interior 15 of the hollow polygon 12 ). The cavity 20 is integral to the hollow polygon 12 (e.g., a molded article). In other words, the walls 19 of the cavity 20 also function as the outer surface of the hollow polygon 12 . In the embodiments shown in FIGS. 1 and 2, the hollow polygon 12 possesses a plurality of cavities 20 that are cylindrical and have a circumference sufficient to receive a standard drink can. Preferably, the cavity 20 extends inwardly to a depth that is less than the height of a standard drink can. This depth allows a portion of the can to extend out of the cooler to facilitate a quick and easy inspection of the cooler's contents. Furthermore, the cavities are separate and apart from one another thereby allowing the temperature controlling substance to substantially surround the perimeter of the cavity 20 .
It will be understood that the phrase “standard drink can” is used in an exemplary rather than limiting sense, and that the cooler 10 can be formed to accommodate cans of different sizes as may be desirable or necessary. If desired, the cavities 20 can differ in size from one another to allow differently sized containers to be carried at the same time.
A handle 22 may be attached to the hollow polygon 12 . In the embodiment shown in FIG. 1, the handle is attached to the top face 18 of the hollow polygon but may be attached to other faces (or to two faces) as well.
Referring now to FIG. 3, another embodiment of the invention is a cooler insert that may be used in conjunction with a traditional cooler. In this embodiment, the invention comprises a hollow polygon 12 having an opening 14 and cavities 20 such as that previously described. As discussed in previous embodiments, the hollow polygon 12 need not possess an opening 14 if the refrigerant is sealed in the polygon 12 . This embodiment also comprises a receptacle 24 having an interior space 25 of substantially the same shape and area as the polygon 12 and sized to receive the polygon 12 in a close mating relationship as shown in FIG. 3 . In certain circumstances the use of a receptacle 24 may be desired. For example, if the hollow polygon 12 is filled with water which is then frozen, the outer surface of the hollow polygon 12 may “sweat” on hot days causing anything placed against the hollow polygon 12 to become damp. Placing the hollow polygon 12 in a receptacle would help contain the sweat. Furthermore, insulating the receptacle 24 would extend the cooling capacity of the cooler.
Finally, a handle 22 and a lid 26 may be incorporated into the design of the receptacle 24 . The lid 26 , when closed, substantially encloses the hollow polygon 12 . Thus, the apparatus according to the invention may operate as an insert to a traditional cooler (i.e., the receptacle 24 and lid 26 ).
The invention has been described in detail, with reference to certain preferred embodiments, in order to enable the reader to practice the invention without undue experimentation. However, a person having ordinary skill in the art will readily recognize that many of the components and parameters may be varied or modified to a certain extent without departing from the scope and spirit of the invention. Furthermore, titles, headings, or the like are provided to enhance the reader's comprehension of this document, and should not be read as limiting the scope of the present invention. Accordingly, only the following claims and reasonable extensions and equivalents define the intellectual property rights to the invention. | A cooler is disclosed that utilizes beverage compartments that are integral to the container holding the refrigerant. The beverage compartments are such that they are completely encircled by yet physically separated from the refrigerant. The design provides easy access to the beverage, close contact between the beverage and refrigerant, and the elimination beverages buried in melting ice. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to electrical connectors and, more particularly, to a land grid array (LGA) socket to provide electrical connection between an LGA package and an electrical substrate, such as a printed circuit board (PCB).
2. Background of the Invention
Various types of conventional electrical connectors for attaching IC packages are known. Each of the IC packages has a large number of contacts arranged in an array of rows and columns. The IC packages are generally classified as pin grid array (PGA) packages, ball grid array (BGA) packages, or land grid array (LGA) packages, depending on shapes of an electric contact portion of the contacts.
Because of the widely used LGA packages, many LGA sockets have been developed to electrically connect the contacts of the IC packages with terminals of the corresponding LGA sockets. A typical LGA socket includes a socket body, in a rectangular shape, and a plurality of electrical terminals assembled on the socket body. A set of retention members is provided to retain the IC package in the socket body so as to establish electrical connection therebetween. To comply with the rectangular socket body, some of the retention members, such as a cover member or a reinforcing plate, are required to have a generally rectangular hollow frame. The hollow frame is provided with a large central rectangular through-hole, which is adapted for receiving the socket body therein.
However, in manufacturing, an abundant of material may be often removed and thereby wasted, because each of these rectangular members is formed by punching of a sheet of metal into the central through-hole frame. This will directly result in much more additional costs to the overall manufacturing of the LGA socket.
In view of the above, it is desired to provide a new LGA socket which overcomes the above-mentioned disadvantages.
SUMMARY OF THE INVENTION
LGA sockets according to preferred embodiments of the present invention are provided with lateral-opened hollow frames for some rectangular frame-like members of the LGA sockets, especially a metallic load plate or a stiffener.
The lateral-opened hollow frame is preferably formed by stamping an elongated strip of metal, and bending into the lateral-opened hollow frame. Alternatively, a plurality of sidewalls may be configured to form the lateral-opened hollow frame.
Due to such formation of the frame-like members, no material is removed and wasted, as opposed to the conventional formation of the load plate and the stiffener. Thus, additional cost associated with the LGA sockets is increasingly reduced.
Other features and advantages of the present invention will become more apparent to those skilled in the art upon examination of the following drawings and detailed description of preferred embodiments, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded, isometric view of an LGA socket in accordance with a preferred embodiment of the present invention;
FIG. 2 is an assembled, isometric view of a part of the LGA socket of FIG. 1 , not showing a socket body therein;
FIG. 3 is an isometric view of a load plate of the LGA socket of FIG. 1 ;
FIG. 4 is an isometric view of a stiffener of the LGA socket of FIG. 1 ; and
FIG. 5 is an assembled, isometric view of the LGA socket of FIG. 1 , but showing the socket body therein.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Reference will now be made to describe preferred embodiments of the present invention in detail.
Referring to FIGS. 1 to 5 , an LGA socket 1 according to a preferred embodiment of the present invention is shown to establish electrical connection between an LGA package (not shown) and a circuit substrate (not shown) mounting on the LGA socket 1 .
The socket 1 includes a simplified socket body 10 embedded with a plurality of terminals 11 . A stiffener 12 is attached to a bottom surface of the socket body 10 . A load plate 14 is pivotally mounted on a first end of the stiffener 12 . A load lever 15 is pivotally supported on an opposite second end of the stiffener 12 . The load lever 15 engages with a free end of the load plate 14 to lock the load plate 14 in a closed position, where the load plate 14 presses the LGA package toward the socket body 10 to bring the LGA package into contact with the terminals 11 of the socket 1 . Thus, through the socket 1 , electrical connection is established between the IC package and the circuit substrate via the LGA socket 1 .
The socket body 10 is made of insulative material, and shaped in the form of a generally rectangular frame. An upper section of the socket body 10 has an receiving region 101 defined between a front part 102 and a rear part 103 of the socket body 10 . The receiving region 101 includes a plurality of passageways (not shown) arranged in columns and rows, for receiving the respective terminals 11 therein. It should be noted that, while the socket body 10 similar to the conventional socket body known in the art is preferred, but any socket body of somewhat different shape may be also employed.
Each of the terminals 11 generally includes a base section 110 secured in the corresponding passageway, an upwardly extending section 112 for electrically mating with a corresponding conductive pad of the LGA package, and a downwardly extending section 114 for electrical connection to a corresponding circuit pad of the substrate.
The stiffener 12 is substantially of a rectangular frame with thereof an off-cut or separated sidewall 1201 adjacent the front part 102 of the socket body 10 . Preferably, the stiffener 12 is formed by stamping an elongated strip of metal, and then bending the strip into a lateral-opened hollow frame. Alternatively, in other embodiments, a plurality of sidewalls may be employed to form the lateral-opened frame by any other suitable machining means, such as welding or fastening means. Accordingly, the stiffener 12 so formed has a central through-hole 121 with a lateral off-cut opening 1200 defined by the sidewall 1201 thereof, without generation of wasted material. The central through-hole 121 is surrounded by the first sidewall 1201 , a second sidewall 1202 , a third sidewall 1203 , a fourth sidewall 1204 . Preferably, the sidewalls 1202 , 1203 , 1204 are continuous, and curved downwards and bent inwards to cooperatively form a common supporting surface 124 to receive the socket body 10 therein. Preferably, a part of the supporting surface 124 adjacent the third sidewall 1203 is slightly wider than that of the other sidewalls 1202 , 1204 , so that the socket body 10 assembled therein can be mostly secured by that part of supporting surface 124 . Opposite ends of the lateral opening 1200 of the first sidewall 1201 are respectively provided with a pair of retaining elements 128 , 129 , for cooperatively supporting at least part of the lever 15 inserted therefrom. The first element 128 is not structurally the same as the second element 129 , but in reversed relationship with the second retaining element 129 . That is, the downward-facing surface of the first retaining element 128 is concave and the upward-facing surface of the reversed retaining element 129 is convex, so as to prevent the interlocking portion 153 of the lever 15 to remove therefrom when the lever 15 is supported by the pair of retaining elements 128 , 129 . The second sidewall 1202 has an interlocking protrusion 127 , for engaging with the actuating portion 151 of the lever 15 . In additional, the third sidewall 1203 has a pair of spaced mounting slots 126 , for engaging with the pair of bearing tongues 144 of the load plate 14 , respectively.
The load lever 15 is generally formed by bending a single metallic wire and includes a pair of spaced rotary shafts 152 , which are partially supported by portions of the first sidewall 1201 . An interlocking portion 153 is disposed between the rotary shafts 152 , and is displaced relative to the rotary shafts 152 , for locking the load plate 14 in the closed position. An actuating portion 151 for rotating the rotary shafts 152 is bent to be at a right angle with respect to the rotary shafts 152 . A distal end of the actuating portion 151 is formed with a finger-like shape in order to form a handle 154 for ease of actuation.
The load plate 14 is also configured to have a generally rectangular hollow frame with a lateral off-cut opening 140 defined by a separated first sidewall 141 thereof. The formation of the load plate 14 is preferably similar to that of the stiffener 12 , but the opening 140 is facing in opposed relationship with the opening 1200 of the stiffener 12 . Therefore, no additional material is wasted during manufacturing of the load plate 14 .
The first sidewall 141 has a curved surface shaped to engage with the third sidewall 1203 of the stiffener 12 , in order to be pivotally movable between an opened position (to be hereinafter described) and the closed position. A pair of spaced bearing tongues 144 projects from portions of the first sidewall 141 adjacent opposite ends of the opening 140 respectively, and is further curved upwards so as to engage with the corresponding mounting slots 126 of the stiffener 12 . A second sidewall 142 opposite the first sidewall 141 is formed with a downwardly curved locking section 143 , for engaging with the interlocking portion 153 of the lever 15 . Additionally, side edges 145 between the first sidewall 141 and the second sidewall 142 are bent slightly downward in the middle portions thereof, in order to engage with the upper surface of the LGA package inserted into the socket body 10 .
Referring to FIGS. 1 and 5 , in assembly, the bearing tongues 144 of the load plate 14 are inserted to engage with the mounting slots 126 of the stiffener 12 respectively, so that the load plate 14 is pivotally movable between the opened position and the closed position by engagement of the tongues 144 and the slots 126 . The lever 15 is assembled into the first sidewall 1201 of the stiffener 12 by the pair of retaining elements 128 , 129 that cooperatively support part of the lever 15 . Then, the socket body 10 embedded with terminals 11 is loaded into the stiffener 12 , and retained by the supporting surface 124 around the central through hole 121 of the stiffener 12 . In that position, a receptacle between the first sidewall 1201 and the front part edge of the socket body 10 is thereby remained to receive the interlocking portion 153 of the lever 15 . It should be noted that, while the above assembly illustrated is preferred, any other possible assembly may also be employed herein.
In operation, the actuating portion 151 of the load lever 15 is released so as to enable the lever interlocking portion 153 to be disengaged from the locking portion 143 of the load plate 14 . When the load plate 14 is placed in an opened position, the LGA package is loaded to be resided within the receiving region 101 of the socket body 10 . The load plate 14 is pivoted to the closed position, and the actuating portion 151 is driven to lower the interlocking portion 153 so as to permit the load plate 14 to press the LGA package toward the socket body 10 to cause electrical connection between pads of the IC package and terminals 11 of the socket body 10 .
While the present invention has been described with reference to preferred embodiments, the description of the invention is illustrative and is not to be construed as limiting the invention. Various of modifications to the present invention can be made to preferred embodiments by those skilled in the art without departing from the true spirit and scope of the invention as defined by the appended claims. | Disclosed is an LGA socket ( 1 ) including a socket body ( 10 ) having a number of terminals ( 11 ) embedded therein. A stiffener ( 12 ) is bottomed to the socket body. A load plate ( 14 ) and a load lever ( 15 ) are pivotally assembled to two opposite ends of the stiffener. At least one of the stiffener and the load plate is formed to have a lateral-opened hollow frame by stamp of an elongated strip of metal. | 7 |
FIELD OF THE INVENTION
The subject disclosure relates to a coaxial style connection system for interconnecting circuit boards such as a daughter board to a backplane.
RELATED APPLICATIONS
This application is related to U.S. patent application Ser. No. 12/422,838, filed on Monday Apr. 13, 2009 (the subject matter of which is incorporated herein by reference).
BACKGROUND OF THE INVENTION
Many different styles of connection systems are used to transmit radio frequency (RF) signals either in cable-to-cable connections or in board-to-board connections. One of the shortcomings of many of the present designs relates to the RF leakage between mated pairs. This shortcoming is multiplied when the lines are placed on a closer center-to-center line spacing. It would therefore be desirable to improve the channel-to-channel isolation.
The object of the present embodiment is to improve upon the channel-to-channel isolation.
SUMMARY OF THE INVENTION
In one embodiment, an electrical connector assembly comprises a first connector assembly comprised of a first housing module having first and second faces, and a receiving opening extending at least partially between the first and second faces; and an electrical contact assembly positioned in the receiving opening of the first housing module and having a first contact interface being positioned internal to the receiving opening and a second contact interface, the electrical contact assembly floating within the receiving opening. A second connector assembly is included which is comprised of a second housing module having first and second faces, and a receiving opening extending at least partially between the first and second faces, the first contact interface of the second connector member being positioned in an opposed manner from the first face of the first housing module; and an electrical contact assembly positioned in the receiving opening of the second housing module and having a first contact interface being receivable internally of the receiving opening of the first housing module, and a second contact interface. The assembly further comprises a seal member positioned intermediate the first and second housings.
In another embodiment, an electrical connector assembly comprises a first connector member comprised of a first housing module having first and second connection interfaces, and a receiving opening extending at least partially between the first and second connection interfaces; and an electrical receptacle assembly positioned in the receiving opening of the first housing module and having a first contact interface being positioned internal to the receiving opening and a second contact interface, the electrical receptacle assembly comprising an outer ground conductor with an inner electrical terminal isolated from the outer ground conductor, and the electrical receptacle assembly being spring loaded towards the first interface.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 discloses a connector plug assembly poised for receipt in a backplane connector;
FIG. 2 discloses a top perspective view of the connector plug assembly;
FIG. 3 discloses a bottom perspective view of the connector plug assembly of FIG. 2 ;
FIG. 4 discloses a cross-sectional view through lines 4 - 4 of FIG. 3 , without the contact assemblies in place;
FIG. 5 discloses an exploded view of the contact assembly for the connector plug assembly;
FIG. 6 discloses a cross-sectional view through lines 6 - 6 of FIGS. 5 ;
FIG. 7 discloses a cross-sectional view through lines 7 - 7 of FIG. 5 ;
FIG. 8 discloses an exploded view of the connector receptacle assembly;
FIG. 9 discloses a cross-sectional view through lines 9 - 9 of FIG. 8 ;
FIG. 10 discloses a cross-sectional view through lines 10 - 10 of FIG. 8 ;
FIG. 11 discloses the assembly of the connector plug assembly;
FIG. 12 discloses a cross-sectional view through the connector plug assembly and connector receptacle assembly and poised for interconnection to each other; and
FIG. 13 is similar to that of FIG. 12 showing the connector plug assembly and connector receptacle assembly assembled.
DETAILED DESCRIPTION
With reference first to FIG. 1 , an electrical connector assembly is shown at 2 comprising a connector plug assembly 4 and a connector receptacle assembly 6 . As shown, connector plug assembly 4 is comprised of a coaxial plug contact assembly 8 and a housing module 10 . Connector receptacle assembly 6 is comprised of a coaxial receptacle contact assembly 12 and a housing module 14 . As it should be appreciated, connector plug assembly 4 is interconnectable to connector receptacle assembly 6 to interconnect the daughter board 16 and the backplane 18 .
With respect to FIGS. 2 and 3 , connector plug assembly 4 is shown in greater detail. As shown, housing module 10 includes a first or front face 20 and a second or rear face 22 with receiving openings 24 extending between the first and second faces 20 , 22 . As shown best in FIG. 3 , coaxial plug contact assembly 8 is shown having a first contact interface 30 positioned adjacent to first face 20 and as best shown in FIG. 2 has a second contact interface 32 positioned adjacent to second face 22 .
As shown best in FIG. 4 , the receiving openings 24 are defined by a bored hole extending inwardly from the first face 20 and defines an enlarged opening portion 40 and a constricted opening portion 42 . Enlarged opening portion 40 opens onto first face 20 and constricted opening 42 opens onto second face 22 . The intersection of the enlarged opening 40 and a constricted opening 42 defines a shoulder 44 adjacent to second face 22 . With respect again to FIG. 2 , housing module 10 further comprises a mounting portion 50 having mounting apertures 52 .
With respect now to FIG. 5 , coaxial plug contact assembly 8 will be described in greater detail. Coaxial plug contact assembly 8 is comprised of inner plug housing portion 60 , outer plug housing portion 62 , insulator 64 , socket contact 66 , compression spring 68 , and retaining ring 70 . Inner plug housing portion 60 includes an L-shaped notch 80 having a longitudinally extending portion 82 , laterally extending portion 84 , and detent 86 . Inner plug housing portion 60 further includes a plurality of ground contacts 88 where the inner plug housing portion 60 is comprised of a conductive material such as a metal. As shown best in FIG. 6 , inner plug housing portion 60 further includes an inner diameter at 90 defining a rearwardly facing shoulder at 92 . Inner plug housing portion 60 further includes inner diameter portion 96 which defines rearwardly facing edge 98 .
With respect again to FIG. 5 , outer housing portion 62 includes a center diameter portion 100 , a ferrule 102 having a raised ring portion 104 , where the ferrule 102 has an inner diameter at 106 and which defines an end face at 108 . An enlarged ring portion 110 is positioned on central portion 100 and defines a forwardly facing surface 112 . Outer housing portion 62 also includes a receptacle portion 116 and as best shown in FIG. 7 , includes an inner diameter at 118 and a reduced diameter at 120 .
With reference still to FIG. 5 , insulator 64 includes an outer diameter at 122 and an internal opening at 124 . Socket contact 66 includes a first socket portion 130 , a second socket portion 132 , and first and second shoulders 134 , 136 . Finally, locking ring 70 includes a circular ring portion 140 having engaging openings at 142 and locking lugs at 144 .
With reference now to FIGS. 8 and 9 , connector receptacle assembly 6 will be described in greater detail. As shown in FIG. 8 , connector receptacle assembly 6 is shown with one of the coaxial receptacle contact assemblies 12 exploded from the housing module 14 . Housing module 14 includes first or front face 150 , second or rear face 152 , and receiving openings 154 extending between faces 150 , 152 . Receiving openings 154 include a first diameter section 158 , defining an end face 160 , and opening portions 162 defined to receive a mating connector as further described herein. Housing module 14 also includes a mounting portion 170 having mounting apertures 172 and a flange portion 174 , where the mounting portion 170 cooperates with flange portion 174 for mounting to an opening in the back plane 18 , as further described herein. Coaxial receptacle contact assemblies 12 define a first contact interface 176 , and a second contact interface 178 ( FIG. 12 ).
With reference still to FIG. 8 , coaxial receptacle contact assembly 12 is shown as comprised of receptacle housing portion 180 , pin terminal 182 , and insulators 184 , 186 . As shown best in FIG. 10 , receptacle housing module 180 includes a rear diameter portion 190 , first inner diameter portion 192 A, second inner diameter portion 192 B, lead-in portion 194 , and diameter portion 196 defining a rearwardly facing shoulder 198 as defined herein.
Pin terminal 182 includes first and second pin portions 200 , 202 , and an intermediate diameter portion 204 defining edges 206 , 208 . Insulator 184 is comprised of a through opening 210 while insulator 186 includes a through opening 212 . As also shown in FIG. 8 , coaxial receptacle contact assemblies 12 further includes D-ring seals 188 which are conductively compressive members. D-ring seals 188 could be made from a material such as a fluoro-silicon or a silicon rubber which is impregnated with conductive particles such as silver.
The assembly of the connector plug assembly 4 and the connector receptacle assembly 6 will be assembled as follows. With respect again to FIG. 5 , coaxial plug contact assembly 8 will be described. Socket contact 66 is first inserted into opening 124 such that insulator 64 is trapped between shoulders 134 , 136 . The combination of the insulator 64 and socket contact 66 is then inserted into the inner diameter 90 ( FIG. 6 ) of the inner plug housing portion 60 until insulator 64 abuts shoulder 92 . Inner plug housing portion 60 , together with insulator 64 and socket contact 66 , can then be positioned over outer plug housing portion 62 such that inner diameter portion 96 ( FIG. 6 ) is received over ferrule 102 . It should be understood that this connection is a semi-permanent connection and can be made by known means such as interference fit, soldering, sweat fitting, threadable connection, or the like. When in position, insulator 64 abuts end face 108 to trap insulator in position between housing portions 60 , 62 .
With reference now to FIG. 11 , this assembly may now be positioned into housing module 10 with diameter portion 100 being positioned into constricted openings 42 ( FIG. 4 ). Compression spring 68 may now be received over inner plug housing portion 60 and retaining ring 70 may now be positioned in a longitudinal sense with the locking lugs 144 aligned with the longitudinally extending portions 82 of the L-shaped recess 80 . It should be appreciated that a tool may grip the engaging openings 142 and the locking ring 70 may be pushed longitudinally inward, compressing compression spring 68 until such time as the locking lugs 144 reach the laterally extending sections 84 whereupon the locking ring 70 may be rotated such that lugs 144 travel in laterally extending sections 84 to the detent 86 where the locking ring is locked in place. As shown in FIG. 12 , compression spring 68 is compressively sprung between shoulder 44 of housing module 10 and locking ring 70 , spring loading coaxial plug contact assembly 8 towards first face 20 of module 10 .
With reference now to FIG. 8 , coaxial receptacle contact assembly 12 is assembled by inserting pin contact 182 into through opening 210 , and inserting insulator 186 with through opening 212 over pin terminal 182 . This assembly may now be received within the inner diameter 192 B ( FIG. 10 ) of receptacle housing 180 until such time as it is received against rearwardly facing shoulder 198 ( FIG. 10 ). This positions pin portion 200 adjacent to inner diameter portion 192 A. This assembly may now be received in housing module 14 with rear diameter portion 190 ( FIG. 10 ) received in first diameter section 158 ( FIG. 9 ), and into the position shown in FIG. 12 . This positions pin portion 202 within inner diameter portion 192 B and positions D-ring seal 188 adjacent to first face 150 .
The two connector assemblies 4 and 6 , and their associated boards 16 , 18 , may now be brought into mating engagement into the configuration shown in FIG. 13 . In this configuration, and as shown in FIGS. 12 and 13 , pin portion 200 engages first socket contact portion 130 and ground contacts 88 contact the inner diameter portion 192 A of receptacle housing portion 180 .
It should also be appreciated that this interface, that is, the position where the first contact interface 30 of coaxial plug contact assembly 8 interfaces with the first contact interface 176 ( FIG. 8 ) of coaxial receptacle contact assembly 12 , occurs within receiving openings 24 , recessed from first face 20 . This interface is also within a metal hosing module 10 . It should also be appreciated that coaxial plug contact assembly 8 is spring loaded towards coaxial receptacle contact assembly 12 . As shown, forwardly facing surfaces 112 of coaxial plug contact assembly 8 is spaced from second face 22 , and as shown, the nominal spacing is in the range of 40 to 50 millimeters allowing coaxial plug contact assembly 8 to spring loadably float within receiving opening 24 by that amount. This ensures that each of the ground contacts 88 is continuously and fully engaged within inner diameter portion 192 A of receptacle housing portion 180 . This also accounts for any discrepancy between the multiple contacts as to their various longitudinal positions. Finally, as shown, D-ring seal 188 is shown compressed between faces 20 and 150 which isolates the space between the surfaces as well as the space between individual receiving openings 24 . All of these items either individually or in the aggregate increase the channel-to-channel isolation of the connection between connector plug assembly 4 and connector receptacle assembly 6 .
As should be appreciated the housing modules 10 , 14 are comprised of conductive material and may be metallic for EMI/RFI purposes. It should also be appreciated that the coaxial plug contact assembly 8 and the coaxial receptacle contact assembly 12 each carry (and interconnect) an RF signal comprised of a signal and a ground, and that each signal is isolated from the other by way of the insulators 64 , 184 and 186 . Further more, it should be appreciated that the first diameter section 158 and pin portion 200 together define a receptacle for the interconnection of a mating connector 250 as shown in FIGS. 12 and 13 . In a like manner, and as shown in FIGS. 12 and 13 , inner diameter 118 and socket portion 132 define a receptacle for the interconnection of a mating connector (not shown). It also be appreciated that the interconnection to a mating connector such as 250 need not be made through a receptacle interface, but could be any form of connection, such as bayonet, screw in, etc.
While this invention has been described as having an exemplary design, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains. | A board to board connection system is disclosed for RF signals, and comprises coaxial interconnection systems which interconnect a daughter card to a backplane. | 7 |
PRIORITY
This application is a continuation of application Ser. No. 10/718,742, filed Nov. 21, 2003, now U.S. Pat. No. 7,280,346 which claims the benefit of provisional application No. 60/507,257, filed Sep. 29, 2003.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to the field of data processing devices. More particularly, the invention relates to versatile input/output and display configurations for a data processing device.
2. Description of the Related Art
Portable data processing devices such as Personal Digital Assistants (“PDAs”) and programmable wireless telephones are becoming more powerful every day, providing users with a wide range of applications previously only available on personal computers. At the same time, due to advances in silicon processing technology and battery technology, these devices may be manufactured using smaller and smaller form factors. Accordingly, users no longer need to sacrifice processing power for portability when selecting a personal data processing device.
Although processing devices with small form factors tend to be more portable, users may find it increasingly difficult to interact with them. For example, entering data may be difficult due to the absence of a full-sized keyboard and reading information may be difficult due to a small, potentially dim Liquid Crystal Display (“LCD”).
To deal with this problem, devices have been produced which physically adjust to an “active” position when in use and an “inactive” position when not in use. For example, the well-known Motorola® Star-TAC® wireless telephone flips open when in use, thereby exposing a telephone keypad, a display and an earpiece. However, when this device retracts to an “inactive” position, the keypad, display, and earpiece are all completely inaccessible.
To solve these problems, the assignee of the present application developed a data processing device 100 with an adjustable display 103 as illustrated in FIGS. 1 a - c . The data processing device 100 includes a keyboard 101 , a control knob/wheel 102 (e.g., for scrolling between menu items and/or data), and a set of control buttons 105 (e.g., for selecting menu items and/or data).
The display 103 is pivotally coupled to the data processing device 100 and pivots around a pivot point 109 , located within a pivot area 104 , from a first position illustrated in FIG. 1 a to a second position illustrated in FIGS. 1 b - c . When in the first position the display 103 covers the keyboard 101 , thereby decreasing the size of the device 100 and protecting the keyboard 101 . Even when the display is in the first position, however, the control knob 102 and control buttons 105 are exposed and therefore accessible by the user. The motion of the display 103 from the first position to a second position is indicated by motion arrow 106 illustrated in FIGS. 1 a - b . As illustrated, when in the second position, the keyboard 101 is fully exposed. Accordingly, the display is viewable, and data is accessible by the user in both a the first position and the second position (although access to the keyboard is only provided in the first position).
In one embodiment, the data processing device 100 is also provided with audio telephony (e.g., cellular) capabilities. To support audio telephony functions, the embodiment illustrated in FIGS. 1 a - c includes a speaker 120 for listening and a microphone 121 for speaking during a telephone conversation. Notably, the speaker 120 and microphone 121 are positioned at opposite ends of the data processing device 100 and are accessible when the screen 103 is in a closed position and an open position.
SUMMARY
A data processing device is described comprising: a body having a surface defining a first plane, the body comprising a first group of control elements and a second group of control elements for entering data and performing control operations; a display having a display area defining a second plane, the display coupled to the data processing device at a pivot point and rotatable around the pivot point from a first position to a second position, wherein the display is viewable in both the first position and the second position and wherein both the first and second groups of control elements are exposed when the display is in the second position, and wherein only the second group of control elements are exposed when the display is in the first position, wherein the first plane and the second plane are substantially parallel when the display is in the first position, and wherein the first plane and the second plane are not parallel when the display is in the second position.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the present invention can be obtained from the following detailed description in conjunction with the following drawings, in which:
FIGS. 1 a - c illustrate a prior art data processing device with an adjustable display.
FIG. 2 illustrates one embodiment of a data processing device in a first orientation and/or operating mode.
FIG. 3 illustrates an embodiment of a data processing device in a second orientation and/or operating mode.
FIG. 4 illustrates an embodiment of the data processing device from a perspective view.
FIGS. 5-7 illustrate one embodiment of the data processing device which includes an adjustable display.
FIG. 8 illustrates one embodiment of the data processing device from a top view in which the display is rotated to expose a keyboard.
FIG. 9 illustrates movement of the display according to one embodiment of the invention.
FIG. 10 illustrates one embodiment of a mechanism for coupling an adjustable display on a data processing device.
FIG. 11 illustrates a second embodiment of a mechanism for coupling an adjustable display to a data processing device.
FIG. 12 illustrates a manner for highlighting glyphs according to one embodiment of the invention.
FIG. 13 illustrates a manner for highlighting glyphs according to another embodiment of the invention.
FIG. 14 illustrates a hardware architecture employed in one embodiment of the invention.
FIG. 15 illustrates an operational mode selection module according to one embodiment of the invention.
FIGS. 16-17 illustrate another embodiment of the invention having an adjustable display screen.
FIGS. 18 a - b , 19 and 20 illustrate embodiments of the invention which includes a moveable numeric keypad integrated between a moveable display and a data processing device.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without some of these specific details. In other instances, well-known structures and devices are shown in block diagram form to avoid obscuring the underlying principles of the present invention.
Several different multi-purpose input/output and display configurations for a data processing device are described below. As will be apparent from the following description, many of these configurations are particularly beneficial when employed on a dual-purpose data processing device such as a personal digital assistant (“PDA”) or other mobile computing device having integrated wireless telephony capabilities (e.g., a combination PDA and cell phone). However, it should be noted that the underlying principles of the invention are not limited to wireless telephony configuration.
A data processing device 200 according to one embodiment of the invention is illustrated in FIGS. 2-4 . The data processing device 200 includes a display 206 with a viewable display area 205 for displaying various types of text and graphics (e.g., graphical navigation menus, email messages, electronic calendars, electronic address books, . . . etc). In one embodiment, the display is a backlit or reflective thin film transistor (“TFT”) display. In another embodiment, the display is a transflective SuperTwisted Nematican (“STN”) display. However, the underlying principles of the invention are not limited to a particular display type.
In one embodiment, the data processing device 200 includes two or more different modes of operation which may be associated with two or more operational orientations. In the first mode of operation, the display 206 is viewed in a first orientation, illustrated generally in FIG. 2 (i.e., images are displayed upright on the display when the device is oriented as shown in FIG. 2 ). By contrast, in the second mode of operation, the display 206 is viewed in a second orientation, illustrated generally in FIG. 3 (i.e., images are displayed upright on the display when the device is oriented as shown in FIG. 3 ).
In one embodiment, the data processing device 200 includes a first set of control elements 210 positioned to the right of the display 206 and a second set of control elements 224 positioned to the left of the display (i.e., to the “left” and “right,” respectively, in the first orientation illustrated in FIG. 2 ). Thus, in the first operational mode, the first set of control elements 210 are readily accessible by a user's right hand and the second set of control elements 224 are readily accessible by a user's left hand. As used herein, the term “control elements” means any type of data input or control mechanism associated with the data processing device 200 including, by way of example and not limitation, data entry keys such as alphanumeric keys, knobs, scroll wheels, or buttons. As will be described in greater detail below, in one embodiment, the various control elements configured on the data processing device 200 may perform different operations in the different operational modes.
In one embodiment, the first set of control elements 210 includes a control wheel 202 positioned between two control buttons 201 and 203 , as illustrated. Various different types of control wheels 202 and control buttons 201 and 203 may be employed such as those currently used on the Blackberry™ line of wireless messaging devices from Research In Motion. The control wheel 202 may be used to move a cursor device, highlight bar or other selection graphic on the display 205 to select menu items, program icons and other graphical or textual display elements. In the embodiment shown in FIG. 2 the first button 201 is configured to select graphical/textual items highlighted on the display screen 205 (as indicated by the check mark), and the second button 203 is configured to de-select items and/or to “back” out of a current application, menu, icon, . . . etc (as indicated by the X mark). Alternatively, or in addition (i.e., depending on the selected mode of operation), the “X” may cancel actions and return to the previous screen, and the check mark may save actions and return to the previous screen. By way of example, if the email application is open, “X” may cancel the composition of a new message, whereas the check mark may send or save a message that has been composed.
By way of example, and not limitation, if an email client application is executed on the device 200 , the control wheel 202 may be configured to scroll through the list of email messages within the user's inbox (e.g., with the current email message highlighted on the display 205 ). The first control button 201 may be configured to select a particular email message within the list and the second control button 203 may be configured as a “back” button, allowing the user to back out of selected email messages and/or to move up through the menu/folder hierarchy. Of course, the underlying principles of the invention are not limited to any particular configuration for the control wheel 202 or control buttons 201 , 203 .
The second set of control elements 210 also includes a keypad 211 for performing various additional control and/or input functions. In one embodiment, the keys of the keypad 211 are configured to perform different input/control operations depending on whether the data processing device 200 is in the first mode/orientation ( FIG. 2 ) or the second mode/orientation ( FIG. 3 ). In addition, as will be described in greater detail below, in one embodiment, a first series of glyphs are highlighted on the keys 211 when the data processing device 200 is in the first mode and a second series of glyphs are highlighted on the keys 211 when the data processing device is in the second mode. Various mechanisms for highlighting a particular set of glyphs may be employed (as described below).
When in the first operational mode, the keypad 211 includes a series of cursor control keys to move a cursor up, down, left, and right, as indicated by the “ ,” “ ,” “<” and “>” glyph pointers, respectively, on four of the keys of the keypad 211 illustrated in FIG. 2 . The keypad 211 also includes “page up” and “page down” keys (e.g., configured to perform typical page up/down functions); a “delete” key for deleting text characters; and a “home” key for jumping to the data processing device's main menu, or performing application-specific functions typically associated with a “home” key (e.g., moving a cursor to the beginning of a line in a word processing document). A “menu” key is also provided which generates a context-specific menu when selected (e.g., a different menu may be generated based on which application is currently running). Various alternate and/or additional keys may be included within the keypad 211 while still complying with the underlying principles of the invention. In addition, two functions keys are provided, F 1 and F 2 , which may be programmed by the end user to perform designated operations (e.g., opening a particular application, jumping to a particular file folder, . . . etc).
Of course, the particular keypad layout illustrated in FIG. 2 is not required for complying with the underlying principles of the invention. For example, alternate configurations could provide “Home” and “Menu” functions on the left hand side of the device, and additional functions like “Back” on the right hand side in the area shared by the keypad. It's also notable that the scroll wheel may be eliminated entirely as the “<,” “>,” “ ,” and “ ” keys are sufficient for making selections and highlighting onscreen items.
The second set of control elements 224 illustrated in FIG. 2 includes a “jump” button 226 which allows a user to jump to designated applications and/or points within the graphical menu/folder hierarchy. For example, the user may jump to a specified application by selecting the “jump” button and one of the keys within the keypad 211 . The second set of control elements 224 also includes a “back” button 226 , allowing the user to back out of selected applications or points within the menu/folder hierarchy. Once again, various additional functions/keys may be included within the second set of control elements 224 while still complying with the underlying principles of the invention.
As mentioned above, in one embodiment, the data processing device 200 includes an integrated telephone with a wireless transceiver for transmitting/receiving audio signals over a wireless telephony network (e.g., a Global System for Mobile Communications (GSM) network or other type of cellular network). As such, in this embodiment, the data processing device 200 is equipped with a telephony input/output port designed to interface with a “hands-free” headset and microphone. In addition, as illustrated, one embodiment of the data processing device 200 includes a speaker 220 at one end and a microphone 215 at the other end, to provide telephony capabilities without a separate headset and/or microphone.
In one embodiment, the functions associated with the various control elements are automatically modified when the data processing device 200 is switched between the first and second operational modes. Specifically, in the embodiment shown in FIG. 3 , the keys of the keypad 211 within first set of control elements 210 are converted from the data entry functions described above to a numeric keypad. As illustrated, the glyphs on the face of each of the keys of the keypad change, both in content and in orientation, to reflect the associated change in function and orientation of the data processing device 200 . The numeric keypad functions are particularly suitable when the data processing device 200 is used as a telephone. Thus, in one embodiment, the second mode is a “telephony mode” in which the data processing device operates as a telephone and in which the user may enter a telephone number and perform other telephony-based functions via the numeric keypad 211 .
In addition, when in the second mode, the functions performed by the control wheel 202 and control buttons 201 and 203 may be automatically modified. For example, if the second mode is a “telephony mode” as described above, the first control button 201 may be used to initiate and answer calls and the second control button 203 may be used to terminate calls. Moreover, in one embodiment, the control wheel may be used to navigate through telephony-based menus such as the user's stored telephone numbers and the telephone menu structure.
In one embodiment, applications, menus and/or user interface features may also be modified to reflect the switch between the first operational mode/orientation and the second operational mode/orientation. For example, when in the first mode of operation, a more advanced user interface may be triggered which is navigable via the first and second sets of control elements 224 and 210 , respectively. By contrast, when in the second mode of operation, a user interface may be provided which is more easily navigable with the limited control functions provided by the control wheel 202 , control buttons 201 and 202 , and numeric keypad 211 . Moreover, telephony-specific applications may be automatically made available or launched when the data processing device 200 is in the second mode (i.e., assuming that the second mode is a “telephony” mode), whereas a more general set of applications may be made available to the user when the data processing device 200 is in the first mode.
In addition, as illustrated generally in FIGS. 2 and 3 , in one embodiment, when switching between the first mode and the second mode, the orientation of images and/or text on the display screen 205 will change. For example, in the first mode, images/text are displayed right-side-up when the device is oriented as shown in FIG. 2 . By contrast, when in the second mode, images are displayed right-side-up when the device is oriented as shown in FIG. 3 (i.e., the images are rotated 90 degrees with respect to the orientation shown in FIG. 2 ). In one embodiment, the specific image orientation to be used for each operating mode may be selected by the end user.
Switching between the first and second operational modes may occur automatically and/or manually. For example, in one embodiment, selecting a designated key or sequence of keys may cause the data processing device 200 to switch between modes (e.g., simultaneously pressing the “back” and “menu” buttons). Alternatively, or in addition, the data processing device 200 may automatically switch between modes based on the specific operations or applications selected by the user (e.g., as described in greater detail below with respect to FIG. 15 ). For example, if the device is in the first mode and the user selects a telephony-based application from the main menu (e.g., a list of stored telephone numbers) the data processing device 200 will automatically switch to the telephony mode 200 .
In one embodiment, motion sensors (not shown) are configured within the data processing device 200 to detect its orientation, and responsively generate control signals identifying its orientation. In response to the control signals, the data processing device 200 then switches between the first and second modes of operation. Various alternate mechanical or logical (e.g., software/hardware) triggers may be employed to switch between the first and second operational modes. Alternate logical mechanisms may include, for example, non-user-initiated software choices such as receiving a phone call, or having a calendar event set up to remind the user to hold a conference call. Alternative mechanical triggers may include, for example, a slide switch which is comfortable to access in either operation mode and which hides/reveals symbols indicating which mode is active, or an illuminated push button switch which toggles between the two modes and illuminates symbols indicating which is the active mode.
In one embodiment, illustrated in FIGS. 5-8 , an alphanumeric keyboard 500 (e.g., a QWERTY keyboard) is configured on/within the data processing device 200 . In this embodiment, the display 206 is configured to rotate around a pivot point 207 from a first position, in which it covers the alphanumeric keyboard 500 (as it does in FIGS. 2-4 ), to a second position, in which it exposes the alphanumeric keyboard 500 (illustrated fully-exposed in FIGS. 7 and 8 ).
In one embodiment, the display 206 rotates from the first position to the second position within a plane defined by the display 206 (e.g., as does the data processing device illustrated in FIGS. 1 a - c ). Alternatively, as illustrated in FIG. 5 , in one embodiment, the front edge 501 of the display 206 initially lifts upward as illustrated in FIG. 5 , creating an angle between the plane defined by the data processing device 200 and the plane defined by the display 206 . To aid the user in lifting the display, in one embodiment, a small nub 502 is formed on the non-viewable portion of the display (e.g., providing a protruding surface for engaging with the user's thumb).
Once elevated, the display 206 rotates around the pivot point 207 to the second position shown in FIG. 7 from a front perspective view and FIG. 8 from a top view. In one embodiment, rather than initially lifting up as illustrated in FIG. 5 , the display will lift upward as it rotates from the first position to the second position. FIG. 6 illustrates the display elevated and rotated halfway between the first position and the second position. A rotation arrow 505 is provided to indicate the rotation of the display 206 .
The display 206 may lift upward at various different angles in relation to the data processing device 200 (e.g., 7 deg, 15 deg, 25 deg, . . . etc), both prior to rotating to the second position and/or after it has reached to the second position. As illustrated in FIG. 9 , in one embodiment, the display 206 is adjustable at a variety of different angles with respect to the data processing device 200 , both from the first position and/or the second position. Of course the display may open from no angle when in the first position to a fixed angle while in the second position while still complying with the underlying principles of the invention.
In one embodiment, the display 206 may be closed over the alphanumeric keyboard 500 from the second position, with the display screen 205 facing the keyboard 500 , thereby exposing the back of the display and protecting both the display screen 205 and the keyboard 500 . This configuration may be particularly useful when the data processing device 200 is stored away for travel (e.g., stored within a suitcase or pocketbook).
In one embodiment, the display 206 initially rotates within a plane defined by the display from the first position to the second position as described above. Then, when the display is in the second position the angle between the display 206 and the data processing device 200 may be adjusted, as described above with respect to FIG. 9 .
As illustrated in FIGS. 2-8 , the display 206 is viewable regardless of whether it is in the first position or the second position (i.e., unless it is closed with the display screen 205 facing the keyboard 500 as described above). When in the first position, the display 206 covers the keyboard 500 thereby decreasing the size of the data processing device 200 and protecting the keyboard 500 . Even when the display 206 is in the first position, however, the first and second sets of control elements 210 and 224 , respectively, are exposed and therefore accessible by the user. When in the second position, the alphanumeric keyboard 500 is fully exposed, providing for fully-functional data entry (e.g., composing of an email message).
In one embodiment, the second position of the display 206 represents a third operational mode/orientation for the device 200 . Thus, when the data processing device 200 switches from the first or second operational modes described above to the third operational mode, different menus, applications and/or other user interface features may be activated. For example, when the device enters the third mode of operation, user interface features associated with applications may change to reflect the availability of the alphanumeric keyboard 500 (e.g., more advanced text-based data entry capabilities may be provided allowing users to enter text directly within the body of email messages or word processing documents).
Two different mechanisms for enabling the motion of the display 206 as shown in FIGS. 5-7 are illustrated in FIGS. 10 and 11 . The mechanism illustrated in FIG. 10 includes a cylindrical chamber 1005 fixedly attached to a rotation element 1020 . A pin 1010 rotates within the chamber as indicated by rotation arrow 1030 . The pin is coupled to the display 206 and rotates in response to upward or downward forces applied on the edge of the display 206 , causing the edge of the display 206 to move upward or downward with respect the data processing device 200 as illustrated in FIG. 9 . A torsion spring 1011 cooperatively mated with both the pin 1010 and the chamber 1005 generates a torque on the pin 1011 which holds the pin, and therefore the display 206 , in place when it is not being manipulated by the user (e.g., to counteract gravity and hold the display 206 in a position such as that shown in FIG. 7 ). Of course, various other well known techniques may be employed to hold the display in place (e.g., using springs and/or friction).
The rotation element 1020 is rotatably coupled to the data processing device 200 . For example, a pin formed on/within the data processing device 200 may fit within a cylindrical chamber located on the underside of the rotation element 1020 , allowing the rotation element 1020 to rotate in the manner indicated by rotation arrow 1031 . The rotation of rotation element 1020 allows the display 206 to rotate from the first position illustrated in FIGS. 2-4 (in which the keyboard 500 is covered) to the second position illustrated in FIGS. 7 and 8 (in which the keyboard 500 is exposed). Once again, various different types of rotational mechanisms may be employed to allow the screen to rotate while still complying with the underlying principles of the invention.
FIG. 11 illustrates another embodiment for enabling the motion of the display 206 . This embodiment includes a first connection element 1105 which is fixedly coupled to the non-viewable side of the display 206 . The first connection element is rotatably coupled to an arm 1121 and rotates around a rotation point 1106 as indicated by rotation arrow 1130 . The arm 1121 is fixedly coupled to a cylindrical element 1120 which rotates around an axis defined by a pin 1110 . The pin 1110 is inserted through a cylindrical chamber within the cylindrical element 1120 . As in the prior embodiment, a torsion spring 1111 may be coupled to the pin 1110 and the chamber 1120 to hold the chamber 1120 and therefore the display 206 in an elevated orientation.
As mentioned above, different glyphs on the control elements 210 and 224 may by highlighted to identify different functions, based on the operational mode of the data processing device 200 (e.g., based on whether the data processing device 200 is in the “first,” “second” or “third” operational modes described herein). Similarly, different glyphs on the alphanumeric keyboard 500 may by highlighted based on the mode of operation and/or user-selected functions. For example, if a first set of functions for standard alphanumeric input (e.g., standard alphanumeric characters) are enabled, glyphs associated with the first set of functions (e.g., glyphs representing the alphabet) are highlighted. In one embodiment, a second and third set of functions may be enabled by the user by holding down an ALT or CTRL key, as with a standard QWERTY keyboard. In this embodiment, different glyphs representing the different functions associated with the keys of the keyboard 500 may be highlighted. For example, if the combination of the CRTL key and the X key (i.e., X when used for standard alphanumeric input) cuts text from a document then, upon selecting the CTRL key, the glyph “CUT” or a different symbol representing the “cut” function (e.g., a pair of scissors) may be highlighted on the key instead of the glyph “X.” Of course, the underlying principles of the invention are not limited to any particular set of key combinations or functions.
Various techniques may be employed to highlight the different glyphs associated with each key within the keyboard 500 and/or control element 210 , 224 . For example, as illustrated in FIG. 12 , in one embodiment, a first glyph 1200 is printed on the face of each key 1201 with a relatively subtle coloring in relation to the color of the key (e.g., a dark gray glyph printed on a light gray key). In one embodiment, the surface of the key and/or the glyph is comprised of a silvered reflective material which reflects light incident upon the surface 1201 from an external light source. Various different types of reflective surfaces may be used for the face of the key 1201 and/or glyph 1200 . In one embodiment, when the data processing device 200 is in a first mode of operation associated with the first glyph 1200 , the light reflected off of the reflective surface 1201 reveals the glyph 1200 because of the different coloring of the glyph 1200 in relation to the remainder of the surface 1201 .
It should be noted that a “silvered reflective material” is not strictly necessary for implementing the multiple glyph features described above. For example, any type of material which reflects sufficient light to hide its internal structure may be employed while still complying with the underlying principles of the invention. This may include, for example, a think coat of a light colored paint, or a fully transparent plastic with enough surface texture to diffuse the light (e.g., and give it a frosted appearance).
In addition, as illustrated in FIG. 12 , a second glyph 1205 is formed on a second surface 1206 beneath the first surface 1201 . In one embodiment, the second glyph 1205 is formed from a translucent or transparent material (e.g., transparent plastic) whereas the remainder of the surface 1206 is opaque. An LED 1210 is positioned beneath the second glyph 1205 and the second surface 1206 . In one embodiment, when the data processing device 200 is in a second mode of operation associated with the second glyph 1205 (e.g., turning the keypad into a numeric keypad illustrated in FIG. 3 ), the LED 1210 generates light from underneath the second surface 1206 and second glyph 1205 . The light passes through the transparent or translucent second glyph 1205 and is blocked by the remainder of the second surface 1206 , thereby highlighting the second glyph 1205 . The light generated by the LED 1210 is of a high enough intensity so that it will pass through the first surface 1201 and glyph 1200 , thereby illuminating the second glyph 1205 for the user 1205 . As described above, the first surface 1201 and first glyph 1200 reflect light incident from outside of the key (as indicated in FIG. 12 ). However, in one embodiment, the first surface 1201 and first glyph 1200 are semi-transparent or semi-translucent with respect to light generated from beneath the key or inside of the key (e.g., from the LED 1210 illustrated in FIG. 12 ).
In another embodiment, separate LEDs are configured to illuminate each glyph. By way of example, FIG. 13 illustrates a key 1300 with an opaque top surface 1305 and two translucent/transparent glyphs 1301 and 1302 . A separate illumination chamber, 1310 and 1311 , is provided underneath each glyph, 1301 and 1302 , respectively. The chambers 1310 and 1311 are separated by an opaque divider 1330 . A first LED 1320 is configured within the first chamber 1310 to provide light to illuminate the first glyph 1301 and a second LED 1321 is configured within the second chamber 1311 to provide light to illuminate the second glyph 1302 . In one embodiment, the different LED's are enabled and/or disabled based on the current operational mode selected on the data processing device 200 . For example, the first LED 1320 may be illuminated for the first operational mode and the second LED 1321 may be illuminated for the second operational mode.
In another embodiment, the same illumination chamber may be shared between different glyphs. In this embodiment, the contrast between glyphs may be controlled by adjusting the color of the light generated by the different LEDs. Once particular implementation for illuminating glyphs is described in the co-pending application entitled “A METHOD OF DYNAMICALLY LIGHTING KEYBOARD GLYPHS,” Filed Aug. 17, 2001, Ser. No. 09/932,195, which is assigned to the assignee of the present application and which is incorporated herein by reference. One embodiment described in this co-pending application adjusts contrast between glyphs by selecting LED colors which are complimentary to the colors of certain glyphs. For example, if an LED color is selected which is complementary to the color of a glyph, that glyph will absorb the complimentary light and will appear dark in relation to the other glyphs. Various alternate and/or additional techniques for highlighting glyphs may be employed while still complying with the underlying principles of the invention.
One embodiment of a data processing device architecture is illustrated in FIG. 14 . It should be noted, however, that the underlying principles of the invention are not limited to any particular device architecture. In fact, the underlying principles of the invention may be implemented on virtually any data processing device capable of processing data and displaying text and graphics.
The particular embodiment illustrated in FIG. 14 is comprised of a microcontroller 1405 , an external memory 1450 , a display controller 1475 , and a battery 1460 . The external memory 1450 may be used to store programs and/or data 1465 transmitted to the data processing device 200 over a network (now shown). In one embodiment, the external memory 1450 is non-volatile memory (e.g., an electrically erasable programmable read only memory (“EEPROM”); a programmable read only memory (“PROM”), . . . etc). Alternatively, the memory 1450 may be a volatile memory (e.g., random access memory or “RAM”) but the data stored therein may be continually maintained via the battery 1460 . The battery 1460 in one embodiment is a coin cell battery such as those used in calculators and watches.
The microcontroller 1405 of one embodiment is comprised of a central processing unit (“CPU”) 1410 , a read only memory (“ROM”) 1470 , and a scratchpad RAM 1440 . The ROM 1470 is further comprised of an interpreter module 1420 and a toolbox module 1430 .
The toolbox module 1430 of the ROM 1470 contains a set of toolbox routines for processing data, text and graphics on the device 100 . These routines include drawing text and graphics on the device's display 430 , decompressing data transmitted from the portal server 110 , reproducing audio on the device 100 , and performing various input/output and communication functions (e.g., transmitting/receiving data over the client link 160 and/or the RF link 220 ). A variety of additional device functions may be included within the toolbox 1430 while still complying with the underlying principles of the invention.
In one embodiment, microprograms and data are transmitted to/from the external memory 1450 of the device via a communication interface 1470 under control of the CPU 1410 . Various communication interfaces 1470 may be employed without departing from the underlying principles of the invention including, for example, a Universal Serial Bus (“USB”) interface or a serial communication (“serial”) interface. The microprograms in one embodiment are comprised of compact, interpreted instructions known as “bytecodes,” which are converted into native code by the interpreter module 1420 before being executed by the CPU 1410 . One of the benefits of this configuration is that when the microcontroller/CPU portion of the device 100 is upgraded (e.g., to a faster and/or less expensive model), only the interpreter module 1420 and toolbox 1430 of the ROM needs to be rewritten to interpret the currently existing bytecodes for the new microcontroller/CPU. In addition, this configuration allows devices with different CPUs to coexist and execute the same microprograms. Moreover, programming frequently-used routines in the ROM toolbox module 1430 reduces the size of microprograms stored in the external memory 1450 , thereby conserving memory and bandwidth over the client link 160 and/or the RF link 220 . In one embodiment, new interpreter modules 1420 and/or toolbox routines 1430 may be developed to execute the same microprograms on cellular phones, personal information managers (“PIMs”), or any other device with a CPU and memory.
One embodiment of the ROM 1470 is comprised of interpreted code as well as native code written specifically for the microcontroller CPU 1405 . More particularly, some toolbox routines may be written as interpreted code (as indicated by the arrow between the toolbox 1430 and the interpreter module 1420 ) to conserve memory and bandwidth for the same reasons described above with respect to microprograms. Moreover, in one embodiment, data and microprograms stored in external memory 1450 may be configured to override older versions of data/microprograms stored in the ROM 1470 (e.g., in the ROM toolbox 1430 ).
As mentioned above, different operational modes may be selected which may correspond to different operational orientations of the data processing device 200 . One embodiment of a data processing device 200 , illustrated in FIG. 15 , includes an operation mode selection module 1500 for selecting between the various operational modes described herein in response different triggering events. The “triggering events” may include the output of one or more operational mode sensors 1502 which automatically detect the correct operating mode for the data processing device 200 . For example, one embodiment of the invention includes a switch which is triggered when the display 206 is moved between the first position ( FIG. 2 ) and the second position ( FIGS. 7-8 ). The operation mode selection module 1500 reads the position of the switch to identify the correct operating mode. Various types of switches may be employed while still complying with the underlying principles of the invention including electrical/magnetic switches and/or mechanical switches.
In one embodiment, the triggering events also include information related to applications 1506 or other types of program code executed on the data processing device 200 . For example, a telephony application may detect incoming calls and provide an indication of the incoming calls to the operation mode selection module 1500 , which may then switch to the “telephony” operational mode described above. Similarly, if a telephony-based application is executed (e.g., because the user opens a telephone list), this may indicate that the user is going to use the data processing device 200 as a telephone. Conversely, if the user opens an instant messaging application or Web browser, this may indicate that the user does not wish to use the device as a telephone but, rather, may wish to use the device for text entry. The operation mode selection module 1500 may monitor various aspects of the applications 1506 executed on the data processing device to determine an appropriate operational mode. The user may also manually select an operational mode as indicated in FIG. 15 (e.g., by selecting a particular control element or series of control elements).
In one embodiment, once the operation mode selection module 1500 identifies the correct operational mode, it adjusts the functions associated with the keys of the keyboard 500 and/or control elements 210 , 224 as described above. In addition, if the keys/control elements are equipped with different glyphs, as described above, then the glyphs associated with the new functions are highlighted.
In addition, in one embodiment, the operation mode selection module 1500 adjusts the user interface 1510 based on the detected operational mode. As mentioned above, in one embodiment, the orientation of text and images rendered on the display 206 are adjusted based on the current operational mode of the data processing device 200 . For example, if the data processing device 200 is in the first operational mode then images may be rendered on the display 206 as illustrated in FIG. 2 (i.e., right-side up when the data processing device 200 is in the orientation shown in FIG. 2 ). If the data processing device is in the second operational mode, then images may be rendered as illustrated in FIG. 3 . Finally, if the data processing device is in the third operational mode (i.e., with the keyboard 500 exposed), then images will be rendered on the display 206 as illustrated in FIG. 8 (i.e., inverted with respect to the orientation shown in FIG. 2 ). Various other graphical user interface features may be modified within the user interface 1510 based on the detected operational mode of the data processing device 200 (e.g., menu layout, application icons, . . . etc).
Another embodiment of a data processing device 1600 is illustrated in FIGS. 16-17 . The data processing device 1600 includes a display 1610 with a viewable display area 1605 for displaying various types of text and graphics. Moreover, as in the embodiments described above, the data processing device 1600 also includes a plurality of different modes of operation which may be associated with a respective plurality of display and/or device orientations. In the first mode of operation, the display is viewed in a first position, illustrated generally in FIG. 16 in which it covers an alphanumeric keyboard 1705 (illustrated in FIG. 17 ). In this first position, the display is located flush within the boundary defined by the non-display portions of the data processing device 1600 .
By contrast, the display is illustrated in a second position in FIG. 17 , in which the alphanumeric keyboard 1705 is exposed and usable for data entry. In one embodiment, the second position of the display corresponds to a second mode of operation as described with respect to other embodiments herein. As shown in FIG. 17 , in one embodiment, the display slides from the first position to the second position in a direction substantially parallel to a plane defined by the front surface of the data processing device 1600 , as indicated by motion arrows 1725 . The sliding motion may be accomplished via pins or posts (not shown) on the backside of the display 1610 that are engaged with tracks 1710 , 1715 located on the face of the data processing device 1600 to the left and right of the alphanumeric keyboard 1705 , respectively.
Various additional/alternative mechanisms may be used to guide the display from the first position to the second position (and vice versa). For example, in one embodiment, substantially the same mechanism as illustrated in FIGS. 5-9 is employed to rotate the display from the first position to the second position. In addition, as in the embodiments illustrated in FIGS. 5-9 , the display 1610 may be configured to lift upward at various different angles in relation to the data processing device, both prior to sliding to the second position and/or after it has reached the second position. The mechanisms illustrated in FIG. 10 or 11 may be employed to enable this type of motion. Of course, various other well-known techniques may also be employed (e.g., using springs and/or friction).
In one embodiment, the data processing device 1600 includes a first set of control elements 1615 positioned to the right of the display 1610 and a second set of control elements 1620 positioned to the left of the display (i.e., to the right and left while the display in the first position illustrated in FIG. 16 ). In one embodiment, the first set of control elements 1615 includes a control wheel 1630 positioned between two control buttons 1626 , 1635 , as illustrated. As in prior embodiments of the invention, the control wheel 1630 may be used to move a cursor control device, highlight bar or other selection graphic on the display to select menu items, program icons and/or other graphical or textual display elements. In one embodiment, the control wheel 1630 is made of clear plastic with an light emitting diode (“LED”) or other light source embedded therein.
In one embodiment, the first control button 1626 , located above the control wheel 1630 , is a “page up” button for generating “page up” control functions. For example, when a word processing document, Web page, email message or other type of document is displayed in the foreground of the display 1610 , selection of the first control button 1626 will jump upward through the displayed data/images by a full display screen's worth of data/images. When navigating through menus, selection of the first control button 1626 may cause a selection element to jump multiple menu items or other graphical elements. Various different/additional “page up” functions may be trigged via the first control button 1626 while still complying with the underlying principles of the invention. The second control button 1635 , located below the control wheel 1630 , is a “page down” button for generating “page down” control functions (e.g., which operate in the same manner as the “page up” control functions but in the opposite direction).
In one embodiment, a series of additional control elements 1650 , 1655 , 1660 , and 1670 are configured on the data processing device 1600 to provide various additional preprogrammed and/or user-specified control functions. For example, a control element 1650 may be a designated “home” key for jumping to the data processing device's main menu, or performing application-specific functions typically associated with a “home” key (e.g., moving a cursor to the beginning of a line in a word processing document). Control element 1655 may be a dedicated a “menu” key which generates a context-specific menu when selected (e.g., a different menu may be generated based on which application is currently running). Control keys 1660 and 1665 may be designated “jump” keys, allowing the user to easily jump to (i.e., execute) a designated application program. The control elements 1650 , 1655 , 1660 and 1665 may be programmed for various alternate and/or additional functions while still complying with the underlying principles of the invention.
In one embodiment, the second set of control elements includes a directional pad 1645 having an integrated speaker 1646 and/or LED (not shown) (or other light source). In one embodiment, the directional pad 1645 is designed in substantially the same manner as the directional pad described in the co-pending application entitled DIRECTIONAL PAD HAVING INTEGRATED ACOUSTIC SYSTEM AND LIGHTING SYSTEM, Ser. No. 10/718,749, filed Nov. 21, 2003, which is assigned to the assignee of the present application and which is incorporated herein by reference.
The directional pad 1645 may be used to move a cursor or other selection graphic in any direction on the display to enable selection of menu items, program icons and other graphical or textual display elements. The directional pad 1645 may be made of frosted translucent plastic and may be white in color, although other materials and colors may be used. The LED contained in the directional pad may be a tri-color LED that generates a variety of colors to alert the user when an incoming message has been received. In “telephony mode” (described below), the speaker 1646 contained in the directional pad 1645 enables the user to hear the party on the other end of a call. In addition, a microphone 1640 is configured at the end of the data processing device 1600 opposite the speaker 1646 so that the data processing device 1600 may be held like a mobile phone while in telephony mode (i.e., when the speaker placed next to the user's ear, the microphone is located in the proximity of the user's mouth).
In one embodiment, when in “telephony mode” the functions performed by the various control elements 1615 , 1620 and/or keys on the keypad 1705 change to designated telephony functions. For example, in the telephony mode of operation, the control button 1626 above the scroll wheel may function as a “call” button with which the user may initiate a telephone call once the number to be called has been entered. The control button 1625 below the scroll wheel 1630 may function as a “hang up” button, with which the user may conclude a telephone call. Similarly, referring to FIG. 17 , to simplify numeric data entry when in telephony mode, a designated set of alphanumeric keys 1720 from the keyboard 1705 may change to a numeric keypad (e.g., the ‘y’ key may change to a ‘ 1 ’ key, the ‘u’ key may change to a ‘ 2 ’ key, . . . etc).
In addition, the glyphs on the control elements 1615 , 1620 and/or keys on the keypad 1705 may change to reflect the change in operation in the same or a similar manner as described in the embodiments above. For example, light emitted by LEDs embedded within the control buttons 1625 and 1626 on either side of the scroll wheel 1630 may be modified to reflect the change in operation in telephony mode. In one embodiment, for example, the “call” and “hang up” glyphs are highlighted on the control buttons 1625 and 1626 , in contrast to “page up” and “page down” glyphs, respectively.
In one embodiment, two-color LEDs are employed within the keys of the alphanumeric keyboard 1705 . When the data processing device is not in telephony mode, both colors of the two-color LEDs are illuminated under all of the alphanumeric keys 1705 , thereby highlighting the standard set of alphanumeric glyphs on the keys. For example, if the two-color LEDs are red and green, the combination will generate an amber color beneath the alphanumeric keys 1705 . By contrast, when in telephony mode, only one color of each of the two-color LEDs is illuminated. Moreover, in one embodiment, the one LED is illuminated only beneath each of the designated set of numeric keypad keys 1720 (as opposed to illuminating the one LED beneath each of the entire alphanumeric keyboard 1705 ). By way of example, if only the green LEDs are illuminated beneath each of the designated set of keys 1720 , then the numeric keypad glyphs (i.e., numbered 1-9) will be illuminated with a green color in contrast to the standard alphanumeric glyphs. Various different techniques may be employed to illuminate the numeric keypad glyphs and/or the standard alphanumeric glyphs based on the mode of operation, including those described above with respect to FIGS. 12 and 13 and those described in the co-pending application entitled “A METHOD OF DYNAMICALLY LIGHTING KEYBOARD GLYPHS,” mentioned above.
Another embodiment of a data processing device 1800 is illustrated in FIGS. 18 a , 18 b , 19 and 20 . This embodiment operates in a substantially similar manner to the embodiments depicted in FIGS. 16-17 but includes additional functionality. Specifically, when the data processing device 1800 is in a “telephony mode,” a third orientation of the display is available, illustrated generally in FIG. 18 a , in which a numeric keypad 1820 is exposed. The display 1810 of this embodiment is moveably attached to the numeric keypad 1820 . In one embodiment, the backside of the display 1810 includes pins or posts which are engaged with tracks 1825 , 1830 located on the face of the numeric keypad 1820 , on either side of the keypad keys. The motion of the display 1810 from a position in which it covers the numeric keypad (shown in FIG. 19 ) to a position in which it exposes the numeric keypad 1820 (shown in FIGS. 18 a - b ) is indicated generally by motion arrows 1840 .
In one embodiment, the data processing device 1800 automatically switches into “telephony mode” in response to the movement of the display from the position shown in FIG. 19 to the position shown in FIG. 18 a - b , thereby triggering one or more of the telephony mode functions described herein. As in prior embodiments, various different types of switches may be employed to detect the motion of the display relative to the numeric keypad 1820 (e.g., mechanical switches, electromechanical switches).
The plane defined by the display 1810 may move in a substantially parallel or co-planar manner with respect to the plane defined by the numeric keypad 1820 as the display moves from the position in FIG. 19 to the position in FIG. 18 a (and vice versa). Alternatively, as illustrated in FIG. 18 b , in one embodiment, the plane defined by the display 1810 moves from a parallel/co-planar position into an angled position with respect to the plane defined by the numeric keypad 1820 (i.e., as the display moves from the position in FIG. 19 to the position in FIG. 18 a - b ). In one embodiment, to enable this movement, only the lower end of the backside of the display 1812 includes pins or posts which are engaged with tracks 1825 , 1830 located on the face of the numeric keypad 1820 . The other end of the display 1813 may move freely around a pivot point defined by the connection between the pins/posts and tracks 1825 , 1830 . In this embodiment, springs (not shown) or a similar torsion mechanism may be employed to apply a force directing the display 1810 back towards the body of the data processing device 1800 , as indicated by force/motion arrow 1814 .
The embodiment illustrated in FIGS. 18 c - d , which shows the device from a side view, employs a different mechanism for moving the display from the position in FIG. 19 to the second position shown in FIG. 18 a . Specifically, this embodiment includes a first pair of linkages 1850 (one of which is shown) rotatably attached to the display 1813 at one end 1856 and rotatably attached to the device/keypad 1820 at the other end 1855 and a second pair of linkages 1851 (only one of which is shown) rotatably attached to the display 1813 at one end 1858 and rotatably attached to the device/keypad 1820 at the other end 1857 . In one embodiment, the first set of linkages 1850 are relatively longer than the second set of linkages 1851 . As such, when the display is moved from the first position, illustrated in FIG. 18 c to the second position, illustrated in FIG. 18 d , it angled with respect to the device/keypad 1820 , as shown, thereby fitting around a user's head more accurately during a telephone call.
Regardless of the specific technique used to move the display 1810 , once the display is in the position illustrated in FIG. 18 a , the exposed numeric keypad 1820 is particularly suitable for entering telephone numbers and performing other telephony-based functions. In the embodiment shown in FIG. 18 a , the numeric keypad includes a standard set of telephone keys, including a send/answer key 1821 for sending/answering calls, an end key 1822 for terminating calls, and a menu key 1823 for generating a telephony-based menu within the viewable area 1805 of the display screen 1810 . Various other keys may be employed on the numeric keypad while still complying with the underlying principles of the invention.
In addition, in one embodiment, the combination of the display 1810 and numeric keypad 1820 are adjustable from the position illustrated in FIG. 19 to the position illustrated in FIG. 20 , in which the full alphanumeric keypad 2015 is exposed. As indicated by motion arrows 2020 , the direction of the motion of the display 1810 and numeric keypad 1820 is substantially perpendicular to the direction of the motion of the display 1810 in FIGS. 18 a - b . In one embodiment, to enable this motion, the backside of the numeric keypad 1820 has pins or posts which are engaged with tracks 2005 , 2010 , located on the face of the alphanumeric keypad 2015 . As with the embodiments described above (see, e.g., FIG. 9 ), the display 1810 /keypad 1820 combination may lift upward at various different angles relative to the data processing device 1800 , both prior to sliding to the second position and/or after reaching the second position.
In one embodiment, the numeric keypad 1820 is a “passive” keypad which does not include any electrical circuitry. In this embodiment, the numeric keypad 1820 is formed from a thin, plastic material (or similar material) having indications of telephony keys printed thereon. Each of the printed telephony keys is positioned to line up with one or more of the keys on the alphanumeric keyboard 2015 when the keypad 1820 is oriented as illustrated in FIG. 18 a . Accordingly, when a user selects a particular key from the numeric keypad 1820 , a force is translated through the numeric keypad key to one or more keys on the alphanumeric keyboard 2015 directly below the keypad key. Thus, when the data processing device 1800 is in the “telephony mode” illustrated in FIGS. 8 a - b , each key of the alphanumeric keyboard 2015 positioned beneath a particular numeric keypad key is configured to perform the operation designated on the corresponding keypad key. For example, when in this mode of operation, the DEL key of the alphanumeric keyboard 2015 may perform the MENU function designated by the menu key 1823 of the numeric keypad 1820 (i.e., because the DEL key is positioned beneath the menu key 1823 . FIG. 20 shows the silhouette of the numeric keypad 1820 keys beneath the display 1805 when the data processing device is in one of the “data entry” modes.
In one embodiment, an “active” numeric keypad may be employed rather than a “passive” numeric keypad, as described above. The active keypad includes an electrical interface which electrically couples the keypad to the data processing device. Of course, the underlying principles of the invention are not limited to any particular type of numeric keypad.
As shown in FIGS. 18 a , 19 and 20 , a speaker 1815 is configured at the top edge of the display 1810 . While in the telephony orientation/mode illustrated in FIGS. 18 a - b , the data processing device may be held like a mobile phone so that the speaker 1815 is close to the user's ear and the microphone 1845 at the other end of the device is close to the user's mouth. In one embodiment, the speaker 1815 and microphone 1845 may also be used for telephone calls when the display 1810 is in the orientation illustrated in FIG. 19 .
In an alternate embodiment (not shown), the display 1810 and numeric keypad may swivel out in unison from the first position to the second position in a fashion similar to that depicted in FIG. 1 c . In this embodiment, the tracks on the alphanumeric keyboard are unnecessary, as are the pins or posts that slide along those tracks. Instead, the display is pivotally coupled to the data processing device and pivots around a pivot point. As with the embodiment shown in FIG. 20 , the display may lift upward at various different angles in relation to the data processing device, both prior to sliding to the second position and/or after it has reached the second position.
In addition, as illustrated generally in FIGS. 18-20 , in one embodiment, when switching between modes, the orientation of images and/or text on the display screen will change. For example, when the data processing device is in telephony mode, as shown in FIG. 18 a , images and/or text are displayed right-side-up when the first set of control elements is oriented at the bottom of the device. By contrast, when the data processing device is in either of the modes shown in FIGS. 19-20 , images and/or text are displayed right-side-up when the first set of control elements is oriented at the right side of the device.
Embodiments of the invention may include various steps as set forth above. The steps may be embodied in machine-executable instructions. The instructions can be used to cause a general-purpose or special-purpose processor to perform certain steps. Alternatively, these steps may be performed by specific hardware components that contain hardwired logic for performing the steps, or by any combination of programmed computer components and custom hardware components.
Elements of the present invention may also be provided as a machine-readable medium for storing the machine-executable instructions. The machine-readable medium may include, but is not limited to, floppy diskettes, optical disks, CD-ROMs, and magneto-optical disks, ROMs, RAMs, EPROMs, EEPROMs, magnetic or optical cards, propagation media or other type of media/machine-readable medium suitable for storing electronic instructions. For example, the present invention may be downloaded as a computer program which may be transferred from a remote computer (e.g., a server) to a requesting computer (e.g., a client) by way of data signals embodied in a carrier wave or other propagation medium via a communication link (e.g., a modem or network connection).
Throughout the foregoing description, for the purposes of explanation, numerous specific details were set forth in order to provide a thorough understanding of the invention. It will be apparent, however, to one skilled in the art that the invention may be practiced without some of these specific details. For example, while the embodiments described above employ specific techniques for highlighting glyphs on keys/control elements, the underlying principles of the invention are not limited to any particular glyph highlighting mechanism. Accordingly, the scope and spirit of the invention should be judged in terms of the claims which follow. | A data processing apparatus is described comprising: a body having a surface defining a first plane, the body comprising a first group of control elements and a second group of control elements for entering data and performing control operations; a display having a display area defining a second plane, the display coupled to the data processing apparatus at a pivot point and rotatable around the pivot point from a first position to a second position, wherein the display is viewable in both the first position and the second position and wherein both the first and second groups of control elements are exposed when the display is in the second position, and wherein only the second group of control elements are exposed when the display is in the first position, wherein the first plane and the second plane are substantially parallel when the display is in the first position, and wherein the first plane and the second plane are not parallel when the display is in the second position. | 7 |
This is a continuation of application Ser. No. 248,800, filed Mar. 30, 1981, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates generally to the field of solderable electrical connectors, and more specifically to a component and method used for making electrical connections to a printed circuit (PC) board or the like.
Various devices are available in the prior art to establish a mechanical and electrical connection between two current-carrying elements. The majority of these connectors involve the mating of male and female component members. In one category of such connectors a spring-loaded or resilient surface on one of the members is placed into contact with a cooperatively shaped surface on the other member. The resiliency then holds the two members together in electrical contact until a separating force is applied to the connector which is sufficient to overcome the retaining tension.
While these resiliently mating connectors provide a convenient device for rapidly making or interrupting electrical connection between two current-carrying members, the resulting connection may not be reliable enough for permanent use in some instances. It is therefore frequently desirable to solder the connection to prevent mechanical separation of the connecting members and to improve the conductivity of the electrical junction. This is especially true in the case of PC board connections, in which the electrical and mechanical quality of the connections must be assured for reliable operation.
Techniques for providing such soldered connections are known in the art, by which a quantity of solder is melted adjacent the junction of two members so that the solder flows, by gravity or capillary action, over the adjacent or abutting surfaces of the members to be soldered. However, when the members to be soldered are closely mating elements, a problem is frequently encountered because of the difficulty of assuring solder flow into the region where the mating members meet.
An example of this occurs in the so-called "Tri-socket" connector for making connection to a throughplated hole on a PC board. This connector, for example, may have a socket at one end for establishing an electrical connection with a pin of a dual in-line (DIP) package when inserted into the socket end of the connector, and a wire wrap post at the other end of the connector around which may be wrapped a wire from an external circuit. This connector also has a resilient tricornered fin arrangement in the middle of the connector, which upon insertion into a plated hole of a PC board is compressed resiliently against the wall of the hole. A rivet of solder is carried by the connector above the resilient arrangement, the rivet resting above the PC board when the resilient arrangement is within the PC board hole. The connector is then soldered in place by heating, as in a heating chamber, which allows the solder rivet to melt and flow into the hole to bond the fin arrangement to the plated hole.
Soldered connections formed with contact elements such as this Tri-socket connector may have mechanical or electrical flaws if the soldering process is not carefully monitored. Since the solder is initially located outside the hole in the PC board before being heated, the soldering process must be planned so that melting solder will flow properly into the hole and then adhere well to both the plating surrounding the hole and the prongs of the contact element. However the flow pattern of the melting solder may be affected by a number of variables, such as the temperature of the solder and the mating members, the angle at which the members are soldered, the shapes of the mating members, and the shape of the path over which the melted solder will run. The resulting unpredictability of this flow pattern may produce mechanical and electrical inconsistencies in the soldered connections which are not apparent from visual inspection. Thus, if the board and connector are not accurately aligned during heating to allow the solder to flow properly into the hole, the resulting connection may be mechanically weak because insufficient solder may reach the connecting region. If solder flows before the mating elements have been heated to the proper temperature, the resulting junction may be electrically poor due to the formation of a "cold joint". Even if the solder flows properly into the hole and adheres well to both connecting members, it may not get close to the region where the surfaces of the mating members are in contact. If the solder could be reliably introduced to this region the electrical junction would be improved and the resulting bond would be considerably strengthened, as it would provide a very thin layer of solder between two substantially conforming surfaces.
OBJECTS OF THE INVENTION
Broadly, it is an object of this invention to provide a connector or contact element and method for improving the quality and reliability of soldered electrical connections.
It is also an object to provide such a component and method which is readily adapted for use in establishing printed circuit board connections, and which may be used in assembly-line operations with mass soldering techniques while avoiding disadvantages present in connectors of the Tri-socket type.
It is yet another object to provide a contact element for making an improved soldered electrical connection, which contact element can be manufactured from a flat metal strip by very simple and efficient stamping steps in multiple-stamping apparatus.
It is still another object to provide a method for manufacturing improved solderable contact elements from a flat metal strip by very simple and efficient stamping steps.
SUMMARY OF THE INVENTION
In accordance with an illustrative embodiment of the present invention, a structure and method are provided for making a soldered electrical connection between two mating members, in which a deposit of solder on the surface of one of the members is juxtaposed to a cooperatively shaped surface on the other member when the two members are mated, so that the solder is in position to melt and bind the two surfaces when heated, with minimum flow of solder. The quality of this connection may be further improved by providing a resilient arrangement for urging the conforming surfaces together as heat is applied.
In one form of contact element embodying the invention a hollow, cylindrical metal shell or sleeve with a longitudinal split provides a resilient fit into a mating member, such as a metal-lined or tinned hole on a printed circuit board. The shell is provided with a deposit of solder on its outer surface where the shell is to engage the metal lining of the hole. The problem of providing a flow of solder into the hole is therefore eliminated, since the deposit of solder is pre-positioned inside the hole upon mating of the members. Furthermore, the placement of solder directly between the surfaces to be bonded reduces the possibility that the solder will melt before the surfaces have been sufficiently heated, thus minimizing the likelihood of forming a "cold joint".
When heat is applied at the location of the desired connection, the resilient action of the shell pushes the melting solder on its surface against the metal lining of the hole, and fills in any gaps which might otherwise form as the solder disperses. The application of pressure between the shell and hole lining during soldering further assures a good electrical connection between the mating surfaces which is maintained upon solidification of the solder.
DESCRIPTION OF DRAWINGS
For a better understanding of the invention, reference should be made to the following description taken together with the accompanying drawings, in which:
FIG. 1 is a perspective view of a contact element constituting one form of the invention;
FIG. 2 is a front elevational view of the contact element of FIG. 1, shown in position for soldering in a metal-lined hole of a PC board which is illustrated in cross-section;
FIG. 3 is a front elevational view of a strip of metal useful in forming the contact element of FIG. 1;
FIG. 4 is a transverse cross-sectional view of the metal strip in FIG. 3, taken through section 4--4;
FIGS. 5 and 5A are a transverse cross-sectional views as in FIG. 4, of the metal strip at a later stage of fabrication, showing in FIG. 5 a filament of solder laid in place in a groove of the metal strip and in FIG. 5A the same filament pressed into and filling the groove;
FIG. 6 depicts the strip of FIG. 5 at a still later stage of fabrication after the strip has been deformed on either side of the groove to retain the solder;
FIG. 7 is a front elevational view of the metal strip of FIG. 6 at a subsequent stage after waste sections have been removed, leaving metal blanks which may be formed into contact elements attached to carrier strips;
FIG. 8 is a front elevational view of the metal strip of FIG. 7 after forming the metal blanks into contact elements;
FIG. 9 is a side elevational view of a second embodiment of a contact element;
FIG. 10 is a cross-sectional view of the contact element of FIG. 9 taken through section 10--10, shown in position for soldering in a metal-lined hole of a PC board, shown in section;
FIGS. 11 and 12 are perspective views of a contact element as in FIG. 1, but with a box-type socket terminal at one end in FIG. 11 and a cantilever spring contact in FIG. 12.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the details of the drawing, FIG. 1 is a perspective view of a contact element or connector 100 incorporating the invention. The contact element of FIG. 1 broadly comprises a male contact having a body 102, such as a sleeve or shell proportioned and shaped for mating connection with a corresponding female contact such as a metal-lined aperture 134 (which may be solder-coated) on a PC board 136 as illustrated in FIG. 2. The male contact 102 has an engaging surface 104 on its outside, which substantially conforms to a portion of the inside surface 138 on the female contact 134 when the two contacts are mated. The resiliency of the sleeve or shell 102 serves to urge the two surfaces 104 and 138 together, when the shell 102 is inserted in hole 134. A deposit of solder 118 is positioned on the shell surface 104 so as to be pressed against the portion of the inside surface 138 of the female contact 134 which conforms to the male contact engaging surface 104, when the contacts 102 and 134 are assembled. The solder 118 preferably projects slightly, as by a few thousandths of an inch, beyond the surface of the body 102. The contact element 100 may further include one or more terminal portions affixed to or integral with it, such as wire wrap posts 108 or other terminals, for simplifying electrical connection from the contact element 100 to other electrical apparatus. It will be understood that any desired terminals may be used in place of the wire wrap posts 108, such as box socket contacts, or spring contacts or sockets, or contact pins, or the like.
In assembly, the contact element 100 of FIG. 1 is first mated with the corresponding female contact 134 by inserting male contact 102 to a depth at which the solder deposit 118 on the engaging surface 104 is inside the female contact 134 and in contact with its inside surface 138. This causes the deposit of solder to rub against and be pressed between the inside surface 138 and the engaging surface 104 prior to soldering due to the resiliency of the shell 102.
After the contacts 102 and 134 have been mated they may be heated by any of various heating methods known in the art, thus causing the solder 118 to melt. As the solder 118 melts and flows between the surfaces 104 and 138 to be bonded, the resiliency of the shell 102 causes its engaging surface 104 to expand outwardly and occupy the space left by the dispersing solder 118. This creates good contact between the members 102 and 134, and results in a highly reliable soldered junction.
In the case of PC boards, a number of contact elements may be simultaneously soldered to the board by a batch method of heating. Such heating may be performed on many printed circuit boards together by placing the boards on a conveyor which carries them into a heating chamber. The elements may then be heated by hot air or vapor within the chamber, to a temperature which exceeds the melting point of solder. After allowing sufficient time for the solder to melt and flow, the conveyor may carry the boards out of the chamber, while simultaneously bringing in a batch of new boards to repeat the soldering process. The invention may therefore be used to provide a large number of reliable soldered connections in a cost-efficient, high-volume production process.
The embodiment of contact element 100 illustrated in FIG. 1 is especially well suited for mass production in a progressive or multiple stamping operation, thus permitting the invention to be produced with substantial savings in cost over other production methods. The contact elements of the invention may be made from a continuous strip of metal which may be initiall partially formed in a continuous operation and thereafter progressively formed in incremental steps by a number of stamping and bending operations to produce the finished product.
FIGS. 3 and 4 are elevational and cross-sectional views of such a continuous metal strip 110, which in the illustrative embodiment described above may have a thickness determined by the preferred dimension of the wire wrap terminal posts 108. The metal strip is provided with a series of pilot holes 112 near each edge, which assist in advancing and assuring proper positioning of the strip 110 as it proceeds from one forming step to the next in the progressive stamping operation. A central slot 114 may be milled out of the strip 110 in order to reduce the thickness of the portion of the metal which will later be formed into the body of the contact element, when such reduction is desired. A groove 116 may be cut out of the strip, as by skiving, to provide a recess for a deposit of solder. The pilot-hole-forming, milling and skiving operations may be performed continuously as the strip passes from one reel to another. Alternatively the pilot holes may be formed in a progressive step-wise stamping operation.
As illustrated in FIG. 5, a filament of solder 118 is placed in the groove 116 of the metal strip 110. This may be done continuously, following the forming of groove 116, by feeding the solder filament continuously from a reel and laying it into groove 116 as the metal strip passes. The solder filament 118 preferably has a diameter substantially fitting the width of groove 116 as shown in FIG. 5. By pressing the filament into the groove, the solder metal will flow to fill the corners of the groove as shown in FIG. 5A. The solder thus fills the groove, and may have a slight excess bulge, as shown. It will be appreciated that the term "filament" indicates a strip of solder with any desired cross-sectional shape and size, including a flat ribbon, or a round or rectangular wire, or any other suitable configuration.
After the solder filament 118 is laid and pressed into groove 116, the sides of the groove 116 may be staked or peened as shown at 140 in FIG. 6 to hold the solder filament in place. Alternatively, the same result could be achieved by forming the groove in the metal strip to have side walls slanting inwardly in the same manner as the staked groove of FIG. 6. The filament of solder may then be pressed into the groove, taking advantage of the malleability of the solder to cause it to flow into the corners of the groove, to be retained by the undercut of the groove. The solder may be positioned in the groove in many other ways, as may be desired, including applying it as a molten metal, to harden in the groove.
After the metal strip 110 has been combined with solder 118 according to the steps described above, it may be stamped and formed to produce the contact element shown in FIG. 1. FIGS. 7 and 8 show progressive stages through which the strip may pass. As shown in FIG. 7, waste sections are removed, which then leaves metal blanks 120 attached to continuous carrier strips 122 at the top and bottom of the original strip. Where desired, only a single carrier strip may be formed. Each metal blank 120 comprises a flat contact body portion 124 and two terminal portions, illustratively wire-wrap posts 108 as seen in FIG. 7. The carrier strips 122 with the pilot holes 112 may then draw the metal blanks through an incremental series of forming steps, as is well-known in the art, to bend each connector body portion 124 about a longitudinal axis (vertical in the figure) to form a series of radially or laterally resilient, split, hollow shells or sleeves 102 as shown in FIG. 8, with carrier strips 122 attached. The solder filament 118 carried on shell 102 then forms a ring 142 about the shell 102, about at its center, which may project slightly radially outward from the shell 102. When such a contact element 100 is mated with a female contact 134, such as a plated hole in a PC board (as shown in FIG. 2), the sleeve 102 is positioned so as to place the ring 142 against the inside surface 138 of hole 134, preferably near the central portion 144 of that inside surface 138. When heated, the solder 118 will then disperse to either side of the central portion 144, coating with solder substantially the entire inside surface 138 juxtaposed to the outside surface of shell 102. This positioning is especially preferred when the walls of the female contact member are convex in transverse section, as in a metal eyelet. In this case the ring of solder 142 should desirably be positioned against the apex of the convexity of the wall, in order to assure pressure on the solder ring as it melts and to promote dispersion of the solder 118 to either side of the apex for maximum bonding strength.
The carrier strips 122 may serve an added function when a group of contact elements 100 are to be inserted together into a corresponding group of mating members having a predetermined spatial relationship. This may be illustrated with reference to a PC board assembly having a number of input or output terminals spaced along a side of the board, each terminal comprising a female contact such as metal-lined hole 134. The holes 134 in this assembly may be sequentially spaced apart from each other at a uniform distance which corresponds to the distance between two contact elements 100 on a carrier strip 122. Another assembly 146 comprising an equal number of male contact elements 100 on carrier strips 122 as in FIG. 8 may be prepared for insertion by detaching one of the two carrier strips 122. This assembly 146 of contact elements 100 may then be positioned in mating alignment with the correspondingly spaced terminals 134 and concurrently mated as described earlier with relation to a single contact element 100. The remaining carrier strip 122 may then be detached and the group of connections soldered simultaneously in a batch heating process, as described earlier.
FIG. 9 is a side elevational view of an alternate embodiment of the contact element 100 of FIGS. 1-8. This embodiment incorporates a ridge 126 around the circumference of the solder ring 142, which provides a visible indication of the state of the solder 118 after the contact element 100 has been mated with a female contact 134 as shown in FIG. 10. The malleability of the solder permits the ridge portion 126 to be spread along the mating surfaces 104 and 138 as the contacts 102 and 134 are mated, extending some solder above the female contact 134, so that a rim of solder 128 will be visible around the circumference of the male contact 102 where it emerges from the female contact 134. After the contacts 102 and 134 have been heated, this rim of solder 128 permits visual inspection of the soldered connection to tell whether the contacts 102 and 134 have been sufficiently heated to melt the main deposit of solder 118 which is hidden from view within the soldered junction.
Longitudinal channels 130 may further be formed in the surface of the shell 102 perpendicular to the groove 116 (vertically in the drawing) and opening into it to permit a connection between the groove 116 and solder from the rim 128 in the event that part of the solder rim 128 is sheared away from the filament of solder 118 when the contact element 100 is inserted into a mating member. The portions of the ridge 126 which are adjacent to the channels 130 would be pushed into the channels 130 and maintain contact with the rim 128 as the members are mated, as shown in FIG. 10. Thus a sheared solder rim 128, which might otherwise be dislodged and create a shortcircuit, would remain in place prior to heating.
It should be noted that the contact element 100 shown in FIG. 9 may require a slightly different depth of insertion than the embodiment shown in FIG. 1, when mated with a female contact 134 as shown in FIG. 10. If the female contact is relatively deep, such as 3/16 of an inch, positioning of the solder filament 118 near the central portion 144 of the inside surface 138 may increase the likelihood of undesirable dislodging of part of the rim of solder 128. In this instance the optimum insertion depth for the solder filament 118 may be above rather than at the central portion 144, as shown in FIG. 10.
FIG. 11 illustrates an embodiment of the contact element 100 of the present invention, with a box socket terminal 132 in place of the wire wrap post terminal 108 shown in FIGS. 1-10. FIG. 12 shows another embodiment substituting a terminal in the form of a cantilever or spring-finger contact 150. It will be understood that many other techniques known in the art for providing electrical connection between a contact element and an electri:al apparatus may be used in place of the wire post or box socket or spring-finger terminals shown. Furthermore, the contact element of the invention may be made integral with another electrical device, such as a terminal of a transistor or DIP, to provide connection of the device directly to a PC board or to another electrical device.
While the resiliency of the contact element 100 depicted in the drawings is provided by a resilient metal shell or sleeve 102 with a longitudinal split which permits circumferential compression, the invention may be practiced with other types of resilient elements. For example, a spring or an elastic plug could be placed between two halves of a metal shell so as to urge them apart from each other. It will therefore be understood that the resilient element need not be integrated into the body of either mating member, but may be a distinct element which is mechanically linked to the mating surfaces.
For purposes of illustration, the contact element of the preferred embodiment is shown and described with a male contact at 102 which has a deposit of solder 118 on its engaging surface 104. It should be understood that the inventive features of this device may also be included in a female contact element, having a deposit of solder on its inner surface. For example the split hollow shell 102 described above could be used as a female contact, and the ring of solder 142 could be positioned in a groove on its inside surface. In this case, a male contact such as a plug or pin with a metallic outer surface could be inserted into the female contact to a depth at which the ring of solder on the inside of the female contact is positioned between the metal outer surface of the plug and the inner surface of the female contact. The resiliency of the female contact in this case would press the deposit of solder against the metal surface of the male contact when the two contacts are mated. Either the male or the female contact element could also be provided with appropriate terminal portions for connection to other electrical apparatus.
The present invention may also be practiced with a connector arrangement having male and female mating members in which the deposit of solder is positioned on one member, and the other member provides the resiliency which presses the two mating surfaces together. An example of this would be a connector arrangement in which the female mating member is a split metal ring and the male mating member is a cylindrical metal plug or pin with a deposit of solder on its surface, preferably in a groove formed thereon. The metal plug could then be inserted into the split ring so that the deposit of solder is between the surfaces of the plug and the ring. It will be appreciated that this combination would then include the advantages of the novel features described above.
As used in the specification and claims to describe the split hollow shell of the present contact element, the term laterally resilient is defined relative to a longitudinal axis along which the male contact travels when it is being inserted into a female contact. Since the contact element of the invention may include either a male contact or a female contact, it will be appreciated that the lateral resiliency of a male contact element exerts an outwardly expansive force toward the wall of the female contact, whereas the lateral resiliency of a female contact element exerts an inwardly compressive force toward the outer surface of a male contact.
It will also be appreciated that a contact element according to the present invention need not have a circular cross-section, but the invention may be practiced with many other shapes such as triangular, oblong and irregular shapes. The term circumferential, therefore, with regard to a contact element of any cross-sectional shape, refers to the outer periphery of a male-type contact element or the inner periphery of a female contact element. Also it will be understood that, in any form of the invention, a stop may be formed on the device to determine its depth of insertion into a PC board or the like, to properly juxtapose the solder ring with the metal-lined hole or eyelet.
Many other additions, modifications or substitutions may be made to the preferred forms of the invention disclosed in this specification, without departing from the scope and spirit of the invention as defined in the accompanying claims. | A component and method are provided for making a soldered electrical connection between two mating members, in which a deposit of solder on the surface of one of the members is juxtaposed to a cooperatively shaped surface on the other member when the two members are mated, so that the solder will melt and bind the two surfaces when heated. The quality of this connection may be further improved by providing a resilient arrangement for urging the conforming surfaces together as heat is applied. In one form of contact element according to the invention a hollow, cylindrical metal shell with a longitudinal split provides a resilient fit into a mating member, such as a metal-lined hole on a printed circuit board. The shell is provided with a deposit of solder in a groove on its outer surface where the shell is to engage the metal lining of the hole. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to multiple input, single output, mechanical actuators which are particularly useful in connection with governors for engines or the like but not limited thereto.
A variety of mechanical apparatus utilize control mechanisms wherein a single output to the mechanism being controlled is provided by the control mechanism in response to any one or more of a plurality of input signals to the control mechanism. Such control mechanisms perform a so-called logical OR function and typically receive input signals of the same medium. For example, each input signal may be a pressurized air signal or a pressurized hydraulic fluid signal, but not both. The input signals may be in the form of electrical signals or in the form of movement of mechanical elements as well. Seldom, if at all, are input signals of different mediums utilized by a single, multiple input, single output actuator and, in many cases, it is required to convert an input signal from one medium to another prior to its application to the control device.
For example, an actuator may receive a pneumatic signal from a source of air under pressure and the apparatus controlled may also generate, as by means of a mechanically operated switch, an electrical signal. The electrical signal is converted to the air medium through the use of a solenoid operated valve prior to its application to the actuator.
Moreover, such actuators are typically designed for a predetermined number of inputs and where a particular apparatus to be controlled requires a greater or lesser number of inputs to the control device, a wholly different actuator must be employed, or input capacity wasted, or multiple actuators utilized, or combinations of the foregoing.
SUMMARY OF THE INVENTION
The present invention is directed to overcoming one or more of the above problems.
According to the present invention, there is provided a multiple input, single output, mechanical actuator comprising a housing. An actuator rod is reciprocally mounted in the housing and has one end projecting therefrom. A plurality of aligned signal responsive elements are located in the housing and each is independently mounted for reciprocation therein towards and away from the rod. A plurality of signal input means are disposed in the housing, one for each of the elements, for applying a force to reciprocably move the associated element towards or away from the rod. There is further provided a plurality of aligned, interengaging links, reciprocably mounted within the housing, one for each of the elements. The links are operatively associated with the rod and each link is relatively movable with respect to its element and slidable with respect thereto for one direction of movement of its element. The link is also movable with the associated element in the other direction of movement of its element.
Other objects and advantages will become apparent from the following specification taken in connection with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially schematic view of one environment of use, namely, a marine propulsion unit and control system, in which the multiple input, single output, mechanical actuator of the invention may be advantageously utilized; and
FIG. 2 is a sectional view of a multiple input, single output, mechanical actuator made according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, an actuator made according to the invention is utilized in a marine propulsion system and control therefor, but it is to be understood that the actuator of the invention is not restricted to use in such systems, but may find use in virtually any control system requiring a mechanical output which is responsive to plural inputs of the same or different mediums.
The marine drive includes an engine 10 contained in an engine room 12 in a ship or the like. The engine 10 drives a propulsion shaft 14 connected to a propeller or the like (not shown). The shaft 14 receives rotational power from the engine 10 via a gear unit 16.
The engine 10 is normally controlled from a pilot house 18 having a conventional speed control 20 connected via an air conduit 22 to a conventional air pressure controller 24 to an engine speed governor 26. The governor 26 may be, for example, a Woodward UG 8 governor manufactured by Woodward Governor Nederland B. V. of Hoofdorp, The Netherlands and forms no part of the present invention. The governor 26 may also be manually controlled within the engine room by means of a conventional mechanical actuator 28.
The engine 10 is provided with a hydro mechanical sensor apparatus 30 of the type available from Caterpillar Tractor Co., the assignee of the present application, as part No. 3N5760. The sensor apparatus 30 will typically monitor the oil pressure of the engine 10, the water temperature in its cooling system, and sense an overspeed condition of the engine 10. When any one of the foregoing parameters reaches an undesirable level, the sensor shutoff apparatus 30 will provide to a conduit 32, a high pressure, hydraulic signal.
The conduit 32 extends to a multiple input, single output, mechanical actuator 34 made according to the invention which, as will be seen, includes a mechanical output which may bear against the conventional shutdown rod of the governor 26, when actuated, to cause the latter to shut off the engine 10.
The pilot house includes a manual control 36 which, when actuated, is adapted to send a high air pressure signal via a conduit 38 to the actuator 34 to achieve the same function. In addition, electrical sensors, shown schematically at 40, may be connected to the actuator 34 and may monitor any of a variety of functions and provide an electrical signal to the actuator 34 in appropriate cases to cause shutdown.
In some cases, the manual control 36, which relies upon air pressure, may be omitted entirely and, in such a case, it is desirable to provide a further manual control 42 in the pilot house 18 which can be actuated to engage the shutdown rod of the governor 26 to disable the engine 10. Alternately, the additional manual control 42 may be utilized as a backup for the manual control 36 to be used in the event of loss of air pressure.
The manual control 42 is connected to the actuator 34 via a flexible cable 44 and is operative to cause engine shut-down in a manner to be described in greater detail hereinafter.
Within the engine room 12, there is also provided a manual actuator 46 for the actuator 34 for causing shutdown of the engine 10 via manual intervention when such shutdown is desired.
Turning now to FIG. 2, the actuator 34 will be described in greater detail. The governor 26 is provided with an upper cover 50 having a threaded bore 52 therein in alignment with the conventional governor shutdown rod 54. A threaded collar 56 on the base of the actuator 34 is threaded into the opening 52 such that an actuator rod 58 mounted for reciprocation within a guide sleeve 59 can engage the shutdown rod 54 and drive the same to cause the governor 26 to shut down the engine.
The actuator 34 is comprised of a housing defined by a plurality of cup-shaped housing modules 60, 62 and 64. The housing modules 60, 62 and 64 are identical except in the respects hereinafter stated and each includes a base 66 and a peripheral, generally cylindrical wall 68 extending therefrom.
Each wall 68, adjacent the base 66, is provided with an external, peripheral relief 70 which will typically be cylindrical in nature and which will have a predetermined axial length. At the same time, the end of each wall 68 remote from the base 66 is provided with an internal, peripheral relief 72, also cylindrical, and sized to nestably receive the base 66 of the adjacent housing modules 60, 62 or 64. The axial length of each internal relief 72 is greater than the axial length of each external relief 70. As a consequence, at the interface of each module there is a space 74 in fluid communication with the interior of the associated module and bounded by the radially outer extremity of the associated relief 72.
The walls 68 of each of the modules are provided with axially extending vent passages 76 which open to the base 66 of each module and to the internal relief 72 of the same module so that the interior of each module remote from the base 66 is in fluid communication with the vent passages 76 via the spaces 74. While the vent passages 76 are shown as aligned in FIG. 2, it will be appreciated that they need not be.
Each of the modules 60-64 is provided with an element 80, 82 and 84, respectively, responsive to a signal. As seen in FIG. 2, the element 80 is an electrical armature, while the elements 82 and 84 are pistons. Each element 80-84 includes an axially extending projection 86 which is slidably received in a bore 88 in the base 66 of the associated module 60-64. Each bore 88 is provided with an annular, radially inwardly opening groove 90 for receipt of an O-ring seal 92 which slidably engages the associated projection 86.
In the case of the module 60, a recess 100 is disposed in the interior surface of the wall 68 and receives an electrical coil 102 which is energizable via leads 104. When energized, it will drive the armature 80 downwardly, as seen in FIG. 2. When used in a marine application, as shown in FIG. 1, the electrical leads 104 will be connected to the electrical monitors 40.
The module 62, adjacent its base, includes an inlet port 106 whereby fluid under pressure, specifically, air from the line 38, may be directed to the upper side of the piston 82. The module 64 includes a similar inlet 108 which may be connected to the conduit 32 for receiving hydraulic fluid under pressure from the sensor apparatus 30. In the case of both of the pistons 82 and 84, in response to the application of air pressure or hydraulic pressure, respectively, the pistons 82 and 84 will be driven downwardly, as viewed in FIG. 2.
Each of the elements 80, 82 and 84 and its associated projection 86 includes an axially extending through bore 110 which slidably receives a respective one of a plurality of links 112. Each of the links 112 includes an enlarged shoulder 114 which engages the underside of its associated element 80-84 so that relative slidable movement between the link 114 and its associated element 80-84 in one direction can occur, but in the opposite direction, such movement is limited.
A perforated spanning washer 118 disposed on a shoulder 120 on the upper surface of the threaded collar 56 guides the rod 58 for reciprocal movement such that an end thereof extends out of the housing defined by the modules and a small return coil spring 122 is interposed between the washer 118 and the underside of the lowermost shoulder 114 to urge the latter into the position illustrated in FIG. 2.
It will be seen that the links 112 are coaxial with each other and in abutment with each other and further are coaxial with the actuator rod 58, with the lowermost link 112 also being in abutment therewith.
Each of the bases 66 of the modules 60-64 is provided with an axially opening recess 128 with the recess 128 in the modules 62 and 64 supporting respective, relatively large diameter coil springs 130 which engage the underside of the elements 80 and 82 of the immediately upwardly adjacent module. A similar coil spring 132 is interposed between the washer 118 and the underside of the element 84 and the springs 130 and 132 normally urge the elements 80-84 to approximately the position illustrated in FIG. 2, that is, upwardly. Various other seals are employed in the assemblage where indicated and a cup-shaped cap 134 is nested in the exterior relief 70 of the uppermost module 60. The cap 134 includes a bore 136 which slidably receives an additional link 138. The cap 134 also mounts a yoke 140 which, in turn, pivotally supports a lever 142.
The lever 142 includes a nose 144 in abutment with the upper surface of the additional link 138 and further is normally biased in a clockwise direction by a coil spring 146. The end of the lever 134 remote from the nose 144 is connected to the cable 44 such that when the cable 44 is operated by the control 42 (FIG. 1), the lever 142 will be pivoted in a counterclockwise direction to drive the additional link 138 downwardly into the housing. Preferably, the manual actuator 46 is disposed on the lever 142 in axial alignment with the nose 144 and may be in the form of a knob which can be pushed to similarly drive the additional link 138 into the housing.
Operation of the apparatus is as follows. In the event the sensor apparatus 30 senses an overspeed condition, improper oil pressure, or, undesirable water temperature, it will generate an elevated hydraulic signal which will be conveyed to the module 68 and drive the element 84 downwardly against the bias of the various springs. Because the element 84 is in abutment with the shoulder 114 on its associated link 112, the latter will be moved downwardly to also move the rod 58 downwardly against the shutdown rod 54 to cause the governor 26 to halt the engine 10. During such downward movement, the only force resisting the same will be that provided by the return spring 122 by reason of the fact that the abutment connection between the link 112 associated with the module 64 and the link 112 associated with the module 62 will extend.
In the case of an air pressure signal generated by the control 36, the element 82 associated with the module 62 will be driven downwardly and due to the presence of the shoulder 114 on the link 112 associated therewith, that link will also be driven downwardly. Because the link 112 associated with the module 62 is in abutment with the link 112 associated with the module 64, the latter will also be driven downwardly to drive the actuator rod 58 and cause shutoff.
Should there be an electrical signal from the electrical monitors 40, the resultant energization of the coil 102 will cause a similar movement, but in this case, all of the links 112 will be moved to cause shutoff.
It will be noted that in none of the cases will movement of the elements 80-84 be resisted by other than their return springs 130 and 132 since the undersides of each such elements are vented via the spaces 74 and the vent passages 76 which can be vented exteriorly of the housing, in the case illustrated, through the perforated washer 118.
In the event manual shutdown is required, the same may be accomplished either by pulling on the cable 44 or by pushing on the knob 46, in which case, the nose 144 of the lever 142 will drive the additional link 138 downwardly and that, in turn, will cause all of the links 112 to urge the rod 58 downwardly.
From the foregoing, it will be appreciated that an actuator made according to the invention can receive actuating signals from the same or a variety of different mediums. In the specific form illustrated in FIG. 2, four different mediums of signals have been utilized including mechanical force applied through the lever 142, electrical signals applied through the coil 102, pneumatic signals applied against the piston 82, and hydraulic signals applied against the piston 84.
It will also be appreciated that by reason of the modular construction of the actuator, as many of the modules 60-64 as are required for any given number of signal inputs may be stacked in nested relation, as illustrated, so that a wide variety of actuators having different capacilities can be formed of but essentially two different types of modules, one electric and one fluid actuated.
Finally, it will be appreciated that in a control system such as that described, use of the actuator allows shutdown of a governor in any of a wide variety of different types of mechanical or electrical failure and combinations thereof, thereby providing a highly adaptable and extremely reliable control system. | A multiple input, single output, mechanical actuator including a housing, an actuator rod reciprocably mounted in the housing and having one end projecting therefrom, a plurality of aligned, signal responsive elements in the housing, each independently mounted for reciprocation therein towards and away from the rod, a plurality of signal input structures in the housing, one for each of the elements, for applying a force to reciprocably move the associated element toward or away from the rod, and a plurality of aligned, interengaging links reciprocably mounted within the housing, one for each of the elements, and operatively associated with the rod, each of the links being relatively movable with respect to its element and slidable with respect thereto for one direction of movement of the element and movable therewith in the other direction of movement of its element. | 5 |
BACKGROUND OF THE INVENTION
1. Technical Field
The apparatus of the present invention relates generally to slingshots. More specifically, it relates to an apparatus for achieving a greater shot-to-shot release uniformity and velocity consistency and hence a greater accuracy. The invention also relates to a sighting apparatus used in conjunction with the slingshot which enables a more accurate sighting of the target.
Currently, most slingshot devices are adapted to be held by one hand and the projectile pouch retracted with the other hand. These devices have extremely large inaccuracies due to the inconsistent shot-to-shot release.
Since the initial velocity, at the point of release, is directly related to the tension in the elastic band at the time of release, it is also clear that these devices suffer from a great shot-to-shot inconsistency of initial velocity due to the inequality of tension placed on the elastic band. Consequently, in the interest of increasing accuracy, it is highly desirable to provide a slingshot apparatus wherein the initial velocity can be consistently maintained from one firing to the next.
2. Description of the Prior Art
Currently, prior art slingshot devices come in one of three typical embodiments. First is the simple hand-held "Y"-shaped stick. The second conventional configuration consists of a slingshot having a design similar to the first mentioned configuration but also having an additional wrist bar adapted to provide stability to the slingshot when the elastic band is being extended. In both of these first two conventional embodiments, the elastic band imparting the initial velocity to the projectile, is extended with the fingers of the operator's free hand. As is well understood in the art, these methods have a great targeting inaccuracy associated therewith due to the shot-to-shot inconsistency of release.
As also known in the art, the key to accuracy when using a slingshot apparatus is a consistent shot-to-shot initial velocity. In a slingshot, the initial velocity is determined by the amount of tension on the elastic band at the time of release. Furthermore, the amount of tension on the elastic band is directly proportional to the distance the band is extended. Thus, if the band is extended a consistent amount from one shot to the next, there is a high probability that the initial velocity will be the same from one shot to the next. A second factor, somewhat related to the first, is the manner in which the band is retracted and more importantly, the manner in which it is released.
Ideally, the elastic band would be extended, held, and released from a single point positioned precisely at the center of the band. Any deviation from a point release results in an uneven release sequence, meaning that some portion of the band is released earlier than some other point. Clearly, this results in some inaccuracies in that the initial projectile vector is not consistent. A third significant factor in accuracy involves the method used to sight the target.
As is well understood in the laws of physics, any object falling in the earth's gravitational field will have a downwardly directed acceleration vector of 32 feet per second, squared. Thus, based on a given amount of time, the vertical displacement of a object may be determined relative to its initial position. If the projectile is also given an initial horizontal velocity vector, its final position may be determined based on knowledge of this initial velocity vector and the elapsed time. A sight may be used to predict the impact point based on an alignment of a forward and rearward sighting points. It is highly desirable for this sighting mechanism to be positioned above the departure path, defined as the initial horizontal velocity vector of the projectile, so that the distance to the final trajectory impact point is maximized. It is clear to those in the art that such sighting considerations are especially important since the slingshot is a low velocity weapon.
A third conventional slingshot apparatus embodiment attempts to remove some of the shot-to-shot inconsistencies inherent in the completely manual embodiments discussed above. This third conventional embodiment is typified by the Kees U.S. Pat. Nos. 4,784,106 and 4,593,673 and Burghardt U.S. Pat. No. 3,857,379. In both of these patents, the elastic band is extended to the stretched position by a mechanical means. The slingshot may be released by a trigger mechanism disengaging the locking means which retains the elastic band in the extended, cocked position. In all three of these devices, the elastic band is mounted in the horizontal plane. This horizontal mounting of the elastic band presents severe problems regarding the sighting mechanism used or prevents the installation of a sighting mechanism altogether. For example, the Burghardt device is completely lacking in any type of sighting device. It is clear that if a sighting member is to be used with a device having a horizontally oriented elastic band, it will either have to be offset from the initial horizontal departure vector or it will necessarily need to be sighted below the horizontal departure plane. Otherwise, if the designer attempts to place the sighting mechanism in vertical alignment with the projectile pouch and in approximately the same horizontal departure plane, the sighting means will present an obstacle to the departure of the projectile. One attempted solution to this problem in Kees was to provide a flexible latex rubber sighting member as the forward sight.
The flexibility of the forward sight was designed to permit the projectile to pass freely thereby without disturbing its flight path even if it should contact the sighting member. However, clearly any physical contact by the projectile with the sighting member is going to alter the projectile's flight trajectory and thereby disturb the targeting accuracy. Conversely, if the sighting mechanism is placed below the projectile departure plane, the target distance is necessarily limited due to the flight trajectory of the projectile as described in more detail below.
Consequently, it is a primary objective of the present invention to provide an enhanced accuracy slingshot apparatus wherein the elastic bands are oriented vertically such that the sighting means may be placed above and in alignment with the departure vector so as to enhance the overall accuracy of the device while providing a maximum targeting distance.
Another objective is to provide an improved accuracy slingshot apparatus wherein the release mechanism is operative to secure and release the projectile pouch from as nearly a single point of contact as possible so as to facilitate a uniform release or initial projectile vector.
Another objective is to provide an improved accuracy slingshot apparatus wherein the degree of tension on the elastic band in the extended, cocked position may be adjusted.
Another objective of the improved accuracy slingshot apparatus of the present invention is to provide a device wherein the elastic band may be maintained in a retracted, holding position awaiting cocking of the apparatus wherein the elastic band is just slightly taut, thereby preventing any excess stretching of the band between shots.
Another objective of the present invention is to provide a sighting means which is positioned above and in vertical alignment with the line of departure for the projectile, thereby increasing its effective range.
A further objective of the present invention is to provide an improved accuracy slingshot apparatus wherein a sighting means may be employed having a plurality of sighting apertures corresponding to a plurality of terminal target distances.
A further objective of the present invention is to provide an improved accuracy slingshot apparatus maximizing the shot-to-shot consistency of the projectile initial velocity.
Another objective of the present invention is to provide an apparatus wherein the handgrips of the apparatus may be adjusted to accommodate the arm lengths of different individuals.
SUMMARY OF THE INVENTION
A slingshot device for accurate shooting of a projectile having an elongated stationary support channel having forward and rearward portions. A movable carriage is slidably engaged by the stationary support channel and movable between an extended, forward cocked position and a retracted rearward holding position. A locking device is mounted on the forward portion of the elongated stationary support channel and operative to releasably lock the carriage in the extended, forward cocked position. An elongated elastic band is mounted in vertically on the carriage. A pouch for releasably retaining the projectile is positioned at a midpoint of the elastic band device. A trigger is mounted on the stationary support channel and movable between an engagement position in releasable engagement with the pouch of the elastic band device, and a release position. Upon movement of the carriage to the forward cocked position, the elastic band is substantially stretched such that when the trigger is released, the elastic band is operative to propel a projectile in the pouch forwardly.
The slingshot apparatus may also include a sighting device mounted above the departure path or line of departure of the projectile. The sighting device may have a plurality of sighting apertures to accommodate different targeting distances.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the improved accuracy slingshot apparatus of the present invention.
FIG. 2 is an end view of the movable carriage which is slidably engaged to the main elongated stationary support channel showing the installation of the elastic band means mounting yoke thereon.
FIG. 3 is a side view of the slingshot apparatus with the movable carriage in the retracted, rearward holding position shown in phantom lines and in the extended, cocked position in solid lines.
FIG. 4 is an exploded view of the trigger and rear sighting mechanism of the apparatus.
FIG. 5 is a top view showing the alignment of the sighting mechanism in addition to the vertical mounting of the elastic band means.
FIG. 6 is an enlarged side view of the trigger means and its movement between a release (in phantom lines) position and in the cocked position (in solid lines).
FIG. 7 is a side view of the forward portion of the apparatus showing the movable carriage in the forward, cocked position and illustrating the release lever used to disengage the forward locking means.
FIG. 8 is a perspective view showing the slingshot apparatus in use.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The perspective view of FIG. 1 best illustrates the overall working configuration of the improved accuracy slingshot apparatus of the present invention. As seen in this figure, an elongated stationary support channel 30 forms the central structure around which the remaining components are built. As seen in the figure, the elongated stationary support channel 30 comprises a generally L-shaped member. This shape provides structural support as well as clearance for travel of pouch 52 and projectile 90. In the forward portion of elongated stationary support channel 30 is placed a series of holes 32 for mounting of locking means 40. As will be described in more detail below, locking means 40 is adapted to lock the movable carriage 20 in the extended, forward cocked position as shown. A plurality of holes 32 allow the position of locking means 40 to be moved lengthwise along the elongated stationary support channel 30. As will also be described in more detail below, the positioning of locking means 40 along stationary support channel 30 determines the extent to which elongated elastic band means 50 is stretched. Consequently, the positioning of locking means 40 determines the initial projectile velocity and thus the distance the projectile 90 will travel. As is well understood by anyone acquainted with slingshots, it is the elongated elastic band 50 which, when released, propels a projectile 90 forwardly. As seen in FIGS. 1 and 3, projectile 90 is releasably held in pouch 52 by frictional engagement. As seen in the figures, when trigger 74 engages lanyard 54, pulling band 50 taut, pouch 52 assumes a "V" shape with projectile 90 fitting snugly in the apex thereof, thereby achieving a degree of frictional engagement sufficient to releasably retain projectile 90.
Elongated stationary support channel 30 may also have handgrip 34 and shoulder butt stock 36 secured to the underside thereof and positioned in the rearward portion thereof as illustrated in the figure. The purpose for handgrip 34 and shoulder butt stock 36 is to provide a means of stabilizing the slingshot apparatus for sighting and firing (Fig. 8). A sighting means 60 is provided for sighting of the slingshot apparatus thereby enhancing its accuracy. The vertical orientation of the band 50 as illustrated, has important implications for sighting means 60 as discussed below.
In the present invention, the sighting means 60 comprises forward and rearward sighting members 64 and 62, respectively. As seen in FIG. 1, the rear sighting member 62 is positioned above and slightly forwardly of handgrip 34. Height adjustment of sight 62 may be made by loosening locking nut 89. FIG. 2 illustrates the positioning of the forward sighting member 64 and will be described in connection therewith. Trigger means 70 is illustrated in the perspective view of FIG. 1 pivotally attached to handgrip 34. The operation of trigger means 70 will be discussed in more detail below in connection with FIGS. 4 and 6. Finally, the movable carriage 20 is illustrated.
Movable carriage 20 comprises a generally L-shaped channel 22 adapted to slide lengthwise along elongated stationary support channel 30. Slidable engagement between movable carriage 20 and elongated stationary support channel 30 is maintained by a plurality of locking tabs 23a-d. It will also be seen from the figure, that in addition to L-shaped member 22, the movable carriage 20 comprises a bracket 26 mounted to the outward surface thereof by means of screws or other similar semi-permanent means. Bracket 26 is used to secure the two ends of elastic band means 50 to slidable carriage 20. The attachment of bracket 26 to slidable carriage L-shaped member 22 is illustrated more clearly in the front view of FIG. 2. Finally, FIG. 2 illustrates an additional forward handgrip 24 secured to the underside of L-shaped channel 22 on slidable carriage 20. The purpose for handgrip 24 is twofold. First, it provides a means for sliding movable carriage 20 to the forward, cocked position. Secondly, it provides an additional means for holding the slingshot apparatus as illustrated below in FIG. 8.
FIG. 2 is an end view of the slidable movable carriage 20 showing the L-shaped channel member 22 and the associated bracket 26 used to connect and support the two ends of elastic band means 50. Also indicated in this view is the forward sighting member 64 of sighting means 60. As indicated by direction arrow 66, the forward sighting member 64 is adapted to be moved horizontally against the top surface of bracket 26. Additionally, the vertical height of the sight 62 may be adjusted by loosening locking nut 89. It will be observed from FIG. 2 that a plurality of vertically spaced sighting apertures 66a-c are provided in sighting means 62. The purpose for providing a plurality of sighting apertures 66a-c is that a plurality of target distances can be specified without the need of altering the sight each time a new target distance is to be sighted in. For example, the top sighting aperture 66a provides the highest sighting angle corresponding to the furthest targeting distance. Conversely, the lowest sighting aperture 66c, corresponds to the lowest sighting angle and consequently the nearest target distance. Thus, a plurality of target sighting distances may be provided simply by providing a plurality of vertically spaced sighting apertures.
FIG. 3 is a side view of the apparatus with the movable carriage 20 in the retracted, rearward holding position shown in phantom lines. It will be observed from this figure that the elastic band means 50 is pulled tight but is not stretched. It may be seen from the figure that the trigger pin 74 has releasably engaged the pouch 52 by means of a lanyard 54.
FIG. 3 also illustrates, in solid lines, the improved accuracy slingshot apparatus of the present invention with the movable carriage 20 in the forward, cocked position and with the elastic band means 50 outstretched. It can also be seen from this figure, that the movable carriage 20 is releasably retained in this forward, cocked position by the engagement of tab 29 on locking arm 28 with stub 42 of locking means 40 attached to the underside of support channel 30 in the forward portion thereof. The releasable retention of carriage 20 in the forward position is illustrated more clearly in FIG. 7.
It will also be clear from FIG. 3, that the releasable engagement of lanyard 54 by trigger pin 74 is operative to retain the elastic band means 50 in the extended, cocked position until trigger means 70 releases trigger pin 74. As seen in the figure and described in more detail below, trigger 72 is pivotally mounted to handle 34 by means of screw 76. Rearward pivoting of trigger 72 is operative to vertically displace pin 74 downwardly below the surface level of plate 82. The attachment and movement of the trigger means 70 is best illustrated in FIG. 6 below.
FIG. 4 is an exploded view of the trigger means 70. The lengthwise adjustable position of trigger means 70 and associated bracket 80 and handgrip 34 is particularly well illustrated in this figure. As seen in the figure, bolt 86 is adapted to releasably secure bracket 80 in the desired position along stationary support channel 30 by means of engagement with one of the plurality of holes 88 positioned lengthwise along channel 30. Therefore, positioning of bracket 80 and associated trigger means and sight 62 may be adjusted simply by removing bolt 86, repositioning bracket 80 and reinstalling and tightening bolt 86.
As seen in the figure, rear sight 62 is fixed in vertical position by means of locking nut 89. Thus, the vertical positioning of sight 62 may be accomplished by loosening nut 89, adjusting the position of sight 62, and re-tightening nut 89. Such a repositioning of the sight might be required for example to adjust the targeting distance. Alternatively, adjustment of the sight might be required if the trigger means 70 and bracket 80 are repositioned as indicated above. The vertical position of the sight may need to be adjusted to achieve the same, previously designated, target distance.
FIG. 5 is a top view illustrating with particular clarity the alignment of sighting means 60 as well as the releasable engagement of pouch 52 and elastic band means 50 to trigger means 70 using the lanyard 54. As seen in the figure, the portion of trigger pin 74 which projects upwardly through the horizontal plate 82 of bracket 80 is adapted to engage the lanyard 54 which forms a loop around this protruding portion of pin 74. The other ends of lanyard 54 are securely fastened to pouch 52 such that when the lanyard 54 is engaged with pin 74, it will releasably secure elastic band means 50 in the retracted, rearward holding position as shown. In the preferred embodiment, lanyard 54 is constructed from 75 pound test fishing line but may be constructed from other suitable material.
An important feature of the present invention is illustrated in the top view of FIG. 5, namely the vertical alignment of the sighting means with the departure vector. As seen in the figure, the forward and rearward sights 64 and 62, respectively, are positioned adjacent the elastic band means 50. Thus, the targeting accuracy of the apparatus is enhanced. As seen in the figure, forward sighting member 64 is pivotally fastened to the upper horizontal arm of bracket 26 by means of screw 65. Screw 65 permits the horizontal adjustment of forward sighting member 64 in the manner illustrated by arrows 66 simply by loosening the screw 65. As is well understood in the art, this lateral adjustment of the forward sight 64 is referred to as the windage adjustment.
FIG. 6 is an enlarged side view of the trigger mechanism 70 of the present invention. As seen in the figure, trigger 72 is pivotally connected to handgrip 34 by means of pin or screw 76. As seen in the figure, this permits the front to back pivotal movement indicated by the direction arrow in the figure. Trigger 72 is illustrated in the rearward, release position in phantom lines and in the forward, engagement position in the solid line. As shown, movement of the trigger 72 from the forward engagement position to the rearward release position causes pin 74 to move downwardly, causing the portion of pin 74 protruding above plate 82 to be retracted. This downward retraction of pin 74 into plate 82 releases lanyard 54 allowing elastic band means 50 to contract. The contraction of band 50 propels the projectile 90, releasably engaged with pouch 52, forwardly. In the preferred embodiment, projectile 90 would be a lead ball of approximately 140 grains weight but could be any number of suitable alternatives, In the preferred embodiment, trigger means 70 also comprises a post 79 which is inserted into handgrip 34 and adapted to contact the rear edge of trigger 72 when pivoted rearwardly to the release position. Thus, post 79 is operative to limit the rearward travel of trigger 72. While not essential to the operation of the apparatus, stop post 79 prevents release trigger pin 74 from traveling downwardly too far and disengaging from plate 82. This prevents the operator from having to reinsert release trigger pin 74 into the hole in plate 82 after each shot. As mentioned above, vertical member 84 of bracket 80 is releasably secured in position to the stationary support channel 30 by means of securement bolt 86. As seen in the figure, a plurality of holes 88 are provided in stationary support channel 30 for adjusting the position of vertical wall 84 and thus bracket 50 lengthwise along stationary support channel 30. The position of bracket 80 may be adjusted simply by loosening and removing bolt 86, repositioning bracket 80 and reinstalling and tightening bolt 86. As mentioned above, after such an adjustment, it may be necessary to re-adjust sighting means 60 and, in particular, the vertical positioning of rear sight 62.
FIG. 7 is an enlarged view of the forward portion of the slingshot apparatus with the movable carriage 20 in the extended, forward cocked position. As seen in this figure and as discussed above, the movable carriage 20 is releasably retained in the extended, forward cocked position by means of locking means 40 and the releasable engagement of locking arm 28 therewith. Locking arm 28 is pivotally connected to movable carriage 20 by means of pin 27. The position of locking arm 28 is adjustable between a locked position indicated in solid lines and a release position indicated by phantom lines. As indicated in the figure, when in the locking position, arm 28 is positioned such that tab 29 engages the forward portion of stub 42 of locking means 40. Locking means 40 is attached to the underside of support channel 30 by means of a bolt 44 or the like. Tension in band 50 urges tab 29 against stub 42, preventing rearward movement of carriage 20. Once the slingshot has been released, or it is desired to uncock the slingshot, the rear portion of locking arm 28 would be pivoted upwardly as indicated by the phantom line. Tab 29 and locking stub 42 would be disengaged, allowing the rearward travel of movable carriage 20. Also seen in this figure are the plurality of tabs 23a-d providing a means for slidably retaining carriage 20 on stationary support channel 30. As mentioned above, a plurality of holes 32 (FIG. 1) are drilled into the underside of the support channel 30 and through which a bolt or screw 44 is placed to releasably secure stub 42 to the underside thereof. Thus, a means is provided for adjusting the position of locking stub 42 lengthwise along stationary support channel 30 simply by removing bolt 44, adjusting the position of stub 42 and reinstalling bolt 44. Also shown in this figure is the means by which the two portions of the elastic band means 50 are secured to bracket 26. As seen in the figure, a plurality of slits are cut into the top arm of bracket 26 allowing the ends of elastic band means 50 to be threadably received therebetween. The pressure contact and resulting frictional engagement of the ends of elastic band means 50 operate to secure the elastic band means 50 in place. Bracket 26 is then rigidly secured to movable carriage 20 by means of a plurality of screws 25a and 25b.
FIG. 8 is an illustration of the operation of the apparatus. As seen in this figure, the forward grip 24 is used to slide carriage 20 forwardly into the locking position, thereby extending elastic band means 50. Shoulder butt stock 36 is then placed against the shoulder and the remaining handgrip 34 is grasped with the index finger resting on the trigger 72. Sight 62 is then used in conjunction with the forward sight 64 to adjust the position of the apparatus in much the same way as with a conventional firearm. Once the target is acquired, the trigger is depressed and the projectile released.
It is obvious that numerous other modifications and variations of the present invention are possible in view of the above teachings. For example, as mentioned the construction materials for various components of the structure such as the projectile and lanyard may be altered. Additionally, the L-shape of the elongated channel is not critical.
Therefore it is to be understood that the above description is in no way intended to limit the scope of protection of the claims and is representative only of the several possible embodiments of the present invention.
There has thus been shown and described an invention which accomplishes at least all of the stated objects. | A slingshot device for accurate shooting of a projectile having an elongated stationary support channel having forward and rearward portions. A movable carriage is slidably engaged by the stationary support channel and movable between an extended, forward cocked position and a retracted rearward holding position. A locking device is mounted on the forward portion of the elongated stationary support channel to releasably lock the carriage in the extended, forward cocked position. An elongated elastic band has opposite ends mounted in vertically spaced relation on the carriage. A pouch for releasably retaining the projectile is positioned at a midpoint of the elastic band device. A trigger is mounted on the stationary support channel and movable between an engagement position in releasable engagement with the pouch of the elastic band device, and a release position. Upon movement of the carriage to the forward cocked position, the elastic band is substantially stretched such that when the trigger is released, the elastic band is operative to propel a projectile in the pouch forwardly.
The slingshot apparatus may also include a sighting device mounted above the departure path of line of departure of the projectile. The sighting device may have a plurality of sighting apertures to accommodate different target distances. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of co-pending U.S. patent application Ser. No. 14/317,468, filed Jun. 27, 2014. The aforementioned related patent application is herein incorporated by reference in its entirety. Synthetic details and characterization of various example polyhexahydrotriazine and polyhemiaminal materials are provided in commonly assigned, co-pending application Ser. No. 14/050,995, filed in the USPTO on Oct. 10, 2013, the entirety of which is incorporated herein by reference.
BACKGROUND
[0002] The present disclosure relates to polymeric materials including hexahydrotriazine or hemiaminal moieties, and more specifically to polyhemiaminals and polyhexahydrotriazines.
[0003] Commercially important nitrogen-containing polymers include polyamides (nylon), polyimides (Kaplon, UPILEX, VTEC), and polyamines. Between these three classes of materials, nitrogen-rich polymers have applications in adhesives, semiconductors, automotive components, electronics, sporting goods, coatings, bottles, foams, yarns, plumbing parts, paints, and hospital equipment, to name a few. Though widely used, nitrogen-containing polymers can be flexible, hygroscopic materials sensitive to acids, bases and oxidants, which prevents their use in other applications.
[0004] In general, highly crosslinked, non-linear polymers are more difficult to process into films and fibers than more linear polymers that are not highly crosslinked. A need exists for chemically resistant nitrogen-containing polymers that have high rigidity and high tensile strength, but are processable into films and fibers.
SUMMARY
[0005] A polyhemiaminal (PHA) is a polymer comprising: i) a plurality of trivalent hemiaminal groups of formula:
[0000]
[0000] covalently linked to ii) a plurality of bridging groups of formula:
[0000]
[0000] and
iii) a plurality of end groups of formula:
K″—*,
wherein y′ is 2 or 3, and K′ is a divalent or trivalent radical comprising at least one 6-carbon aromatic ring, and K″ is a monovalent radical comprising at least one 6-carbon aromatic ring. Each starred bond of a given hemiaminal group is covalently linked to a respective one of the bridging groups or the end groups. Starred bonds represent attachment points to other portions of the chemical structure. Additionally, each starred bond of a given bridging group or a given end group is covalently linked to a respective one of the hemiaminal groups.
[0007] In the polymeric material, an overall ratio of K′ to K″ groups is less than 3:1 and greater than or equal to 1:2. That is, some but not all trivalent hemiaminal groups in the polymer can have only K′ groups attached thereto. And, of course, on any given trivalent hemiaminal group, the number of K″ groups cannot exceed 2 if the group is incorporated into the PHA polymer.
[0008] In an embodiment, a polyhexahydrotriazine (PHT) is a polymer comprising i) a plurality of trivalent hexahydrotriazine groups of formula:
[0000]
[0000] covalently linked to ii) a plurality of divalent bridging groups of formula:
[0000]
[0000] (where y′=2 or 3); and
iii) a plurality of monovalent bridging groups K″ of formula
K″—*,
Each starred bond of a given hexahydrotriazine group is covalently linked to a respective one of the bridging groups K′ or a respective one of the end groups K″. And K′ is a divalent or trivalent radical comprising at least one 6-carbon aromatic ring, and K″ is a monovalent radical comprising at least one carbon. In an embodiment, K″ is a monovalent radical comprising at least one 6-carbon aromatic ring. Each starred bond of a given bridging group or a given end group is covalently linked to a respective one of the hexahydrotriazine groups. The overall ratio of bridging groups (K′) to end groups (K″) in the PHT polymer is less than 3:1 and greater than or equal to 1:2.
[0010] Also disclosed is a method of forming a polymer coating on a component, comprising: forming a PHA film on a component, heating the PHA film to a first temperature that is above a glass transition temperature of the PHA film, heating the PHA film to a second temperature that is greater than the first temperature, wherein the PHA film, comprises a plurality of trivalent hemiaminal groups having the structure:
[0000]
[0000] and
a plurality of bridging groups of formula:
[0000]
[0000] and
a plurality of monovalent end groups of formula: W′
[0000]
[0000] wherein W′ is selected from the group consisting of: —H, —NH(R′), —N(R 2 )(R 3 ), —OH, —O(R 4 ), —S(R 5 ), —P(R 6 ), —R 7 , —CF 3 , and combinations thereof, wherein R 1 comprises at least 1 carbon, R 2 comprises at least 1 carbon, R 3 comprises at least 1 carbon, R 4 comprises at least 1 carbon, R 5 comprises at least 1 carbon, R 6 comprises at least 1 carbon, R 7 comprises at least one carbon, and each of R 1 -R 7 may be independent or the same. Each starred bond of a given hemiaminal group is covalently linked to a respective one of the bridging groups or a respective one of the monovalent end groups. Each starred bond of a given bridging group is linked to one of the hemiaminal groups. And each starred bond of a given monovalent end group is linked to one of the hemiaminal groups. The second temperature is at or above a temperature at which the PHA film converts to a polyhexahydrotriazine (PHT) film.
[0011] As used herein, a “component” is a rigid or semi-rigid substrate. A component may be, without limitation, a printed circuit board, a microchip, a semiconductor device, a light-emitting diode, a semiconductor wafer, a hard disk drive platter, a pipewall, a filter medium, a countertop, a door handle, or a portion of any of the foregoing.
[0012] The above-described and other features and advantages of the present invention will be appreciated and understood by those skilled in the art from the following detailed description, drawings, and appended claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0013] FIG. 1 is a series of cross-sectional layer diagrams illustrating the preparation of a polyhemiaminal (PHA) film.
[0014] FIG. 2 is a series of cross-sectional layer diagrams illustrating the preparation of a polyhexahydrotriazine (PHT) film.
[0015] FIG. 3 depicts a method of coating a component with a polymer.
[0016] FIG. 4 is a 1 H NMR spectrum of N,N-dimethyl-p-phenylenediamine in d 6 -DMSO.
[0017] FIG. 5 is a 1 H NMR spectrum of a hemiaminal formed by the reaction of N,N-dimethyl-p-phenylenediamine with paraformaldehyde.
[0018] FIG. 6 is a 1 H NMR spectrum of crude 4,4′,4″-(1,3,5-triazinane-1,3,5-triyl)tris(N,N-dimethylaniline) formed by the reaction of N,N-dimethyl-p-phenylenediamine with paraformaldehyde (Example 1).
[0019] FIG. 7 is a 1 H NMR spectrum of purified 4,4′,4″-(1,3,5-triazinane-1,3,5-triyl)tris(N,N-dimethylaniline) formed in Example 1.
[0020] FIG. 8 is a solid state 13 C NMR spectrum of the polyhemiaminal formed in Example 2.
[0021] FIG. 9 is a 1 H NMR spectrum of a polymer formed in Example 4.
[0022] FIG. 10 is a solid state 13 C NMR spectrum of a polymer formed in Example 4.
DETAILED DESCRIPTION
[0023] Methods are disclosed for preparing polyhemiaminals (PHAs) and polyhexahydrotriazines (PHTs) by the reaction of aromatic amines, aromatic diamines, and paraformaldehyde. Aliphatic diamines may also be adopted in some embodiments. The PHAs and PHA films are stable intermediates in the preparation of the PHTs and PHT films, respectively. The PHAs are generally prepared at a temperature of about 20° C. to about 120° C., more preferably at about 20° C. to about 100° C., and further preferably at about 40° C. to about 60° C. The PHAs form films when cast from a polar aprotic solvents (e.g., NMP), and the PHA films are stable at a temperature of about 20° C. to less than 150° C. The PHA films can have a Young's modulus of about 6 GPa, which is exceptionally high for an organic film. PHA materials are also melt processable as well so can be used to in molding and extrusion applications.
[0024] The PHT films are formed by thermally treating a PHA film at a temperature of at least 150° C., preferably about 165° C. to about 280° C., more preferably about 180° C. to about 210° C., and most preferably about 190° C. to about 210° C. for a period of time of about 1 minute to about 24 hours, and more preferably about 1 hour. The PHT films can have high heat resistance as measured by dynamic mechanical analysis (DMA). The PHT films can also have a high Young's modulus as measured by nanoindentation methods. In some instances, the Young's modulus of a PHT film can have a value in a range of about 8 GPa to about 14 GPa, exceeding that of bone ( 9 GPA).
[0025] In an embodiment, a polyhemiaminal (PHA) comprises i) a plurality of trivalent hemiaminal groups of formula:
[0000]
[0000] covalently linked to ii) a plurality of bridging groups of formula:
[0000]
[0000] and
iii) a plurality of end groups of formula:
K″—*,
wherein y′ is 2 or 3, and K′ is a divalent or trivalent radical comprising at least one 6-carbon aromatic ring, and K′ is a monovalent radical comprising at least one 6-carbon aromatic ring. In the polymeric material, an overall ratio of K′ to K″ groups will be less than 3:1 and greater than or equal to 1:2. That is, some but not all trivalent hemiaminal groups in the polymer can have only K′ groups attached thereto. And, of course, on any given trivalent hemiaminal group, the number of K″ groups cannot exceed 2 if the group is incorporated into the PHA polymer. Starred bonds represent attachment points to other portions of the chemical structure. Each starred bond of a given hemiaminal group is covalently linked to a respective one of the bridging groups or the end groups. Additionally, each starred bond of a given bridging group or a given end group is covalently linked to a respective one of the hemiaminal groups.
[0027] In some embodiments, a polyhemiaminal (PHA) comprises, a plurality of trivalent hemiaminal groups having the structure:
[0000]
[0000] a plurality of bridging groups of formula:
[0000]
[0000] and
a plurality of monovalent end groups of formula:
[0000]
[0000] wherein W′ is selected from the group consisting of: —H, —NH(R′), —N(R 2 )(R 3 ), —OH, —O(R 4 ), —S(R 5 ), —P(R 6 ), —R 7 , —CF 3 , and combinations thereof, wherein R 1 comprises at least 1 carbon, R 2 comprises at least 1 carbon, R 3 comprises at least 1 carbon, R 4 comprises at least 1 carbon, R 5 comprises at least 1 carbon, R 6 comprises at least 1 carbon, R 7 comprises at least one carbon, and each of R 1 -R 7 may be independent or the same. Each starred bond of a given hemiaminal group is covalently linked to a respective one of the bridging groups or a respective one of the monovalent end groups. Each starred bond of a given bridging group is linked to one of the hemiaminal groups. And each starred bond of a given monovalent end group is linked to one of the hemiaminal groups.
[0028] As an example, a polyhemiaminal can be represented herein by formula (8):
[0000]
[0000] In this instance, each K′ is a trivalent radical (y′=3) comprising at least one 6-carbon aromatic ring and K″ is a monovalent radical comprising at least one 6-carbon ring. It should be understood that each nitrogen having two starred wavy bonds in formula (1) is a portion of a different hemiaminal group. The inclusion of K″ reduces the number of potential crosslink connection points in the polyhemiaminal network.
[0029] Non-limiting exemplary trivalent bridging groups include:
[0000]
[0030] The bridging groups can be used singularly or in combination. The remainder of the description discusses divalent bridging groups K′. It should be understood that the methods and principles below also apply to trivalent linking groups.
[0031] Polyhemiaminals composed of divalent bridging groups K′ and monovalent end groups K″ can be represented herein by formula (2):
[0000]
[0000] wherein K′ is a divalent radical (y′=2) comprising at least one 6-carbon aromatic ring, and K″ is a monovalent radical comprising at least one 6-carbon aromatic ring. Each nitrogen having two starred wavy bonds in formula (2) is a portion of a different hemiaminal group.
[0032] Certain bridging groups K′ have the formula (3):
[0000]
[0000] wherein L′ is a divalent linking group selected from the group consisting of *—O—*, *—S—*, *—N(R′)—*, *—N(H)—*, *—R″—*, *—P(R″)—* and combinations thereof, wherein R′, R″, and R′″ independently comprise at least 1 carbon. In an embodiment, R′, R″, and R′″ are independently selected from the group consisting of methyl, ethyl, propyl, isopropyl, phenyl, and combinations thereof. Other L′ groups include methylene (*—CH 2 —*), isopropylidenyl (*—C(Me) 2 —*), and fluorenylidenyl:
[0000]
[0000] And, as described above, a bridging group can also be of the formula (4):
[0000]
[0033] Polyhemiaminals composed of divalent bridging groups of formula (3) and monovalent end groups K″ can be represented herein by formula (5):
[0000]
[0000] wherein L′ is a divalent linking group selected from the group consisting of *—O—*, *—S—*, *—N(R′)—*, *—N(H)—*, *—R″—*, *—P(R′″)—* and combinations thereof, wherein R′, R″, and R′″ independently comprise at least 1 carbon. K″ is again a monovalent end group including at least one 6-carbon aromatic ring. Each nitrogen having two starred wavy bonds in formula (5) is a portion of a different hemiaminal group.
[0034] An embodiment of a polyhexahydrotriazine (PHT) comprises, i) a plurality of trivalent hexahydrotriazine groups of formula:
[0000]
[0000] covalently linked to ii) a plurality of divalent bridging groups of formula:
[0000]
[0000] (where y′=2 or 3); and
iii) a plurality of monovalent bridging groups K″ of formula
K″—*,
Each starred bond of a given hexahydrotriazine group is covalently linked to a respective one of the bridging groups K′ or a respective one of the end groups K″. And K′ is a divalent or trivalent radical comprising at least one 6-carbon aromatic ring, and K″ is a monovalent radical comprising at least one carbon. In an embodiment, K″ is a monovalent radical comprising at least one 6-carbon aromatic ring. Each starred bond of a given bridging group or a given end group is covalently linked to a respective one of the hexahydrotriazine groups. The overall ratio of bridging groups (K′) to end groups (K″) in the PHT polymer is less than 3:1 and greater than or equal to 1:2.
[0036] For PHTs comprising bridging groups of formula (3) and end groups K″, the polyhexahydrotriazine is represented herein by formula (6):
[0000]
[0000] wherein L′ is a divalent linking group selected from the group consisting of *—O—*, *—S—*, *—N(R′)—*, *—N(H)—*, *—R″—*, and combinations thereof, wherein R′ and R″ independently comprise at least 1 carbon. K″ is here a monovalent end group including at least one 6-carbon ring aromatic. Each nitrogen having two starred wavy bonds in formula (5) is a portion of a different hexahydrotriazine group.
[0037] For a PHT comprising a bridging group of formula (4) (see above) and an end group of formula (7):
[0000]
[0000] the PHT may be depicted using the following formula (8):
[0000]
[0038] The polyhexahydrotriazine of formula (8) is an example of a PHT with reduced crosslink density and a more linear form. This PHT is a soluble, processable polymer. In this context, “polymer” includes an oligiomer comprising the same repeating units indicated in formula (8). In formula 8, “x” represents the overall percentage of linear repeat units in the PHT material and “y” represents the overall percentage of crosslinking units in the PHT material.
[0039] Exemplary non-limiting divalent bridging groups corresponding to formula (3) further include:
[0000]
[0000] and combinations thereof
[0040] As discussed, embodiments of PHA and PHT further comprise monovalent aromatic groups K″ (referred to herein as end groups), which do not participate in chemical crosslinking and therefore serve to control the crosslink density as well as the physical and mechanical properties of the PHA and PHT polymers. Monovalent end groups K″ may have, for example, a structure corresponding to the following:
[0000]
[0000] wherein W′ is selected from the group consisting of: —H, —NH(R′), —N(R 2 )(R 3 ), —OH, —O(R 4 ), —S(R 5 ), —P(R 6 ), —R 7 —CF 3 , and combinations thereof, wherein R 1 comprises at least 1 carbon, R 2 comprises at least 1 carbon, R 3 comprises at least 1 carbon, R 4 comprises at least 1 carbon, R 5 comprises at least 1 carbon, R 6 comprises at least 1 carbon, R 7 comprises at least one carbon, and each of R 1 -R 7 may be independent or the same. The starred bond is linked to a nitrogen of a hemiaminal group or a nitrogen of a hexahydrotriazine group.
[0041] Non-limiting exemplary end groups K″ further include:
[0000]
[0000] wherein the starred bond is linked to a nitrogen of a hemiaminal group or a nitrogen of a hexahydrotriazine group. End groups can be used singularly or in combination—that is, only a single end group type may be incorporated or two or more end group types may be incorporated into the final reaction product.
[0042] The reactivity of a given end group precursor may vary according to whether the substituent(s) attached to aromatic ring are electron rich or electron poor. In general, more strongly electron withdrawing (electron poor) substituents reduce reactivity of the monomer and more strongly electron donating (electron rich) substituents increase reactivity. As such, it is possible to control the ratio of different end groups in the final product by selecting end group precursors on the basis of expected reactivity (and/or adjusting feed ratios). Additionally, electron poor substituents react more slowly and can be used to vary the character of the reaction end-product between hemiaminal and hydrotriazine. That is, less reactive (electron poor) monomer units will tend produce a reaction product having more hemiaminal groups as compared to more reactive (electron rich) monomer units.
[0043] The ratio of bridging groups and end groups in the final reaction product can similarly be adjusted using the relative reactivity of the bridging group monomers and the end group monomers. A more reactive end group (e.g., one with a substituent which is electron rich) will tend to reduce cross-link density and molecular weight in the final polymer. A less reactive end group (e.g., one with a substituent which is electron poor) will tend to increase crosslink density because fewer hemiaminal or hexahydrotriazine groups will bond to such an end group and will instead be bonded only to bridging groups, which results in crosslinks.
[0044] A method of preparing a polyhemiaminal (PHA) comprising divalent bridging groups comprises forming a first mixture comprising i) a first monomer comprising two or more primary aromatic amine groups (e.g., corresponding to K′ with primary amines (—NH 2 ) at the*locations)), ii) a second monomer having only one aromatic primary amine group (e.g., corresponding to K″ with a primary amine at the*location), iii) paraformaldehyde, and iv) a solvent. The first mixture is then preferably heated at a temperature of about 20° C. to about 120° C. for about 1 minute to about 24 hours, thereby forming a second mixture comprising the PHA.
[0045] The mole ratio of paraformaldehyde to total moles of primary aromatic amine groups (e.g., 2×moles diamine monomer+1×moles monoamine monomer) is preferably about 1:1 to about 1.25:1, based on one mole of paraformaldehyde equal to 30 grams.
[0046] Non-limiting exemplary first monomers comprising two primary aromatic amine groups include 4,4′-oxydianiline (ODA), 4,4′-methylenedianiline (MDA), 4,4′-(9-fluorenylidene)dianiline (FDA), p-phenylenediamine (PD), 1,5-diaminonaphthalene (15DAN), 1,4-diaminonaphthalene (14DAN), and benzidene, which have the following structures:
[0000]
[0047] Non-limiting exemplary second monomers having only one primary amine include N,N-dimethyl-p-phenylenediamine (DPD), p-methoxyaniline (MOA), p-(methylthio)aniline (MTA), N,N-dimethyl-1,5-diaminonaphthalene (15DMN), N,N-dimethyl-1,4-diaminonaphthalene (14DMN), and N,N-dimethylbenzidene (DMB), which have the following structures:
[0000]
[0048] The second monomer can be used in an amount of 1 mole % to about 99 mole % based on total moles of first monomer and second monomer. In a particular embodiment, the second monomer can be used in an amount of 10 mole % to about 67 mole % based on total moles of first monomer and second monomer.
[0049] The solvent can be any suitable solvent. Preferred solvents include dipolar aprotic solvents such as, for example, N-methyl-2-pyrrolidone (NMP), dimethylsulfoxide (DMSO), N,N-dimethylformamide (DMF), N,N-dimethylacetamide (DMA), propylene carbonate (PC), and propylene glycol methyl ether acetate (PGMEA). In a typical embodiment, the solvent is NMP.
[0050] A method of preparing a polyhexahydrotriazine (PHT) comprises forming a first mixture comprising i) a first monomer comprising two aromatic primary amine groups, ii) a second monomer having only one aromatic primary amine group, iii) paraformaldehyde, and iv) a solvent, and heating the first mixture at a temperature of at least 150° C., preferably about 165° C. to about 280° C., thereby forming a second mixture comprising a polyhexahydrotriazine. The heating time at any of the above temperatures can be for about 1 minute to about 24 hours.
[0051] Alternatively, the PHT can be prepared by heating the solution comprising the PHA at a temperature of at least 150° C., preferably about 165° C. to about 280° C. even more preferably at about 180° C. to about 220° C., and most preferably at about 200° C. for about 1 minute to about 24 hours.
[0052] Also disclosed is a method of preparing a polyhemiaminal film, illustrated in the cross-sectional layer diagrams of FIG. 1 . A mixture comprising a polyhemiaminal and a solvent prepared as described above is disposed on a surface 12 of a substrate 10 , thereby forming structure 20 comprising an initial film layer 22 comprising the polyhemiaminal, solvent and/or water disposed on covered surface 24 of substrate 10 . Initial film layer 22 is heated at a temperature of about 20° C. to about 120° C. for about 1 minute to about 24 hours, thereby forming structure 30 comprising polyhemiaminal (PHA) film layer 32 disposed on the covered surface 34 of substrate 10 . PHA film layer 22 is substantially free of solvent and/or water.
[0053] The substrate can be any suitable substrate, in particular any substrate whose Young's modulus is a factor of 5 greater than the polyhemiaminal and/or polyhexahydrotriazine. Non-limiting examples of these materials include semiconductor wafers (e.g., silicon wafers), most metals, refractory materials, and possibly harder polymers.
[0054] The solvent mixture containing the PHA can be cast onto the substrate using any suitable coating technique (e.g., spin coating, dip coating, roll coating, spray coating, and the like).
[0055] Also disclosed is a method of preparing a polyhexahydrotriazine (PHT) film from a PHA film, illustrated in the cross-sectional layer diagrams of FIG. 2 . The polyhemiaminal film layer 32 of structure 30 can be heated at a temperature of at least 150° C., preferably about 165° C. to about 280° C. even more preferably at about 180° C. to about 220° C., and most preferably at about 200° C., thereby forming structure 40 comprising polyhexahydrotriazine (PHT) film layer 42 disposed on covered surface 44 of substrate 10 . The heating time at any of the above temperatures can be about 1 minute to about 24 hours. PHT film layer 42 is substantially free of solvent and water. The hemiaminal groups of the PHA film are substantially or wholly converted to hexahydrotriazine groups by heating the PHA film at a temperature in this range.
[0056] The number average molecular weight (Mn) of the PHA and/or PHT polymers in certain embodiments can be in a range of 1000 to 500,000, preferably in a range of 1000 to 50,000, and most preferably in a range of 1000 to 20,000.
[0057] The polyhexahydrotriazines are attractive for applications requiring lightweight, rigid, strong thermosets such as aerospace engineering, electronics, and as mixtures for increasing the modulus of known resins and composites. When end group monomers are incorporated to limit resin crosslink density, the resulting PHA and PHT monomers have improved properties with respect to applications related to processing for molding applications and film and fiber formation. That is, highly cross-linked PHA and PHT materials have comparatively low post-synthesis workability as compared to PHA and PHT materials with lower cross-link density.
[0058] FIG. 3 depicts an embodiment of a method for coating a component with a polymer. In element 300 of the method, a PHA film is formed on a substrate. The substrate in this example is a microelectronic component and the polymer is to be a portion of microelectronic packaging for protection against environmental contaminants, physical abrasion, or the like. In element 310 , the PHA film is heated to a first temperature that is above a glass transition temperature of the PHA film. When a polymer has a glass transition temperature (T g ), the polymer behaves in the manner of a rubber material at temperatures above the glass transition temperature. When in a rubber-like state the polymer may be more processable/moldable.
[0059] In element 320 , the PHA is processed, for example, molded to a predetermined shape. The processing and heating may occur simultaneously or in sequence. The heated, above T g polymer may more easily fill gaps, pores, cracks or the like than when in a glassy (sub-T g ) state. Additionally, the PHA and PHT materials are also solvent soluble, and this allows them to be processed by solvent filling or casting applications. It is also possible in some embodiments to prepare PHA/PHT materials by forming a pre-polymer liquid (e.g., monomeric/oligiomeric materials) and then cure (polymerize) the PHA/PHT material in a desired location using the described curing processes.
[0060] In element 330 , the PHA film is heated to a second temperature that is greater than the first temperature. In this embodiment, the second temperature is at or above a temperature at which the PHA film converts to a polyhexahydrotriazine (PHT) film (element 340 ).
[0061] The PHA film used in this example comprises a plurality of trivalent hemiaminal groups having the structure ( 5 ):
[0000]
[0000] and
a plurality of bridging groups of formula (2):
[0000]
[0000] and
a plurality of monovalent end groups of formula (3):
[0000]
[0000] wherein W′ is selected from the group consisting of: —H, —NH(R′), —N(R 2 )(R 3 ), —OH, —O(R 4 ), —S(R 5 ), —P(R 6 ), —R 7 —CF 3 , and combinations thereof, wherein R 1 comprises at least 1 carbon, R 2 comprises at least 1 carbon, R 3 comprises at least 1 carbon, R 4 comprises at least 1 carbon, R 5 comprises at least 1 carbon, R 6 comprises at least 1 carbon, R 7 comprises at least one carbon, and each of R 1 -R 7 may be independent or the same. Each starred bond of a given hemiaminal group is covalently linked to a respective one of the bridging groups (formula (2)) or a respective one of the monovalent end groups (formula (3)). Each starred bond of a given bridging group is linked to one of the hemiaminal groups. And each starred bond of a given monovalent end group is linked to one of the hemiaminal groups. As an example, the resulting PHT material has the structure depicted by formula (17).
[0062] The following examples illustrate the preparation of the PHA and PHT solids and films, and the characterization of their physical properties.
EXAMPLES
[0063] Materials used in the following examples are listed in Table 1.
[0000]
TABLE 1
ABBREVIATION
DESCRIPTION
SUPPLIER
PF
Paraformaldehyde
Sigma Aldrich
PD
p-Phenylenediamine
Sigma Aldrich
4-Å molecular sieves
Sigma Aldrich
DMF
Dimethylformamide
Sigma Aldrich
NMP
N-Methylpyrollidone
Sigma Aldrich
DPD
N,N-dimethyl-p-phenylenediamine
Sigma Aldrich
HTPT
Hexahydro-1,3,5-
Prepared below
triphenyl-1,3,5-triazine
MDA
4,4′-Methylenedianiline
Sigma Aldrich
ODA
4,4′-Oxydianiline
Sigma Aldrich
FDA
4,4′-(9-fluorenylidene)dianiline,
Sigma Aldrich
MW 348.4
[0064] Herein, Mn is the number average molecular weight, Mw is the weight average molecular weight, and MW is the molecular weight of one molecule.
[0065] N-Methyl-2-pyrrolidone (NMP), paraformaldehyde, 4,4′-diaminephenylmethane (MDA), and 4,4′-(9-fluorenylidene)dianiline (FDA) were purchased from Aldrich and used as received. 4,4′-Oxydianiline (ODA) was purchased from Aldrich, rinsed with acetone and dried in an Abderhalden drying pistol overnight prior to use. d 9 -NMP, d 6 -DMSO and CDCl 3 were purchased from Cambridge Isotope Laboratories (CIL) and used as received. d 9 -NMP, d 6 -DMSO and CDCl 3 were purchased from Cambridge Isotope Laboratories (CIL) and used as received.
[0066] 1 H NMR spectra were recorded on a Bruker Avance 400 spectrometer (400 MHz). Chemical shifts are reported in ppm from tetramethylsilane with the solvent resonance as the internal standard (CDCl 3 : delta 7.26 ppm; d 6 -DMSO: delta 2.50 ppm; d 9 -NMP: delta 3.23, 2.58, 1.80; d 6 -acetone: delta 2.05 ppm).
[0067] 13 C NMR spectra were recorded on a Bruker Avance 400 spectrometer (100 MHz) spectrometer with complete proton decoupling. Chemical shifts are reported in ppm from tetramethylsilane with the solvent resonance as the internal standard (CDCl 3 : delta 77.16 ppm; d 6 -DMSO: delta 39.51). Data are reported as follows: chemical shift, integration, multiplicity (s=singlet, d=doublet, t=triplet, q=quartet, sep=septet, bs=broad singlet, m=multiplet), and coupling constants (Hz).
[0068] Gel permeation chromatography (GPC) was performed in THF or DMF using a Waters system equipped with four 5 -micrometer Waters columns (300 mm×7.7 mm) connected in series with an increasing pore size (100, 1000, 10 5 , 10 6 Å), a Waters 410 differential refractometer, and a 996 photodiode array detector. The system was calibrated with polystyrene standards.
Syntheses
Example 1 (Comparative)
[0069] Reaction of aniline with paraformaldehyde to form hexahydrotriazine compound 4,4′,4″-(1,3,5-triazinane-1,3,5-triyl)tris(N,N-dimethylaniline) (HTPT).
[0000]
[0070] N,N-dimethyl-p-phenylenediamine (DPD, 0.21 g, 0.15 mmol) and paraformaldehyde (PF, 0.0046 g, 0.15 mmol, 1 equivalent (eq.)) were weighed out into a 2-Dram vial inside a glovebox. DMSO (0.91 g, 1.0 mL) was added. The reaction mixture was removed from the glovebox, and heated in an oil bath at 180° C. for 20 minutes. The DMSO was removed in vacuo and 4,4′,4″-(1,3,5-triazinane-1,3,5-triyl)tris(N,N-dimethylaniline) was collected as a brown solid (0.04 g, 79% yield).
[0071] The following procedure was used for a 1 H NMR time study of hemiaminal formation. DPD (0.021 g, 1.6 mmol ( FIG. 4 , 1 H NMR)) and PF (0.0057 g, 1.9 mmol, 1.2 eq.) were carefully weighed into a dried 2-Dram vial with stirbar in the dry box and d 6 -DMSO (1.0 mL, 1.6 M) was added by syringe. The mixture was transferred to a dried NMR tube and the condensation reaction was monitored over time. At 50° C. ( FIG. 5 , 1 H NMR), there are signals corresponding to the formation of hemiaminal, and no hexahydrotriazine is observed. After heating at 180° C., however, >98% conversion to the hexahydrotriazine product HTPT is observed ( FIG. 6 , 1 H NMR).
[0072] The purified HTPT has a singlet resonating at delta 4.5 ppm ( FIG. 7 , 1 H NMR spectrum) for the six methylene protons of HTPT. 1 H NMR (d 6 -DMSO, 400 MHz): delta 6.97 (d, 2H, J=8 Hz), 6.66 (d, 2H, J=8 Hz), 4.53 (s, 2H), 2.78 (s, 6H) ppm.
Example 2 (Comparative)
[0073] Preparation of polyhemiaminal P-1 by reaction of 4,4′-oxydianiline (ODA) with paraformaldehyde (PF). The product is a powder.
[0000]
[0074] 4,4′-Oxydianiline (ODA, 0.20 g, 1.0 mmol) and paraformaldehyde (PF, 0.15 g, 5.0 mmol, 5 equivalents (eq.)) were weighed out into a 2-Dram vial inside a N 2 -filled glovebox. N-methylpyrrolidone (NMP, 6.2 g, 6.0 mL) was added (0.17 M). The vial was capped but not sealed. The reaction mixture was removed from the glovebox, and heated in an oil bath at 50° C. for 24 hours (after approximately 0.75 hours, the polymer begins to precipitate in NMP). The polyhemiaminal P-1 was precipitated in acetone or water, filtered and collected to yield 0.22 g, >98% yield as a white solid. 13 C NMR (solid-state): 70, 120, and 145 ppm ( FIG. 8 ).
Example 3 (Comparative)
[0075] Preparation of polyhexahydrotriazine P-2 by reaction of p-phenylenediamine (PPD) and paraformaldehyde (PF). Product precipitates in water.
[0000]
[0076] p-Phenylenediamine (PPD, 0.11 g, 1.0 mmol) and paraformaldehyde (PF, 0.15 g, 5.0 mmol, 5 equivalents (eq.)) were weighed out into a 2-Dram vial inside a N 2 -filled glovebox. N-methylpyrrolidone (NMP, 6.2 g, 6.0 mL) was added (0.17 M). The vial was capped but not sealed. The reaction mixture was removed from the glovebox, and heated in an oil bath at 50° C. for 10 minutes hours. The polyhexahydrotriazine P-2 was precipitated in water, filtered and collected to as an off-white solid. 13 C NMR (solid-state): 70, 120, and 145 ppm.
Example 4
[0077] Preparation of polyhexahydrotriazine P-3 by reaction of p-phenylenediamine (PPD), N,N-dimethyl-p-phenylenediamine (DPD), and paraformaldehyde (PF). Product precipitates in diethylether and is soluble in dimethylformamide (DMF).
[0000]
[0078] Para-formaldehyde (0.090 g, 3.0 mmol), N,N-dimethylamino p-phenylenediamine (0.136 g, 1.0 mmol), and p-phenylenediamine (0.216 g, 2.0 mmol) were weighed out into a flask inside the glovebox. DMF was added (25% solids) and 0.400 g of 4-A molecular sieves were added to the flask to remove water over the course of the reaction. The reaction mixture was removed from the glovebox, and set up to heat in an oil bath set to 100° C. The reaction mixture was allowed to stir for 3.25 hours (after approximately 6 hours, the polymer begins to precipitate from the DMF solution). The resulting polymer was precipitated in diethylether, filtered and collected to yield 0.196 g, 70% yield as a brown solid. (Mn=15,069 Mw=21,560 PDI=1.43).
[0079] FIG. 9 is 1 H NMR data (sample collected after 3.25 hours) on the reaction product. 1 H NMR data is consistent with hexahydrotriazine formation as new signals were observed in the diagnostic methylene region between δ 4.0-5.0 ppm as well as downfield signals corresponding to electronically differentiated aromatic protons. FIG. 10 is a solid state 13 C NMR spectrum further confirming the formation of the polymer of example 4.
[0080] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. When a range is used to express a possible value using two numerical limits X and Y (e.g., a concentration of X ppm to Y ppm), unless otherwise stated the value can be X, Y, or any number between X and Y.
[0081] The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiments were chosen and described in order to best explain the principles of the invention and their practical application, and to enable others of ordinary skill in the art to understand the invention. | Polyhexahydrotriazine (PHT) and polyhemiaminal (PHA) materials incorporating divalent or trivalent bridging groups tend to form highly cross-linked polymers. While highly cross-linked polymers have certain advantageous with respect to stability and various physical characteristics, they are difficult to process once formed. PHA and PHT materials incorporating a plurality of trivalent PHA/PHT groups, a plurality of divalent bridging groups, and a plurality of monovalent end groups are disclosed. According to an embodiment, the cross-link density and molecular weight can be controlled by the inclusion of the end groups. Lower cross-link density and molecular weight give PHA and PHT materials improved characteristics with respect to film and fiber formation methods. A method of coating a component or substrate with a polymer is also disclosed. Embodiments of the method can be used to form either a PHA or PHT film on a substrate, such as microelectronic component. | 2 |
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates to an osteosynthesis device for providing fixation of oblique or spiroidal fractures or the fixation of lateral splinters through a ligature which is incomplete, non constrictive and with continuous resilient pressure.
When the bone is split into various fragments, it has been attempted to maintain the various fragments in place by means of ligatures with a thread of ligatures made with Parham type tapes. However, said ligatures which completely surround the bone are thereby constrictive, and their effect is to interrupt or gravely compromise the vascularization to a point that in such a case the bone thus squeezed breaks on the seat of the ligature.
On the other hand, when the medullary canal of a bone is occupied by a prosthesis or a nail, it is impossible to position a plate or to fix a fragment by positioning correctly a screw, that is by perforating the bone from cortical to cortical.
The device according to the present invention is characterized in that it is made of an open and resilient bracelet formed on it inner wall with several support points which contact the bone during use. Preferably, the number of said support points is three.
The invention will become more apparent from the following description of non limitative embodiments, reference being made to the accompanying drawings wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an embodiment of the device of the invention;
FIGS. 2 and 3 are partly sectional schematic views showing two examples of the positioning of the bracelet on a bone;
FIGS. 4 and 5 are two partial cross-sectional schematic views showing two examples of the positioning of the bracelet on a bone, in combination with a plate;
FIG. 6 is a perspective view showing an example of the positioning of the bracelet with a plate on a bone;
FIG. 7 is a partial cross-sectional schematic view showing an example of the positioning of the bracelet on a nailed bone;
FIG. 8 is a perspective view of an alternative embodiment,
FIG. 9 is a cross-sectional view of the device of FIG. 8;
FIG. 10 is a partial cross-sectional schematic view of a further embodiment of the invention,
FIG. 11 is a schematic view of clamps used for the frontal positioning of a bracelet according to the invention, and
FIG. 12 is a schematic view of a clamp provided for the lateral positioning of a bracelet according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, the device is a circular bracelet 1 formed with an opening over an angle slightly superior to 90°. The inner wall of the bracelet comprises three bosses 3, 4 and 5 which are pointed and form preferably an apex angle of 90°. As is shown in the figure, bosses 3 and 5 are positioned at the two ends of bracelet 1, boss 4 being in the center.
Each of the outer walls of the bracelet is respectively formed at its ends with a perforated wing 6 or 7.
FIGS. 2 and 3 show the manner in which the open bracelet 1 is used. The splinter B is maintained pressed onto the bone A through the support applied by point A, bracelet 1 being anchored through bosses 3 and 5 onto the bone. In FIG. 3, the bone is broken practically in its middle portion, boss 3 being engaged on one portion and bosses 4 and 5 on the other portion.
The bracelet may also be used for fixating a plate. Normally, a plate has to be screwed by a screw extending completely through the bone from cortical to cortical and through the medullar canal. But, as is shown in FIG. 4, it may happen that the medullar canal is obstructed by a nail such as at 8. In thus case, one of the bosses, such as boss 4, may be introduced into the holes provided in the plate and plate 9 is maintained in place on the bracelet. Generally, the plate screw holes are formed with a countersinking with an apex angle of 90° so that the boss may perfectly fit into the hole. Preferably, the depth of the the screw head countersinking is determined such that the boss 4 point may be in contact with the bone.
FIG. 5 shows an alternative use of the bracelet 1 for maintaining a plate 9 according to which plate 9 is maintained by an end boss of the bracelet.
FIG. 6 shows the use of several bracelets for maintaining a plate 9 along a femur provided with a prosthesis of the femur head comprising a nail 8 driven into the medullar canal.
Plate 9 is screwed by screws 10 in the inner portion of the bone and is maintained by bracelet 1 positioned either astride as is shown in FIG. 4 or by providing a lateral squeeze as is shown in FIG. 5.
FIG. 7 shows a further example of the use of the bracelet 1 on a multi-fragment fracture nailed by means of a slit nail.
FIGS. 8 and 9 show an alternative of the embodiment, according to which the bracelet 1 is formed with a plurality of tapped holes 12 in which the threaded bosses 13 can be engaged and the depth of which can be set, the length of each boss protruding inside the bracelet. Moreover, as there are more than three tapered openings 12, it is possible to vary the position of bosses 13.
The bracelet thus described is not circular and touches the bone only in three points. The result is that it can be perfectly adapted to any bone, whatever the irregularities of the contour of the latter.
Moreover, since only the points of the bosses are in contact with the cortical of the bone, or of the fragment splinters, whereas the body as such of the bracelet is out of contact, there is no constriction effect as is the case with the known devices.
Since the bracelet is put in position through resilient deformation, it acts like a spring and applies a constant pressure.
Further, it is always very easy to take away since it cannot be trapped into the bone mass.
FIG. 10 shows an alternative embodiment wherein the bracelet is triangular in shape whereby it can be adapted to the very particular shape of the tibia.
The bracelet is put in position by means of a spreading clamp, the branches of which are provided at their ends with protrusions 14 engaging the perforated wings 6 and 7; such a clamp may be straight as is shown in FIG. 11, or angled as is shown in FIG. 12. | A device for holding together the parts of a fractured bone which has the shape of an open resilient bracelet and which contacts the bone only at several support points. | 0 |
FIELD OF THE DISCLOSURE
[0001] This patent generally pertains to dock levelers and, more specifically, to curved transition plates for pivotal dock leveler decks.
BACKGROUND
[0002] A typical loading dock of a building includes an exterior doorway with an elevated platform for loading and unloading vehicles such as trucks and trailers. Many loading docks have a dock leveler to compensate for a height difference that may exist between the loading dock platform and an adjacent bed of a truck or trailer. A dock leveler often includes a deck that is hinged along its back edge so that the deck can pivotally adjust the height of its front edge to an elevation that generally matches the height of the rear edge of the truck or trailer bed. The deck usually has an extendible lip at its front edge that is extended to rest upon the trailer bed to form a bridge between the deck and the bed. This allows personnel and material handling equipment, such as a forklift truck, to readily move on and off the trailer during loading and unloading operations.
[0003] The hinge area at the rear edge of the deck, unfortunately, can present a surface interruption or discontinuity. As the wheels of material handling equipment roll over this area, the surface interruption can jar the moving equipment and its driver.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is a side view of an example dock leveler showing a rear portion of the deck in a cross-traffic position.
[0005] FIG. 2 is a side view similar to FIG. 1 , but showing the rear portion of the deck in a raised position.
[0006] FIG. 3 is a side view similar to FIG. 1 , but showing the rear portion of the deck in a lowered position.
[0007] FIG. 4 is a side view similar to FIG. 1 , but showing the deck in the cross-traffic position.
[0008] FIG. 5 is a side view similar to FIG. 2 , but showing the deck in the raised position and a lip of the deck partially extended.
[0009] FIG. 6 is a side view similar to FIG. 3 , but showing the deck in the lowered position.
[0010] FIG. 7 is a side view of the dock leveler of FIGS. 1-6 showing the deck in a slightly raised position with the lip engaging the bed of a vehicle.
[0011] FIG. 8 is a top view of FIG. 3 .
DETAILED DESCRIPTION
[0012] FIGS. 1-8 show an example dock leveler 10 for facilitating the loading and unloading of cargo on a trailer bed 12 or some other vehicle or truck bed. Dock leveler 10 includes a pivotally adjustable deck 14 with an extendible lip 16 that together provide a path or ramp over which a forklift and other material handling vehicle can travel between vehicle bed 12 and an elevated platform 18 of a loading dock 20 . A transition plate 22 provides a relatively smooth transition over which the wheels of the material handling vehicles can travel between platform 18 and a rear edge 24 of deck 14 .
[0013] To adjust the height of the deck's front edge 26 to roughly align with vehicle bed 12 and/or to move dock leveler 10 between a stored position ( FIGS. 1 and 4 ) and various operating positions, a rear hinge 28 allows deck 14 to pivot about a pivotal axis 30 . Deck 14 can pivot between a range of positions including, but not limited to, a raised position ( FIGS. 2 , 5 and 7 ), a cross-traffic position ( FIGS. 1 and 4 ), and a lowered position ( FIGS. 3 , 6 and 8 ). The pivotal motion is driven by any suitable means, examples of which include, but are not limited to, a hydraulic cylinder, a pneumatic cylinder, a fluid powered bladder, a motor driven linear actuator, a mechanical spring, a pneumatic spring, a winch, manual force, and/or various combinations thereof.
[0014] When deployed as shown in the example of FIG. 7 , deck 14 is in a slightly raised position with lip 16 extended and resting upon vehicle bed 12 . Although the illustrated example shows lip 16 being extendible by virtue of a hinge 32 that pivotally connects lip 16 to the deck's front edge 26 , other example dock levelers include a lip that extends and retracts in translation relative to the deck. Pivoting or translation of various example lips is driven by any suitable means, examples of which include, but are not limited to, a hydraulic cylinder, a pneumatic cylinder, a fluid powered bladder, a motor driven linear actuator, a mechanical spring, a pneumatic spring, a winch, manual force, linkage between deck 14 and lip 16 , and/or various combinations thereof.
[0015] In the illustrated example, dock leveler 10 includes a frame 34 installed within a pit 36 . In some installations, a shim pack 38 is placed underneath frame 34 such that when deck 14 is in the cross-traffic position ( FIGS. 1 and 4 ), a top surface 40 of deck 14 is generally horizontal and/or flush with platform 18 . Referring to FIGS. 1 and 8 , a hinge pin 42 of rear hinge 28 pivotally couples a plurality of frame lugs 44 of frame 34 to a plurality of deck lugs 46 of deck 14 , thereby rendering deck 14 pivotal about axis 30 .
[0016] To provide a smooth traffic surface over and/or adjacent to lugs 44 and 46 , transition plate 22 fully spans a horizontal distance 48 between a rear wall 50 of pit 36 and the deck's rear edge 24 . To provide such full coverage, transition plate 22 comprises a planar portion 22 a and a curved portion 22 b that span the distance 48 . Planar portion 22 a is adjacent to an upper edge 52 of rear wall 50 , and curved portion 22 b extends underneath rear edge 24 of deck 14 such that axis 30 is between rear wall 50 and a lower edge 53 of curved portion 22 b . Planar portion 22 a is substantially coplanar with platform 18 and surface 40 when deck 14 is in the cross-traffic position. In some examples, a tack weld joint 54 connects planar portion 22 a to the pit's upper edge 52 and edge 52 includes a structural angle 56 with an anchor 58 embedded within the concrete of platform 18 . In some examples, transition plate 22 is a unitary piece with portions 22 a and 22 b being integral extensions of each other to provide a preferably smooth seamless transition between portions 22 a and 22 b.
[0017] Having transition plate 22 extend fully and/or continuously from the pit's edge 52 to beyond the deck's rear edge 24 not only reduces and/or minimizes joints adjacent the rear edge 24 of the deck 14 , but also allows the deck's top surface 40 to extend substantially seamlessly from the deck's front edge 26 to the rear edge 24 . Also, transition plate 22 being mounted in a fixed, stationary location provides additional benefits that can be appreciated when the adjacent deck 14 moves or rises to the raised position of FIGS. 2 and 5 .
[0018] As deck 14 rises from the position of FIG. 1 to that of FIG. 2 , not only does the deck's front edge 26 rise, but rear edge 24 also rises. As rear edge 24 rises, any debris or obstruction at a gap 60 between plate 22 and deck 14 would tend to be lifted up and away by the upward movement of the deck's rear edge 24 , rather than being pulled down into gap 60 . Moreover, if melting snow or other moisture is on the top surface 40 as deck 14 rises to the position of FIGS. 2 and 5 , rear edge 24 extending above transition plate 22 tends to direct the moisture onto the top of transition plate 22 where the moisture can readily be removed (e.g., mopped or swept away). In contrast, if the deck's rear edge 24 were below the transition plate, dirt-laden water on deck 14 would tend to drain down through gap 60 and accumulate in pit 36 where removal or cleaning can be difficult.
[0019] Yet another benefit provided by the transition plate 22 of the illustrated example pertains to traction between the deck 16 and the wheels of material handling equipment. For greater traction, the deck's top surface 40 preferably is textured with an embossed pattern 62 commonly known as “diamond plate,” which is a herringbone pattern of raised rhombi 64 . During manufacturing, however, it may be difficult to bend the diamond plate into curved shapes by brake tooling (although it can be done), as the embossed pattern can interfere with the forming operation. So if a curved transition plate were attached directly to deck 14 , forming the curved plate would be easier if the plate is smooth. A smooth transition plate, however, provides less traction, and traction in the area of the transition plate is particularly important if the plate pivots with the deck. Moreover, if curved portion 22 b were an integral extension of a deck with a diamond plate top surface, the embossed rhombi 64 on the curved surface would make it difficult to maintain an even radial hinge gap (gap 60 ) at the curved surface. With the illustrated example, the deck's entire top surface 40 is comprised of a unitary piece of diamond plate that provides a seamless span 64 ( FIG. 4 ) from front edge 26 to rear edge 24 .
[0020] During manufacturing and/or installation, transition plate 22 being designed for stationary mounting at a fixed location makes handling plate 22 easier and less awkward than if it were attached to a large pivotal deck, which can be quite cumbersome. In some installation examples, transition plate 22 is attached to structural angle 56 at pit edge 52 and frame 34 after frame 34 is installed within pit 36 . Deck 14 would then be hung or coupled to the installed structure of frame 34 , transition plate 22 , and structural angle 56 , which can make the dock leveler 10 easier to install.
[0021] In the illustrated example, axis 30 of rear hinge 28 is co-axial with the center of curvature for curved portion 22 b . This ensures gap distance 60 between edge 24 and curved portion 22 b remains substantially constant as deck 14 pivots about axis 30 . In other examples, the axis 30 of the rear hinge 28 may be eccentric relative to a center of curvature of the curved portion 22 b.
[0022] In some examples, transition plate 22 includes notches 66 ( FIG. 8 ) that provide deck lugs 46 with additional clearance for allowing deck 14 to pivot upward and/or to facilitate the assembly of dock leveler 10 . In some examples, notches 66 provide clearance for receiving deck lugs 46 . In other examples, the notches are sized to provide clearance for both frame lugs 44 and deck lugs 46 . The axial clearances illustrated in FIG. 8 are exaggerated to show more clearly how transition plate 22 and lugs 44 and 46 fit together.
[0023] Some of the aforementioned examples may include one or more features and/or benefits including, but not limited to, the following:
[0024] Some example dock levelers include a curved transition plate slightly spaced apart from a pivotal deck's top surface, wherein both the transition plate and the top surface are separate unitary pieces, and the deck's top surface is a diamond plate that runs seamlessly from a front to rear edge of the deck.
[0025] Some example dock levelers include a curved transition plate that extends underneath the rear edge of a pivotal deck.
[0026] Some example dock levelers include a pivotal deck with a front edge and a rear edge that both rise as the deck pivots upward to a raised position.
[0027] Some example dock levelers include a curved transition plate that can be attached after a frame of the dock leveler is installed within a pit.
[0028] Some example dock levelers include a pivotal deck with a rear edge that can move or push debris and/or other obstructions up and away from a hinge gap.
[0029] Some example dock levelers include a pivotal deck with a rear edge that moves up and over the top of a curved transition plate as the deck rises, whereby water runoff from atop the inclined deck tends to drain onto the transition plate rather than down through a hinge gap that leads to a relatively inaccessible area beneath the deck.
[0030] Some example dock levelers include a transition plate that is structured for stationary mounting at a fixed location, which makes handling of the plate easier and less awkward than if the plate were attached directly to a large cumbersome deck.
[0031] Although certain example methods, apparatus and articles of manufacture have been described herein, the scope of the coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus and articles of manufacture fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents. | Example dock levelers at a truck-loading platform include a stationary curved transition plate extending between a rear edge of the leveler's pivotal deck and a rear edge of a pit at which the leveler is installed. The transition plate has a curved portion that extends underneath the deck's rear edge. The plate provides a smooth transition for forklifts traveling between the platform and the deck, thus reducing and/or minimizing the jarring of the forklift and its driver. To prevent debris and obstructions from getting trapped within the deck's rear hinge, the rear edge of the deck rises up and over the transition plate as the deck pivots upward, thereby providing a self-cleaning effect. With the rear edge of an inclined deck being above the transition plate, water runoff from the deck drains onto the transition plate rather than through the hinge gap to a generally inaccessible area underneath the deck. | 1 |
FIELD OF THE INVENTION
The present invention relates to a method for buffering media data. The invention also relates to a system, transmitting device, receiving device, an encoder, a decoder, an electronic device, a computer product, and a signal.
BACKGROUND OF THE INVENTION
Published video coding standards include ITU-T H.261, ITU-T H.263, ISO/IEC MPEG-1, ISO/IEC MPEG-2, and ISO/IEC MPEG-4 Part 2. These standards are herein referred to as conventional video coding standards.
Video Communication Systems
Video communication systems can be divided into conversational and non-conversational systems. Conversational systems include video conferencing and video telephony. Examples of such systems include ITU-T Recommendations H.320, H.323, and H.324 that specify a video conferencing/telephony system operating in ISDN, IP, and PSTN networks respectively. Conversational systems are characterized by the intent to minimize the end-to-end delay (from audio-video capture to the far-end audio-video presentation) in order to improve the user experience.
Non-conversational systems include playback of stored content, such as Digital Versatile Disks (DVDs) or video files stored in a mass memory of a playback device, digital TV, and streaming. A short review of the most important standards in these technology areas is given below.
A dominant standard in digital video consumer electronics today is MPEG-2, which includes specifications for video compression, audio compression, storage, and transport. The storage and transport of coded video is based on the concept of an elementary stream. An elementary stream consists of coded data from a single source (e.g. video) plus ancillary data needed for synchronization, identification and characterization of the source information. An elementary stream is packetized into either constant-length or variable-length packets to form a Packetized Elementary Stream (PES). Each PES packet consists of a header followed by stream data called the payload. PES packets from various elementary streams are combined to form either a Program Stream (PS) or a Transport Stream (TS). PS is aimed at applications having negligible transmission errors, such as store-and-play type of applications. TS is aimed at applications that are susceptible of transmission errors. However, TS assumes that the network throughput is guaranteed to be constant.
The Joint Video Team (JVT) of ITU-T and ISO/IEC has prepared a standard published as ITU-T Recommendation H.264 and ISO/IEC International Standard 14496-10 (MPEG-4 Part 10). The standard is referred to as the JVT coding standard in this paper, and the codec according to the draft standard is referred to as the JVT codec.
The codec specification itself distinguishes conceptually between a video coding layer (VCL), and a network abstraction layer (NAL). The VCL contains the signal processing functionality of the codec, things such as transform, quantization, motion search/compensation, and the loop filter. It follows the general concept of most of today's video codecs, a macroblock-based coder that utilizes inter picture prediction with motion compensation, and transform coding of the residual signal. The output of the VCL are slices: a bit string that contains the macroblock data of an integer number of macroblocks, and the information of the slice header (containing the spatial address of the first macroblock in the slice, the initial quantization parameter, and similar). Macroblocks in slices are ordered in scan order unless a different macroblock allocation is specified, using the so-called Flexible Macroblock Ordering syntax. In-picture prediction is used only within a slice.
The NAL encapsulates the slice output of the VCL into Network Abstraction Layer Units (NAL units or NALUs), which are suitable for the transmission over packet networks or the use in packet oriented multiplex environments. JVT's Annex B defines an encapsulation process to transmit such NALUs over byte-stream oriented networks.
The optional reference picture selection mode of H.263 and the NEWPRED coding tool of MPEG-4 Part 2 enable selection of the reference frame for motion compensation per each picture segment, e.g., per each slice in H.263. Furthermore, the optional Enhanced Reference Picture Selection mode of H.263 and the JVT coding standard enable selection of the reference frame for each macroblock separately.
Reference picture selection enables many types of temporal scalability schemes. FIG. 1 shows an example of a temporal scalability scheme, which is herein referred to as recursive temporal scalability. The example scheme can be decoded with three constant frame rates. FIG. 2 depicts a scheme referred to as Video Redundancy Coding, where a sequence of pictures is divided into two or more independently coded threads in an interleaved manner. The arrows in these and all the subsequent figures indicate the direction of motion compensation and the values under the frames correspond to the relative capturing and displaying times of the frames.
Transmission Order
In conventional video coding standards, the decoding order of pictures is the same as the display order except for B pictures. A block in a conventional B picture can be bi-directionally temporally predicted from two reference pictures, where one reference picture is temporally preceding and the other reference picture is temporally succeeding in display order. Only the latest reference picture in decoding order can succeed the B picture in display order (exception: interlaced coding in H.263 where both field pictures of a temporally subsequent reference frame can precede a B picture in decoding order). A conventional B picture cannot be used as a reference picture for temporal prediction, and therefore a conventional B picture can be disposed of without affecting the decoding of any other pictures.
The JVT coding standard includes the following novel technical features compared to earlier standards:
The decoding order of pictures is decoupled from the display order. The picture number indicates decoding order and the picture order count indicates the display order. Reference pictures for a block in a B picture can either be before or after the B picture in display order. Consequently, a B picture stands for a bi-predictive picture instead of a bi-directional picture. Pictures that are not used as reference pictures are marked explicitly. A picture of any type (intra, inter, B, etc.) can either be a reference picture or a non-reference picture. (Thus, a B picture can be used as a reference picture for temporal prediction of other pictures.) A picture can contain slices that are coded with a different coding type. In other words, a coded picture may consist of an intra-coded slice and a B-coded slice, for example.
Decoupling of display order from decoding order can be beneficial from compression efficiency and error resiliency point of view.
An example of a prediction structure potentially improving compression efficiency is presented in FIG. 3 . Boxes indicate pictures, capital letters within boxes indicate coding types, numbers within boxes are picture numbers according to the JVT coding standard, and arrows indicate prediction dependencies. Note that picture B 17 is a reference picture for pictures B 18 . Compression efficiency is potentially improved compared to conventional coding, because the reference pictures for pictures B 18 are temporally closer compared to conventional coding with PBBP or PBBBP coded picture patterns. Compression efficiency is potentially improved compared to conventional PBP coded picture pattern, because part of reference pictures are bi-directionally predicted.
FIG. 4 presents an example of the intra picture postponement method that can be used to improve error resiliency. Conventionally, an intra picture is coded immediately after a scene cut or as a response to an expired intra picture refresh period, for example. In the intra picture postponement method, an intra picture is not coded immediately after a need to code an intra picture arises, but rather a temporally subsequent picture is selected as an intra picture. Each picture between the coded intra picture and the conventional location of an intra picture is predicted from the next temporally subsequent picture. As FIG. 4 shows, the intra picture postponement method generates two independent inter picture prediction chains, whereas conventional coding algorithms produce a single inter picture chain. It is intuitively clear that the two-chain approach is more robust against erasure errors than the one-chain conventional approach. If one chain suffers from a packet loss, the other chain may still be correctly received. In conventional coding, a packet loss always causes error propagation to the rest of the inter picture prediction chain.
Two types of ordering and timing information have been conventionally associated with digital video: decoding and presentation order. A closer look at the related technology is taken below.
A decoding timestamp (DTS) indicates the time relative to a reference clock that a coded data unit is supposed to be decoded. If DTS is coded and transmitted, it serves for two purposes: First, if the decoding order of pictures differs from their output order, DTS indicates the decoding order explicitly. Second, DTS guarantees a certain pre-decoder buffering behavior provided that the reception rate is close to the transmission rate at any moment. In networks where the end-to-end latency varies, the second use of DTS plays little or no role. Instead, received data is decoded as fast as possible provided that there is room in the post-decoder buffer for uncompressed pictures.
Carriage of DTS depends on the communication system and video coding standard in use. In MPEG-2 Systems, DTS can optionally be transmitted as one item in the header of a PES packet. In the JVT coding standard, DTS can optionally be carried as a part of Supplemental Enhancement Information (SEI), and it is used in the operation of an optional Hypothetical Reference Decoder. In ISO Base Media File Format, DTS is dedicated its own box type, Decoding Time to Sample Box. In many systems, such as RTP-based streaming systems, DTS is not carried at all, because decoding order is assumed to be the same as transmission order and exact decoding time does not play an important role.
H.263 optional Annex U and Annex W.6.12 specify a picture number that is incremented by 1 relative to the previous reference picture in decoding order. In the JVT coding standard, the frame number coding element is specified similarly to the picture number of H.263. The JVT coding standard specifies a particular type of an intra picture, called an instantaneous decoder refresh (IDR) picture. No subsequent picture can refer to pictures that are earlier than the IDR picture in decoding order. An IDR picture is often coded as a response to a scene change. In the JVT coding standard, frame number is reset to 0 at an IDR picture.
H.263 picture number can be used to recover the decoding order of reference pictures. Similarly, the JVT frame number can be used to recover the decoding order of frames between an IDR picture (inclusive) and the next IDR picture (exclusive) in decoding order. However, because the complementary reference field pairs (consecutive pictures coded as fields that are of different parity) share the same frame number, their decoding order cannot be reconstructed from the frame numbers.
The H.263 picture number or JVT frame number of a non-reference picture is specified to be equal to the picture or frame number of the previous reference picture in decoding order plus 1. If several non-reference pictures are consecutive in decoding order, they share the same picture or frame number. The picture or frame number of a non-reference picture is also the same as the picture or frame number of the following reference picture in decoding order. The decoding order of consecutive non-reference pictures can be recovered using the Temporal Reference (TR) coding element in H.263 or the Picture Order Count (POC) concept of the JVT coding standard.
The draft RTP payload of the JVT codec (S. Wenger, et. al, “RTP Payload Format for H.264 Video,” draft-ieff-avt-rtp-h264-11.txt, August 2004) specifies three packetization modes: single NAL unit mode, non-interleaved mode, and interleaved mode. In the single NAL unit and non-interleaved modes, the decoding order of NAL units is identical to their transmission order. In the interleaved packetization mode, the transmission order of NAL units is allowed to differ from the decoding order of the NAL units. Decoding order number (DON) is a field in the payload structure or a derived variable that indicates the NAL unit decoding order. The DON value of the first NAL unit in transmission order may be set to any value. Values of DON are in the range of 0 to 65535, inclusive. After reaching the maximum value, the value of DON wraps around to 0. The decoding order of two NAL units in the interleaved packetization mode is determined as follows. Let DON(i) be the decoding order number of the NAL unit having index i in the transmission order. Function don_diff(m,n) is specified as follows:
If DON( m )==DON( n ), don_diff( m,n )=0
If (DON( m )<DON( n ) and DON( n )−DON( m )<32768), don_diff( m,n )=DON( n )−DON( m )
If (DON( m )>DON( n ) and DON( m )−DON( n )>=32768), don_diff( m,n )=65536−DON( m )+DON( n )
If (DON( m )<DON( n ) and DON( n )−DON( m )>=32768), don_diff( m,n )=−(DON( m )+65536−DON( n ))
If (DON( m )>DON( n ) and DON( m )−DON( n )<32768), don_diff( m,n )=−(DON( m )−DON( n ))
A positive value of don_diff(m,n) indicates that the NAL unit having transmission order index n follows, in decoding order, the NAL unit having transmission order index m. When don_diff(m,n) is equal to 0, then the NAL unit decoding order of the two NAL units can be in either order. For example, when arbitrary slice order is allowed by the video coding profile in use, all the coded slice NAL units of a coded picture are allowed to have the same value of DON. A negative value of don_diff(m,n) indicates that the NAL unit having transmission order index n precedes, in decoding order, the NAL unit having transmission order index m.
A presentation timestamp (PTS) indicates the time relative to a reference clock when a picture is supposed to be displayed. A presentation timestamp is also called a display timestamp, output timestamp, and composition timestamp.
Carriage of PTS depends on the communication system and video coding standard in use. In MPEG-2 Systems, PTS can optionally be transmitted as one item in the header of a PES packet. In the JVT coding standard, PTS can optionally be carried as a part of Supplemental Enhancement Information (SEI). In ISO Base Media File Format, PTS is dedicated its own box type, Composition Time to Sample Box where the presentation timestamp is coded relative to the corresponding decoding timestamp. In RTP, the RTP timestamp in the RTP packet header corresponds to PTS.
Many of the conventional video coding standards feature the Temporal Reference (TR) coding element that is similar to PTS in many aspects. In some of the conventional coding standards, such as MPEG-2 video, TR is reset to zero at the beginning of a Group of Pictures (GOP). In the JVT coding standard, there is no concept of time in the video coding layer. The Picture Order Count (POC) is specified for each frame and field and it is used similarly to TR in direct temporal prediction of B slices, for example. POC is reset to 0 at an IDR picture.
Buffering
Streaming clients typically have a receiver buffer that is capable of storing a relatively large amount of data. Initially, when a streaming session is established, a client does not start playing the stream back immediately, but rather it typically buffers the incoming data for a few seconds. This buffering helps to maintain continuous playback, because, in case of occasional increased transmission delays or network throughput drops, the client can decode and play buffered data. Otherwise, without initial buffering, the client has to freeze the display, stop decoding, and wait for incoming data. The buffering is also necessary for either automatic or selective retransmission in any protocol level. If any part of a picture is lost, a retransmission mechanism may be used to resend the lost data. If the retransmitted data is received before its scheduled decoding or playback time, the loss is perfectly recovered.
Coded pictures can be ranked according to their importance in the subjective quality of the decoded sequence. For example, non-reference pictures, such as conventional B pictures, are subjectively least important, because their absence does not affect decoding of any other pictures. Subjective ranking can also be made on data partition or slice group basis. Coded slices and data partitions that are subjectively the most important can be sent earlier than their decoding order indicates, whereas coded slices and data partitions that are subjectively the least important can be sent later than their natural coding order indicates. Consequently, any retransmitted parts of the most important slice and data partitions are more likely to be received before their scheduled decoding or playback time compared to the least important slices and data partitions.
Pre-Decoder Buffering
Pre-decoder buffering refers to buffering of coded data before it is decoded. Initial buffering refers to pre-decoder buffering at the beginning of a streaming session. Initial buffering is conventionally done for two reasons explained below.
In conversational packet-switched multimedia systems, e.g., in IP-based video conferencing systems, different types of media are normally carried in separate packets. Moreover, packets are typically carried on top of a best-effort network that cannot guarantee a constant transmission delay, but rather the delay may vary from packet to packet. Consequently, packets having the same presentation (playback) time-stamp may not be received at the same time, and the reception interval of two packets may not be the same as their presentation interval (in terms of time). Thus, in order to maintain playback synchronization between different media types and to maintain the correct playback rate, a multimedia terminal typically buffers received data for a short period (e.g. less than half a second) in order to smooth out delay variation. Herein, this type of a buffer component is referred as a delay jitter buffer. Buffering can take place before and/or after media data decoding.
Delay jitter buffering is also applied in streaming systems. Due to the fact that streaming is a non-conversational application, the delay jitter buffer required may be considerably larger than in conversational applications. When a streaming player has established a connection to a server and requested a multimedia stream to be downloaded, the server begins to transmit the desired stream. The player does not start playing the stream back immediately, but rather it typically buffers the incoming data for a certain period, typically a few seconds. Herein, this buffering is referred to as initial buffering. Initial buffering provides the ability to smooth out transmission delay variations in a manner similar to that provided by delay jitter buffering in conversational applications. In addition, it may enable the use of link, transport, and/or application layer retransmissions of lost protocol data units (PDUs). The player can decode and play buffered data while retransmitted PDUs may be received in time to be decoded and played back at the scheduled moment.
Initial buffering in streaming clients provides yet another advantage that cannot be achieved in conversational systems: it allows the data rate of the media transmitted from the server to vary. In other words, media packets can be temporarily transmitted faster or slower than their playback rate as long as the receiver buffer does not overflow or underflow. The fluctuation in the data rate may originate from two sources.
First, the compression efficiency achievable in some media types, such as video, still images, audio and text, depends on the contents of the source data. Consequently, if a stable quality is desired, the bit-rate of the resulting compressed bit-stream varies. Typically, a stable audio-visual quality is subjectively more pleasing than a varying quality. Thus, initial buffering enables a more pleasing audio-visual quality to be achieved compared with a system without initial buffering, such as a video conferencing system.
Second, it is commonly known that packet losses in fixed IP networks occur in bursts. In order to avoid bursty errors and high peak bit- and packet-rates, well-designed streaming servers schedule the transmission of packets carefully. Packets may not be sent precisely at the rate they are played back at the receiving end, but rather the servers may try to achieve a steady interval between transmitted packets. A server may also adjust the rate of packet transmission in accordance with prevailing network conditions, reducing the packet transmission rate when the network becomes congested and increasing it if network conditions allow, for example.
Yet another advantage of pre-decoder buffering is that it enables arranging of transmission units from the reception order to decoding order. The reception order is identical to the transmission order provided that no re-order of transmission units happened in the transmission path.
Transmission of Multimedia Streams
A multimedia streaming system consists of a streaming server and a number of players, which access the server via a network. The network is typically packet-oriented and provides little or no means to guaranteed quality of service. The players fetch either pre-stored or live multimedia content from the server and play it back in real-time while the content is being downloaded. The type of communication can be either point-to-point or multicast. In point-to-point streaming, the server provides a separate connection for each player. In multicast streaming, the server transmits a single data stream to a number of players, and network elements duplicate the stream only if it is necessary.
When a player has established a connection to a server and requested for a multimedia stream, the server begins to transmit the desired stream. The player does not start playing the stream back immediately, but rather it typically buffers the incoming data for a few seconds. Herein, this buffering is referred to as initial buffering. Initial buffering helps to maintain pauseless playback, because, in case of occasional increased transmission delays or network throughput drops, the player can decode and play buffered data.
In order to avoid unlimited transmission delay, it is uncommon to favor reliable transport protocols in streaming systems. Instead, the systems prefer unreliable transport protocols, such as UDP, which, on one hand, inherit a more stable transmission delay, but, on the other hand, also suffer from data corruption or loss.
RTP and RTCP protocols can be used on top of UDP to control real-time communications. RTP provides means to detect losses of transmission packets, to reassemble the correct transmission order of packets in the receiving end, and to associate a sampling time-stamp with each packet. Among other things RTCP conveys information about how large a portion of packets were correctly received, and, therefore, it can be used for flow control purposes.
In conventional video coding standards, the decoding order is coupled with the output order. In other words, the decoding order of I and P pictures is the same as their output order, and the decoding order of a B picture immediately follows the decoding order of the latter reference picture of the B picture in output order. Consequently, it is possible to recover the decoding order based on known output order. The output order is typically conveyed in the elementary video bitstream in the Temporal Reference (TR) field and also in the system multiplex layer, such as in the RTP header.
Some RTP payload specifications allow transmission of coded data out of decoding order. The amount of disorder is typically characterized by one value that is defined similarly in many relevant specifications. For example, in the draft RTP Payload Format for Transport of MPEG-4 Elementary Streams, the maxDisplacement parameter is specified as follows:
The maximum displacement in time of an access unit (AU, corresponding to a coded picture) is the maximum difference between the time stamp of an AU in the pattern and the time stamp of the earliest AU that is not yet present. In other words, when considering a sequence of interleaved AUs, then:
Maximum displacement=max{TS( i )−TS( j )}, for any i and any j>i,
where i and j indicate the index of the AU in the interleaving pattern and TS denotes the time stamp of the AU
It has been noticed in the present invention that in this method there are some problems:
RTP timestamp indicates the capture/display timestamp. The JVT coding standard allows decoding order different from output order. The receiver buffer is used to reorder packets from transmission/reception order to decoding order. Thus, displacement specified between differences in RTP timestamps cannot be used to arrange transmission units from transmission order to decoding order.
The U.S. patent application 60/483,159 describes buffering operation based on parameter sprop-interleaving-depth, which specifies the maximum number of VCL NAL units that precede any VCL NAL unit in the NAL unit stream in transmission order and follow the VCL NAL unit in decoding order. Constant N is the value of the sprop-interleaving-depth parameter incremented by 1. If the parameter is not present, a 0 value number could be implied. The receiver buffering operates as follows.
When the video stream transfer session is initialized, the receiver allocates memory for the receiving buffer for storing at least N pieces of VCL NAL units. The receiver then starts to receive the video stream and stores the received VCL NAL units into the receiving buffer, until at least N pieces of VCL NAL units are stored into the receiving buffer.
When the receiver buffer contains at least N VCL NAL units, NAL units are removed from the receiver buffer one by one and passed to the decoder. The NAL units are not necessarily removed from the receiver buffer in the same order in which they were stored, but according to the decoding order number (DON) of the NAL units, as described below. The delivery of the packets to the decoder is continued until the buffer contains less than N VCL NAL units, i.e. N−1 VCL NAL units.
It has been noticed that the buffering operation in the U.S. patent application 60/483,159 has some problems. For example, if there are transmission losses the decoder may not receive all the transmitted transmission units. Therefore, the decoding buffer is filled more slowly in the decoder than in a situation in which all transmission units are received. Thus, the pictures may be output from the decoder buffer slower than what is optimal for the decoder. Another problem may arise when consecutive decoding order numbers in transmission order do not follow a constant pattern. In other words, if the difference of decoding order numbers of two successively decodable transmission units changes from time to time then sprop-interleaving-depth is selected according the largest number of VCL NAL units in the receiver buffer that must be present in order to arrange NAL units correctly in decoding order and therefore buffering for an individual NAL unit may last longer than necessary to output it from the receiver buffer in correct decoding order.
SUMMARY OF THE INVENTION
According to a first aspect of the present invention there is provided a method for buffering media data in a buffer,
the media data being included in data transmission units, the data transmission units having been ordered in a transmission order which is at least partly different from a decoding order of the media data in the data transmission units, the decoding order having been indicated with a quantitative indicator for at least part of the transmission units, wherein the method comprises: defining a parameter for a relation of the quantitative indicators of transmission units; checking the relation of transmission units in the buffer against the parameter, the result of the checking being indicative of at least one transmission unit in the buffer preceding, in decoding order, any transmission unit in a sequence of transmission units not having been buffered in the buffer before the checking.
According to a second aspect of the present invention there is provided a method for buffering media data in a buffer,
the media data being included in data transmission units, the data transmission units having been ordered in a transmission order which is at least partly different from a decoding order of the media data in the data transmission units, the decoding order having been indicated with a quantitative indicator for at least part of the transmission units, wherein the method comprises: defining a parameter for a relation of the quantitative indicators of transmission units; checking the relation of transmission units in the buffer against the parameter, the result of the checking being indicative of whether at least one of the transmission units in the buffer can be output.
According to a third aspect of the present invention there is provided a method for transmitting media data comprising
including the media data in data transmission units; ordering the data transmission units in a transmission order which is at least partly different from a decoding order of the media data in the data transmission units; indicating the decoding order with a quantitative indicator for at least part of the transmission units; defining a parameter for a relation of the quantitative indicators of transmission units; transmitting transmission units to a receiver; receiving transmission units in the receiver; buffering the received transmission units in a buffer, checking the relation of transmission units in the buffer against the parameter; the result of the checking being indicative of at least one transmission unit in the buffer preceding, in decoding order, any transmission unit in a sequence of transmission units not having been buffered in the buffer before the checking.
According to a fourth aspect of the present invention there is provided a decoder for decoding media data,
the media data being included in data transmission units, the data transmission units having been ordered in a transmission order which is at least partly different from a decoding order of the media data in the data transmission units; and the decoding order having been indicated with a quantitative indicator for at least part of the transmission units; the decoder comprising: an input for receiving transmission units; a buffer for buffering transmission units; a verifier for checking the relation of two transmission units in the buffer against a parameter defined for a relation of the quantitative indicators of two transmission units, and for providing a result of the checking being indicative of whether at least one of the transmission units in the buffer can be output.
According to a fifth aspect of the present invention there is provided a module for buffering media data,
the media data being included in data transmission units, the data transmission units having been ordered in a transmission order which is at least partly different from a decoding order of the media data in the data transmission units; and the decoding order having been indicated with a quantitative indicator for at least part of the transmission units; the module comprising: an input for receiving transmission units; a verifier for checking the relation of two transmission units in a buffer against a parameter defined for a relation of the quantitative indicators of two transmission units, and for providing a result of the checking being indicative of whether at least one of the transmission units in the buffer can be output.
According to a sixth aspect of the present invention there is provided an encoder for arranging media data in transmission units comprising:
an input for inputting media data; a handler for including the media data in data transmission units; an arranger for ordering the data transmission units in a transmission order which is at least partly different from a decoding order of the media data in the data transmission units; a quantitative indicator for indicating the decoding order for at least part of the transmission units; and a definer for defining a parameter for a relation of the quantitative indicators of transmission units.
According to a seventh aspect of the present invention there is provided a system comprising
an encoder for arranging media data in transmission units, the encoder comprising: an input for inputting media data; a handler for including the media data in data transmission units; an arranger for ordering the data transmission units in a transmission order which is at least partly different from a decoding order of the media data in the data transmission units; a quantitative indicator for indicating the decoding order for at least part of the transmission units; and a definer for defining a parameter for a relation of the quantitative indicators of transmission units; a transmitter for transmitting the transmission units; a receiver for receiving the transmission units; a decoder for decoding media data included in the transmission units, the decoder comprising: an input for receiving transmission units; a buffer for buffering transmission units; a verifier for checking the relation of two transmission units in the buffer against a parameter defined for a relation of the quantitative indicators of two transmission units, and for providing a result of the checking being indicative of whether at least one of the transmission units in the buffer can be output.
According to an eighth aspect of the present invention there is provided a device comprising
an input for inputting media data; a handler for including media data in data transmission units; an arranger for ordering the data transmission units in a transmission order which is at least partly different from a decoding order of the media data in the data transmission units; a quantitative indicator for indicating the decoding order for at least part of the transmission units; and a definer for defining a parameter for a relation of the quantitative indicators of transmission units.
According to a ninth aspect of the present invention there is provided a device comprising
an input for inputting transmission units included with media data; a buffer for buffering received transmission units; and a verifier for checking the relation of two transmission units in the buffer against a parameter defined for a relation of the quantitative indicators of two transmission units, and for providing a result of the checking being indicative of whether at least one of the transmission units in the buffer can be output.
According to a tenth aspect of the present invention there is provided a wireless communication device comprising
an input for inputting media data; a handler for including media data in data transmission units; an arranger for ordering the data transmission units in a transmission order which is at least partly different from a decoding order of the media data in the data transmission units; a quantitative indicator for indicating the decoding order for at least part of the transmission units; and a definer for defining a parameter for a relation of the quantitative indicators of transmission units; and a transmitter for transmitting the transmission units.
According to an eleventh aspect of the present invention there is provided a signal for transmitting media data in data transmission units comprising
the data transmission units ordered in a transmission order which is at least partly different from a decoding order of the media data in the data transmission units; a quantitative indicator indicating the decoding order for at least part of the transmission units; a parameter defined for a relation of the quantitative indicators of transmission units.
According to a twelfth aspect of the present invention there is provided a computer program product comprising machine executable steps for buffering media data in a buffer,
the media data being included in data transmission units, the data transmission units having been ordered in a transmission order which is at least partly different from a decoding order of the media data in the data transmission units, the decoding order having been indicated with a quantitative indicator for at least part of the transmission units, wherein the computer program product comprising machine executable steps for: defining a parameter for a relation of the quantitative indicators of transmission units; and checking the relation of transmission units in the buffer against the parameter, the result of the checking being indicative of whether at least one of the transmission units in the buffer can be output.
According to a thirteenth aspect of the present invention there is provided a computer program product for arranging media data in transmission units comprising machine executable steps for:
including the media data in data transmission units; ordering the data transmission units in a transmission order which is at least partly different from a decoding order of the media data in the data transmission units; indicating the decoding order with a quantitative indicator for at least part of the transmission units; and defining a parameter for a relation of the quantitative indicators of transmission units.
The present invention may reduce the buffering delay before the decoder can start to decode the media data in the transmission units and output the decoded data.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an example of a recursive temporal scalability scheme,
FIG. 2 depicts a scheme referred to as Video Redundancy Coding, where a sequence of pictures is divided into two or more independently coded threads in an interleaved manner,
FIG. 3 presents an example of a prediction structure potentially improving compression efficiency,
FIG. 4 presents an example of the intra picture postponement method that can be used to improve error resiliency,
FIG. 5 depicts an advantageous embodiment of the system according to the present invention,
FIG. 6 depicts an advantageous embodiment of the encoder according to the present invention,
FIG. 7 depicts an advantageous embodiment of the decoder according to the present invention,
FIG. 8 depicts a signal according to the present invention,
FIG. 9 depicts a diagram of the method and a computer program according to the present invention employing the use of the quantitative indicator of the decoding order, and
FIG. 10 depicts a diagram of the method and a computer program according to the present invention employing the use of the quantitative indicator of the decoding order and an indicator of the transmission unit order.
DETAILED DESCRIPTION OF THE INVENTION
An example of a scheme where the invention can be applied follows. The sequence is spliced into pieces of a number of transmission units. The transmission units are transmitted in the following transmission order, where the numbers indicate the decoding order numbers of the transmission units:
0, 8, 12, 2, 24, 14, 31, . . .
If the decoder buffer receives all the above mentioned transmission units, the calculated maximum (absolute) difference between decoding order numbers of transmission units in the decoding buffer are as follows, if no transmission units are outputted from the buffer:
after the second transmission unit, the difference would be 8 (the absolute difference between the first and the second decoding order number);
after the third transmission unit, the difference would be 12 (the absolute difference between the first and the third decoding order number);
after the fourth transmission unit, the difference would be 12 (the absolute difference between the first and the third decoding order number);
after the fifth transmission unit, the difference would be 24 (the absolute difference between the first and the fifth decoding order number);
after the sixth transmission unit, the difference would be 24 (the absolute difference between the first and the fifth decoding order number);
after the seventh transmission unit, the difference would be 31 (the absolute difference between the first and the seventh decoding order number).
The signal carrying the above described example of a sequence is depicted in FIG. 8 as a reference 802 .
Let us assume that a maximum value for the difference is defined as 16. This means that the decoder begins to output the decoded pictures when the fifth transmission unit is received and decoded. The outputting may happen before the fifth transmission unit is stored to the buffer, or after the fifth transmission unit is stored to the buffer, or even simultaneously (in-place replacement).
The reference 801 in FIG. 8 depicts a part of a signal which carries the parameter max-don-diff.
When transmission units are removed from the buffer according to the invention in the above sequence, and the maximum value for the difference is defined as 16, the buffer behaves as follows:
after the second transmission unit, the difference would be 8, and the buffer contents would be [0, 8];
after the third transmission unit, the difference would be 12, and the buffer contents would be [0, 8, 12];
after the fourth transmission unit, the difference would be 12, and the buffer contents would be [0, 8, 12, 2];
after the fifth transmission unit, the difference would be 16, and the buffer contents would be [8, 12, 24], since the maximum difference was exceeded and transmission units 0 and 2 were outputted;
after the sixth transmission unit, the difference would be 16, and the buffer contents would be [8, 12, 24, 14];
after the seventh transmission unit, the difference would be 7, and the buffer contents would be [24, 31], since the maximum difference was exceeded and transmission units 8, 12 and 14 were outputted.
In the situation in which transmission errors exist, the calculated difference values can be different from calculated difference values when no transmission units are lost during transmission. For example, if the decoder receives the following transmission units 0, 8, 2, 24, 14, 31, . . . i.e. the third transmission unit is lost, the decoder calculates the maximum (absolute) difference between decoding order numbers of transmission units in the decoding buffer. The results of the calculation are in this example:
after the second transmission unit, the difference would be 8, and the buffer contents would be [0, 8];
after the third transmission unit, the difference would be 8, and the buffer contents would be [0, 8, 2];
after the fourth transmission unit, the difference would be 16, and the buffer contents would be [8, 24], since the maximum difference was exceeded and transmission units 0 and 2 were outputted;
after the fifth transmission unit, the difference would be 16, and the buffer contents would be [8, 24, 14];
after the sixth transmission unit, the difference would be 7, and the buffer contents would be [24, 31], since the maximum difference was exceeded and transmission units 8 and 14 were outputted.
This means that the condition for the maximum value is fulfilled after the fourth transmission unit is received to the decoder buffer whereafter the decoder may also begin to output the decoded picture after decoding the fourth transmission unit. It can be seen from the above that in this example situation the decoder begins to output the decoded pictures when the transmission unit in which the decoding order number is 24 in both the errorless transmission situation and in the situation in which a transmission unit is lost. The present invention can therefore reduce the extra delay in the outputting of decoded pictures caused by the transmission losses compared to prior art solutions.
In the following, an independent GOP consists of pictures from an IDR picture (inclusive) to the next IDR picture (exclusive) in decoding order. The stored video signals can either be uncoded signals stored before encoding, as encoded signals stored after encoding, or as decoded signals stored after encoding and decoding process. For example, an encoder produces bitstreams in transmission order. A file system receives audio and/or video bitstreams which are encapsulated e.g. in decoding order and stored as a file. The file can be stored into a database from which a streaming server can read the NAL units and encapsulate them into RTP packets.
Furthermore, in the following description the invention is described by using encoder-decoder based system, but it is obvious that the invention can also be implemented in systems where the encoder outputs and transmits coded data to another component, such as a streaming server, in a first order, where the other component reorders the coded data from the first order to another order, defines the required buffer size for the another order and forwards the coded data in its reordered form to the decoder.
In the following the invention will be described in more detail with reference to the system of FIG. 5 , the encoder 1 of FIG. 6 and decoder 2 of FIG. 7 . The pictures to be encoded can be, for example, pictures of a video stream from a video source 3 , e.g. a camera, a video recorder, etc. The pictures (frames) of the video stream can be divided into smaller portions such as slices. The slices can further be divided into blocks. In the encoder 1 the video stream is encoded to reduce the information to be transmitted via a transmission channel 4 , or to a storage media (not shown). Pictures of the video stream are input to the encoder 1 . The encoder has an encoding buffer 1 . 1 ( FIG. 6 ) for temporarily storing some of the pictures to be encoded. The encoder 1 also includes a memory 1 . 3 and a processor 1 . 2 in which the encoding tasks according to the invention can be applied. The memory 1 . 3 and the processor 1 . 2 can be common with the transmitting device 6 or the transmitting device 6 can have another processor and/or memory (not shown) for other functions of the transmitting device 6 . The encoder 1 performs motion estimation and/or some other tasks to compress the video stream. In motion estimation similarities between the picture to be encoded (the current picture) and a previous and/or latter picture are searched. If similarities are found the compared picture or part of it can be used as a reference picture for the picture to be encoded. In JVT the display order and the decoding order of the pictures are not necessarily the same, wherein the reference picture has to be stored in a buffer (e.g. in the decoded picture buffer 5 . 2 ) as long as it is used as a reference picture. The encoder 1 may also insert information on display order of the pictures into the transmission stream.
From the encoding process the encoded pictures are moved as NAL units to an picture interleaving buffer 5 . 3 , if necessary. Furthermore, the encoded reference pictures are decoded and inserted into the decoded picture buffer 5 . 2 of the encoder. The encoded pictures are transmitted from the encoder 1 to the decoder 2 via the transmission channel 4 . In the decoder 2 the encoded pictures are decoded to form uncompressed pictures corresponding as much as possible to the encoded pictures.
The decoder 1 also includes a memory 2 . 3 and a processor 2 . 2 in which the decoding tasks according to the invention can be applied. The memory 2 . 3 and the processor 2 . 2 can be common with the receiving device 8 or the receiving device 8 can have another processor and/or memory (not shown) for other functions of the receiving device 8 .
Encoding
Let us now consider the encoding-decoding process in more detail. Pictures from the video source 3 are entered to the encoder 1 and advantageously stored in the encoding buffer 1 . 1 . The encoding process is not necessarily started immediately after the first picture is entered to the encoder, but after a certain amount of pictures are available in the encoding buffer 1 . 1 . Then the encoder 1 tries to find suitable candidates from the pictures to be used as the reference frames for motion estimation. The encoder 1 then performs the encoding to form encoded pictures. The encoded pictures can be, for example, predicted pictures (P), bi-predictive pictures (B), and/or intra-coded pictures (I). The intra-coded pictures can be decoded without using any other pictures, but other type of pictures need at least one reference picture before they can be decoded. Pictures of any of the above mentioned picture types can be used as a reference picture.
The encoder attaches for example two time stamps to the pictures: a decoding time stamp (DTS) and output time stamp (OTS). The decoder can use the time stamps to determine the correct decoding time and time to output (display) the pictures. However, those time stamps are not necessarily transmitted to the decoder or it does not use them.
The NAL units can be delivered in different kinds of packets. In this advantageous embodiment the different packet formats include single NAL unit packets and aggregation packets. The aggregation packets can further be divided into single-time aggregation packets (STAPs) and multi-time aggregation packets (MTAPs).
A video sequence according to this specification can be any part of NALU stream that can be decoded independently from other parts of the NALU stream.
The buffering model is presented next. The pre-encoding buffer 1 . 0 , decoded picture buffer 5 . 2 and interleaving buffer 5 . 3 are initially empty. Uncompressed pictures in capturing order are inserted to the pre-encoding buffer. When any temporal scalability scheme is applied, more than one uncompressed picture is buffered in the pre-encoding buffer before encoding. After this initial pre-encoding buffering, the encoding process starts. The encoder 5 performs the encoding process. As a result of the encoding process, the encoder produces decoded reference pictures and NAL units and removes picture that was encoded from the pre-encoding buffer. The decoded reference pictures are inserted in the decoded picture buffer 5 . 2 and NAL units are inserted in the interleaving buffer 5 . 3 . The transmitting device selects NAL units from the interleaving buffer to be transmitted. A transmitted NAL unit is removed from the interleaving buffer.
Transmission
The transmission and/or storing of the encoded pictures (and the optional virtual decoding) can be started immediately after the first encoded picture is ready. This picture is not necessarily the first one in decoder output order because the decoding order and the output order may not be the same.
When the first picture of the video stream is encoded the transmission can be started. The encoded pictures are optionally stored to the interleaving buffer 5 . 3 . The transmission can also start at a later stage, for example, after a certain part of the video stream is encoded.
The decoder 2 should also output the decoded pictures in correct order, for example by using the ordering of the picture order counts, and hence the reordering process need be defined clearly and normatively.
De-Packetizing
The de-packetization process is implementation dependent. Hence, the following description is a non-restrictive example of a suitable implementation. Other schemes may be used as well. Optimizations relative to the described algorithms are likely possible.
The general concept behind these de-packetization rules is to reorder NAL units from transmission order to the NAL unit delivery order.
The receiver 8 collects all packets belonging to a picture, bringing them into a reasonable order. The strictness of the order depends on the profile employed. The received packets are stored into the receiving buffer 9 . 1 (pre-decoding buffer, de-interleaving buffer). The receiver 8 discards anything that is unusable, and passes the rest to the decoder 2 .
In the following there is a description of the de-packetization process according to an example embodiment of the present invention with reference to FIG. 9 .
The receiver receives (block 901 in FIG. 9 ) and stores incoming NAL units in reception order into the de-interleaving buffer as follows. NAL units of aggregation packets are stored into the de-interleaving buffer individually. Those NALUs are processed as if they were received in separate RTP packets, in the order they were arranged in the aggregation packet. The value of DON is calculated and stored for all NAL units.
Function AbsDON denotes such decoding order number of the NAL unit that does not wrap around to 0 after 65535. In other words, AbsDON is calculated as follows: Let m and n are consecutive NAL units in transmission order. For the very first NAL unit in transmission order (whose index is 0), AbsDON(0)=DON(0). For other NAL units, AbsDON is calculated as follows:
If DON( m )==DON( n ), Abs DON( n )= Abs DON( m )
If (DON( m )<DON( n ) and DON( n )−DON( m )<32768), Abs DON( n )= Abs DON( m )+DON( n )−DON( m )
If (DON( m )>DON( n ) and DON( m )−DON( n )>=32768), Abs DON( n )= Abs DON( m )+65536−DON( m )+DON( n )
If (DON( m )<DON( n ) and DON( n )−DON( m )>=32768), Abs DON( n )= Abs DON( m )−(DON( m )+65536−DON( n ))
If (DON( m )>DON( n ) and DON( m )−DON( n )<32768), Abs DON( n )= Abs DON( m )−(DON( m )−DON( n ))
where DON(i) is the decoding order number of the NAL unit having index i in the transmission order.
Parameter sprop-max-don-diff is an integer in the range of 0 to 32767, inclusive. sprop-max-don-diff is calculated as follows ( 902 ):
sprop-max-don-diff=max{ Abs DON( i )− Abs DON( j )}, for any i and any j>i,
where i and j indicate the index of the NAL unit in the transmission order.
The NAL units to be removed from the de-interleaving buffer are determined ( 903 ) as follows:
All NAL units m for which don_diff(m,n) is greater than sprop-max-don-diff are removed ( 904 ) from the de-interleaving buffer and passed to the decoder in the order specified below. Herein, n corresponds to the NAL unit having the greatest value of AbsDON among the received NAL units.
The order that NAL units are passed to the decoder is specified as follows:
Let PDON be a variable that is initialized to 0 at the beginning of the an RTP session. For each NAL unit associated with a value of DON, a DON distance is calculated as follows. If the value of DON of the NAL unit is larger than the value of PDON, the DON distance is equal to DON−PDON. Otherwise, the DON distance is equal to 65535−PDON+DON+1. NAL units are delivered to the decoder in ascending order of DON distance. If several NAL units share the same value of DON distance, they can be passed to the decoder in any order. When a desired number of NAL units have been passed to the decoder, the value of PDON is set to the value of DON for the last NAL unit passed to the decoder.
In the following there is a description of the de-packetization process according to an example embodiment of the present invention with reference to FIG. 10 . There are two buffering states in the receiver: initial buffering (blocks 1001 - 1006 in FIG. 10 ) and buffering while playing (blocks 1007 - 1012 in FIG. 10 ). Initial buffering occurs when the RTP session is initialized. After initial buffering, decoding and playback is started and the buffering-while-playing mode is used.
Regardless of the buffering state the receiver stores (block 1002 ) incoming NAL units in reception order into the de-interleaving buffer as follows. NAL units of aggregation packets are stored into the de-interleaving buffer individually. Those NALUs are processed as if they were received in separate RTP packets, in the order they were arranged in the aggregation packet. The value of DON is calculated and stored for all NAL units.
Function AbsDON denotes such decoding order number of the NAL unit that does not wrap around to 0 after 65535. In other words, AbsDON is calculated as follows: Let m and n are consecutive NAL units in transmission order. For the very first NAL unit in transmission order (whose index is 0), AbsDON(0)=DON(0). For other NAL units, AbsDON is calculated as follows:
If DON( m )==DON( n ), Abs DON( n )= Abs DON( m )
If (DON( m )<DON( n ) and DON( n )−DON( m )<32768), Abs DON( n )= Abs DON( m )+DON( n )−DON( m )
If (DON( m )>DON( n ) and DON( m )−DON( n )>=32768), Abs DON( n )= Abs DON( m )+65536−DON( m )+DON( n )
If (DON( m )<DON( n ) and DON( n )−DON( m )>=32768), Abs DON( n )= Abs DON( m )−(DON( m )+65536−DON( n ))
If (DON( m )>DON( n ) and DON( m )−DON( n )<32768), Abs DON( n )= Abs DON( m )−(DON( m )−DON( n ))
where DON(i) is the decoding order number of the NAL unit having index i in the transmission order.
Parameter sprop-interleaving-depth of the JVT codec specifies the maximum number of VCL NAL units that precede any VCL NAL unit in the NAL unit stream in transmission order and follow the VCL NAL unit in decoding order. Constant N is the value of the sprop-interleaving-depth parameter incremented by 1.
Parameter sprop-max-don-diff is an integer in the range of 0 to 32767, inclusive. If sprop-max-don-diff is not present, the value of the parameter is unspecified. sprop-max-don-diff is calculated as follows:
sprop-max-don-diff=max{ Abs DON( i )− Abs DON( j )}, for any i and any j>i (1003),
where i and j indicate the index of the NAL unit in the transmission order.
Parameter sprop-init-buf-time signals the initial buffering time that a receiver must buffer before starting decoding to recover the NAL unit decoding order from the transmission order. The parameter is the maximum value of (transmission time of a NAL unit—decoding time of the NAL unit) assuming reliable and instantaneous transmission, the same timeline for transmission and decoding, and starting of decoding when the first packet arrives.
Initial buffering lasts until one of the following conditions is fulfilled:
There are N VCL NAL units in the de-interleaving buffer ( 1004 ). If sprop-max-don-diff is present, don_diff(m,n) is greater than the value of sprop-max-don-diff ( 1005 ), in which n corresponds to the NAL unit having the greatest value of AbsDON among the received NAL units and m corresponds to the NAL unit having the smallest value of AbsDON among the received NAL units. Initial buffering has lasted for the duration equal to or greater than the value of the sprop-init-buf-time parameter ( 1006 ).
The NAL units to be removed from the de-interleaving buffer are determined as follows:
If the de-interleaving buffer contains at least N VCL NAL units ( 1008 ), NAL units are removed from the de-interleaving buffer and passed to the decoder in the order specified below until the buffer contains N−1 VCL NAL units ( 1009 ). If sprop-max-don-diff is present, all NAL units m for which don_diff(m,n) is greater than sprop-max-don-diff ( 1011 ) are removed from the de-interleaving buffer and passed to the decoder in the order specified below ( 1012 ). Herein, n corresponds to the NAL unit having the greatest value of AbsDON among the received NAL units.
The order that NAL units are passed to the decoder is specified as follows:
Let PDON be a variable that is initialized to 0 at the beginning of the an RTP session. For each NAL unit associated with a value of DON, a DON distance is calculated as follows. If the value of DON of the NAL unit is larger than the value of PDON, the DON distance is equal to DON−PDON. Otherwise, the DON distance is equal to 65535−PDON+DON+1. NAL units are delivered to the decoder in ascending order of DON distance. If several NAL units share the same value of DON distance, they can be passed to the decoder in any order. When a desired number of NAL units have been passed to the decoder, the value of PDON is set to the value of DON for the last NAL unit passed to the decoder.
Decoding
The DPB 2 . 1 contains memory places for storing a number of pictures. Those places are also called as frame stores in the description. The decoder 2 decodes the received pictures in the order they are removed from the de-interleaving buffer (i.e. in decoding order).
The present invention can be applied in many kinds of systems and devices. The transmitting device 6 including the encoder 1 advantageously include also a transmitter 7 to transmit the encoded pictures to the transmission channel 4 . The receiving device 8 include the receiver 9 to receive the encoded pictures, the decoder 2 , and a display 10 on which the decoded pictures can be displayed. The transmission channel can be, for example, a landline communication channel and/or a wireless communication channel. The transmitting device and the receiving device include also one or more processors 1 . 2 , 2 . 2 which can perform the necessary steps for controlling the encoding/decoding process of video stream according to the invention. Therefore, the method according to the present invention can mainly be implemented as machine executable steps of the processors. The buffering of the pictures can be implemented in the memory 1 . 3 , 2 . 3 of the devices. The program code 1 . 4 of the encoder can be stored into the memory 1 . 3 . Respectively, the program code 2 . 4 of the decoder can be stored into the memory 2 . 3 . | A method for buffering media data in a buffer where the media data is included in data transmission units which have been ordered in a transmission order which is at least partly different from a decoding order of the media data in the data transmission units. The decoding order is indicated with a quantitative indicator for at least part of the transmission units. In the method a parameter is defined for a relation of the quantitative indicators of transmission units. The relation of transmission units in the buffer is checked against the parameter. The result of the checking is indicative of at least one transmission unit in the buffer preceding, in decoding order, any transmission unit in a sequence of transmission units not having been buffered in the buffer before the checking. | 7 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims the priority of German Patent Application Serial No. DE 10 2010 022 150.3, filed May 18, 2010, pursuant to 35 U.S.C. 119(a)-(d), the subject matter of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention is in the field of seating devices, especially in the area of a meditation stool.
The present invention refers to a seating device for seating in a kneeling seating position including:
a seating surface for supporting the buttocks a support supporting the seating surface against the floor, and a foot rest for supporting the instep of feet resting on the foot rest wherein the seating surface, for changing its incline, is able to roll in forward direction via at least one rocker encompassed by the support.
A seating device of a meditation stool is known from the DE 20 2005 003 423 U1. The meditation stool that is described there shows a seating surface close to the floor, supported against the floor by a central column shaped support. The end of the column-shaped support that is supported by the floor is widened in T-shaped manner perpendicular to the seating surface. The meditation stool is for sitting in a kneeling position, wherein the lying instep is supported by a foot rest. In order to avoid disintegration of the intervertebral disc, when seated for hours on the stool, the disclosed seating device makes it possible to conduct small exercise movements. For this purpose, the T-shaped end of the support is curved, such that the seating surface can be slightly tilted in all directions in order to follow the subconscious little movements of the person on the stool by tilting in each of the compensating directions. To stabilize the construction, the column-shaped support is encompassed on all sides by the foot rest, wherein the distance between support and foot rest make small degree compensation movements possible. Additional possibilities for relieving pressure on the intervertebral discs by means of ergonomical adjustments of the seating device are not contemplated with that meditation stool. For easy transport of the seating device, the foot rest can be retracted under the seating surface.
Before this background, it is an aspect of the present invention, to provide a seating device of the afore-stated type, which has improved adjustments to ergonomic requirements of the seated person in order to realize a healthy and comfortable seating on the seating device.
This object is solved by means of the present invention in a seating device of the afore-stated type where the foot rest comprised in the seating device is configured and disposed at the seating device in such a way that, when adjusting the seating device to a ergonomically meaningful angle of the seating surface, the rocker is able to roll in forward direction in an unencumbered through the foot rest.
The invention is based on the realization that a comfortable and healthy seating in kneeling seating position is essentially realized by the individual adjustment of three parameters, namely, seating height, angle of inclination of the seating surface in forward direction and length of the thigh of the seated person. Depending on the length of the thigh of the seated person and predetermined seating height, an angle specific to the seated person between thigh and spine is chosen to upright the pelvis and to allow the spine to be held in a vertical position without force. The seating device according to the invention makes it possible to attain an ergonomically advantageous seating posture by means of a very precise adjustment of the seating surface tilt.
According to the present invention, this angle of the seating position is adjusted from a seating position in a dynamic way in that the tilting angle of the seating surface is adjustable at any time relative to the seating sensation. It is not necessary to leave the seating position in order to change and/or fix the tilting angle. This is based on the realization that an adjustment of the optimal tilting angle of the seating surface is not possible without being seated, as each time a seating position is taken, the effective seating height of the tilted seating surface varies.
When adjusting the tilting angle of the seating surface, a much larger angle area must be accommodated as compared to the movement of the seating surface during the small compensation movements according to the prior art. While the rockers roll in forward direction, the point of support of the rocker can be shifted in this direction. This depends on whether the rocker is supported stationary or movable. In the latter case, the rolling of the rocker across a significantly larger adjustment area of the tilting angle according to the present invention shifts the seating surface in forward direction. This leads to an inconsistent relationship between the seating height and the distance between the point of support of the knee and the point of support of the rocker, such that when adjusting the seating surface tilt by means of the movably supported rocker, this effect is to be taken into account.
It would therefore be desirable and advantageous to provide an improved seating device to obviate prior art shortcomings and to provide a secure, healthy and ergonomic seating device.
SUMMARY OF THE INVENTION
In view of the afore-stated drawbacks, the present invention recognizes that through pressure put on the seating surface that is tilted in forward direction, a shifting of the rocker support point into the starting position can be realized.
Thus according to one aspect of the present invention, a person seated on the seating device, by means of successive tilting and shifting of the seating surface, can adjust the seating surface to an optimal tilting angle of the seating surface.
In accordance with the present invention, the foot rest is constructed and arranged at the seating device so that the rocker can be rolled in forward direction unencumbered due to the foot rest, in order to adjust the seating surface to an ergonomically useful tilting angle. In other words, the foot rest allows for at least one forward extending track, such that the rocker can roll along the track without a stop. Expressed differently, the foot rest does not prevent a tilting of the rocker and the entire support arranged above within a necessary angle range, whereby the necessary angle range is defined through ergonomically useful tilting angle of the seating surface. A delay of the rolling motion due to the foot rest may thus be desirable.
According to a first embodiment of the seating device according to the present invention, the rocker is arranged above the foot rest, such that the support encompasses the at least one rocker and also the associated counter support from which the rocker can roll off. According to a second embodiment of the present invention, the rolling surface of the rocker is on the floor, such that the support that extends between the seating surface and the rocker is carried by the rocker. According to that embodiment, the seating device can comprise two rockers, which are arranged in a rolling manner to the right and the left of the foot rest. In this case, the kneeling person positioned on the seating device places the feet between the two rockers, which can roll unencumbered, due to the foot rest, in a forward direction. According to a third embodiment the seating device comprises a rocker arranged centrally, which for example, is able to roll by means of a counter support that is formed by the foot rest. This avoids scratching of the floor during the rolling motion of the rocker. In this case it is important that the counter support formed by the foot rest is constructed such that a tilting of the rocker and the entire support arranged above is realized without a stop across the entire necessary angle range, whereby the necessary angle range is defined through the ergonomically useful tilting angle of the seating surface. According to a fourth embodiment, the foot rest is divided into two parts by means of a cut extending in forward direction, wherein between the two parts of the foot rest a rocker is disposed for rolling on the floor. The two parts of the foot rest permit a track extending in forward direction having a width which corresponds at least to the width of the support that moves through the foot rest while the rocker is rolling so that a smooth and unencumbered rolling of the rocker is realized.
A further essential advantage of the present invention is that in addition to the seating device being adjustable relative to the seating surface, the seating device allows dynamic balancing movements around the adjusted angle, so that the intervertebral disks of the seated person are further relieved of pressure.
The curvature of the rocker can be selected so that the seating height during the rockers rolling is approximately constant. According to a fifth embodiment of the seating device, the height of the seating surface can be adjusted separately. Thereby, the angle between thigh and lower leg of the seated person and thus the degree of the knee bend can be varied.
Advantageous embodiments of the present invention are provided in the following description and in the dependent claims, the features of which can be applied in particular as well as in any combination.
A preferred embodiment of the present invention provides that
the rocker is movable in forward direction, and the length of the rocker pointing in forward direction is larger than its width.
The configuration of the rocker according to the first feature, the distance between the foot rest and the rocker, is adjustable through shifting the rocker in forward direction. As this distance is adjusted to the seating height and the individual parameters length of the thigh and lower leg, a comfortable and healthy position of the foot on the foot rest is realized. Also, a counter support holding the rocker in fixed position is not necessary.
By configuring the rocker according to the second feature, a small point of support results, so that the rocker can roll or move more easily. In addition, this configuration of the rocker saves weight which allows easier transport of the seating device.
In a kneeling seating position, the width of the rocker does not markedly contribute to a better and more secure seating position. For a better and secure seating position, it is the length of the rocker in forward positions that counts which, upon the forward tilting of the seating surface, also prevents a toppling over of the seating device. It is thus advantageous when the length of the rocker is substantially larger than the width of the rocker. Due to the smaller width of the rocker, a light tilting of the seating surface in perpendicular direction is realized, if the seating device includes one rocker, whereby the seated person can carry out balancing movements in this direction that ease the spine. A curvature of the rocker support surface in perpendicular direction is thus no longer required as compared to the prior art.
It is also viewed as an advantage that the length of the rocker pointing in forward direction corresponds to minimum one half of the length of the seating surface.
In accordance with this configuration of the present invention, the seating surface is supported along at least one half of it length by the rocker. Thereby, the person seated on the seating device can shift the seating position in longitudinal direction relative to the seating surface, without the seating device toppling over either forward or rearward. Thus, the seated person has a greater sense of security and on the other hand, makes it possible to vary the effective seating height by just shifting the seating position. With this, the seating device can be even better adjusted to the ergonomic need of the seated person.
Within the scope of the present invention for determining the length of the seating surface, any extensions of the seating surface which have no function as a seating surface, are ignored
In an advantageous variant, it is contemplated that the support perpendicular to the seating surface is configured narrowly, such that the foot rest extends both right and left past the support.
This makes it possible for the seated person to individually choose the horizontal angle between the thigh and the lower leg, without the feet hitting the support.
It can also be of advantage that the seating device comprises exactly one rocker. Thereby, the weight and the measurements of the seating device can be further reduced. The rocker is disposed centrally beneath the seating surface. If the rocker has a suitably small width, a small tilting of the seating surface in perpendicular direction is realized such that the person seated on the seating device can make small balancing movements in that direction.
An especially robust and simple construction of a preferred embodiment of the present invention contemplates that the rocker is extended in U-shape by means of two legs, whereby the ends of each of the legs are successively connected to the seating surface in forward direction.
In addition to the robust and simple construction, the foregoing configuration has the advantageous that a foot rest which extends to the right and to the left of the rocker can be connected through the opening of the U-shaped rocker, so that the rocker despite this connection can roll unencumbered due to the foot rest.
According to a fifth embodiment of the present invention, the legs are rigidly connected to the seating surface. According to a sixth embodiment of the present invention, for the separate adjustment of the seating height, the legs are connected to the seating surface via a connecting means that is adjustable.
It is further advantageous that the foot rest supporting the instep of the feet is an upholstered longitudinal body to be disposed crosswise to the seating surface.
A foot rest that is configured in that manner includes especially small measurements. The body of the foot rest can simply have an upholstered surface, or it can be made entirely of soft material. In accordance with one embodiment, that body is made of foam core covered with fabric material. This is particularly light weight. The foot rest disposed perpendicular to the seating surface, for example, is connected removable or unremovable with the seating device. The foot rest can be disposed so that the at least one rocker can roll unencumbered because of the foot rest and the foot rest extends perpendicular to the seating surface. The longitudinal body can be configured as either a unitary piece or can be configured as several pieces.
In a further advantageous variant of the present invention, the foot rest has a substantially semi-circular cross section. Thus, the foot rest points upwardly with the curved side, so that a person kneeling in seated position on the seating device can comfortably position the feet with the instep pointing downward at the curved side of the foot rest. The semi-circular cross section of the foot rest realizes an especially healthy position of the feet resting on the foot rest.
It can also be advantageous that the foot rest is divided once across so that the rocker is disposed between the two partial sections, so that the rocker sweepingly rolls through the foot rest.
According to this embodiment, the rolling motion of the rocker is delayed by the foot rest but not encumbered. According to one embodiment, the foot rest is crosswise divided into two separate parts by means of a forward extending cut. According to a further embodiment, the two parts are not entirely separated by the forwardly extending cut, so that the cut forms only a deep groove in the foot rest. The rocker is disposed between the two partial sections. The rocker is arranged between the two partial sections so that the rocker side surfaces pointing crosswise adjoin at least partially the front faces of the partial sections that are facing each other, so that the rocker can roll sweepingly through the foot rest. The rolling motion of the rocker is carried out against a frictional resistance which is generated by the contact of the rocker side surfaces with the front faces of the partial sections. This results in the slower rolling motion of the rocker, in order to realize a more precise adjustment of the seating surface tilt. Moreover, if the seating device includes only one rocker, this configuration prevents a sideways toppling of the seating surface when leaving the seating device.
It can also be advantageous that the two partial sections are connected via at least one connecting means which extends through an opening in the support.
The frictional resistance that slows down the rolling motion of the rocker can be increased by means of the length of the connecting means. According to one embodiment, the connecting means are elastic. The size and the shape of the opening in the seating device are to be selected so that the rocker can roll unencumbered by the foot rest.
In a further advantageous embodiment, it is contemplated that the foot rest is lifted up to under the seating surface, so that both ends of the foot rest are foldable vertically in downward direction into a transport position. In this folded position, the seating device has favorable measurements for transport.
It is furthermore advantageous that the foot rest is removably disposed at the seating device for separate usage of the foot rest. For example, the foot rest can be utilized independent of the seating device, as support for the head or a knee of a person lying down.
The features as recited in the claims refer, unless otherwise stated, to a seating device mode of seating a person. The present invention encompasses also those seating devices which exhibit at least one other mode or operation or one other mode of transport where those features are not necessarily realized.
The seating device according to the present invention is configured for seating in a kneeling position. According to one embodiment, the seating device can have a seating surface close to the floor, such that knees and feet of the seated are at the floor level. The scope of the present invention encompasses also those embodiments of seating devices that merely extend the height of the seating surface. For example, such a seating device could be mounted on a platform.
BRIEF DESCRIPTION OF THE DRAWING
Other features and advantages of the present invention will be more readily apparent upon reading the following description of currently preferred exemplified embodiments of the invention with reference to the accompanying drawing, in which:
FIG. 1 is a top and side perspective view of an embodiment of the seating device according to the present invention;
FIG. 2 is an oblique perspective view of the bottom side of the seating surface and the support of the embodiment of seating device in FIG. 1 ;
FIG. 3 is a side and perspective view of the foot rest of the embodiment of the seating device in FIG. 1 ;
FIG. 4 is a perspective side view of a detail of the embodiment of the seating device in FIG. 1 shown with a seated person.
FIG. 5 is a side view of the embodiment of the seating device according to the present invention, with an upholstered seating surface and upholstered foot rest.
FIG. 6 is a front side perspective view of the embodiment shown in FIG. 5 ;
FIG. 7 is a rear elevational view of the embodiment of the seating device in FIG. 5 ; and
FIG. 8 is a top plan view of the embodiment of the seating device in FIG. 5 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Throughout all the Figures, same or corresponding elements are generally indicated by same reference numerals.
Turning now to the drawing, and in particular to FIG. 1 , there is shown an embodiment of the seating device 1 according to the present invention including a seating surface 2 and support 3 which supports the seating surface 2 against the floor. The support 3 includes exactly one rocker 3 a for rolling off the floor, whose length pointing in forward direction V is substantially larger than the width of the rocker. The length of the rocker 3 a corresponds approximately to the length of the seating surface 2 . The rocker 3 a extends through two legs 3 b in U-shape, wherein the ends of the legs 3 b are successively connected with the seating surface 2 in forward direction. The rocker 3 b and portions of the legs 3 b are disposed between two partial sections 4 a , 4 b of a foot rest 4 .
The foot rest 4 is a longitudinal body disposed crosswise to the seating surface 2 with the cross section of the body essentially semi-circular shaped. The foot rest 4 is divided exactly once across with the rocker 3 a disposed between partial sections 4 a , 4 b . The support 3 is configured narrowly crosswise to the seating surface 2 , such that the foot rest 4 projects past the support 3 at the right and at the left.
The foot rest 4 is configured and disposed at the seating device 1 in such a manner that the rocker 3 a can roll unencumbered in forward direction V due to the foot rest 4 , in order to adjust an ergonomically suitable tilting angle of the seating surface 2 . The foot rest 4 thus leaves free a forward leading track 5 so that the rocker 3 a can roll along the track 5 without any stop. The foot rest 4 does not prevent a tilting of the rocker 3 a and the leg 3 b located above the rocker 3 a , so that the tilting of the seating surface can be adjusted within a certain ergonomically suitable angle range. In order to facilitate adjustment of the angle and to prevent the toppling over of the seating surface 2 in perpendicular direction, the two partial sections 4 a , 4 b are connected to each other via connecting means as seen in FIG. 3 . The connecting means extend through the opening 6 of the U-shape and draws on the front sides 7 of partial sections 4 a , 4 b at the side surfaces 8 of the rocker 3 a , so that upon the rolling movement of rocker 3 a carried out against a frictional resistance, the rocker 3 a sweeps through the foot rest 4 . The opening 6 of the U-shape has a size and shape such that the connecting means surrounded by the foot rest 4 , does not prevent a rolling and shifting of the rocker 3 a in forward direction V. For transporting the seating device 1 , the foot rest 4 can be lifted up to underneath the seating surface 2 , in order to fold the partial sections 4 a 4 b at the support vertically downwards with the side surfaces 9 in direction of the floor. In this transport position, the seating device 1 is cylinder shaped. In order to utilize the foot rest 4 separately from the seating device 1 , the foot rest 4 can be separated from the seating device 1 . For example the connecting means disposed between the partial sections 4 a and 4 b can be detached. If the foot rest 4 consists of a soft material, the foot rest 4 can also be detached from the seating device 1 , by pulling the foot rest 4 through the opening 6 .
FIG. 2 shows the seating surface 2 and the support 3 of the seating device as shown in FIG. 1 in a single depiction obliquely from below. The seating surface 2 sits head down on the floor, so that the seating bottom side 10 can be seen. The support 3 is fastened to the seat bottom side, 10 , and comprises one rocker 3 a and two legs 3 b extending rocker 3 a in an U-shaped manner. Rocker 3 a has a length 22 and a width 23 . The side surfaces 8 of rocker 3 a is flat formed based on the board shaped configuration of the support 2 . The ends 11 of the legs 3 b are fastened at seat bottom 10 of seating surface 2 . For example, the ends of legs 3 b are screwed together with seating surface 2 . The seating surface 2 has a seating surface length 24 which corresponds approximately to the length 22 of rocker 3 a . The upper surface 12 of seating surface 2 is upholstered. A foam core is placed on the hard top of the seating surface 2 which is then covered with suitable fabric material 13 and fixed with fixing means 14 at the seating bottom side 10 .
FIG. 3 shows the foot rest 4 in the seating device as shown in FIG. 1 in an illustration obliquely from above. The longitudinal body of the foot rest 4 is divided across into partial sections 4 a and 4 b . Extended between the partial sections 4 a and 4 b is the connecting means, which connects the two partial sections with each other, whereby the connecting means 25 would extend through the opening 6 at the support 3 in the arrangement of the foot rest 4 in an embodiment as seen in FIG. 1 . The foot rest 4 detached from the seating device 1 has also other utility due to the semi-circular cross section 26 and the soft surface. In the embodiment as shown, the embodiment can be used as a head rest or as support for a knee by a person lying down. If placing the undersides 15 b , 15 a next to each other, a double size bolster results. This can for example be used as a back support. In this position, the undersides 15 a , 15 b facing each other, the foot rest 4 disposed at the seating device 1 would be in a transport position. For this, the foot rest 4 is lifted up to the seating surface 2 in the seating device 1 as shown in FIG. 1 and then folded with both ends 27 vertically downward so that the side surfaces 9 of the foot rest 4 is pointing in the direction of the floor and the front sides 7 of the foot rest 4 in the direction of the seating surface 2 .
FIG. 4 shows a detail of the seating device 1 according to the present invention corresponding to the embodiment as shown in FIG. 1 together with a person 16 sitting on the seating device 1 . Person 16 sits in a kneeling seated position on the seating device 1 . The person's buttocks 17 are on the seating surface 2 . The knees 18 of person 16 are placed on the floor or on a thin blanket 19 placed on the floor. Feet 20 are laying on the foot rest 4 , whereby the foot rest 4 supports the instep 21 in lying position. Seating surface 2 is supported against the floor by support 3 . By rolling off the floor, the rocker 3 a encompassed by the support 3 , the tilting of the seating surface 2 can be adjusted by the person 16 from the seated position. By means of the rolling and shifting of the rocker 3 a in forward direction V, person 16 can find an optimal tilting angle of the seating surface 2 and an optimal distance between foot- and rocker support point. Within the scope of the present invention, the forward direction is a group of parallel directions. The rolling and shifting of rocker 3 a in the forward direction encompasses thus a forward and backward motion.
FIG. 5 shows another embodiment of the seating device according to the present invention in a side view. Both the foot rest 4 and the seating surface are upholstered with a felt-type fabric material 13 . The rocker 3 a , 3 b made from wood are shown from a side perspective.
FIG. 6 shows the same embodiment as FIG. 5 where the seating surface 2 is now tilted in forward direction. FIG. 7 shows the same embodiments in a rear view where the seating surface is in upright position. The rocker 3 a , 3 b seen by the front side 30 has a series of grooves 31 in the front side 30 and the support 3 where it is in contact with the floor includes a band of rubber 32 which extends through the curvature of the support 3 . FIG. 8 is a top view of the seating device 1 showing clearly the upholstered portions of the seating surface 2 and the foot rest 4 .
While the invention has been illustrated and described as embodied in a seating device, it is not intended to be limited to the details shown since various modifications and structural changes may be made without departing in any way from the spirit of the present invention. The embodiments were chosen and described in order to best explain the principles of the invention and practical application to thereby enable a person skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated.
What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims and their equivalents. | A seating device is proposed for a person sitting in an ergonomic position helpful to relieve pressure on intervertebral disks, which includes a seating surface for supporting the buttocks of the person and where the instep of the person's feet is placed on a foot rest provided. The seating surface is supported by at least one U shaped support which includes a rocker by which the seated person can tilt the seating surface into the most comfortable and ergonomic position. The foot rest is divided into two partial sections which flank the support and which are connected by connecting means so that the rocking motion of the support can proceed unencumbered. | 0 |
BACKGROUND OF THE INVENTION
Acceleration sensing devices for use in connection with machines which require monitoring and shutting down under certain conditions of operation are known in the prior art. Some examples of the patented prior art to which the present invention relates are U.S. Pat. Nos. 2,942,456; 3,448,228 and 3,641,290.
A need exists for a simpler, less expensive and more reliable acceleration sensing unit of the class shown in the above prior art patents, and it is the objective of this invention to satisfy this need. In accordance with the present invention, a shock and vibration responsive device employs an operating mechanism which embodies significantly fewer parts than comparable prior art devices. The invention has a fuller range of adjustability including a unique and simplified sensitivity adjustment of the armature carried by a spring-loaded lever arm in relation to an opposing stationary potted magnet. An improved soft rubber valve closure disc or seat adjustably mounted on the pivoted lever arm and resiliently biased toward the control fluid vent valve constitutes another key improvement over the prior art. An adjustable spring-loaded manual reset button for the device also serving as a visual trip indicator forms a further feature of the invention. Another important feature resides in an adjustable leveling stop for the pivoted lever arm assuring parallelism between the arm and the holding face of the potted magnet when the arm is latched in the vent valve closing position. A fluid pressure responsive remote resetting means for the pivoted lever, separate from the manual resetting button, is also provided on the unit.
Other features and advantages of the invention will become apparent during the course of the following description.
BRIEF DESCRIPTION OF DRAWING FIGURES
FIG. 1 is a side elevational view of the invention with the body or housing in section showing the control lever arm in the magnetically latched position.
FIG. 2 is a plan view of the device in FIG. 1 with the cover plate and associated parts removed.
FIG. 3 is a similar plan view with the pivoted lever arm and associated parts removed.
FIG. 4 is a view similar to FIG. 1 showing the device tripped in response to acceleration and in a control fluid venting mode.
FIG. 5 is a vertical section taken on line 5--5 of FIG. 1.
FIG. 6 is a fragmentary vertical section taken on line 6--6 of FIG. 1.
FIG. 7 is a similar section taken on line 7--7 of FIG. 1.
FIG. 8 is a similar section on an enlarged scale taken on line 8--8 of FIG. 1.
DETAILED DESCRIPTION
Referring to the drawings in detail wherein like numerals designate like parts, the numeral 10 designates a body or housing for the acceleration sensing mechanism including a flat mounting face 11 which may be arranged horizontally, vertically or at an intermediate angle with relation to a wall of the machine being protected. The body 10 is fixedly mounted by bolts, not shown, received through openings 12 in flange extensions of the body 10. The unit will be mounted in any case so that the anticipated shock or vibration (acceleration) axis is across the pivoted control lever arm and parallel to the axis of the permanent magnet.
The body or housing 10 is open at the side opposite the flat mounting face 11 and this open side is covered by a removable cover plate 13 having a sealing gasket 14. The cover plate 13 serves to mount an adjustable manual reset and visual indicator assembly 15, to be described in detail.
Internally, the body 10 has a raised stepped boss 16, on the lower step of which is fixedly mounted a potted permanent magnet 17 disposed near an end wall 18 of the body 10. The potted magnet is recessed at 19 for the reception of a magnet attaching screw 20 having threaded engagement with the boss 16. The head of the screw 20, FIG. 5, is recessed well below the top flat attractive face of the magnet 17.
Another elevated boss 21 within the body 10 and near the other end of the body serves to mount a control fluid (air) vent valve 22 whose threaded stem 23, FIG. 7, is anchored within the boss 21 in communication with a control fluid passage 24 receiving a fluid inlet fitting 25 of a conventional type projecting from the end face of the body 10 remote from the wall 18. A vent port 26 opens through the same end of the body 10, preferably near the top thereof, and this port communicates directly with the interior chamber of the device, housing the trip mechanism.
Additionally, FIG. 4, the body 10 is provided in its same end with another threaded port 27 adapted to receive a pressure fluid inlet fitting, not shown, for delivering fluid pressure against the heat 28 of a remote reset plunger 29 received movably in a bore 30 and biased outwardly to a non-resetting position by a spring 31, the outward movement of the plunger 29 limited by a stop washer 32 thereon engageable with a flat internal face 33 of body or housing 10.
A pivoted rigid control lever arm 34, preferably of channel formation in cross section, overlies the bosses 16 and 21 and has end extensions 35 pivoted on a cross pin 36 to a support bracket 37 rigidly attached at 38, FIG. 8, to the top of boss 21. A torsional coil spring 39 surrounding pivot pin 36 resiliently biases lever arm 34 to a tripped or venting position shown in FIG. 4 where the lever arm has separated from the holding magnet 17 in response to acceleration forces. The biasing force exerted on lever arm 34 by spring 39 is somewhat less than the attractive force of magnet 17, but when the spring force is coupled with the acceleration force which the device is set to sense or respond to, the control lever arm 34 will assume the tripped or venting position shown in FIG. 4.
On the lever arm 34 relatively near the pivot element 36 and in opposing relation to the venting valve element 22 is a very efficient adjustable spring-loaded valve closure unit 40. The unit or assembly 40 comprises a housing 41 fixed on lever arm 34 by a snap ring 42 or the like and containing a stem 43, FIG. 7, having an adjustable stop nut 44 on a top threaded end portion thereof which adjusts the extent of axial movement of the stem 43 relative to the housing 41 under influence of a biasing spring 45 in the housing 41 bearing on a head 46 of this stem. The end face of head 46 carries a soft rubber vent valve closure disc 47 adapted to abut and seal the control fluid escape port of the valve 22 as shown in FIG. 7 when the lever arm 34 is latched by the magnet 17 as shown in FIG. 1. At this time, the rubber disc 47 is compressed against the mouth of valve 22 to effectively seal it. This rubber closure element 47 is superior to other types of closures, such as balls, since it cannot wear, corrode or the like. It is more effective in resisting clogging of the vent valve by foreign matter than other types of closure elements or seats.
Near the end of the lever arm 34 remote from its pivot 36 is an adjustable armature 48, FIG. 5, forming an important feature of the invention. This disc-like armature 48 which opposes the magnet 17 and is latched thereby at proper times is carried by one end of a threaded adjusting stem 49 having threaded engagement in a tubular nut 50 affixed to the lever arm 34. An opening 51 in the cover plate 13 is aligned with the stem 49 so that the latter may be turned with a screwdriver from the exterior of the closed assembly. The arrangement forms a fine sensitivity adjustment for the armature 48 and lever arm 34 relative to the stationary magnet 17 and the adjustment can be made from the exterior of the closed unit, as stated.
A further feature of the invention resides in the provision near the longitudinal center of the lever arm 34 of an adjustable screw leveling stop 52 anchored in the top step of boss 16, FIG. 4, and accessible for adjusting through an opening 53 provided in the arm 34. This screw stop or leveling stop assures parallelism between the working face of armature 48 and the opposing flat face of permanent magnet 17. This, in turn, assures an efficient "bond" or latching action between the permanent magnet and armature.
As previously mentioned, the manual reset and visual indicator assembly 15 is mounted bodily on the cover plate 13 and consists of a threaded body 54, FIG. 6, adjustably held in a threaded opening of the cover plate and locked in the adjusted position by a lock nut 55. A reset plunger or stem 56 having an outer end push button 57 is mounted to reciprocate in the adjustable body 54 and is biased by a spring 58 into yielding contact with the top of lever arm 34 at a point spaced substantially from the pivot 36 and spaced a considerably lesser distance from the armature 48 and associated sensitivity adjustment means. The lower end of stem 56 carries a lever contact element 59 formed of molded nylon or the like and this element serves to seat one end of the spring 58.
A transparent removable cap 60 serves to enclose the push button 57 which may be brightly colored to serve as a visual indicator when the lever arm 34 has been tripped by shock or vibration forces, FIG. 4. The button 57 is normally depressed, FIG. 1, when the mechanism is latched by magnetic attraction and the control fluid vent valve 22 is closed. The button 57 following removal of the cap 60 additionally forms a convenient manual resetting means for the control lever arm 34, and accessible from the exterior of the assembly.
To facilitate remote resetting of the mechanism by fluid pressure from the already-described plunger means 29, the lever arm 34 at its pivoted end carries an upturned extension 61 immediately in advance of the spring retracted plunger 29. When the lever arm is tripped, FIG. 4, and when fluid pressure is applied to the plunger head 28, the plunger will extend against the force of spring 31 and by engagement with lever extension 61 will reset the lever arm 34 with its armature 48 magnetically coupled with permanent magnet 17. It will be clear to anyone skilled in the art that when the lever arm 34 is tripped by acceleration forces, FIG. 4, the valve 22 will vent control fluid such as air. When the lever arm is latched, FIG. 1, the vent valve will be closed and sealed by the rubber disc 47. The sensitivity of the device may be finely regulated by turning the stem 49 with a screwdriver. The screw stop 52 assures leveling or parallelism of the lever 34 and armature 48 with respect to the fixed magnet 17. The spring loading of the stem 56 assures contact thereof with the lever arm 34 regardless of the angle at which the body 10 is mounted. The other operational features of the device require no further description and should be fully understood by anyone skilled in the art.
It is to be understood that the form of the invention herewith shown and described is to be taken as a preferred example of the same, and that various changes in the shape, size and arrangement of parts may be resorted to, without departing from the spirit of the invention or scope of the subjoined claims. | A vibration or shock (acceleration) responsive lever is normally held by magnetic attraction in a latched position for closing a control fluid (air) vent valve. The lever is resiliently biased to a tripped vent valve opening position by a force of lesser magnitude than the magnetic latching force. The unit may be mounted vertically or horizontally and possesses manual and remote lever reset means. A sensitivity adjustment is directly accessible through the cover plate of the body or housing of the device. Fewer parts of simpler construction are employed compared to the prior art. | 6 |
DESCRIPTION OF THE PRIOR ART
Building braces have been used in the walls of buildings under construction to maintain the studs and trusses a distance apart and to strengthen the walls and ceiling anchored thereto under normal building loads and warping conditions.
U.S. Pat. No. 1,725,414 discloses a structural bracing member for spaced floor joists comprising a vertical portion arranged to be affixed to a joist and a bracing element extending from the bottom of the vertical portion. The top of the vertical portion is affixed to the end of a cooperating bracing element.
U.S. Pat. No. 1,742,045 discloses a brace bar having portions at one end for individually engaging different faces of the wooden studs against which the end of the bar is disposed.
U.S. Pat. No. 2,455,904 discloses an adjustable bridging member for building structures comprising a pair of brace arms pivotally connected to each other.
U.S. Pat. No. 2,865,059 discloses a horizontal bar connectable at its opposite ends to and extends transversely between adjacent joists. A second bar of inverted V-shape is connected at its apex to the midlength portion of the first bar and has short, horizontal extensions at its ends adapted to be secured to the bottom edges of the joists.
U.S. Pat. No. 2,914,816 discloses a bracing extending diagonally between adjacent joists and a fixed clamp for engaging the bracing elements in thrust relationship to the adjacent joists.
SUMMARY OF THE INVENTION
In accordance with the invention claimed an improved brace or bridging member is provided for connecting spaced joists, studs, rafter trusses and like parallel structural beams together.
It is, therefore, one object of this invention to provide an improved brace or bridging member which will aid the carpenter in parallelly arranging structural beams during assembly and will provide improved resistance to twisting under tension and stretching under load.
Another object of this invention is to provide an improved building brace which aligns and holds in place parallelly arranged juxtapositioned structural beams and prevents them from laterally distorting or deflecting.
A further object of this invention is to provide an improved bracing member which when used by the carpenter to position juxtapositioned structure beams also braces them for preventing lateral displacement including warping but does so with a relatively inexpensive bracing structure.
A still further object of this invention is to provide an improved bridging member which self spaces the parallel support members requiring no temporary lay-out or temporary bracing previous to installation.
A still further object of this invention is to provide an improved bridging member employing ears for placement over the tops of adjacent trusses for ease in installation.
It should be noted that throughout the description of the invention floor and ceiling joists, roof rafters, trusses, studding and the like will be included in the term "joists".
Further objects and advantages of the invention will become apparent as the following description proceeds and the features of novelty which characterize this invention will be pointed out with particularity in the claims annexed to and forming part of this specification.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be more readily described by reference to the accompanying drawing in which:
FIG. 1 is a perspective view of a bracing structure embodying the invention installed in place between two parallelly arranged structural beams;
FIG. 2 is a cross-sectional view of FIG. 1 taken along the line 2--2;
FIG. 3 is a plan view of the bracing structure shown in FIG. 1;
FIG. 4 is the top view of FIG. 3;
FIG. 5 is a partial perspective view of a modification of the bracing structural shown in FIGS. 1-4;
FIG. 6 is a cross-sectional view of FIG. 5 taken along the line 6--6;
FIG. 7 is a perspective view of a further modification of the bracing structure shown in FIG. 1 but differs therefrom by eliminating the extending wings on the bottom horizontal member;
FIG. 8 is a still further modification of the bracing structures shown in FIGS. 1-7 wherein the top member of FIG. 1 is eliminated with wings laterally attached to the vertical legs of the structure and the bottom horizontal member formed without the end portions shown in FIG. 1;
FIG. 9 illustrates a perspective view of a V-shaped brace forming a further modification of the structure shown in FIGS. 1-8; and
FIG. 10 illustrates a perspective view of structure brace formed from the interlocking of two of the V-shaped braces shown in FIG. 9.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to the drawing by characters of reference, FIGS. 1-4 disclose a parallel structural beam bridging member or cross brace 10. This brace is used for bracing studs, rafters, trusses or joists 11 to hold them together and in place during building and when these structural elements receive floor, ceiling and wall boards the brace maintains them in place under building loads and stresses. As shown in dash lines in FIG. 1, the trusses may be flat or pitched members.
These braces are located wherever desired along the length of the joists and are usable to advantage in positioning on parallel beam relative to an adjacent beam during construction as well as to bridge these beams for proper weight distribution and to prevent the spread of the joists and warpage thereof under load conditions.
As shown in FIGS. 1-3, each cross brace 10 comprises a box shaped member having elongated top and bottom beam members 12 and 13 spacedly connected by two parallelly arranged spaced perpendicularly positioned members 14 and 15. Each cross brace further comprises a pair of arms 16 and 17 of substantially equal length assembled in face-to-face relationship in an X-shaped formation crossing at a mid point of their length at which point they may be suitably secured, if desired, such as by rivit 17A, welding, crimping etc. Each arm is preferably formed of a flat strip of material which is relatively narrow in relationship to its length and is correspondingly thin. As shown, each arm terminates at each of its ends in a corner formed by the intersection of top and bottom members 12 and 13 with the laterally positioned members 14 and 15.
Although the cross braces 10 may be formed of metal they also may be satisfactorily formed of a suitable plastic material.
Openings 18 are provided in each of the top and bottom members near their ends outside of the box like outline formed by the top and bottom members 12 and 13 and the lateral or perpendicular members 14 and 15. These openings as well as similar holes 18 in the perpendicular members 14 and 15 are provided for the passage of nails 19 or the like, one of which is shown in FIG. 1, into the beams to which the unit is to be secured, as shown in FIG. 1. The openings 18 are preferably disposed in more or less staggered relationship to each other thereby avoiding, as much as possible, the positioning of the nails or the like in rows which would tend to split the beam along the grain of the wood.
In its application, as shown in FIG. 1, each cross brace is placed between the beams 11 with the ends of the top and bottom members 12 and 13 extending over the tops and bottoms 11A and 11B of the joists. The cross brace then may be nailed securely to the joists from their top and later from their bottom surfaces, if so desired. Any extra length of the top and bottom members extending over the edges of the joist may be bent down against the vertical side 11C of the joist. Although this feature is not shown in the drawing, the technique is well known in the trade. If desired, the holes 18 may be in line with the ends of the top and bottom member shortened so that they end on the center line of the beam on which they rest.
As evident from FIG. 1, the cross braces 10 may be disposed in rows between the beams or joists or may be installed in any other suitable manner as required such as in a staggered relationship. Since the cross braces are formed of thin material they ensure that there will be no appreciable interference with the leveling of an overlying surface such as flooring, ceiling and walls. Equally important in the structure of FIGS. 1-3 is the characteristic that the perpendicular members 14 and 15 lie closely adjacent the sides 11C of the joists so that when the brace is places between the joists and nailed in place they not only hold one joist relative to the adjacent one at just the right distance apart but the members 14 and 15 hold and keep them from laterally twisting and warping. The arms 16 and 17 further aid in this feature of the cross brace but also aid in distributing between the joists the building loads and stress later encountered.
FIGS. 5 and 6 disclose a modification of the cross brace structure shown in FIGS. 1-4 wherein the cross brace 20 comprises a top beam member 21 similar to top beam member 12 but having a trinagular knock out protrusion 22 serving as a nail for engaging the joist. In this instance the cross brace must be set down over adjacent joists and the like so that the bottom member 23 must terminate at the perpendicular member 24, as shown. In this instance two spaced perpendicular members 24 may be formed of a single piece of material.
FIG. 7 illustrates a further modification of the cross braces, shown in FIGS. 1-6, wherein the cross brace 26 comprises a top beam member 27, perpendicular members 28 and 29, and cross arms 30 and 31 similar to that shown in FIGS. 1-4 but the bottom member 32 merely extends between the perpendicular members 28 and 29. This cross brace may be reversed for use with the bottom serving as the top etc. It also can be used by eliminating either the top or bottom member from the structure.
FIG. 8 illustrates a further modification of the cross brace structure shown in FIGS. 1-7 wherein the cross brace 33 comprises an integral bottom beam member and perpendicular members 34, 35 and 36, respectively, wherein the ends of the perpendicular members terminate at each end in lateral outwardly extending plates or tabs 37, and 38 whose planes are disposed substantially at right angles to the plane of each perpendicular member for extending over the top surfaces of the joists 11. Each tab may have the usual nail holes 18 and cross arms 16 and 17 of the type shown in FIGS. 1-4. It should be noted that the bottom member 34 may be omitted as a further modification of the cross brace.
FIG. 9 illustrates a V-shaped cross brace 40 which may be used individually or in combination, as shown in FIG. 10, with a similar cross brace 41 to form a composite interlocking cross brace 42.
Each of the V-shaped cross braces 40 and 41, one of which is a mirror image of the other, is provided with laterally extending tabs 40A, 40B, 41A and 41B at their ends which are provided with nail holes 18 for lying flat on top of adjacent joists. As shown each V-shaped cross brace is provided with a pair of slits 42 and 43 which interlock with similar slots of the mating V-shaped brace to form the unitary structure shown in FIG. 10.
With reference to FIG. 10, cross brace 42 may be formed of one integral member similar to FIG. 8 without the bottom member 34.
Although but a few embodiments of the present invention have been illustrated and described, it will be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the spirit of the invention or from the scope of the appended claims. | A cross brace or bridging member for parallel structure beams, such as joists, studs, rafter trusses and the like which spaces and holds them in place relative to each other during assembly, and under normal building load conditions holds them in place longitudinally and prevents or greatly reduces lateral warpage or deflection thereof. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a sealing method and apparatus for sealing an annulus between an outer surface of an oil and/or gas well tubing or casing hanger and an inner surface of a wellhead housing.
2. Description of the Prior Art
Oil and/or gas wells typically include one or more pipe strings extending downwardly into the earth from its surface. The strings are included one within the other and serve various purposes, such as maintaining the structural integrity of the well and for controlling fluid flow and fluid pressures within the well. A "string" is referred to as casing if there is at least one string within that string, and the innermost string is referred to as tubing.
At the wellhead, various types of wellhead members are connected and sealed to the casing and tubing and perform various functions, among which are: to support the casing and tubing from the surface; to provide means for connecting fluid conduits to the tubing as well as to the annuli defined by the tubing and the various casing strings surrounding it; and for maintaining control of the fluid pressures experienced within the wellhead. To maintain control of the often very high fluid pressures, it is necessary to provide seals between the various wellhead members and the tubing and casing. Elastomeric seals have been provided in such devices which provide a seal against the tubing and casing when the seal is pressed inwardly thereagainst. This is achieved in various devices by exerting pressure vertically against the seal causing it to expand inwardly against the tubing or casing thus to seal it off. The elastomeric seal may be urged inwardly also by pressure exerted upon its outer circumferential surface. For example, such seals have been in use for many years wherein fluid pressure is exerted in an annulus surrounding the outer diameter of the elastomeric seal thus to urge it inwardly. The annulus is connected to the exterior of the device by means of a check valve through which fluid under pressure is introduced. In some types of sealing methods, a liquid plastic under pressure is injected through the check valve for forming the seals, and thereafter the plastic hardens so that the seal is permanently maintained.
Many well operators believe that elastomeric seals may be unreliable under extremes of temperature and high pressures, which may cause them to breakdown, leading to an undesirable failure of the seal. Accordingly, metal-to-metal type seals have been adopted for use in order to overcome the foregoing temperature sensitivity problems of elastomeric materials. Various types of metal-to-metal seals have been proposed; however, they suffer from many disadvantages. Examples of such disadvantages include high setting force loads are required in order to force the seal into engagement. In many instances, complex hydraulically-operated systems are required to energize the seal, and typically include additional tools to lock the seal in the desired sealing engagement. Many metal-to-metal type seals utilize a solid wedge to force the seal into engagement with the desired surface; however, temperatures changes experienced by the wellhead and casing or tubing strings, and differential expansion and/or contraction of the various metal parts associated with such temperature changes, can cause the desired sealing to be lost. Some prior art seals permit movement of some components with respect to each other after achieving the desired sealing, whereby it is possible that undesired movement of some components can cause the seal to fail.
Some types of metal-to-metal seals seal against a tapered surface disposed on the wellhead housing and/or tubing or casing hanger. If there is longitudinal movement of either the seal or the adjacent tapered surface, which can be caused by differential expansion or contraction caused by temperature changes or changing tensile force loads on the casing or tubing, the seal may move off the tapered surface and thus destroy the desired sealing. Another disadvantage associated with many types of metal-to-metal seals is that the seals may not be subjected to an external pressure test, nor can the well operator visually determine if the desired sealing has been accomplished. Another disadvantage is that some types of metal-to-metal seals do not provide for a stored energy preload force which takes advantage of the resilience and the elastic/plastic properties of the metal used to make the seal, so as to constantly urge the seal into the desired sealing engagement with its adjacent surfaces. A further disadvantage with many metal-to-metal seals, which utilize multiple seals, is that the multiple seals are set at the same time, rather than independently of one another. It may be difficult to determine whether or not all of the multiple seals have been properly set into sealing engagement.
Accordingly, prior to the development of the present invention, there has been no single sealing method and apparatus for sealing an annulus between an outer surface of an oil and/or gas well tubing or casing hanger and an inner surface of wellhead housing which: does not require high setting force loads; does not require a complex hydraulically operated system and additional tools to lock the seal in its desired sealing engagement; does not use a solid wedge subject to differential temperature changes which could cause the seal to fail; is not sealed against a tapered sealing surface; permits an external pressure test and enables the well operator to visually determine if sealing has been accomplished; has a stored energy preload force to maintain the desired sealing; sets multiple seals independently of each other; and upon sealing becomes a relatively solid seal assembly, the various components of which are not subject to movement relative to each other. Therefore, the art has sought a sealing method and apparatus for sealing an annulus between an outer surface of an oil and/or gas well tubing or casing hanger and an inner surface of a wellhead housing which: does not require high setting force loads; does not require a complex hydraulically operated system to set the seals, and additional tools to lock the seal in the desired sealing engagement with adjacent surfaces; does not utilize a solid wedge subject to differential temperature changes which can cause the seal to fail; seals upon a straight, non-tapered sealing surface; can be tested by an external pressure test and can permit the well operator to visually determine the setting of the seal; has a stored energy preload force to constantly urge the seal into sealing engagement; sets multiple seals independent of each other; and upon sealing becomes a relatively solid assembly with its individual components not subject to movement relative to each other so as to maintain the desired sealing.
SUMMARY OF THE INVENTION
In accordance with the present invention, the foregoing advantages have been achieved through the present seal assembly for sealing an annulus between concentric spaced apart inner and outer generally cylindrical surfaces, each surface having an upper and a lower portion, the seal assembly adapted to be disposed within the annulus. The present invention includes: an upper seal member formed of a metallic material and adapted to be disposed adjacent the upper portions of the surfaces; a lower seal member formed of a metallic material and adapted to be disposed adjacent the lower portions of the surfaces; an energizing ring member, disposed between the upper and lower seal members, for energizing the upper and lower seal members to engage, and seal against, adjacent surfaces; means for causing relative motion between the energizing ring and the upper and lower seal member; and first means for staging the energizing of the upper and lower seal members to cause the lower seal member to engage, and seal against, the lower portions of the surfaces before the upper seal member engages, and seals against the upper portions of the surfaces. A feature of the present invention is that the lower seal member may have an inner seal adapted for engaging, and sealing against, the lower portion of the inner generally cylindrical surface, and an outer seal adapted for engaging, and sealing against, the lower portion of the outer generally cylindrical surface; and a second means for staging the energizing of the inner and outer seals of the lower seal member, to cause one of the seals of the lower seal member to engage, and seal against, one of the lower portions of one of the surfaces, before the other seal of the lower seal member engages, and seals against, the other lower portion of the other surface.
Another feature of the present invention is that the upper seal member may have an inner seal adapted for engaging, and sealing against, the upper portion of the inner generally cylindrical surface, and an outer seal, adapted for engaging, and sealing against, the upper portion of the outer generally cylindrical surface; and a third means for staging the energizing of the inner and outer seals of the upper seal member, to cause one of the seals of the upper seal member to engage, and seal against, one of the upper portions of one of the surfaces, before the other seal of the upper seal member engages, and seals against, the other upper portion of the other surface. A further feature of the present invention is that the inner seal may be an interference type seal, wherein sealing between the inner seal and the lower portion of the inner surface is accomplished by an interference fit of the inner seal with the lower portion of the inner surface; and the outer seal is a wedge type seal, wherein the sealing between the outer seal and the lower portion of the outer surface is accomplished by the outer seal being wedged into sealing engagement with the lower portion of the outer surface.
In accordance with another aspect of the present invention, the foregoing advantages have also been achieved through the present seal assembly for sealing an annulus between concentric spaced apart inner and outer generally cylindrical surfaces, each surface having an upper and a lower portion, the seal assembly adapted to be disposed within the annulus. The present invention may include an upper ring-shaped seal member formed of a metallic material and adapted to be disposed adjacent the upper portions of the surfaces, the upper seal member having a generally U-shaped configuration with inner and outer downwardly extending leg members, with an inner seal disposed on the inner leg member and an outer seal disposed on the outer leg member; a lower ring-shaped seal member formed of a metallic material and adapted to be disposed adjacent to the lower portions of the surfaces, the lower seal member having a generally U-shaped configuration with inner and outer upwardly extending leg members, with an inner seal disposed on the inner leg member and an outer seal disposed on the outer leg member; an energizing ring member, disposed between the upper and lower seal members, for energizing the upper and lower seal members to engage, and seal against the surfaces; and means for causing relative motion between the energizing ring member and the upper and lower seal members. A further feature of the present invention is that the inner seals on the upper and lower inner leg members may be interference type seals and sealing between the inner seals and their adjacent inner surfaces is accomplished by an interference fit of the inner seals, disposed on the inner leg members, with their adjacent inner surfaces; and the outer seals are wedge type seals, and the sealing between the upper seals and their adjacent outer surfaces is accomplished by the outer seals being wedged into sealing engagement with the adjacent outer surfaces.
Another feature of the present invention is that portions of the energizing ring member may engage the outer leg members to wedge the outer seals into sealing engagement with their adjacent outer surfaces, which causes portions of the energizing ring member to be deflected inwardly toward the inner leg members, and the deflected portions of the energizing ring members apply an outwardly extending force upon the outer leg members to maintain the outer seals in sealing engagement with the adjacent outer surfaces. An additional feature of the present invention is that the deflected portions of the energizing ring member may be spaced from the inner leg members to permit the deflected portions of the energizing ring to store energy to apply the outwardly extending force to the outer leg members and outer seals.
In accordance with another aspect of the present invention, the foregoing advantages have also been achieved through the present oil and/or gas well tubing or casing hanger, for use with a seal assembly having an upper and lower seal member. This aspect of the present invention may include: a generally tubular shaped member having upper and lower ends, and an outer surface; the outer surface of the upper end having a first tapered surface, adapted to be disposed adjacent to the upper seal member, which first tapered surface tapers downwardly and outwardly to provide the upper end of the tubular shaped member with a first enlarged diameter; and the outer surface of the upper end having a second tapered surface, adapted to be disposed adjacent the lower seal member, which second tapered surface tapers downwardly and outwardly to provide the upper end of the tubular shaped member with a second enlarged diameter. A feature of this aspect of the present invention is that the second enlarged diameter may be larger than the first enlarged diameter.
In accordance with another aspect of the present invention, the foregoing advantages have also been achieved through the present method for sealing an annulus between concentric, spaced apart inner and outer generally cylindrical surfaces, each surface having an upper and lower portion. This aspect of the present invention may include the steps of: disposing a seal assembly, having upper and lower metallic seal members, within the annulus adjacent the inner and outer surfaces; energizing the seal assembly to first cause the lower seal member to engage, and seal against, the lower portions of the surfaces, before the upper seal member has engaged, and sealed against, the upper portions of the surfaces; and energizing the seal assembly to then cause the upper seal member to engage, and seal against, the upper portions of the surfaces. A feature of this aspect of the present invention includes the steps of: utilizing a lower seal member having an inner seal for engaging, and sealing against, the lower portion of the inner surface and an outer seal for engaging, and sealing against, the lower portion of the outer surface; and energizing the seal assembly to cause seal for engaging, and sealing against, the lower portion of the outer surface; and energizing the seal assembly to cause one of the seals of the lower seal member to engage, and seal against, one of the lower portions of one of the surfaces, before the other seal of the lower seal member engages, and seals against, the other lower portion of the other surface.
Another feature of this aspect of the present invention includes the steps of: first locking the lower seal member to maintain the inner and outer seals of the lower seal member in sealing engagement with the lower portions of the inner and outer surfaces, after the inner and outer seals of the lower seal member have sealed against the lower portions of the surfaces; and thereafter energizing the seal assembly to cause the upper seal member to engage, and seal against, the upper portions of the surfaces. Another feature of the present invention may include the steps of: utilizing, as the lower seal member inner seal, an interference type seal, and sealing between the inner seal and the lower portion of the inner surface by forcing the inner seal into an interference fit with the lower portion of the inner surface; utilizing, as the lower seal member outer seal, a wedge type seal, and sealing between the outer seal and the lower portion of the outer surface by wedging the outer seal into sealing engagement with the lower portion of the outer surface.
A further feature of the present invention may include the steps of: utilizing an upper seal member having an inner seal for engaging, and sealing against, the upper portion of the inner surface, and an outer seal for engaging, and sealing against, the upper portion of the outer surface; and energizing the seal assembly to cause one of the seals of the upper seal member to engage, and seal against, one of the upper portions of one of the surfaces, before the other seal of the upper seal member engages, and seals against, the other upper portion of the other surface. An additional feature of the present invention may include the steps of storing energy member. A further feature of the present invention may include the step of applying a pressure force from an external source to a cavity, disposed between the upper and lower seal members, to test the pressure integrity of the upper and lower seal members.
A further feature of the present invention may include the step of utilizing a torque force to energize the upper and lower seal members of the seal assembly, and the torque force may be applied to the seal assembly by rotating an actuation sleeve member downwardly into engagement with the upper seal member to cause relative motion between the upper seal member and the lower seal member. A further feature of the present invention may include the step of sealing the inner seals of the upper and lower seal members against an inner surface which is parallel with the longitudinal axis of the seal assembly.
The sealing method and apparatus of the present invention, when compared with previously proposed sealing methods and apparatus, have the advantages of: not requiring high setting force loads; does not require a complex hydraulically-operated system to set the seals and additional tools to lock the seals in their desired sealing engagement; not being readily susceptible to differential temperature and pressure changes, which could cause a failure of the seal; not sealing upon a tapered sealing surface; permitting an external pressure test of the seals and permitting the well operator to visually determine the setting of the seals; providing for a stored energy preload force to constantly apply a force to maintain the desired sealing engagement; setting multiple seals independently of one another; and, upon sealing, becoming a relatively solid assembly, wherein the components of the seal assembly are not subject to movement relative to each other.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial cross-sectional view of a wellhead housing provided with the seal assembly of the present invention, a portion of the seal assembly being encircled by dotted lines;
FIG. 2 is a cross-sectional view along the longitudinal axis of a seal assembly of the present invention;
FIG. 3 is a cross-sectional view of a lower seal member of the seal assembly of the present invention, taken along line 3--3 of FIG. 4;
FIG. 4 is a partial cross-sectional view of the lower seal member of FIG. 3;
FIGS. 5-9 are partial cross-sectional views of the seal assembly of the present invention illustrating the successive stages of energizing the seal assembly of the present invention to seal an annulus disposed between a wellhead housing and a tubing hanger;
FIG. 10 is a partial cross-sectional view of another embodiment of a seal assembly in accordance with the present invention;
FIGS. 11-13 are partial cross-sectional views of another embodiment of a seal assembly in accordance with the present invention, illustrating the successive stages of energizing the seal assembly;
FIG. 14 is an exploded cross-sectional view of a seal member of FIGS. 11-13, upon the seal member being sealed against a wellhead housing; and
FIGS. 15-16 are partial cross-sectional views of another embodiment of a seal assembly in accordance with the present invention, illustrating the successive stages of energizing the seal assembly.
While the invention will be described in connection with the preferred embodiment, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, a seal assembly 20 in accordance with the present invention is shown disposed in an annulus 21 between concentric spaced apart inner and outer generally cylindrical surfaces 22, 23 with each surface, having an upper portion 24, 25, and a lower portion 26, 27. As illustrated in FIG. 1, inner surface 22 of the annulus 21 is the outer surface 28 of a tubing hanger 29, and outer surface 23 of the annulus 21 is the inner surface 30 of a wellhead housing 31. Seal assembly 20 may be utilized to seal the annulus 21 between a wellhead housing 31 and tubing hanger 29, or as is conventional in the art, between a casing hanger (not shown) and wellhead housing 31. Wellhead housing 31 may be of conventional construction, but is typically part of a "multibowl" wellhead system, wherein seal assembly, or assemblies, 20 are installed through a blowout preventer stack (not shown).
With reference to FIGS. 1 and 2, seal assembly 20 is shown to generally comprise: an upper seal member 35 formed of a metallic material and adapted to be disposed adjacent the upper portions 24, 25 of the inner and outer surfaces 22, 23; a lower seal member 36 formed of a metallic material and adapted to be disposed adjacent the lower portions 26, 27 of inner and outer surfaces 22, 23; an energizing ring member 37, disposed between the upper and lower seal members 35, 36, for energizing the upper and lower seal members 35, 36 to engage, and seal against, adjacent surfaces 24-27; a means for causing relative motion 38 between the energizing ring 37 and the upper and lower seal members 35, 36, or an actuation sleeve member 39; and a first means for staging the energizing 40 of the upper and lower seal members 35, 36 to cause the lower seal member 36 to engage, and seal against, the lower portions 26, 27 of the surfaces 22, 23 before the upper seal member 35 engages, and seals against, the upper portions 24, 25 of the inner and outer surfaces 22, 23. Upper and lower seal members 35, 36, as well as energizing ring member 37 and actuation sleeve member 39, may be made of any suitable metallic material having the required strength characteristics for use in an oil and/or gas well wellhead system, which can be subject to high pressure and temperature conditions, as is known in the industry.
With reference to FIGS. 2-4, lower seal member 36 is a ring-shaped member 41 having a generally U-shaped configuration with inner and outer upwardly extending leg members 42, 43 with an inner seal 44 disposed on the inner leg member 42 and an outer seal 45 disposed on the outer leg member 43. Upper seal member 35 is of a generally similar construction, and comprises a ring-shaped member 51 having a generally U-shaped configuration with inner and outer downwardly extending leg members 52, 53 with an inner seal 54 disposed on the inner leg member 52 and an outer seal 55 disposed on the outer leg member 53. Energizing ring member 37 is disposed between upper and lower seal members 35, 36, and has upper and lower wedges 61, 62 formed integral with centrally disposed ring member 63, the operation of upper and lower wedges to be hereinafter described in greater detail.
Still with reference to FIGS. 2-4, actuation sleeve member 39 is a ring member 70 disposed on top of upper seal member 35, and as will be hereinafter described in greater detail, is rotatably mounted with respect to upper seal member 35. The internal surface 71 of actuation sleeve member 39 is provided with a set of threads which are adapted for threaded engagement with a set of threads 73 (FIGS. 1 and 5) on the upper portion 24 of inner surface 22, or outer surface 28 of tubing hanger 29. Lower seal member 36 and upper seal member 35 are each provided with an annular groove 75 which receives a plurality of balls 76, which balls 76 are also received within an annular groove 77 disposed on the interior surface 78 of energizing ring member 37, whereby upper and lower seal members 35, 36 are releasably connected to energizing ring member 37, and may be moved upwardly and downwardly with respect to energizing ring member 37 along their common longitudinal axis 79, as balls 76 roll within cooperating grooves 75, 77. Suitable openings 80 are provided in energizing ring member 37, to permit balls 76 to pass through energizing ring member 37 and be disposed within cooperating grooves 75, 77. Similarly, actuation sleeve member 39 is rotatably mounted within upper seal member 35, as by a plurality of balls 81 disposed in annular groove 82 formed in the outer surface 83 of actuation sleeve member 39, the balls 81 being passed through an opening 84 in upper seal member 35, whereby actuation sleeve member 39 can be rotated with respect to upper seal member 35.
With reference to FIGS. 2-5, inner seals 54, 44 of upper and lower seal members 35, 36 are preferably interference type seals, which may take the form of an internally disposed annular projection, or rib 90, disposed on the inner leg members 52, 42 of upper and lower seal members 35, 36. As will be hereinafter described in greater detail in connection with FIGS. 5-9, sealing between the inner seals 44, 54 and inner surface 22, or outer surface 28 of tubing hanger 29, is accomplished by an interference fit of the inner seals 44, 54 with their adjacent inner surfaces 26, 24, in that the inner diameter of the projecting rib 90 is slightly smaller than the outer diameter of the surfaces 24, 26, against which inwardly projecting annular ribs 90 are sealed against. Outer seals 55, 45, of upper and lower seal members 35, 36 are preferably wedge type seals, which are preferably formed as an outwardly extending annular projection, or rib, 91 disposed on outer legs 53, 43 of upper and lower seal members 35, 36. Outer seals 55, 45, are placed in sealing engagement with upper and lower outer surfaces 25, 27, or the interior surface 30 of wellhead housing 31, by wedging, or forcing, outer seals 55, 45 into sealing engagement with the adjacent outer surfaces 25, 27. Preferably outer seals 55, 45 are wedged, as will be hereinafter described in greater detail, by upper and lower wedges 61, 62, moving into contact with the interior surfaces 92, 93 of lower outer leg member 43 and upper outer leg member 53, as will be hereinafter described in greater detail.
With reference to FIGS. 2-5, first staging means 40 includes a means for initially restraining movement 100 of the upper seal member 35 with respect to the energizing ring member 37. As will be hereinafter described in greater detail, after a predetermined amount of force is applied and exceeded between the upper seal member 35 and energizing ring member 37, movement of the upper seal member 35 with respect to energizing ring member 37 will then be permitted. Preferably, the means for initially restraining movement 100 of the upper seal member 35 is a first shear ring 101 which engages both the upper seal member 35 and the energizing ring member 37. Preferably, a portion 102 of the downwardly extending inner leg member 52 of upper seal member 35 is provided with a shoulder 103 upon which is seated first shear ring 101. First shear ring 101 has an outer flange portion 104 which is received within a groove 105 disposed within energizing ring member 37. Until a predetermined amount of force is applied downwardly in the direction of longitudinal axis 79, upper seal member 35 will be secured to energizing ring member 37 by first shear ring 101. After the predetermined amount of force is applied and exceeded in the direction of longitudinal axis 79, first shear ring 101 will be sheared, whereby outer flange 104 will remain in groove 105, as upper seal member 35 moves downwardly with respect to energizing ring member 37, at which time, ball 76 will move downwardly within groove 77, as will hereinafter be described in greater detail. Alternatively, at least one shear pin could be utilized in lieu of first shear ring 101 to releasably connect upper seal member 35 to energizing ring member 37 and for initially restraining movement of the upper seal member 35 with respect to the energizing ring member 37, until a predetermined amount of force has been applied and exceeded, as previously described.
Still with reference to FIGS. 2-5, an upper portion 105 of inner leg member 42 of lower seal member 36 is also preferably provided with a shoulder 106 upon which is mounted a second shear ring 111, and outer flange 107 of shear ring 111 is similarly received within groove 107 of energizing ring member 37. Second shear ring 111, as will be hereinafter described in greater detail, serves as a second means for staging 115 the energizing of the inner and outer seals 44, 45, to cause one of the seals 44, 45 of the lower seal member 36 to engage, and seal against, one of the lower portions 26, 27 of one of the surfaces 22, 23, before the other seal 44, 45 of the lower seal member 36 engages, and seals against, the other portion 26, 27 of the other surface 22, 23. Second shear ring 111 serves as a means for initially restraining movement 116 of the lower seal member 36 with respect to the energizing ring member 37, until a predetermined amount of force is applied between the lower seal member 36 and the energizing ring member 37, until a predetermined amount of force is applied between the lower seal member 36 and the energizing ring member 37, as will be hereinafter described in greater detail. Similarly, as previously described, at least one shear pin (not shown) may be utilized in lieu of second shear ring 111 to serve as the means for initially restraining movement 116 of the lower seal member 36 with respect to the energizing ring member 37.
With reference to FIGS. 5-9, a method of the present invention for sealing an annulus 21 between a tubing hanger 29 and a wellhead housing 31 will be described. After seal assembly 20 has been assembled as illustrated in FIG. 2, and after the casing or tubing hanger 29 has been landed in wellhead housing 31, as illustrated in FIG. 1, the seal assembly 20 is run through the blowout preventer stack while attached to a installation tool (not shown). The installation tool may be of conventional construction and have a plurality of projections (not shown) for engagement with a plurality of mating openings 120 disposed along the periphery of actuation sleeve member 39, so as to permit actuation sleeve member 39 to be rotated as will be hereinafter described. Seal assembly 20 may be preferably passed through the blowout preventer stack on one or more joints of drill pipe (not shown). As seal assembly 20 reaches tubing hanger 29, seal assembly 20 slides over the top of the tubing hanger 29 until threads 72 on actuation sleeve member 39 contact the threads 73 at the top of the outer surface 28 of tubing hanger 29. A torque force is applied to actuation sleeve member 39 to rotate actuation sleeve member 39 with respect to upper seal member 35. An axial force along the longitudinal axis 79 of seal assembly 20 is generated by the torque applied to the actuation sleeve member threads 72.
With reference to FIG. 5, outer surface 28 of tubing hanger 29 is provided with a first tapered surface 120 adjacent the inner leg member 52 of upper seal member 35. The first tapered surface 120 tapers downwardly and outwardly toward the upper seal member 35 to provide the tubing hanger 29 with a first enlarged diameter D1 adjacent the inner leg member 52 of upper seal member 35. The outer surface 28 of tubing hanger 29 is further provided with a second tapered surface 122 adjacent the inner leg member 42 of the lower seal member 36, and the second tapered surface 122 tapers downwardly and outwardly toward the lower seal member 36 to provide the tubing hanger 29 with a second enlarged diameter D2 adjacent the inner leg member 42 of lower seal member 35. (Preferably, the second enlarged diameter D2 is greater than the first enlarged diameter D1).
Still with reference to FIG. 5, as the axial force upon seal assembly 20 is generated by the torque force applied to the actuation sleeve member 39, the seal assembly 20 moves downwardly within annulus 21. The inner seal 44, or inwardly projecting annular rib 90, on inner leg member 42 of lower seal member 36 moves downwardly along second tapered surface 122 on tubing hanger 29 and downwardly onto straight portion 123 of tubing hanger 29 which has the second enlarged diameter. Because the inner diameter of inner seal 44, or inwardly projecting annular rib 90, is slightly smaller than second enlarged diameter D2, inner seal 44 is forced into an interference fit with straight portion 123 of the outer surface 28 of tubing hanger 29 which is disposed below second tapered surface 122. The wall surface portion 123 is preferably straight, or disposed substantially parallel with the longitudinal axis 79 of seal assembly 20.
Further rotation of actuation sleeve member 39 causes seal assembly 20 to continue to move downwardly within annulus 21, until the bottom 124 of lower seal member 36 bottoms out on a shoulder 125 disposed on tubing hanger 29, as illustrated in FIG. 6. While seal assembly 20 is moving downwardly within annulus 21, the axial force being applied by the torque force used to rotate actuation sleeve member 39, is insufficient to shear the first shear ring 101 of the means for initially restraining movement 100 of the upper seal member 35 with respect to the energizing ring member 37 of first staging means 40. The axial force generated, while seal assembly 20 moves downwardly from the position illustrated in FIG. 5 to that illustrated in FIG. 6, is also insufficient to shear the second shear ring 111 of the means for initially restraining movement 116 of the lower seal member 36 with respect to the energizing ring member 37 of the second staging means 115. Thus, as seal assembly moves downwardly within annulus 21 from the position illustrated in FIG. 5 to that illustrated in FIG. 6, inner seal 44 remains in an interference fit with the straight portion 123 of the tubing hanger 29. During this downward movement, outer seal 45 of outer leg member 43 of lower seal member 36 is in engagement with the inner surface 30 of wellhead 31; however, outer seal 45 has not sealed against inner surface 30 of wellhead 31 so as to prevent fluids from passing between outer seal 45 and the inner surface 30 of wellhead housing 31.
While seal assembly is moving downwardly into the configuration shown in FIG. 6, the second means for initially restraining movement 116 of the lower seal member 36 with respect the energizing ring member 39, or second shear ring 111 of the second staging means 115, in addition to transferring the axial force to the lower seal member 36, also prevents premature energizing of the outer seal 45 of lower seal member 36. When seal assembly is in the configuration illustrated in FIG. 6, it should be noted that neither of the seals 54, 55 of the upper seal member 35 are sealed against either the outer surface 28 of tubing hanger 29, or the inner surface 30 of wellhead housing 31. The only seal in sealing engagement, when seal assembly 20 is in the configuration illustrated in FIG. 6, is the inner seal 44 of lower seal member 36.
With reference to FIG. 7, upon an additional and increased torque force being applied to actuation sleeve member 39, which force is converted by mating threads 72 and 73 into a downward axial force along longitudinal axis 79 of seal assembly 20, a sufficient axial force is generated to shear second shear ring 111, whereby the central portion of second shear ring 111 remains on the shoulder 106 at the top of lower seal member 36, and the outer flange portion 107 remains in groove 108 disposed in energizing ring member 37. After second shear ring 111 has been sheared, upper seal member 35 and energizing ring member 37 continue to move downwardly within annulus 21, during which time the lower wedge 62 of energizing ring member 37 contacts the tapered inner surface 92 of outer leg member 43 of lower seal member 36 and exerts an outwardly extending force upon outer leg member 43 and outer seal 45 of lower seal member 36. The continued downward movement of upper seal member 35 and energizing ring member 37 causes lower wedge 62 to wedge, or force, the outer seal 45 of lower seal member 36 into sealing engagement with the lower portion 27 of outer surface 23, or inner surface 30 of wellhead housing 31. As lower wedge 62 forces outer leg member 43 and outer seal 45 of lower seal member 36 outwardly to engage, and seal against, inner surface 30 of wellhead housing 31, the lower wedge is deflected inwardly toward the inner leg member 42 of lower seal member 36.
As seen in FIG. 7, the deflected portion of energizing ring member 37, or lower wedge 62, is spaced from the inner leg member 42 as seen at annular cavity 130. Because of the resilience and the elastic/plastic properties of the metal of which energizing ring member 37 is made, energy is stored in the deflected lower wedge 62, so that it can constantly apply an outwardly extending force to the outer seal 45 of the lower seal member 36 to maintain the outer seal 45 in sealing engagement with the inner surface 30 of the wellhead housing 31. Accordingly, if the tubing hanger 29 and wellhead housing 31, and lower seal member 36 are subjected to differential expansion and contraction caused by temperature changes, the interference type inner seal 44 remains in sealing engagement, as does the outer seal 45 of lower seal member. For example, if tubing hanger 29 were to expand due to exposure to an increased temperature and cause the width of annulus 21 to decrease, outer seal 45 would remain in sealing engagement, while lower wedge 62 would be deflected further inwardly to accommodate the expansion of tubing hanger 29. Upon cooling of tubing hanger 29, and its attendant contraction, which could cause the width of annulus 21 to increase, the energy stored in deflected lower wedge 62 would still be constantly applying an outwardly extending force against out leg member 43 of lower seal member 36, so as to cause outer seal 45 to remain in sealing engagement with inner surface 30 of wellhead housing 31.
While outer seal 45 of lower seal member 36 is being set into the desired sealing engagement with the inner surface 30 of wellhead housing 31, upper seal member 35 and energizing ring member 37 continue to move downwardly until inner shoulder 146 of energizing ring member 137 abuts the top of second shear ring 111 as illustrated in FIG. 7. During this downward movement, the movement of upper seal member 35 with respect to energizing ring member 37 is restrained by the first staging means 40, or first shear ring 101 remaining engaged in both the upper seal member 35 and the energizing ring member 39.
With reference to FIG. 8, after the inner and outer seals 44, 45 of lower seal member have been energized into sealing engagement, as previously described in connection with FIG. 7, an additional torque force is applied to actuation sleeve member 39. This force results in a downwardly extending axial force along longitudinal axis 79 of seal assembly 20, to cause upper seal member 35 to be further compressed downwardly against energizing ring member 37. When the axial force exceeds the force necessary to shear the first shear ring 101, as illustrated in FIG. 8, the central portion of first shear ring 101 remains on shoulder 103 on the inner leg member 52 of the upper seal member 35, and the outer flange 104 of first shear ring 101 remains within groove 105. As upper seal member 35 moves downwardly, the inner seal 45, or inwardly projecting annular rib 90 on the inner leg member 52 of upper seal member 35 passes over first tapered surface 120 and engages, and seals against, the portion of outer surface 28 of tubing hanger 29, disposed below first tapered surface 120, which has the first enlarged diameter D1.
Because of the shearing of first shear ring 101, some of the axial load being applied to the lower seal member 36 may be reduced, whereby it is desirable to prevent energizing ring member 37 from moving upwardly, so as to prevent any loss of the energy being stored in deflected lower wedge 62. Preferably, seal assembly 20 is provided with a means for locking 135 the lower seal member 36 to the energizing ring member 37, after the inner and outer seal 44, 45 of the lower seal member 36 have engaged, and sealed against, their adjacent surfaces 26, 27. Preferably, the locking means 135 comprises mating surfaces 136, 137, disposed upon the upper end of inner leg member 42, and upon energizing ring member 37, which surfaces are designed to create a press fit there between upon energizing ring member 37 moving downwardly from the position illustrated in FIG. 6, into the position illustrated in FIGS. 7.
As upper seal member 35 moves downwardly from the position illustrated in FIG. 7, to that illustrated in FIG. 8, upper wedge 61 contacts the tapered inner surface 93 of the outer leg 53 of upper seal member 35 and wedges, or forces, outer seal 55 of outer leg member 53 of upper seal member 35, into sealing engagement with the inner surface 30 of wellhead housing 31, in the same manner as previously described in connection with the energizing of the outer seal 45 of lower seal member 36. Upper wedge 61 is deflected inwardly toward inner leg 52 of upper seal member 36 and is spaced from inner leg member 52, as by cavity 140. The deflected wedge 61 can then store energy to apply the desired outwardly extending force to the outer leg member 53 of upper seal member 35, to maintain outer seal 55 in the desired sealing engagement with inner surface 30 of wellhead housing 31.
With reference to FIGS. 5-9, it should be noted that the first staging means 40, or first shear ring 101, has an additional function other than staging the energizing of the upper and lower seal members 35, 36 to cause the lower seal member 36 to engage, and seal against, the wellhead housing 31 and tubing hanger 29 before the upper seal member 35 engages, and seals against, the wellhead housing 31 and tubing hanger 29. The first shear ring 101 also serves as a third means for staging the energizing of the inner and outer seals 54, 55 of the upper seal member 35, to cause the inner seal 54 to engage, and seal against, the tubing hanger 29, before the outer seal 55 engages, and seals against, the wellhead housing 31.
With reference to FIG. 9, actuation sleeve member 39 has been rotated until the first and second shear rings 101, 111 are in an abutting relationship with inner shoulders 145, 146 of energizing ring member 137, at which time no further movement of upper and lower seal members 35, 36, energizing ring member 137, and actuation sleeve member 39 is possible. Seal assembly 20 is thus locked into a relatively solid unit, whereby the seals 44, 45, 54, 55, of upper and lower seal members 35, 36 cannot become disengaged. The pressure integrity of the upper and lower seal members 35, 36 may be tested by applying a pressure force, such as high pressure fluid, from an external source 148 through a test port 149 formed in wellhead housing 31 (FIG. 1) which leads to a cavity 150 (FIG. 9) between the upper and lower seal members 35, 36. The lower seal member 35 is adapted to hold pressure coming from the top of the seal assembly 20, and the pressure force acting on the inner and outer legs 42, 43 of the lower seal member 36 will enhance the contact stresses between the inner and outer seals 44, 45 against the tubing hanger 29 and wellhead housing 31. The upper seal member 35 is likewise adapted to hold pressure forces from below seal assembly 20 in the same manner.
It should be noted that it is possible for a well operator to visually determine whether or not the various seals of seal assembly 20 have been set, as by viewing the instrumentation associated with applying the torque force to the actuation sleeve member 39. For example, the torque readings will remain steady as the seal assembly moves downwardly in annulus 21. When the inner seal 44 of the lower seal member 36 first encounters the first tapered surface 122, as illustrated in FIG. 5, the torque reading will begin to increase, indicating the setting of seal 44. Similarly, the torque reading will increase until the second shear ring is sheared, at which time the torque readings will decrease, thus indicating the shearing of the second shear ring 111 and the subsequent setting of the outer seal 45 of the lower seal member. Similarly, the torque reading will increase as the inner seal 52 of the upper seal member 35 passes downwardly over the first tapered surface 120, indicating the setting of the inner seal 52. The torque reading will also momentarily decrease after the first shear ring 101 has been sheared, indicating the subsequent setting of the outer seal 55 of the upper seal member 35. Continued increases in the torque reading, when actuation sleeve member can no longer be rotated, will indicate that all the seals of the upper and lower seal members 35, 36 have been secured in place.
In connection with seal assembly 20 of FIGS. 1-9, it should be noted that the configuration of the upper and lower seal members 35, 36 could be reversed. The inner seals 44, 54 could be wedge type seals, and the outer seals 45, 55 could be interference type seals.
With reference to FIG. 10, another embodiment of seal assembly 20' is illustrated. Identical reference numerals will be utilized for identical elements previously described in connection with FIGS. 1-9, and primed reference numerals will be used for elements of seal assembly 20' which are similar in operation and construction to those previously described in connection with FIGS. 1-9. Seal assembly 20' generally comprises a ring-shaped seal member 36; an energizing ring member 37' for energizing the inner and outer seals 44, 45 of seal member 36 to engage, and seal against their adjacent inner and outer surfaces 28, 30; means for causing relative motion 38 between the energizing ring member 37' and seal member 36, or actuation sleeve member 37; and a means for staging 115 the energizing of the inner and outer seals 44, 45 of the seal member 36 to cause one of the seals 44 or 45 to engage, and seal against, its adjacent surface 28 or 30, before the other seal 44 or 45 engages, and seals against, its adjacent surface 28 or 30. Staging means 115 preferably includes a means for initially restraining movement 116 of the energizing ring member 37' with respect to the seal member 36. Preferably, the movement restraining means 116 is a shear ring 111 which engages both the seal member 36 and the energizing ring member 37', as by a flange 107 disposed within a groove 108 in energizing ring member 37'. The seal assembly 20' of FIG. 10 is illustrated in the fully sealed configuration, after energizing ring member 37' has moved downwardly to shear off the annular flange 107 of shear ring 111, in a manner previously described in connection with FIG. 7.
Tubing hanger 29 is preferably provided with a tapered surface 122 which provides for a first enlarged diameter D1 on straight wall surface portion 123 of tubing hanger 29. The operation of seal assembly 20' is the same as that previously described in connection with the operation of seal member 36 of seal assembly 20, but seal assembly 20' does not utilize an upper seal member as does seal assembly 20'. Seal assembly 20' may be utilized when it is desired to provide a seal assembly when lower pressure conditions are encountered, or for smaller diameter tubing hangers, or when other similar tubing is to be sealed within an outer tubing, or wellhead member.
With reference to FIGS. 11-14, another embodiment of a seal assembly 20" is illustrated. Seal assembly 20" generally comprises: an upper seal member 35'; a lower seal member 36'; an energizing ring member 37'; a means for causing relative motion 38, between the energizing ring 37' and the upper and lower seal members 35', 36' or actuation sleeve member 39; and a first means for staging 40 the energizing of the upper and lower seal members 35', 36' to cause the lower seal member 36' to engage, and seal against, its adjacent surfaces 28, 30 before the upper seal member 35' engages, and seals against, its adjacent surfaces 28, 30. The first staging means 40 preferably includes a first means 100 for initially restraining movement of the upper seal member 35' with respect to the energizing ring member 37', until a predetermined amount of force is applied between the upper seal member 35' and the energizing ring member 37'. Preferably, the means for initially restraining movement 100 is a first shear ring 101', as will be hereinafter described in greater detail.
Still with reference to FIGS. 11-13, the upper and lower seal members 35', 36' have a generally U-shaped configuration with inner and outer upwardly extending legs 42', 43'. Each of the leg members 42' has an inner seal 44' disposed thereon, and the outer leg members 43' have an outer seal 45' disposed thereon. Each of the seals 44', 45' is a wedge type seal similar in construction to the outwardly projecting annular rib seal 91 previously described in connection with FIGS. 1-9. Energizing ring member 37' includes a downwardly depending wedge member 62' which, as will be hereinafter described in greater detail, serves to force inner and outer wedge type seals 44', 45' of lower seal member 36' into sealing engagement with tubing hanger 29 and wellhead housing 31. Seal assembly 20" is also provided with a supplemental energizing ring member 200 which is disposed above upper seal member 35' and below actuation sleeve member 39. Supplemental energizing ring member 200 also has a downwardly depending wedge member 201 which, as will also be hereinafter described in greater detail, moves downwardly within upper seal member 35' to force the inner and outer seals 44', 45' of upper seal member 35' into sealing engagement with tubing hanger 29 and wellhead housing 31.
With reference to FIG. 11, seal assembly 20" is illustrated in its configuration for being run into annulus 21, and prior to energizing any of the seals 44', 45'. Lower seal member 36' is releasably secured to energizing ring member 37', as by at least one shear pin 202 which engages both wedge member 62' and the upper end of outer leg 43' of lower seal member 36'. A roller pin 203 is secured within wedge member 62', and projects within a slotted opening 204 formed at the upper end of the inner leg member 42' of lower seal member 36'. Upper seal member 35' is secured to energizing ring member 37' by a similar roller pin 205, which passes through the lower portion of upper seal member 35' and is received within mating openings 206 in the upper end of energizing ring member 37'. Wedge member 201 of supplemental energizing ring member 200 is movably mounted within the upper end of upper seal member 35', as by a roller pin 210 which is secured to wedge member 201 and projects outwardly into slotted grooves 211 formed in the upper ends of the inner and outer leg members 42', 43' of upper seal member 35'.
With reference to FIGS. 11-14, the operation of seal assembly 20" will be described. After the bottom of lower seal member 36' bottoms out upon shoulder 102 of tubing hanger 29, an additional torque force is applied to actuation sleeve member 39 as previously described in connection with the seal assembly 20 of FIGS. 1-9. As additional force is applied, shear pin 202 is sheared, whereby wedge member 62' continues to move downwardly into lower seal member 36' and forces the inner and outer legs 42', 43' of lower seal member 36' into sealing engagement with tubing hanger 29 and wellhead housing 31, as shown in FIG. 12. At this time, the axial force exerted upon seal assembly 20" is not sufficient to shear the shear ring 101' of energizing staging means 40. Thus, all the axial force is directed downwardly to cause wedge member 62' to outwardly deflect, or force outwardly, the inner and outer leg members 42', 43', of lower seal member 36'. As illustrated in FIG. 12, at this time the seals 44', 45' of upper seal member 35' are not in sealing engagement with tubing hanger 29 and wellhead housing 31.
With reference to FIG. 13, upon an additional torque force being applied to actuation sleeve member 39, supplemental energizing ring member 200 and wedge 201 move downwardly within upper seal member 35' and shear off the shear ring 101'. Shear ring 101' is affixed to a vertical support member 215 disposed between wedge member 201 and upper seal member 35'. Upper seal member 35' has a tubular opening 216 for receipt of the vertical support member 215 after shear pin 101' has been sheared off. Continued application of a torque force to actuation sleeve member 39 results in wedge member 201 moving downwardly to force outwardly the inner and outer legs 42', 43' of upper seal member 35', to cause inner and outer seals 44', 45' into sealing engagement with tubing hanger 29 and wellhead housing 31, as illustrated in FIG. 13. FIG. 14 illustrates, in greater detail, the wedging of one of the seals 44', 45' into sealing engagement with one of the outer surfaces 28, 30.
With reference to FIGS. 15 and 16, another sealing assembly 20'" is illustrated, and seal assembly 20'" is very similar in operation and construction to seal assembly 20". In general, the difference between seal assembly 20'" and seal assembly 20" is that seal assembly 20'" does not utilize a supplemental energizing ring member 200, and the upper seal member 35" has downwardly extending leg members 52', 53'. Seal assembly 20'" generally comprises: an upper seal member 35"; a lower seal member 36'; an energizing ring member 37"; means for causing relative motion 38 between the energizing ring member and the upper and lower seal members 35", 36', or actuation sleeve member 39; and a first means for staging 40 the energizing of the upper and lower seal members 35", 36' to cause the lower seal member 36' to engage, and seal against, the tubing hanger 29 and wellhead housing 31 before the upper seal member 35" engages, and seals against the adjacent surfaces 28, 30 of tubing hanger 29 and wellhead housing 31.
Still with reference to FIGS. 15 and 16, energizing ring member 37" has a lower depending wedge member 62' and an upper wedge member 61', for energizing the lower and upper seal members 36', 35". Vertical support member 215 has disposed thereon a shear ring 101' which functions in the same manner of the shear ring 101' and vertical support member 215 of FIGS. 11-14. FIG. 15 illustrates seal assembly 20'" after it has been landed upon shoulder 102, before any sealing of seals 44', 45', 54', 55' has been achieved. FIG. 16 illustrates seal assembly 20'", after shear pin 202 has been sheared, thus energizing lower seal member 36'; and after shear pin 101' has been sheared off. Upper wedge member 61' has entered the interior of upper seal member 35" and energized seals 54', 55' of upper seal member 35", by wedging inner and outer leg members 52', 53' of upper seal member 35" outwardly into engagement with tubing hanger 29 and wellhead housing 31.
It is to be understood that the invention is not limited to the exact details of construction, operation, exact materials or embodiments shown and described, as obvious modifications and equivalents will be apparent to one skilled in the art. Accordingly, the invention is therefore to be limited only by the scope of the appended claims. | A metal-to-metal sealing method and apparatus for use on oil and/or gas wells, utilizes an upper seal member and a lower seal member, wherein the energizing of the seal members is staged to cause the lower seal member to become sealingly engaged. before the upper seal member becomes sealingly engaged. The seal members may have two seals of different construction; one seal is an interference type seal, and the other seal is a wedge type seal. | 4 |
The present invention relates to production of nitrosamine-free silicone articles. More particularly, it is concerned with production of nitrosamine-free silicone articles by means of filler treatment.
BACKGROUND OF THE INVENTION
Several reports have been published describing the presence of volatile N-nitrosamines in various rubber products. The present concern about the occurrence of volatile N-nitrosamines in baby bottle rubber nipples and the possible migration of these compounds into infant formula was prompted by a report of Preussmann et al., (1981) Am. Chem. Soc. Symp. Ser. 174, American Chemical Society, Washington, D.C., p. 217.
A method was described for the estimation of volatile N-nitrosamines in the rubber nipples of babies bottles. In study of rubber nipples from one manufacturer, N-nitrosodimethylamine, N-nitrosodiethylamine and N-nitrosopiperidine were determined by gas chromatography, using a thermal energy analyser, and their presence was confirmed by mass spectrometry with average levels of individual nitrosamines ranging from 22 to 281 ppb. When the nipples were sterilized in a conventional sterilizer together with milk or infant formula the three nitrosamines migrated into the milk or formula. Storing a bottle of milk with a rubber nipple inverted in it for 2 hr at room temperature or overnight in a refrigerator after sterilization resulted in an 8-13 % average increase in the nitrosamine levels migrating into the milk. On repeated sterilization of a single nipple, the quantities of nitrosamines migrating into milk from rubber nipples declined steadily, but after seven sterilizations, nitrosamines were still readily detectable in the milk. Nitrosamine levels were higher in rubber nipples after sterilization, indicating the presence of nitrosamine precursors in the nipples. No nitrosamines were found in raw, uncured rubber. Chemical accelerators and stabilizers added during the vulcanization process are the source of the amine precursors in rubber nipples.
On Jan. 1, 1984, the U.S. Food and Drug Administration (hereinafter "FDA") established an action level of 60 ppb total N-nitrosamines in rubber nipples. The action level was reduced to 10 ppb on Jan. 1, 1985.
A collaborative study was conducted on the FDA dichloromethane extraction method for determining volatile N-nitrosamines in baby bottle rubber nipples. Following dichloromethane extraction, N-nitrosamines were determined by gas chromatography-thermal energy analysis. Six pairs of blind duplicate rubber nipple samples representing 6 lots were analyzed by 11 collaborating laboratories. All samples were portions taken from equilibrated composites of cut-up rubber nipples obtained from manufacturers in the United States. Recoveries of the internal standard (N-nitrosodipropylamine) at approximately 20 ppb ranged from 10 to 120%. Reproducibility relative standard deviations (RSD) were between 35 and 45% for N-nitrosamine levels from 10 to 20 ppb. However, when data from laboratories with recoveries less than 75% were excluded (this is now specified in the method), RSD, values were between 11 and 32% for N-nitrosamine levels from 6 to 26 ppb. Values were consistent with or better than those reported for other analytical techniques designed to quantitate trace contaminants at the low ppb level, e.g., aflatoxin in food. The method has been adopted official first action for the quantitation of volatile N-nitrosamines in baby bottle rubber nipples. See Gas Chromatographic-Thermal Energy Analysis Method for Determination of Volatile N-Nitrosamines in Baby Bottle Rubber Nipples: Collaborative Study, by Gray & Stachiw, J. Assoc. Off. Anal. Chem. (1987) 70, March Issue.
Although research in the rubber industry has been devoted to lowering or eliminating nitrosamines, none of these studies have included silicone rubber materials. Silicone elastomeric compositions, in contrast to synthetic rubber compounds, are usually prepared from a vinyl-containing polydiorganosiloxane, an organohydrogensilicone crosslinker, and a platinum catalyst. The compositions of this type are desirable for many reasons. For instance, they cure without by-products. They can cure at room temperature or at elevated temperatures. They can be stabilized for storage at room temperature by utilization of a platinum catalyst inhibitor. And, they can be made from high and low viscosity polymers. These compositions utilize components that are low enough in viscosity that they are easily pumpable or extrudable as well as have a fast cure time. These compositions also provide cured silicone elastomers which are characterized by high strength and high durometer.
Cross-linked silicone polymers with their particularly low intermolecular interactions have low tensile strengths. Only with the addition of reinforcing fillers can high-strength silicone polymers be obtained. Particularly suitable are fumed silicas with BET surface areas of 150 to 400 m 2 /g which increase the tensile strength about 20 fold to 10-12 MPa. At the same time, viscosity is considerably increased because fumed silicas have a strong thickening effect. This effect is caused by formation of agglomerates of the primary silica particles. These agglomerates build a three-dimensional network (tertiary structure) via hydrogen bonds so that the bulk density of the fumed silica is only about 50 g/l. To produce a mixture of 40 parts silica, in 100 parts polymer therefore requires addition of 8 volume parts of filler for 1 volume part of polymer. These ratios clearly indicate the necessity of using treating agents which reduce interactions between filler agglomerates as much as possible. The most effective and most commonly used treating agents is hexamethyldisilazane (hereinafter "HMDZ"). The fillers treated with HMDZ have a considerably reduced thickening effect and therefore are particularly suitable for the use in liquid silicone rubbers.
Since silicone elastomer are entirely different polymers, these silicones became leading candidates to replace the synthetic rubber compounds, Analysis of the cured silicone elastomers showed no presence of nitrosamines. However, to applicants' surprise, upon post-baking as required by FDA, the presence of nitrosamines was detected. For silicones to serve these FDA regulated markets, a method of removing the nitrosamines must be found.
SUMMARY OF THE INVENTION
There is provided by the present invention a method for making nitrosamine-free silicone articles comprised by mixing (A) vinyl-containing organopolysiloxane; (B) silicon hydride siloxane; (C) filler; (D) a catalytic amount of a platinum metal group compound or a peroxide and (E) an effective amount of acid, curing and post baking the mixture.
The critical feature that led to this invention is based on the discovery that if the polymer/filler mixture is treated with an effective amount of acid, the resultant part is substantially free of nitrosamine.
DETAILED DESCRIPTION OF THE INVENTION
Component (A), the vinyl-containing organopolysiloxanes, generally has a viscosity of from 5,000 to 1,000,000 centipoise at 25° C. The preferred vinyl-containing organopolysiloxanes are vinyl-stopped polymer having the general formula M Vi D x M Vi , vinyl-on-chain copolymers such as MD Vi x D y M, vinyl-stopped, vinyl-on-chain copolymers such as M Vi D x D VI y M Vi , vinyl and trimethylsilyl-stopped copolymers such as MD x M Vi , or a mixture thereof, wherein Vi represents a vinyl radical, M represents a trimethylsiloxy radical, M Vi represents dimethylvinylsiloxy, D is dimethylsiloxy. Such polymers are taught by U.S. Pat. Nos. 5,082,886, 4,340,709, 3,884,866 issued to Jeram et al., U.S. Pat. No. 5,331,075 issued to Sumpter et al., U.S. Pat. No. 4,162,243 issued to Lee et al., U.S. Pat. No. 4,382,057 issued to Tolentino, and U.S. Pat. No. 4,427,801 issued to Sweet, hereby incorporated by reference.
Component (B), the silicon hydride siloxane or silicon hydride siloxane fluid used in the invention can have about 0.04 to about 1.4 % by weight of chemically combined hydrogen attached to silicon. One form of the silicon hydride siloxane is a "coupler" having the formula, ##STR1## where R 1 is selected from C 1-13 monovalent hydrocarbon radicals free of olefinic unsaturation and n is an integer having a value sufficient to provide the "coupler" with a viscosity of 1 to 500 centipoises at 25° C. and from about 3 to 9 mole percent of chain-stopping diorganohydride siloxy units, based on the total moles of chemically combined siloxy units in the silicon hydride siloxane fluid.
In addition to the silicone hydride coupler of formula (1), the silicon hydride siloxane fluid used in the heat curable organopolysiloxane compositions of the present invention also can include silicon hydride resins consisting essentially of the following chemically combined units, ##STR2## chemically combined with SiO 2 units, where the R 2 +H to Si ratio can vary from 1.0 to 2.7. Silicon hydride resin also can have units of the formula, ##STR3## chemically combined with SiO 2 units and (R 4 ) 2 SiO units, where the R 3 +R 4 +H to Si ratio can vary from 1.2 to 2.7, where R 2 , R 3 and R 4 are C 1-13 monovalent hydrocarbon radicals free of olefinic unsaturation selected from R 1 radicals.
The silicon hydride siloxane fluid also can include linear hydrogen containing polysiloxane having the formula, ##STR4## where R 5 is a C 1-13 monovalent hydrocarbon radical free of olefinic unsaturation, selected from R 1 radicals, and p and q are integers having values sufficient to provide a polymer having a viscosity of from 1 to 1,000 centipoises at 25° C.
In formulas (1) and (2) and the chemically combined units described above, R 1 , R 2 , R 3 , R 4 and R 5 can be the same or different radicals selected from the group consisting of alkyl radicals of 1 to 8 carbon atoms, such as methyl, ethyl, propyl, etc.; cycloalkyl radicals such as cyclohexyl, cycloheptyl, etc.; aryl radicals such as phenyl, tolyl, xylyl, etc.; and haloalkyl radicals such as 3,3,3-trifuloropropyl.
Component (C), the filler is any reinforcing or extending filler known in the prior art. In order to get the high tensile strength, for example, a reinforcing filler is incorporated. Illustrative of the many reinforcing fillers which can be employed are titanium dioxide, lithopone, zinc oxide, zirconium silicate, silica aerogel, iron oxide, diatomaceous earth, calcium carbonate, fumed silica, silazane treated silica, precipitated silica, glass fibers, magnesium oxide, chromic oxide, zirconium oxide, aluminum oxide, alpha quartz, calcined clay, asbestos, carbon, graphite, cork, cotton, synthetic fibers, etc.
Preferably, the filler is either a fumed or precipitated silica that has been treated. The treating process may be done in accordance with the teachings of U.S. Pat. No. 4,529,774 issued to Evans et al., U.S. Pat. No. 3,635,743 issued to Smith, U.S. Pat. No. 3,847,848 issued to Beers; hereby incorporated by reference, Alternatively, and most preferably, the filler is treated in-situ; that is the untreated silica filler and the treating agents are added to the silicone elastomer composition separately, and the treatment process is accomplished simultaneously with the mixture of the filler into the elastomer. This in-situ process is taught by Evans in U.S. Pat. No. 4,529,774; hereby incorporated by reference.
Alternatively, the fillers can be replaced by the vinyl treated silica filler of U.S. Pat. No. 4,162,243 issued to Lee et al.; and U.S. Pat. No. 4,427,801 issued to Sweet; hereby incorporated by reference.
Component (D), the catalyst, is any compound that promotes the hydrosilation reaction between a silicon hydride and an ethylenically unsaturated polyorganosiloxane. Typically, it is a precious metal compound; usually platinum. Such catalysts are well known in the art. Preferred catalysts are taught by in U.S. Pat. Nos. 3,917,432, 3,197,433 and 3,220,972 issued to Lamoreaux, U.S. Pat. Nos. 3,715,334 and 3,814,730 issued to Karstedt, and U.S. Pat. No. 4,288,345 issued to Ashby et al., hereby incorporated by reference.
Alternatively, the catalyst can be a peroxide or it can be a combination of peroxides comprising a low temperature peroxide and a high temperature peroxide.
Since mixtures containing Components A, B, and C with the catalyst, Component D, may begin to cure immediately on mixing at room temperature, it may be desirable to inhibit the action of the catalyst at room temperature with a suitable inhibitor if the composition is to be stored before molding. Platinum catalyst inhibitors are used to retard the catalytic activity of the platinum at room temperature, but allow the platinum to catalyze the reaction between Components A, B and C at elevated temperature.
One suitable type of platinum catalyst inhibitor is described in U.S. Pat. No. 3,445,420 issued to Kookootsedes et al. which is hereby incorporated by reference to show certain acetylenic inhibitors and their use. A preferred class of acetylenic inhibitors are the acetylenic alcohols, especially 2-methyl-3-butyn-2-ol.
A second type of platinum catalyst inhibitor is described in U.S. Pat. No. 3,989,667 issued to Lee et al. which is hereby incorporated by reference to show certain olefinic siloxanes, their preparation and their use as platinum catalyst inhibitors.
A third type of platinum catalyst inhibitor is a polymethylvinylcyclosiloxane having three to six methylvinylsiloxane units per molecule.
The optimum concentration of platinum catalyst inhibitor is that which will provide the desired storage stability at ambient temperature without excessively prolonging the time interval required to cure the compositions at elevated temperatures. This amount will vary widely and will depend upon the particular inhibitor that is used, the nature and concentration of platinum-containing catalyst and the nature of the organohydrogensiloxane.
The mixture of component (A) and component (C) is treated with component (E) an effective amount of acid. The acid used in this invention can be any acid which is compatible with silicone, such as formic acid, acetic acid, phosphoric acid, HCl, HBr, HI sulfuric, etc. The acid is added to polymer/filler mixture and the mixture is cooked at temperatures of about 50° to about 100° C. for 0.5 to 2.0 hours, preferably at temperatures of about 55° to about 90° C. for 0.5 to 1.5 hours, and most preferably at temperatures of about 60° to about 85° C. for one hour. The resulting mixture is then stripped until the system is substantially volatile free.
Compositions of the present invention can be used in a liquid injection molding process in which the composition is injected into light weight molds under low pressures, such as 600 kPa cylinder pressure. Such compositions can be cured very rapidly in a hot mold and removed without cooling the mold. The type of molding, extruding or curing process used is not narrowly critical and can include those known in the art. An advantage of the compositions of this inventions is the extrudability which makes it adaptable to molding processes such as liquid injection molding at low pressures. The prepared compositions have a viscosity such that at least 45 grams per minute can be extruded through a 3.175 millimeter orifice under a pressure of 620 kilopascals. Preferably, the viscosity is such that at least 50 grams per minute can be extruded.
The silicone elastomeric compositions can readily be prepared in conventional mixing equipment because of its fluid nature. The order of mixing is not critical if the composition is to be used immediately. However, it is preferable to combine (A), (C) following the acid treatment and thereafter add (D) and (B). This permits the small amount of (D) to become well dispersed in (A) and (C) prior to the beginning of any curing reaction. Suitable two package composition can be made using such as technique. For example, a convenient two package composition can be prepared by mixing part of acid treated mixture of (A) and (C) and all of (D) in one package and the remainder of acid treated (A) and (C) and all of (B) in a second package such that equal amounts of package one and package two can be mixed to produce the compositions of this invention. Single package compositions can be prepared by mixing (A),(B), (C), (D), (E) and a platinum catalyst inhibitor. These inhibited compositions can be stored for extended periods of time without curing, but the compositions will still cure when heated above 70° C., preferably when heated above 100° C. to shorten the cure time.
In order to demonstrate various features of this invention, the following examples are submitted. They are for illustrative purposes and are not intended to limit in any way the scope of this invention.
EXAMPLE 1
Test Specimen Preparation
A silicone LIM base compound was prepared according to the teachings of this invention using the formulation of Table I.
TABLE I______________________________________64.5 pts 40,000 cps vinyl chainstopped polydimethylsiloxane polymer25 pts 325 m.sup.2 /gm octamethylcyclotetrasiloxane treated fumed silica or 300 m.sup.2 /gm dimethyldichlorosilane treated fumed silica1 pt vinyltriethoxysilane6 pts hexamethyldisilazane3 pts water3 pts acid solution4 pts 500 cps vinyl chainstopped, polydimethyl, methylvinyl copolymer4 pts 500 cps trimethylsilyl and dimethylvinyl chainstopped polydimethylsiloxane polymer2.5 pts MQ resin______________________________________
The 40,000 cps vinyl chainstopped polymer, 3 parts. water and hexamethyldisilazane were mixed together in a cooled mixer. The 325 m 2 /gm D 4 or 300 m 2 /gm dimethyldichlorosilane treated filler was added slowly and mixed until it was completely incorporated. After all the filler was incorporated, the vinyltriethoxysilane was added and mixed well. The mixer was sealed and heated for 1 hour at 70°-80° C. The acid solution was added and the mixture was cooked for 1 hours at 60°-88° C. The batch was stripped at 140° C. under full vacuum to remove all the filler treating reaction by products and then cooled to 80° C. The two 500 cps vinyl containing copolymers were added and mixed well. 2.5 pts of the MQ resin release agent was added. Pulled vacuum to deair the batch.
Component A was prepared by adding sufficient amount of Karstedt platinum organosiloxane complex to obtain 20-40 ppm Pt as platinum. Component B was prepared by adding approximately 330 ppm H of hydride crosslinker (M H D x D y H M H ) and approximately 0.4 parts methyl butynol, mixed until well dispersed. A LIM composition was prepared by mixing 100 parts of component A with 100 parts of component B in a static mixer with no air being introduced. The A/B mixture was then molded 20 seconds at 375° F. into 3"×5"×0.070" sheets.
EXAMPLE 2
A sheet prepared according to Example 1 was post baked for one hour @400° in an air circulating oven and cooled to room temperature. The sample was referred to as PBO. A second sheet was wrapped in aluminum foil and post baked under the same conditions. The sample was referred to as PBS. The results are shown below:
______________________________________ PBO PBS 1 hr at 400° F. 1 hr at 400° F. ppb DMNA* ppb DMNA*______________________________________3 pts H.sub.2 O (control) 4.0 42.83 pts H.sub.2 O (Extended Cook) 2.7 9.73 pts 1N HCL <1 <13 pts 0.5N HCL <1 2.23 pts 0.25N HCL <1 2.33 pts 0.10N HCL <1 2.23 pts 1N HC.sub.2 H.sub.3 O.sub.2 <1 7.5______________________________________ *DMNA is dimethylnitrosamine
The results clearly indicate that the standard 3 parts H 2 O when cooked at an extended cook cycle lowered the DMNA level but does not totally eliminate them. 1N HCL totally eliminated the DMNA, whereas 0.5N, 0.25N, and 0.1N HCL eliminated the DMNA when post baked open, but the sealed results indicates that the part is cured substantially free of DMNA. 1N HC 2 H 3 O 2 also eliminated DMNA when post baked open, but some nitrosamines were generated when post baked sealed.
EXAMPLE 3
Same materials as described in the above examples except 300m 2 /gm dimethyldichlorosilane treated fumed silica was used and the acid solutions were added as noted. This filler is not HMDZ in-situ treated as opposed to the in-situ filler treatment in Example 2. Samples were post baked 1 hr at 400° F. in air.
______________________________________ PBO PBS 1 hr at 400° F. 1 hr at 400° F. ppb DMNA ppb DMNA______________________________________3 pts H.sub.2 O no additional filler <1 2.0treatment3 pts H.sub.2 O filler and HMDZ 1.2 13.1treatmentfiller + HMDZ + 0.1N HCL 1.7 11.0filler + HMDZ + 1N HCL <1 <1______________________________________
The results clearly indicate that 3 parts H 2 O without additional filler treatment substantially eliminated the DMNA. 3 parts H 2 O with filler and HMDZ treatment reduced the DMNA to 1.2 ppb when post baked open, but the sealed result yielded at 13.1 ppb when post baked sealed. 1N HCL totally eliminated the DMNA, whereas 0.1N HCL reduced the DMNA when post baked open. The sealed results yields 11.0 ppb which some DMNA is still being generated. | The present invention relates to a method for making nitrosamine-free silicone articles by treating vinyl-containing organopolysiloxanes with an effective amount of an acid. | 2 |
This application is a Division of application Ser. No. 10/730,839, filed Dec. 8, 2003, which application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a current source circuit used in electronic equipment and a semiconductor integrated circuit, and an amplifier using the current source circuit.
2. Description of the Related Art
Conventionally, a current source circuit used in electronic equipment and a semiconductor integrated circuit is disclosed as a current mirror circuit, for example, in JP 2(1990)-124609 A, and Semiconductor Circuit Design Technology (Nikkei Business Publishers Inc., edited by T. Tamai, 1st edition, p. 302).
FIG. 20 is a circuit diagram showing an exemplary configuration of a conventional current source circuit. In FIG. 20 , reference numeral 1 denotes a power supply terminal for supplying a voltage for operating a circuit, 2 denotes a reference current source for supplying a reference current, 4 denotes an output terminal through which a current flows out, 5 denotes an output terminal through which a current flows in, M 2 , M 12 , and M 7 denote n-channel MOS transistors, and M 6 and M 20 denote p-channel MOS transistors. M 2 , M 12 , and M 7 constitute a current mirror circuit, and M 6 and M 20 also constitute a current mirror circuit.
Next, the operation of the current source circuit thus configured will be described. The current that flows in from the reference current source 2 is received by the n-channel MOS transistor M 2 , and inverted by the n-channel MOS transistors M 7 and M 12 , respectively. The current inverted by the n-channel MOS transistor M 7 is drawn in through the output terminal 5 . The current inverted by the n-channel MOS transistor M 12 is received by the p-channel MOS transistor M 20 , and further inverted by the p-channel MOS transistor M 6 to flow out through the output terminal 4 .
FIG. 21 is a circuit diagram showing an exemplary configuration of a current source circuit configured in the same way as in FIG. 20 , which includes the reference current source 2 through which a current flows out, the p-channel MOS transistors M 2 , M 12 , and M 7 , and the n-channel MOS transistors M 6 and M 20 .
Furthermore, a common feedback circuit for setting an operation point of an amplifier using the current source circuit shown in FIG. 20 is disclosed, for example, in “CMOS Analog Circuit Design Second Edition” (p. 196, published by OXFORD, Phillip E. Allen, Douglas R. Holberg). FIG. 22 shows the configuration of this amplifier.
In FIG. 22 , reference numeral 6 denotes a voltage source, 8 and 9 denote input terminals of the amplifier, 11 and 12 denote loads, 13 and 14 denote output terminals of the amplifier, M 10 , M 11 , M 18 , and M 19 denote n-channel MOS transistors, and M 6 a , M 6 b , M 8 , and M 9 denote p-channel MOS transistors.
Next, the operation of the amplifier thus configured will be described. Signals input from the input terminals 8 and 9 of the amplifier are converted into currents by the n-channel MOS transistors M 18 and M 19 constituting a differential amplifier, and formed into amplified voltages by the loads 11 and 12 to be taken out from the output terminals 13 and 14 of the amplifier. In order to determine an operation point of the amplifier, the voltage at a connection point between the loads 11 and 12 is compared with the voltage of the voltage source 6 by the n-channel MOS transistors M 10 and M 11 constituting the differential amplifier (error amplifier), whereby currents flowing through the current mirror circuits M 8 , M 6 a , and M 6 b are adjusted. As a result, the operation points of the loads 11 and 12 are set to be the voltage of the voltage source 6 .
Conventionally, in the case where an inflow current and an outflow current are used simultaneously in a current source circuit of electronic equipment and a semiconductor integrated circuit and a current source circuit used in an amplifier, there is a problem that these currents are not equal to each other.
In MOS transistor properties, a current Ids is represented by the following expression:
Ids=k× ( Vgs−Vt ) 2 ×(1+λ× Vds )
where Ids is a current of a MOS transistor, k is an amplification ratio, Vgs is a gate—source voltage, Vt is a threshold voltage, λ is a channel length modulation coefficient, and Vds is a drain—source voltage. A supplied current is influenced by a channel modulation effect every time it passes through a MOS transistor. Assuming that the sizes of the transistors are designed to be equal to each other, Vds is set to be substantially the same, and λ of the n-channel is substantially the same as that of the p-channel, a current ratio of an inflow current I 5 flowing through the output terminal 5 to an outflow current I 4 flowing through the output terminal 4 in FIG. 20 is approximated as follows:
I4 / I5 = ( 1 + λ × Vds ) 2 / ( 1 + λ × Vds ) = ( 1 + λ × Vds )
and the current ratio is not 1. For example, when λ=0.05 and Vds=1.5 V, an error of 7.5% occurs, and thus, an outflow current is larger than an inflow current.
Similarly, even in the common feedback circuit shown in FIG. 22 , a similar error occurs. However, this error further can be reduced by a loop gain A 1 determined by the n-channel MOS transistors M 10 , M 11 constituting a differential amplifier (error amplifier), the current mirrors M 8 , M 6 a , M 6 b , and the loads 11 and 12 . It should be noted that the loop gain A 1 cannot be set to be large in order to prevent oscillation, and can be set to be at most 10 times. Thus, the error is reduced to 1/10, and 0.75% error remains. Furthermore, the loads 11 and 12 are placed in a loop of the common feedback circuit, so that they cannot take large values in order to prevent oscillation. Consequently, the gain of the differential amplifier composed of the n-channel MOS transistors M 18 and M 19 cannot be set to be large.
SUMMARY OF THE INVENTION
Therefore, with the foregoing in mind, it is an object of the present invention to provide a current source circuit capable of prescribing an outflow current to be equal to an inflow current.
Furthermore, it is another object of the present invention to provide an amplifier capable of setting a gain to be large while ensuring a stable operation point.
In order to achieve the above-mentioned object, a first current source circuit according to the present invention includes: a reference current source supplying a reference current; a first transistor group M 1 , M 2 ) connected in series to the reference current source, and converting the reference current into a voltage. A first transistor (M 7 ) has a current mirror relationship with the first transistor group, and allows an output current to flow therethrough. An error amplifier (Op. Amp) receives a voltage generated in the first transistor group at one input terminal, and compares the voltage at the one input terminal with a voltage supplied to the other input terminal. A second transistor (M 5 ) is driven with an output voltage of the error amplifier. A third transistor (M 6 ) is driven with the output voltage of the error amplifier, and allows an output current to flow therethrough in a direction opposite to the output current of the first transistor with respect to an output terminal. A second transistor group (M 3 , M 4 ) is connected in series to the second transistor, and converts a current flowing through the second transistor into a voltage to supply the voltage to the other input terminal of the error amplifier.
Furthermore, in order to achieve the above-mentioned object, a second current source circuit according to the present invention includes: a reference current source supplying a reference current and a first transistor (M 2 ) connected in series to the reference current source, and converting the reference current into a voltage. A second transistor (M 4 ) has a current mirror relationship with the first transistor, and converts a current into a voltage. A third transistor (M 7 ) has a current mirror relationship with the first transistor, and allows an output current to flow therethrough. An error amplifier (Op. Amp) receives a voltage generated in the second transistor at one input terminal, and compares the voltage at the one input terminal with a voltage supplied to the other input terminal to output an error voltage. A voltage source supplies a voltage to the other input terminal of the error amplifier. A fourth transistor (M 5 ) is connected in series to the second transistor, and is driven with an output voltage of the error amplifier. A fifth transistor (M 6 ) is driven with the output voltage of the error amplifier, and allows an output current to flow therethrough in a direction opposite to the output current of the third transistor with respect to an output terminal.
According to the above-mentioned first and second current source circuits, the outflow current of the output terminal can be set to be equal to the inflow current thereof.
Furthermore, in order to achieve the above-mentioned object, a first amplifier according to the present invention includes a reference current source supplying a reference current and a first transistor (M 2 ) connected in series to the reference current source, and converting the reference current into a voltage. A second transistor (M 4 ) has a current mirror relationship with the first transistor, and converts a current into a voltage. A third transistor (M 7 ) has a current mirror relationship with the first transistor, and allows a first current to pass therethrough. An error amplifier (Op. Amp) receives a voltage generated in the second transistor at one input terminal, and compares the voltage at the one input terminal with a voltage supplied to the other input terminal to output an error voltage. A voltage source supplies a voltage to the other input terminal of the error amplifier. A fourth transistor (M 5 ) is connected in series to the second transistor and is driven with an output voltage of the error amplifier. A fifth transistor (M 6 ) is driven with the output voltage of the error amplifier and allows a second current to flow therethrough. A differential amplifier (Diff. Amp) is operated using the first current flowing through the third transistor as one supply current and using the second current flowing through the fifth transistor as the other supply current, and amplifies a voltage supplied to an input terminal.
In the first amplifier, the reference voltage at an operation point of the differential amplifier is set to be the voltage of the voltage source.
In order to achieve the above-mentioned object, a second amplifier according to the present invention includes a reference current source supplying a reference current and a first transistor (M 2 ) connected in series to the reference current source, and converting the reference current into a voltage. A second transistor (M 4 ) has a current mirror relationship with the first transistor, and allows a first current to pass therethrough. A third transistor (M 7 ) has a current mirror relationship with the first transistor, and allows a second current to pass therethrough. A first differential amplifier (1st Diff. Amp) is operated using the first current flowing through the second transistor as one supply current, and receives a voltage supplied to an input terminal. An error amplifier (Op. Amp) receives an output voltage of the first differential amplifier at the one input terminal, and compares the voltage at the one input terminal with a voltage supplied to the other input terminal to output an error voltage. A voltage source supplies a voltage to the other input terminal of the error amplifier. A fourth transistor (M 5 ) operates the first differential amplifier, using a third current driven to flow with an output voltage of the error amplifier as the other supply current. A fifth transistor (M 6 ) is driven with the output voltage of the error amplifier, and allows a fourth current to pass therethrough. A second differential amplifier (2nd Diff. Amp) is operated using the second current flowing through the third transistor as one supply current and using the fourth current flowing through the fifth transistor as the other supply current, and amplifies a voltage supplied to the input terminal.
In the second amplifier, a reference voltage at an operation point of the second differential amplifier is set at a voltage of the voltage source.
According to the above-mentioned first and second amplifiers, a gain can be set to be large while a stable operation point is ensured.
These and other advantages of the present invention will become apparent to those skilled in the art upon reading and understanding the following detailed description with reference to the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram showing an exemplary configuration of a current source circuit according to Embodiment 1 of the present invention.
FIG. 2 is a circuit diagram showing a first specific example of the current source circuit shown in FIG. 1 .
FIG. 3 is a circuit diagram showing a second specific example of the current source circuit shown in FIG. 1 .
FIG. 4 is a circuit diagram showing a modified example of the current source circuit shown in FIG. 1 .
FIG. 5 is a circuit diagram showing a first specific example of the current source circuit shown in FIG. 4 .
FIG. 6 is a circuit diagram showing a second specific example the current source circuit shown in FIG. 4 .
FIG. 7 is a circuit diagram showing an exemplary configuration of a current source circuit according to Embodiment 2 of the present invention.
FIG. 8 is a circuit diagram showing an exemplary configuration of an amplifier according to a third embodiment of the present invention.
FIG. 9 is a circuit diagram showing a first specific example of an amplifier shown in FIG. 8 .
FIG. 10 is a circuit diagram showing a second specific example of the amplifier shown in FIG. 8 .
FIG. 11 is a circuit diagram showing a third specific example of the amplifier shown in FIG. 8 .
FIG. 12 is a circuit diagram showing a fourth specific example of the amplifier shown in FIG. 8 .
FIG. 13 is a circuit diagram showing a modified example of the amplifier shown in FIG. 8 .
FIG. 14 is a circuit diagram showing an exemplary configuration of an amplifier according to Embodiment 4 of the present invention.
FIG. 15 is a circuit diagram showing a first specific example of the amplifier shown in FIG. 14 .
FIG. 16 is a circuit diagram showing a second specific example of the amplifier shown in FIG. 14 .
FIG. 17 is a circuit diagram showing a third specific example of the amplifier shown in FIG. 14 .
FIG. 18 is a circuit diagram showing a fourth specific example of the amplifier shown in FIG. 14 .
FIG. 19 is a circuit diagram showing a modified example of the amplifier shown in FIG. 14 .
FIG. 20 is a circuit diagram showing an exemplary configuration of a conventional current source circuit.
FIG. 21 is a circuit diagram showing a modified example of a conventional current source circuit.
FIG. 22 is a circuit diagram showing an exemplary configuration of a conventional amplifier.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, the present invention will be described by way of preferred embodiments with reference to the drawings.
Embodiment 1
FIG. 1 is a circuit diagram showing an exemplary configuration of a current source circuit according to Embodiment 1 of the present invention. In FIG. 1 , reference numeral 3 denotes an error amplifier (Op. Amp) composed of an operational amplifier, M 1 , M 2 , M 3 , M 4 , M 7 denote n-channel MOS transistors, and M 5 , M 6 denote p-channel MOS transistors. The n-channel MOS transistors M 1 and M 2 , which are included in a first transistor group, constitute a converter for converting a current of a reference current source 2 into a voltage. Furthermore, the n-channel MOS transistors (first transistors) M 2 and M 7 constitute a current mirror circuit. The p-channel MOS transistor (second transistor) M 5 and the p-channel MOS transistor (third transistor) M 6 constitute a current source driven with an output voltage of the error amplifier 3 . Furthermore, the n-channel MOS transistors M 3 and M 4 , which are included in a second transistor group, constitute a converter for converting a current of the p-channel MOS transistor into a voltage.
FIG. 2 is a circuit diagram showing a first specific example of the current source circuit shown in FIG. 1 . In FIG. 2 , M 8 , M 9 denote p-channel MOS transistors, M 10 , M 11 , M 12 denote n-channel MOS transistors, and C denotes a capacitor. The n-channel MOS transistor M 12 functions as a current source, the n-channel MOS transistors M 10 and M 11 function as a differential transistor pair, and the p-channel MOS transistors M 8 and M 9 function as a current mirror that is an active load of the differential transistor pair M 10 and M 1 . The transistors M 8 to M 12 and the capacitor C constitute the error amplifier 3 .
Next, the operation of the current source circuit according to Embodiment 1 configured as above will be described.
A voltage generated in the first transistor group (M 1 , M 2 ) and a voltage generated in the second transistor group (M 3 , M 4 ) are input to the error amplifier 3 , and a gate voltage of the p-channel MOS transistor M 5 is adjusted so that these voltages are equal to each other. Thus, a current flowing from the p-channel MOS transistor M 5 is equal to that of the reference current source 2 , and a gate of the p-channel MOS transistor M 6 is driven with the same voltage as the gate voltage of the p-channel MOS transistor M 5 . Therefore, a current of the p-channel MOS transistor M 6 also is substantially equal to that of the reference current source 2 . When a current ratio of an inflow current I 5 of an output terminal 5 to an outflow current I 4 of an output terminal 4 is calculated by adopting the same approximation as that in the conventional example, the following result is obtained:.
I4
/
I5
=
(
1
+
λ
×
Vds
)
/
(
1
+
λ
×
Vds
)
=
1
As described above according to the present embodiment, by providing the first transistor group (M 1 , M 2 ) for converting a current into a voltage, the second transistor group for converting a current into a voltage, the error amplifier for amplifying the difference of the respective converted voltages (error voltage), and the p-channel MOS transistors M 5 and M 6 driven by the error amplifier, an outflow current of the output terminal 4 can be set to be equal to an inflow current of the output terminal 5 .
In the present embodiment, the transistors that are stacked in series in two stages are used as a converter. However, as shown in FIG. 3 , the current source of the error amplifier 3 is omitted, and a one-stage transistor may be used as a converter.
Furthermore, in the present embodiment, the current source circuit is configured using the n-channel MOS transistors as a converter. However, as shown in FIGS. 4 , 5 , and 6 , a current source circuit may be configured using the p-channel MOS transistors as a converter.
Furthermore, in the present embodiment, a current source circuit is configured using the MOS transistors. However, a current source circuit may be configured using bipolar transistors.
Embodiment 2
FIG. 7 is a circuit diagram showing an exemplary configuration of a current source circuit according to Embodiment 2 of the present invention. In FIG. 7 , the components having the same configurations and functions as those in Embodiment 1 are denoted with the same reference numerals as those therein, and their description will be omitted here. In FIG. 7 , reference numeral 6 denotes a voltage source for determining an operation point of an amplifier.
Next, the operation of the current source circuit according to Embodiment 2 configured as above will be described.
In FIG. 7 , gate voltages of the p-channel MOS transistors M 5 and M 6 are adjusted so that a voltage at a connection point between a drain of the transistor M 4 and a drain of the transistor M 5 is equal to a voltage of the voltage source 6 . In this case, a current ratio of the inflow current I 5 flowing through the output terminal 5 to the outflow current I 4 flowing through the output terminal 4 is obtained as follows:
I4
/
I5
=
(
1
+
λ
×
Vds
)
/
(
1
+
λ
×
Vds
)
=
1
As described above, according to the present embodiment, by providing the voltage source 6 for generating a reference voltage at an operation point, the error amplifier 3 , and the p-channel MOS transistors M 5 and M 6 driven by the error amplifier 3 , the outflow current of the output terminal 4 can be set to be equal to the inflow current of the output terminal 5 .
Embodiment 3
FIG. 8 is a circuit diagram showing an exemplary configuration of an amplifier according to Embodiment 3 of the present invention. The amplifier according to the present embodiment uses the current source circuit according to Embodiment 2.
In FIG. 8 , reference numeral 10 denotes a differential amplifier (Diff. Amp) that includes input terminals 8 , 9 and output terminal 13 , 14 . A load 11 is connected between the output terminal 13 and the voltage source 6 , and a load 12 is connected between the output terminal 14 and the voltage source 6 . The differential amplifier 10 is driven using a current flowing through the transistors M 6 and M 7 as a supply current.
FIG. 9 is a circuit diagram showing a first specific example of the amplifier according to the present embodiment. In FIG. 9 reference numeral 15 denotes a voltage source, M 16 , M 17 denote p-channel MOS transistors, and M 18 , M 19 denote n-channel MOS transistors. A current supplied from the p-channel MOS transistor M 6 is divided by the voltage source 6 and the p-channel MOS transistors M 16 and M 17 . Furthermore, currents from the n-channel MOS transistors M 18 and M 19 are supplied to the n-channel MOS transistor M 7 through the p-channel MOS transistors M 16 and M 17 , respectively.
Next, the operation of the amplifier according to Embodiment 3 configured as above will be described.
In FIG. 9 , signals input to the differential transistor pair (M 18 and M 19 ) are amplified by the loads 11 and 12 to be output to the output terminals 13 and 14 . At this time, as a necessary condition for the operation, the operation center of the output terminals 13 and 14 must be operated with the voltage of the voltage source 6 . For this purpose, the following is required: the outflow current due to the p-channel MOS transistor M 6 is equal to the inflow current due to the n-channel MOS transistor M 7 ; the differential transistor pair (M 18 , M 19 ) equally distributes the current due to the n-channel MOS transistor M 7 at the operation center; and furthermore, the voltage source 15 and the p-channel MOS transistors M 16 and M 17 equally distribute a current due to the p-channel MOS transistor M 6 .
Consequently, the voltage at the operation center of the output terminals 13 and 14 is equal to the voltage at the connection point between the drain of the p-channel MOS transistor M 5 and the drain of the n-channel MOS transistor M 4 . This voltage is equal to that of the voltage source 6 because of the error amplifier 3 , and the voltage at the operation center of the output of the differential amplifier 10 also is equal to that of the voltage source 6 .
At this time, the loads 11 and 12 are not included in the loop of the error amplifier 3 . Therefore, the loads 11 and 12 of the differential amplifier 10 composed of the differential transistor pair (M 18 , M 19 ) can have a large resistance. Because of this, the gain of the amplifier can be increased. Furthermore, the loads 11 and 12 can be omitted, and an amplifier with a large gain set at an output impedance of the MOS transistor also can be configured.
As described above, according to the present embodiment, by providing the current source circuit according to Embodiment 2 and the differential amplifier for amplifying a signal, a gain can be set to be large while a stable operation point is ensured.
In the present embodiment, the voltage source 6 and the p-channel MOS transistors M 16 and M 17 are used as a current distributor. However, as shown in FIG. 10 , the p-channel MOS transistor M 16 shown in FIG. 9 is divided into M 6 a and M 6 b , and the voltage source 15 and the p-channel MOS transistors M 16 and M 17 shown in FIG. 9 may be omitted.
Furthermore, in the present embodiment, a signal is input to the n-channel MOS transistor. However, as shown in FIG. 11 , a signal may be input to the p-channel MOS transistor.
Furthermore, in the present embodiment, the voltage source 6 and the p-channel MOS transistors M 16 and M 17 are used as a current distributor. However, as shown in FIG. 12 , the n-channel MOS transistor M 7 shown in FIG. 9 is divided into M 7 a and M 7 b , and the voltage source 15 and the p-channel MOS transistors M 16 and M 17 shown in FIG. 9 may be omitted.
Furthermore, in the present embodiment, the amplifier is configured using the n-channel MOS transistors shown in FIG. 8 as a current mirror. However, as shown in FIG. 13 , the amplifier may be configured using the p-channel MOS transistor as a current mirror.
Furthermore, in the present embodiment, the amplifier is configured using the MOS transistors. However, the amplifier may be configured using bipolar transistors.
Embodiment 4
FIG. 14 is a circuit diagram showing an exemplary configuration of an amplifier according to Embodiment 4 of the present invention. In FIG. 14 , reference numeral 7 denotes a first differential amplifier (1st Diff. Amp), and 10 denotes a second differential amplifier (2nd Diff. Amp) having a configuration equivalent to the first differential amplifier 7 . The other configuration is the same as that of Embodiment 3 shown in FIG. 8 .
FIG. 15 is a circuit diagram showing a specific example of the amplifier shown in FIG. 14 . In FIG. 15 , n-channel MOS transistors M 13 and M 14 constitute a differential transistor pair, a p-channel MOS transistor M 15 constitutes a gate ground circuit, and the transistors M 13 , M 14 , and M 15 constitute a first differential amplifier 7 equivalent to the second differential amplifier 10 .
Next, the operation of the amplifier according to Embodiment 4 configured as above will be described.
In Embodiment 3, the channel modulation effect λ and Vds of the MOS transistor are approximated to be substantially constant. However, by providing the equivalent first differential amplifier 7 , the operation state of the MOS transistor of the first differential amplifier 7 becomes equal to the operation state of the MOS transistor of the second differential amplifier 10 , and an error ascribed to the current ratio of the inflow current of the output terminal 5 to the outflow current of the output terminal 4 is reduced further.
As described above, according to the present embodiment, by providing the differential amplifier 7 equivalent to the differential amplifier 10 in Embodiment 3, a gain is set to be large while ensuring a stable operation point, and an error can be reduced further.
In the present embodiment, the voltage source 6 and the transistors M 15 , M 16 , and M 17 shown in FIG. 15 are used as a current distributor. However, as shown in FIG. 16 , the transistor M 6 shown in FIG. 15 is divided into M 6 a and M 6 b , and the voltage source 15 and the transistors M 15 , M 16 , and M 17 shown in FIG. 15 may be omitted.
Furthermore, in the present embodiment, a signal is input to the n-channel MOS transistor. However, as shown in FIG. 17 , a signal may be input to a p-channel MOS transistor.
Furthermore, in the present embodiment, the voltage source 6 and the transistors M 15 , M 16 , and M 17 shown in FIG. 15 are used as a current distributor. However, as shown in FIG. 18 , the transistor M 7 shown in FIG. 15 is divided into M 7 a and M 7 b , and the voltage source 15 and the transistors M 15 , M 16 , and M 17 shown in FIG. 15 may be omitted.
Furthermore, in the present embodiment, the amplifier is configured using the n-channel MOS transistors as a current mirror. However, as shown in FIG. 19 , the amplifier may be configured using the p-channel MOS transistors as a current mirror as shown in FIG. 19 .
Furthermore, in the present embodiment, the amplifier is configured using the MOS transistors. However, the amplifier may be configured using bipolar transistors.
As described above, according to the present invention, an excellent current source circuit can be realized, which is capable of prescribing an inflow current to be equal to an outflow current of the output terminal.
Furthermore, an excellent amplifier can be realized, which is capable of setting a gain to be large while ensuring a stable operation point.
The invention may be embodied in other forms without departing from the spirit or essential characteristics thereof. The embodiments disclosed in this application are to be considered in all respects as illustrative and not limiting. The scope of the invention is indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein. | There is provided a current source circuit in which a outflow current of an output terminal is equal to an inflow current thereof. The current source circuit includes a first transistor group converting a reference current from a reference current source into a voltage and a first transistor having a current mirror relationship with the first transistor group, and allowing an output current to flow therethrough. An error amplifier compares a voltage generated in the first transistor group and supplied to one input terminal with a voltage supplied to the other input terminal. A second transistor is driven with an output voltage of the error amplifier. A third transistor is driven with the output voltage of the error amplifier, and allows an output current to flow therethrough in a direction opposite to the output current of the first transistor with respect to an output terminal. A second transistor group converts a current flowing through the second transistor into a voltage to supply the voltage to the other input terminal of the error amplifier. | 6 |
CLAIM OF PRIORITY/CROSS REFERENCE OF RELATED APPLICATION(S)
[0001] Not applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE OF AN APPENDIX
[0003] Appendices A-B are contained herein. A portion of the disclosure of this patent document may contain material, which is subject to copyright/trademark protection. The copyright/trademark 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 file or records, but otherwise reserves all copyright/trademark rights whatsoever.
BACKGROUND
[0004] 1. Field of the Invention
[0005] The present invention relates generally to data processing and more particularly, to a novel machine, process and manufacture for synchronizing data across a plurality of integrated applications.
[0006] 2. Description of Related Art
[0007] Application integration is the process of bringing data or a function from one application program together with that of another application program. Implementing application integration has previously been a tedious process involving long development and programming hours. However, the current trend is to use specialized integration products (prepackaged “middleware” solutions), such as message brokers and applications servers, to provide a common connecting point among disparate applications.
[0008] Several patents and publications disclose various application integration methods, portions of which are briefly summarized as follows:
[0009] U.S. Pat. No. 6,236,994 entitled “Method and apparatus for the integration of information and knowledge,” issued on May 22, 2001 to Swartz, et al., and discloses a method and apparatus for “integrating the operation of various independent software applications directed to the management of information within an enterprise. The system architecture is, however, an expandable architecture, with built-in knowledge integration features that facilitate the monitoring of information flow into, out of, and between the integrated information management applications so as to assimilate knowledge information and facilitate the control of such information. Also included are additional tools which, using the knowledge information enable the more efficient use of the knowledge within an enterprise, including the ability to develop a context for and visualization of such knowledge.”
[0010] U.S. Pat. No. 6,256,676 entitled, “Agent-adapter architecture for use in enterprise application integration systems,” issued on Jul. 3, 2001 to Taylor, et al., and discloses “an agent-adapter architecture used in systems and methods to integrate applications of the type normally deployed across a networked enterprise. A plurality of adapters, each of which is adapted to perform a discrete function associated with respective ones of the plurality of enterprise applications is encapsulated by an agent. The agent is extensible, including one or more embedded objects, each of which is adapted to perform a discrete function that may or may not be associated with respective ones of the plurality of enterprise applications.”
[0011] Enterprise Application Integration, A Wiley Tech Brief by Willam A. Ruh et al, Wiley Computer Publishing, 2001, describes various technologies, architectures and approaches currently available for application integration.
[0012] Finally several integrated-related Internet resources such as the “EAI Journal,” www.eaiijournal.com and the “EAI Forum,” www.eaiforum.com, describe the current state of application integration technologies.
SUMMARY OF THE INVENTION
[0013] One of several objects of the present invention (sometimes referred to as PDX) is to provide user-driven, on-demand integration of applications, particularly primarily stand-alone applications.
[0014] Further objects of the present invention include, but are not limited to: 1) providing a link to a “vertical” integration mechanism to enable the horizontally integrated applications to integrate with other platform resources, such as mainframes and servers (Unix and NT), 2) streamlining workflows, 3) eliminating redundant data, 4) move data among integrated applications with minimal effort, 5) linking data records and synchronizing linked data records across applications, 6) providing a migration path to a future state, and 7) minimizing data required by applications.
[0015] Therefore in accordance with one aspect of the present invention, there is generally provided an apparatus, method and article of manufacture for integrating a plurality of heterogeneous applications using a common integration architecture wherein said apparatus, method and article of manufacture employs a Links Table for associating related data. Utilization of the Links Table enhances processing time over those techniques that search cumbersome data stores of integrated applications for relevant information during synchronization.
[0016] The above-mentioned aspect(s) and other aspects, objects, features and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING(S)
[0017] Referring briefly to the drawings, embodiments of the present invention will be described with reference to the accompanying drawings in which:
[0018] [0018]FIG. 1 is a general representation of various components that comprise an integration architecture constructed in accordance with the teachings herein;
[0019] [0019]FIG. 2 depicts an exemplary message structure in accordance with the teachings herein;
[0020] [0020]FIG. 3 depicts an exemplary user interface in accordance with the teachings herein;
[0021] [0021]FIG. 4 depicts an exemplary synchronization flow in accordance with the teachings herein;
[0022] FIGS. 5 - 10 each depict a detail of the flow set forth in FIG. 4;
[0023] [0023]FIG. 11 depicts a Links Table in accordance with the teachings herein.
[0024] FIGS. 12 - 16 depict exemplary application flows in accordance with the teachings herein.
[0025] FIGS. 17 - 22 are representations of user interface screens depicting aspects of the present invention.
DETAILED DESCRIPTION
[0026] Referring more specifically to the drawings, for illustrative purposes the present invention is embodied in the system configuration, method of operation and product or computer-readable medium, such as floppy disks, conventional hard disks, CD-ROMS, Flash ROMS, nonvolatile ROM, RAM and any other equivalent computer memory device, generally shown in FIGS. 1 - 22 . It will be appreciated that the system, method of operation and product may vary as to the details of its configuration and operation without departing from the basic concepts disclosed herein.
GLOSSARY
[0027] In describing the present invention, the following terms are used herein.
[0028] “Data store” is a place where information is saved, preferably, in a persistent manner (e.g. on a hard drive). It may include relational databases, flat files, and proprietary storage formats.
[0029] “Horizontal integration” is integration across a single platform as opposed to integration between different platforms (e.g. client and server).
[0030] Integration software refers to the software/components used to synchronize information between applications.
[0031] “IOD” or “Integration on demand” is a user-driven approach to integration and not an automated replication model.
[0032] Vertical integration is integration between two or more platforms.
[0033] Working Client is that person whose information is designated as the current working set for any particular application and may not necessarily be a “client” of the enterprise as that term is used herein.
INTEGRATED ARCHITECTURE
[0034] To facilitate the integration and synchronization of required information, aspects and features of the present invention are embodied in a common integrated architecture. FIG. 1, illustrates on example of such an integrated architecture 100 constructed in accordance with the teachings presented herein. As shown, the integrated architecture comprises several interrelated components, namely an Integration Engine having an Integration Engine Service Adapter and an Integration Engine Data Store associated therewith (collectively enumerated as 105 ), a plurality of Applications having associated Application Service Adapters and Application Data Stores (collectively enumerated as 110 ), Messages 115 having a predefined syntax, and a Dashboard user interface 120 , all arranged in a logical hub-and-spoke configuration.
[0035] Together the Integration Engine, its Service Adapter and Data Store, function as the “hub” of the architecture. Responsibilities of the integration engine include routing messages between service adapters based on type or content, transforming a message or message content based on the requirements of the integrated applications, and controlling the flow of information between service adapters.
[0036] The predefined Messages form the spokes. The content of every Message conforms to a standard syntax. All applications/resources produce and consume Messages that conform to a standard syntax, thus the present solution supports “plug-and-play” capabilities.
[0037] Finally, the Applications and the Application Service Adapters are the ends of the spokes. Depending on a particular task, Application Service Adapters can either serve as sources or as destinations and are responsible for accessing applications/resources to retrieve requested information and transforming this information into a common syntax and back again to its original format.
[0038] Attention now turns to details of the aforementioned components.
INTEGRATION ENGINE
[0039] The Integration Engine, its Service Adapter and Data Store are situated at center of the architecture. Together, these integration components implement intelligent messaging by triggering and executing integration flows to process events and rules that evaluate, modify, and route event data. Specific responsibilities include setting application definitions for integrated applications, setting Dashboard's settings, and implementing updates and/or additions to the Links Table (see below).
[0040] The Integration Engine's Service Adapter can be called directly from the Dashboard or the integration flows.
[0041] The design specification for the Integration Engine Service Adapter is set forth as Appendix B.
APPLICATION SERVICE ADAPTERS
[0042] An adapter is an access point (logic) logic that provides access to the application in a structured manner. Thus, an adapter is an interface into the application that defines the requests the receiver will accept while hiding the underlying complexity of accomplishing the integration.
[0043] The Application Service Adapters herein are built to be plug and play with the system. That is to say, a new Application Service Adapter can be plugged in and removed from the architecture without impacting the remaining Application Service Adapters.
[0044] Each application has its own data requirements. Typically, data requirements will not match from application to application. Therefore, it is the responsibility of the Application Service Adapter to understand and provide services to its underlying data store and further perform the necessary business logic to the data being passed to or retrieved from it.
[0045] While all Application Service Adapters speak in a standard syntax, nonetheless should an application require another standard, it can easily be supported by the transformation capabilities of the Integration Engine. To that end, the Integration Engine communicates with the Application Service Adapters via predefined Messages (see below).
[0046] The design specification for an Application Service Adapter is set forth as Appendix C.
MESSAGES
[0047] The predefined Messages recognized by the present invention form the spokes in the integrated architecture. In FIG. 3, for visual simplicity, the spokes also include the technology transport of the messages. The content of every Message conforms to a standard syntax. Specifically, the structure of the Messages created and processed in the present invention may be logically divided into three main sections, a Message Root section 202 , a Message Envelope section 204 and a Message Body section 206 . The Message Envelope section is further divided into a Source section 208 and a Destination section 210 . The Message Body section is further divided a Parameters section 212 and a Payload section 214 . The Payload section is still further divided into a Status section 216 , a Links section 218 , and a Pay Load Item section 220 . Each of the foregoing sections and subsections will now be further explained below.
[0048] 1. Message Root
[0049] The Message Root section contains header information about a given message.
[0050] The Message Root comprises an IONS identifier (IONSID) field and a message request type (RequestType) field. A description of each of the foregoing fields follow.
Property Description IONSID A unique identifier for a user, e.g., the user's Windows ® operating system login id. RequestType The name/type of the request message, e.g., GetPerson_RQ message or SyncPerson_RQ message. See Appendix A for additional message types.
[0051] The Message Envelope section comprises a Source section and a Destination section containing routing information, which lets the Integration Engine know which Service Adapter(s) to send the message to. In cases where source information is not needed, the initiator of the message need not supply source information.
[0052] Note: in order to maintain the principle that a user should have exactly the same rights to the information in an application data store that they have when using the application itself, we must maintain information about users.
[0053] A. Source
[0054] The Source section consists of several fields having information pertaining to the Service Adapter of the Source Application. The relevant fields are described below.
Property Description DataSourceDescription A description of the data source, usually the ODBC DSN or a File Name. Name The name of the Service Adapter. UserID An application user identifier. Note: This is not the IONSID mentioned above. Password An application user password associated with the UserID. The password is used to validate an applications settings when a user customizes the Dashboard. There is no requirement to store the password.
[0055] B. Destination
[0056] The Destination section consists of several fields having information pertaining to the Service Adapter of the Destination Application. The relevant fields are similar to that of the Source section and are described below.
Property Description DataSourceDescription A description of the data source, usually the ODBC DSN or a File Name. Name The name of the Service Adapter. UserID An application user identifier. Note: This is not the IONSID mentioned above. Password An application user password associated with the UserID. The password is used to validate an applications settings when a user customizes the Dashboard. There is no requirement to store the password.
[0057] 3. Message Body
[0058] The Message Body section contains information to enable a receiver of the message to process a request and further holds the requested information or data. As described earlier, the Message Body is divided into two sections—Parameters and Payload. A description the these sections follows.
[0059] A. Parameters
[0060] The Parameters section contains the parameters that a message requires. In cases where a message does not utilize a parameter this section will be blank. The Parameters section comprises two fields, which are described below.
Property Description Name The name of the parameter Value The value of the parameter.
[0061] B. Payload
[0062] The Payload section contains the results of the message request. The Payload section divides into three sub-sections, namely a Status section, a Links section and a Payload Items section. The foregoing sub-sections are described below.
[0063] i. Status
[0064] The Status section contains information related to the completion of the message. If the message is successful, it will contain a status code and description indicating success. It is also here that you will find information about any errors that were encountered during the messages execution. There can be many occurrences of this section. The Status section comprises several fields, each of which are described below.
Property Description StatusCode The status code of the error. Description A description of the error. OriginatedFrom The name of the dynamic link library (DLL) that the error occurred in. ModuleName The name of the module that the error occurred in. MethodName The name of the method where the error occurred.
[0065] ii. Links
[0066] The Links section is utilized during synchronization. Among other information, the Links section contains a record of a Service Adapter's actions, that is whether an “Add” or “Update” was done. In addition, it contains certain information a Service Adapter needs during processing, for example, the unique identifiers assigned to the Source and Destination Applications. The Links section comprises several fields, each of which are described below.
Property Description DataSourceDescription A description of a data source, usually the ODBC DSN or a File Name Name The Service Adapter's name *SourceID A unique identifier for the object, e.g. a person or an organization, in the Source Application *DestinationID A unique identifier for the object in the Destination Application. *PartyID A unique identifier for the object within the system. *ObjectType Identifies the object as a person or an organization. *ActionPerformed The action that the Service Adapter performed on the object, e.g., “Add” or “Update”
[0067] iii. Payload Item
[0068] The Payload Item section contains the results of a request. For example, a receiver of a Search_RQ request message would place the search results in the Payload Item section of a response message. There can be one or more instances of a payload item. Since a request can be sent to multiple destinations, to track what part, or “item”, in the payload came from a particular Service Adapter the following properties/fields are included at the beginning of each Payload Item section.
Property Description DataSourceDescription The description of a data source. Usually the ODBC DSN or a File Name. Name The Name of the Service Adapter
[0069] The rest of Payload Item section varies based on the request. Specific message types used herein are set forth in the Appendices.
USER INTERFACE
[0070] The present system includes a graphical user interface that enables a user to work with the aforementioned integration flows.
[0071] Accordingly, FIG. 3 depicts an exemplary embodiment of an “Integrated Client Dashboard” graphical user interface (“Dashboard”) utilized in the present invention. The Dashboard is designed to facilitate user-driven data integration across integration Applications via a flexible application workflow model.
[0072] For example and referring to the insurance industry, a user who starts the sales process by entering information in a prospecting application (CDS) and then moves on to discovery and analysis using a discovery application (DIS) and an analysis application (PAS) can use the Dashboard to move client information from the CDS to DIS/PAS applications by activating the buttons on the Dashboard. Similarly, an alternative workflow is also supported wherein a user begins prospecting by enter information into illustrations application (ISP) and then moves to the discovery application.
[0073] As shown, the look and feel of the illustrated embodiment of the Dashboard is based on the look and feel of the popular Shortcut Bar used in Microsoft® Office suite. The Dashboard spans the length of the display device and is initially situated at the bottom of the display medium, such as a window object or computer screen. However, as is conventional, the Dashboard may be resized and also positioned elsewhere on the display device as preferences dictates.
[0074] The Dashboard includes several areas, namely a Menu Access area 302 , an Integration area 304 , a Non-Integrated area 306 , and a Status area 308 , which together invoke aspects and features of the present invention. The details of each of these areas will now be discussed.
[0075] Menu Access Area
[0076] The Menu access area comprises a Menu Access button. Upon selection of the Menu access button a menu bar appears like that shown in FIG. 22. As indicated, the menu bar provides access to certain commands/functions, for example, Auto Hide, Customize, Help and Exit, that control certain aspects of the instant invention. The Auto Hide command enables the Dashboard to reside behind other applications displayed on the display device. The Customize command allows the user to alter settings for the Dashboard, for example, adding/removing application files to/from the Dashboard, modifying information about a particular application, and modifying other attributes of the Dashboard, including color and size.
[0077] Selecting the Help command launches the Help facility and selecting the Exit command exits the Dashboard. Other commands/function may also be displayed.
[0078] Integration Area
[0079] The Integration area is a collection of buttons that serve as shortcuts for executing and controlling the synchronization process describe herein.
[0080] For example, the embodiment shown in FIG. 3 depicts, a Help button (A), a Search button (B), a MultiSync button (C) and several buttons representing applications integrated with the present system (D-H).
[0081] Selecting the Search button launches a search applet for searching integrated applications. The search applet returns and displays results based on the search criteria entered. Using the returned results a user may take the following actions: 1) select a Working Client causing information about the Working Client to appear in Status area of the Dashboard); 2) select the Working Client and view all data relating to the Working Client, and 3) select a Working Client and launch directly to the application where the client resides.
[0082] Selecting the MultiSynch button synchronizes data from Source to Destination Applications.
[0083] Selecting any one of the integrated application buttons will process the Working Client's information in accordance with the teachings expressed herein, for example, push data from a source to the selected integrated application.
[0084] Non-Integrated Area
[0085] The non-integrated area includes a non-integrated application button and one or more specific application/website buttons. Upon selection of the non-integrated application button, a drop down list appears. The drop down list sets forth at least all external, non-integrated applications/web sites having buttons appearing on the Dashboard. Selecting any one of the application/website buttons will launch the particular application/website.
[0086] Status Area
[0087] The Status area displays information that is relevant to the current Working Client, for example, the name of and the Working Application containing the Working Client.
[0088] When the Dashboard restarts, it will retain all prior settings at shut down including the Working Client and Working Application information and the Dashboard's last position on the display device
[0089] Other Features/Embodiments of the Dashboard
[0090] The Dashboard, in its most basic embodiment, may be customized to only consist of a Menu Access area, an Integration area and a Status Area and yet still retain the desired functionality.
[0091] In alternative embodiments of the Dashboard, certain areas of the Dashboard will display hover text indicating the function of the area. For example, to display the function of the Multi Sync button, a user positions the mouse over the button for a few moments to generate a hover text stating “Send Working Client to Multiple Applications.”
[0092] Further, when a user right-mouse-button clicks anywhere on the Dashboard, the system displays a shorter, modified menu bar. This menu has three of the same functions as the regular menu—Auto Hide, Customize, and Exit. These behave exactly the same as on the regular menu.
DATA SYNCHRONIZATION
[0093] An application of the present solution will now be described with reference to FIGS. 4 - 11 . The sections that follow demonstrate how customer demographic information is modified across several integrated heterogeneous applications.
[0094] [0094]FIG. 4 depicts a high level view of an exemplary data synchronization flow in accordance with the principles expressed herein comprising several interrelated software modules, namely, a Set Working Client & Application module 400 , a Verify Links module 402 , a Find Matches module 404 , a Verify Destination Application Availability module 406 and a Synchronization module 408 .
[0095] When a user clicks on an application icon on the Dashboard signaling data synchronization, an integration request message is generated by the dashboard and sent to the Integration Engine where certain pre-processing steps are first performed before the integration request message is handled. An integration request message is a template by which all the messages described herein are derived from. The messages have a certain attributes that are the same regardless of what type of request is being made (for example, whether the request is a Search, Sync, etc.). Specifically, all messages have the following properties, IONSID, REQUEST_TYPE, SOURCE, DESTINATION, PARAMETERS.
[0096] As shown in FIG. 4, to begin synchronization, the Set Working Client & Application module executes. This module performs the pre-processing steps of verifying whether a desired Working Client has been properly selected and whether a desired Working Application (Source Application) is available for synchronization. If true, the Verify Links module 4 is dynamically created (see below) and utilized as a basis for the synchronization flow.
[0097] If the Working Client is properly set and the Source Application is available for synchronization, the Verify Links module 402 executes. This module is dynamically created and utilized as a basis for the synchronization flow. Specifically, this module first verifies that signatures exist in the Destination Application data store. For example, when a signature check is performed, a getSignature message is constructed and sent to a Destination Application's Service Adapter. Next, an attempt to retrieve the links for the Working Client in both the Source and Destination Applications is performed against the Integration Engine's database.
[0098] Attention will now turn to the Links Table as that data structure is used herein. A dynamic Link Table like that shown in FIG. 11 is populated whenever a user establishes links among integrated applications for a particular customer/person/client. As shown, the Link Table has five columns entitled, Link Key, User Application Id, Party Id, Client Id and Last Sync Date.
[0099] The Link Key column contains unique identifiers associated with each row in the Link Table. In the present example, each row is number sequentially. Thus, row one has a link key of 1 , row 2 has a link key of 2 and so on.
[0100] The User Application Id column contains unique identifiers associated with the integrated applications. Thus, in the example illustrated in FIG. 11, the CDS application is assigned a user application id of 5 , the ISP application is assigned a user application id of 6 and the PAS application is assigned a user application id of 7 .
[0101] The Party Id column contains global identifiers associated with each customer/person/client in the Integration Engine data store. Thus, in the example illustrated in FIG. 11, customer/client/person William Brown is assigned a party id of 2 and customer/client/person J. Doe is assigned a party id of 2 . Notably, a glance down the Party Id column immediately tells a reviewer that only two people are currently linked in the Integration Engine data store.
[0102] The Client Id column contains unique identifiers associated with customers/clients/persons in their respective native applications. Thus, in the example illustrated in FIG. 11, the CDS application assigns customer/client/person W. Brown a client id of 20 and assigns customer/client/person J. Doe a client id of 200 . The PAS application assigns a client id of 20 to customer/client/person W. Brown and assigns customer/client/person J. Doe a client id of 200 .
[0103] The Last Sync Date column sets forth the most recent date synchronization was done for a particular customer/clients/person. Thus, in the example illustrated in FIG. 11, data was last synchronized in the CDS application for customer/client/person W. Brown on Jan. 18, 2001 and in the ISP and PAS applications on May 22, 2001. For customer/client/person J. Doe, data was last synchronized in the CDS and PAS applications on Feb. 4, 2001.
[0104] Due to the inherent nature of technology, unforeseen glitches may occur and as a result cause an application's data to become corrupted. However, once an application's data is restored, all of the unique identifiers in the application's data store will change where the identifier is a sequentially generated one. Consequently, the identifiers will no longer match what is stored in the Link table for that application data store.
[0105] Without correction, a synchronize action will associate and overlay information with the wrong individual/object/item in the application's data store.
[0106] Because of the necessity to provide correct and consistent information, the present invention provides for the Links Table to be updated whenever a particular application's data store has been corrupted, reloaded or refreshed.
[0107] The first time an application's data store is used, a signature record should be written into the data store where the data store uses a unique identifier for an individual/item/object that will change upon a data reload (e.g. have a sequentially generated unique identifier).
[0108] The unique identifier for the signature record is recorded in the link table. On start up, a check of all signature records will be performed. If a signature record does not exist in one or more application data stores, an error message is generated display an information and warning message for each application such as “XYZ data appears to have been refreshed. Links are no longer valid. Do you want to clear all links for this application?” If a user selects “Yes”, the link table entries for that application are reset and a new signature record is written to the application data store. If “No” is instead selected, all add and update actions for that application is disabled. For example and referring to FIG. 11, if the CDS application's data store was corrupted and subsequently refreshed and a user selects Yes, all links for CDS in the Links Table, that is Rows 1 and 4 , would be removed and replaced with updated information. If a user selects No the user will unable to use the CDS application button on the Dashboard for synchronization.
[0109] Referring back to FIG. 4, if no links for the Working Client in the Source and Destination Applications were found in the Verify Links module 402 , the Find Matches module 404 executes. Otherwise, the Find a Match module 404 is bypassed and control passes to the Verify Destination Application Availability module 406 . The Find Matches module 404 searches within data stores associated with selected Destination Applications to locate information matching that of the Working Client.
[0110] Next, the Verify Destination Application Availability module 406 executes. This module determines whether the desired Destination Application(s) is/are currently available for synchronization. If true, a SyncPerson_RQ message will be created (see below) and utilized in the Synchronization module described below.
[0111] Finally, the Synchronization module 408 executes. This module, among other things, performs the desired task of synchronizing data from the Source Application to the desired Destination Application(s).
[0112] For a better understanding of the present solution, the above modules will now be further described in the sections that follow.
[0113] Set Working Client and Application
[0114] Referring to FIG. 5, there is shown an exemplary block diagram detailing an exemplary process flow of the Verification module in accordance with the principles expressed herein.
[0115] In response to an integration request message, a determination is first made as to whether the desired Working Client is set. If the Working Client is not set, execution terminates and in one embodiment of the present solution, an error message is generated indicating that the Working Client is not set. If, on the other hand, the Working Client is set than a determination is made as to whether a selected Working Application is available for data synchronization. During the synchronization process, the Working Application will serve as the Source Application. If the Source Application is not available for data synchronization, execution terminates and in one embodiment of the present solution, an error message is generated indicating that the Working Application is not available for synchronization. However, if the Working Application is available for synchronization, the Verify Links module will be dynamically constructed based upon the original integration request message.
[0116] That is to say, in preparing the Verify Links module, certain information is extracted from the original integration request message and included in the Verify Links module, but not limited to, the Working/Source Application, the Working Client, and all Destination Applications.
[0117] Finally, after the Working and Client applications have been properly verified and the Verify Links module constructed, control passes to the next module in sequence.
[0118] Verify Links
[0119] Upon completion of the Verification module, the Verify Links module executes in accordance with the following exemplary process flow.
[0120] In one embodiment of the present invention, the Verify Links module logically divides into two sub-processes. First, signatures are checked and second, links between the Working Client and Destination Applications(s) are checked in accordance with the following exemplary process flow.
[0121] A. Check Signatures in Destination Application's Data Store
[0122] Referring to FIG. 6, first, the Integration Engine's Service Adapter constructs a GetSignature_RQ message based upon the contents of the VerifyLinks message. Specifically, the Integration Engine's Service Adapter constructs a GetSignature_RQ message for each application contained in the Source and Destination sections of the VerifyLinks message envelope and transmits the same to the Service Adapters of the Destination Application(s).
[0123] Next, in response to the GetSignature_RQ message, each Destination Application's Service Adapter determines whether a signature already exists in the Destination Application's data store and whether the Destination Application's Service Adapter supports the integration request message. In determining whether a signature exists, the Service Adapter checks the value in the Status Code section of the GetSignature_RQ message. If a signature does not exist, then the Destination Application's Service Adapter constructs a ClearLinks_RQ message for the Destination Application and execution control returns to process the next Destination Application contained in the GetSignature_RQ message. If the Service Adapter supports the integration request message, the Destination Application's Service Adapter constructs a ClearLinksByDate_RQ message for the Destination Application and execution control returns to process the next Destination Application contained in the GetSignature_RQ message.
[0124] If the Destination Application's Service Adapter supports the integration request message but the relevant signature does not exist in the Destination Application's data store, both the ClearLinks_RQ and the ClearLinksByDate_RQ messages are transmitted to the Integration Engine's Service Adapter. In response to the two messages, the Integration Engine's Service Adapter constructs an AddSignature_RQ message and transmits the message to the Destination Application contained in the ClearLinks_RQ message. In response to the AddSignature_RQ message, the Destination Application's Service Adapter will add the signature to the Destination Application's data store. The foregoing process is done for all Destination Applications wherein the Destination Application's Service Adapter supports the integration request message but the relevant signature does not exist in the Destination Application's data store.
[0125] B. Check Links Using Links Table
[0126] Referring to FIG. 7, after signatures have been checked, links between the Working Client and Destination Applications(s) are also checked.
[0127] First, the Integration Engine's Service Adapter constructs a CheckLinks_RQ message based upon information derived from the original integration request message and transmits the same to the Destination Applications. The CheckLinks_RQ message will check to see if a link or links for the Working Client/Person exist between the Source Application and the Destination Application.
[0128] In response to the CheckLinks_RQ message and for each Destination Application contained in the message envelope of the CheckLinks_RQ message, the Integration Engine's Service Adapter will check the Links Table to determine whether a link for the Working Client/Person exists between the Source Application and the Destination Application. A CheckLinksResponse message is then constructed and transmitted indicating the results of the query.
[0129] Find Matches
[0130] Referring to FIG. 8, the Find Matches module executes, if required, in accordance with the following exemplary process flow. Note the Find Matches module executes only if no link was found in the previous module.
[0131] For each Destination Application contained in the message envelope of the original integration message, the following steps occur:
[0132] First, the Integration Engine Service Adapter constructs and transmits a ServiceAvailable_RQ message to the Destination Application's Service Adapter to determine whether the Destination Application is available for synchronization and more particularly, whether the Destination Application's Services are available.
[0133] If the response to the ServiceAvailable_RQ message is positive (that is the Destination Application has synchronization capability), The Integration Engine Service Adapter issues a GetPersonDetails_RQ message to the Source Application's Service Adapter. In response to GetPersonDetails_RQ message, the the Source Application's Service Adapter retrieves and transmits the desired customer demographic information. If, however, the Destination Application's Services are not available, execution terminates and, in one embodiment of the present solution, an error message is generated indicating that the Destination Application is not configured for synchronization.
[0134] Next, a determination is made as to whether a link exists for the Working Client between the Source Application and the Destination Application.
[0135] If a link exists for the Working Client between the Source Application and the Destination Application, then execution control passes to the next module in sequence, namely the Determine Destination Application Availability module.
[0136] If, on the other hand, there is no link for the Working Client between the Source Application and the Destination Application, the Destination Application's Service Adapter searches the Destination Application's data store to find a potential Matching Client for the Working Client using the following exemplary search criteria: Social Security Number, Date of Birth, Last Name, and First Name. This process is done to avoid duplicate entries of the Working Client in the Destination Application's data store. Note: the Working Client may in fact exist in the Destination Application's data store but a link may not exist for the Working Client between the Source Application and the Destination Application. If there are no potential Matching Clients, execution control passes to the next module in sequence, namely the Determine Destination Application Availability module.
[0137] If one or more potential Matching Clients are found, they are displayed to the user. The user is then provided with three options.
[0138] Option 1: The user wishes to add the Person because none of the potential Matching Clients actually matches the Working Client;
[0139] Option 2: The user desires to update and link the Person because at least one of the potential Matching Clients actually matches the Working Client; or
[0140] Option 3: The user cancels and control is returned to the Dashboard.
[0141] Referring to options 1 and 2, if the user selects option 1, execution control passes to the next module in sequence. If the user selects option 2, a determination is made as to whether a link for the Working Client between the Source Application and the Destination Application exists in the Integration Engine's Database.
[0142] Outcome 1—No link For Working Client Exists in the Integration Engine's Database
[0143] If there are no links for the Working Client in the Integration Engines database, a determination is then made as to whether a link for the selected Matching Client between the Source Application and the Destination Application exists in the Integration Engine data store via the Verify Links module.
[0144] In response to the CheckLinks_RQ message, the Integration Engine's Service Adapter will check the Links Table to determine whether a link for the Matching Client exists between the Source Application and the Destination Application. A CheckLinksResponse message is then constructed and transmitted indicating the results of the query.
[0145] If a link for the selected Matching Client exists, an UpdateLinks message is constructed and executed resulting in a link being created between the Working Client in the source application and the selected Matching Client in the Destination Application. Note: Since a link already exists, the PartyID of the link for the person selected will be used when creating link. Thereafter, execution control returns to the beginning of the iterative loop to process the next Destination Application contained in the message envelope of the original integration request message.
[0146] If, on the other hand a link for the selected Matching Client does not exist in the Integration Engine data store, an UpdateLinks message is constructed and executed, resulting in a link being created between the Working Client in the
[0147] Source application and the selected Matching Client in the Destination Application. Note: Since no link existed for the Working Client or selected Matching Client, a new PartyID will be created upon completion. Thereafter, control returns to the beginning of the iterative loop to process the next Destination Application contained in the message envelope of the original integration request message.
[0148] Outcome 2—Link for the Working Client Exists
[0149] If a link for the Working Client exists in the Integration Engine data store, an UpdateLinks message is created and executed resulting in a link being created between the Working Client in the Source Application and the selected Matching Client in the Destination Application, Note: Since a link already exists, the PartyID of the link for the working client will be used when creating link. Thereafter, execution control returns to the beginning of the iterative loop to process the next Destination Application contained in the message envelope of the original integration request message.
[0150] After all Destination Applications contained in the message envelope of the original integration request message having been processed, execution control passes to the next module in sequence.
[0151] Determine Destination Application Availability
[0152] Referring to 9 , upon completion of the preceding modules, the Verify Destination Application Availability module executes in accordance with the following exemplary process flow.
[0153] First, a SyncPerson_RQ message is prepared based on the original integration request message as follows: the Source Application of the SyncPerson_RQ message is set to the Source Application of the original integration request message and the Working ClientID of the original integration request message is used as a parameter of the SyncPerson_RQ message.
[0154] For each Destination in the Destinations Section of the SyncPerson_RQ message the following steps occur:
[0155] First, a determination is made as to whether the Destination Application's Services are available by issuing a ServiceAvailable_RQ Message to the Destination Application Service Adapter.
[0156] If the Destination Application's Services are available, the Destination Application is added to the message envelope (that is, the Destinations section) of the SyncPerson_RQ message. Thereafter, execution control returns to the beginning of the loop to process the next Application requiring synchronization.
[0157] If the Destination Application's Services are not available, execution terminates and, in one embodiment of the present solution, an error message is generated indicating the same.
[0158] Finally, after all Destination Applications have been added to the message envelope of the SyncPerson_RQ message, control passes to the next module in sequence.
[0159] 5. Synchronization
[0160] Referring to FIG. 10, after the Verify Destination Application Availability module has executed, control passes to the Synchronization module, which executes in accordance with the following exemplary process flow.
[0161] First, signatures are checked via the Verify Links module (see above).
[0162] Next, a GetPerson_RQ message is constructed based upon information derived from the SyncPerson_RQ message as follows: the Destination Application of the GetPerson_RQ message is set to the Source Application of the SyncPerson_RQ message and the PersonID parameter of the SyncPerson_RQ message is passed as a parameter of the GetPerson_RQ message.
[0163] Next, the GetPerson_RQ message is sent to the Service Adapter of the Destination Application. The Destination Application's Service Adapter retrieves the appropriate customer demographic data, constructs and transmits a reply message (GetClientResponse message) having the requested demographic data.
[0164] Next, a GetLinks_RQ message is constructed based upon information derived from the GetClientResponse message. The GetLinks_RQ message retrieves other relationships linked to the desired person, such as mother, father, son, etc.
[0165] Next, the GetLinks_RQ message is sent to the Integration Engine's Service Adapter. The Integration Engine's Service Adapter retrieves any existing linked relationships, constructs and transmits a GetLinksResponse reply message having the linked relationships
[0166] Next, an UpdateLinksRequest request message is constructed using information derived from the original integration request message. (Note: at this stage in the process, the SynchPerson_RQ message is still being prepared for execution.)
[0167] Next, for each Destination Application in the Destinations section of the SyncPerson_RQ message, the following steps occur:
[0168] Next, the SyncPerson_RQ message is further populated with the following information: the Destination Application is loaded in the Destination section of the SyncPerson_RQ message, the payload of the GetClientResponse message (having demographic information) is loaded in the Payload section of the SyncPerson_RQ message and the Links section of the GetLinksResponse message is loaded in the Links section of the SyncPerson_RQ message
[0169] Next, the SyncPerson_RQ message is sent to the Destination Application's Service Adapters. In response to the SyncPerson_RQ request, the Destination Application's Service Adapter retrieves the desired data from the data store of the Destination Application (sync data from the Source Application's data store to the Destaintion Application's data store), constructs and sends a GetSyncPersonResponse reply message indicating if the synchronization was successful or not. If an error was encountered during the processing, this error will be included in the message along with information about the error itself, such as, number description, etc.
[0170] Next, the Link section of the UpdateLinks_RQ message is updated to include the link information of the Links section of the GetSyncPersonResponse reply message.
[0171] Control returns to the beginning of the loop to process the next Destination Application in the Destinations section of the SyncPerson_RQ request message.
[0172] After all Destination Applications have been processed (synched), the UpdateLinksRequest message is sent to the Service Adapter of the Integration Engine. In response to the UpdateLinks_RQ request, the Integration Engine's Service Adapter uses the information stored in the Links section of the UpdateLinks_RQ to update the Links Table. More particularly, once synchronization is complete, the SyncPerson_RQ message will add or update the links for the Source and Destination(s) if necessary.
[0173] Thereafter, the Integration Engine's Service Adapter constructs and dispatches an UpdateLinksResponse reply message indicating whether the process was successful or not. If not, an appropriate error message will be returned.
[0174] Next, an UpdateSignature message is constructed for all applications in the Source and Destination sections of the SyncPerson_RQ message, and dispatched to the Integration Engine's Service Adapter. The Service Adapter then adds the date of the synchronization to the Links Table.
[0175] Finally, in response to the UpdateSignature message, the Integration Engine's Service Adapter constructs and dispatches an Output message based on information derived from the SyncPerson_RQ and UpdateLinks_RQ messages.
ALTERNATIVE APPLICATION INTEGRATION FLOWS
[0176] FIGS. 12 - 16 depict alternative integration flows associated with certain aspects of the present invention.
[0177] In each figure, the integrated software architecture is divided into levels, namely several Application levels, a User Interface/Dashboard level, an Integration Services Level and a Data Source Level.
[0178] As shown, the Application level contain standard native applications, namely, Application A, Application B as well as Other Applications. The User Interface/Dashboard Level contain the user interface. The Integration Services level contain the requisite integration components, such as the integration engine and service adapters. Finally, the Data Source Level contains the various data stores that are created, managed and stored for the purposes of synchronizing data across applications.
[0179] Referring back to the figures, FIG. 12 depicts how a user, using a standard application (in this case, Application A), creates a client record for a new person/client/customer/prospect in accordance with the present invention. As evidenced by the illustrated flow, there is no interaction with any of the integration components of the system, that is the Dashboard or the Integration Services, during this process. Because of this, the integration components are unaware of the new client record. This situation would be accounted for in future work-flows by either the user or by the integration software.
[0180] Alternatively, FIG. 13 depicts how a user, using the Dashboard, creates a client record for a new person/client/customer/prospect in accordance with the present invention.
[0181] [0181]FIG. 14 depicts how a user, selects a Working Client using the Dashboard, in accordance with the present invention. This integration flow assumes that the selected Working Client already exists in the Link Table.
[0182] The flow of FIG. 15 depicts synchronization of a linked client and FIG. 16 depicts how links between applications are established.
PRACTICAL APPLICATIONS
[0183] The following sections provide practical applications of the present solution in order to fully appreciate features of the present solution.
[0184] In the use cases that follow, Agent Ms. Angie Baker will begin her workflow by prospecting for a potential customer, a Mr. William R. Brown. Among the various integrated applications on Ms. Baker's Dashboard include: a prospecting, a discovery, an analysis application, an asset allocation application, a product illustrations application and an electronic assistant application. For simplicity, the foregoing applications shall hereinafter be referred to as a CDS application, a DIS application, a PAS application, a PLAM application, an ISP application and EA application, respectively. Ms. Baker's Dashboard also includes one or two external, non-integrated applications, for example, a web browser application such as Microsoft® Internet Explorer®.
[0185] Use Case 1: Creating a New Person and Pushing Information into a Second Application
[0186] This use case can take place over a period of several days or weeks. After prospecting with the CDS application, Ms. Baker meets with a potential customer or prospect, a Mr. William R. Brown, and gathers information about Mr. Brown using the Discovery application. Ms. Baker further analyzes the prospects information using the PAS application.
[0187] To propose insurance policies to the prospect, Ms. Baker moves on to ISP to create illustrations of the products for the prospect. When the prospect chooses an insurance policy and chooses to open an investment account, Ms. Baker uses the PLAM application to capture required investor information. Finally, Ms. Baker uses the EA application to submit the new business information.
[0188] After many days of calling Mr. Brown for a follow-up meeting, Ms. Baker finally sets up an appointment with Mr. Brown. Ms. Baker meets with Mr. Brown and gathers information about Mr. Brown and completes a paper-based Fact Finder on Mr. Brown during the meeting. Ms. Baker returns to her office to enter the Fact Finder data into the Discovery application.
[0189] To begin entering the Fact Finder data into the Discover application, Ms. Baker clicks on the “Search” button of the Dashboard.
[0190] The search dialog appears and Ms. Baker enters the name search criteria, such as “Brown” in the last name field and “William” in the first name field, selects the Source applications she wants to search (e.g. CDS, ISP), and clicks on the “Search” button. After Ms. Baker submits the search request, the results appear as a list of William Brown's found in the selected applications.
[0191] Ms. Baker highlights the William Brown she wants to work with (from the CDS application database in this case since she first entered Mr. Brown's information in the CDS application) based on the information displayed (such as address and Tax ID) and clicks on the “Working Client” button, thereby setting William R. Brown as the current client. The “Working Client: William R. Brown (CDS:)” is then set and indicated in the Status area of the Dashboard. Note: the term “Working Client” refers to both customers and prospects.
[0192] Ms. Baker then clicks on “PAS/Discovery” button. A dialog box opens asking “This action will create information about the Working Client in PAS/Discovery. Do you want to continue?” Ms. Baker sees a “Yes” button, a “No” button, and a check box titled “Don't ask anymore. Just do it.” Ms. Baker has become familiar with the Dashboard interface and checks the “Don't ask” check box. If William R. Brown records were already in the PAS/Discovery applications, the dialog box would have said “This action will update existing information about the working client in PAS/Discovery. Do you want to continue?” The existence of William R. Brown in the PAS/Discovery applications is based on information in the Link Table and therefore a search of the PAS/Discovery database(s) is not done.
[0193] The Integration Engine pulls William R. Brown's information from the CDS application's database and pushes it into the PAS application's database and then launches the Discovery application to displays the newly created William R. Brown record in the Discovery application. Ms. Baker then enters the information from the Fact Finder into the Discovery application for use in the PAS application.
[0194] When Ms. Baker is done entering the information from the Fact Finder into the Discovery application and because it is the end of the day on Friday, Ms. Baker shuts down her computer and heads home for the weekend.
[0195] Use Case 2: Pushing Person Information from One Source Application into Another Destination Application
[0196] On the following Monday, Ms. Baker is scheduled to meet with Mr. Brown for an implementation meeting. During this meeting she will use the ISP application. To save time and eliminate re-keying of data, client specific information from the CDS application will be pushed into the ISP application.
[0197] In preparation for the meeting with Mr. Brown, Ms. Baker turns on her computer, which automatically launches the Dashboard. The Working Client is set to Mr. Brown and the Working/Source Application is still set to the CDS Application as evidenced by the caption “Working Client: William R. Brown (CDS:)” in the Status area of the Dashboard.
[0198] Ms. Baker then clicks on the “ISP” application button on the Dashboard to push information about Mr. Brown from the CDS application into the ISP application. Note: since Ms. Baker previously checked the “Don't ask” check box, no dialog box appears. Thereafter, the ISP application automatically launches and displays Mr. Brown's record.
[0199] Use Case 3: Pushing Client Specific Information from One Source Application into More Than One Destination Application
[0200] The next day, Ms. Baker must use both the PLAM and the EA applications because she successfully sold an insurance policy and an investment account to Mr. Brown. Rather than following an application-by-application workflow, she decides (as a sophisticated user) to populate these applications at the same time with Mr. Brown's information.
[0201] Hence, Ms. Baker turns on her computer, which automatically launches the Dashboard. Again, the Working Client is set to Mr. Brown and the Working/Source Application is set to the CDS Application as evidenced by the caption “Working Client: William R. Brown (CDS)” in the Status area of the Dashboard.
[0202] Using the Dashboard, Ms. Baker clicks on the “Search” button, launching the Search applet. The applet forms are automatically populated with information from the Working Client. Ms. Baker selects the PLAM and EA applications and then clicks on the “Synchronize” button to push Mr. Brown's information from the CDS application to the PLAM and EA applications
[0203] After synchronization is complete, Ms. Baker clicks on the “EA” button, which launches the EA application and displays Mr. Brown's record created in the EA application as a result of the “Synchronize” action. After completing the EA application, Ms. Baker launches the PLAM application through the Dashboard in the same manner.
[0204] Use Case 4: Searching for a Person
[0205] After taking an extended leave of absence from work, Ms. Baker cannot recall who she previously worked on and entered into the various applications.
[0206] Furthermore, during her leave her assistant Ms. Green worked on several cases, which Ms. Baker is unaware of.
[0207] To get up to speed, Ms. Baker turns on her computer, which automatically launches the Dashboard. However, the Working Client is no longer set to Mr. Brown but to a different client.
[0208] When Ms. Baker receives calls from unfamiliar people, she clicks on the “Search” button on the Dashboard and uses the name search function. She can then launch into each application from the list of people displayed in the results area of the search window by double-clicking on a person's row or by highlighting the person and clicking on the “Launch Application” button. Using this method, she can get background information on each person she has searched.
[0209] Use Case 5: Synchronizing Information
[0210] Later that day, Ms. Baker realizes that while she had linked Mr. William R. Brown together, his address information is not the same across all of the applications.
[0211] Thus, Ms. Baker brings up all occurrences of William R. Brown using the Dashboard “Search” button. All of the same William Brown rows are highlighted. She realizes that she missed an occurrence of William R. Brown in another application. She highlights that row as well and then clicks on the “Synchronize” button.
[0212] Ms. Baker confirms that the freshest information is in the CDS application. She knows that the currently highlighted row in the results list will be used as the source of the freshest information. By default, the currently highlighted row is the “Working Client” row. She recognizes the currently highlighted row because it is highlighted differently from the others. The other occurrences of Mr. Brown will be updated with the information from the CDS application.
[0213] After synchronization, the search result list is refreshed with the updated information.
[0214] Finally, FIGS. 17 - 22 are representations of user interface screens depicting aspects of the present invention described hereinabove.
CONCLUSION
[0215] Having now described a preferred embodiment of the invention, it should be apparent to those skilled in the art that the foregoing is illustrative only and not limiting, having been presented by way of example only. All the features disclosed in this specification (including any accompanying claims, abstract, and drawings) may be replaced by alternative features serving the same purpose, and equivalents or similar purpose, unless expressly stated otherwise. Therefore, numerous other embodiments of the modifications thereof are contemplated as falling within the scope of the present invention as defined by the appended claims and equivalents thereto.
[0216] Moreover, the techniques may be implemented in hardware or software, or a combination of the two. Preferably, the techniques are implemented in computer programs executing on programmable computers that each include a processor, a storage medium readable by the processor (including volatile and non-volatile memory and/or storage elements), at least one input device and one or more output devices. Program code is applied to data entered using the input device to perform the functions described and to generate output information. The output information is applied to one or more output devices.
[0217] Each program is preferably implemented in a high level procedural or object oriented programming language to communicate with a computer system, however, the programs can be implemented in assembly or machine language, if desired. In any case, the language may be a compiled or interpreted language.
[0218] Each such computer program is preferably stored on a storage medium or device (e.g., CD-ROM, hard disk or magnetic diskette) that is readable by a general or special purpose programmable computer for configuring and operating the computer when the storage medium or device is read by the computer to perform the procedures described in this document. The system may also be considered to be implemented as a computer-readable storage medium, configured with a computer program, where the storage medium so configured causes a computer to operate in a specific and predefined manner. | There is provided an apparatus, method and article of manufacture for integrating a plurality of applications using a common integration architecture wherein said apparatus, method and article of manufacture employs a Links Table for associating related data thus obviating the need to search cumbersome data stores of integrated applications for pertinent information during synchronization. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to Japanese Patent Application No. 2002-227447 filed Aug. 5, 2002, which application is herein expressly incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a bearing apparatus for rotatably supporting a driving wheel of a vehicle.
BACKGROUND OF THE INVENTION
[0003] A power transmission apparatus transmits power from the vehicle engine to the vehicle wheels. The apparatus enables radial, axial and moment displacements caused by the bound of wheels and the turning of the vehicle during travel. The apparatus includes a drive shaft 100 arranged between the engine and the driving wheel. One end of the drive shaft 100 is connected to a differential gear 102 via a slidable constant velocity universal joint 101 . The other end of the drive shaft is connected to a wheel 105 via a bearing apparatus 104 which includes a fixed type constant velocity universal joint 103 , as shown in FIG. 13.
[0004] A prior art bearing apparatus 104 for a vehicle driving wheel is shown in FIG. 11. The apparatus 104 includes a wheel hub 106 for mounting the wheel 105 , a double row rolling bearing 107 for rotatably support the wheel hub 106 and a fixed type constant velocity universal joint 103 . The universal joint 103 is adapted to be connected to the wheel hub 106 to transmits the power to the wheel hub.
[0005] It is known that torsion is created in the drive shaft 100 by a large torque from the engine, via the slidable constant velocity universal joint 101 , at a low engine speed, such as during starting movement of a vehicle. As a result, torsion is also created on an inner ring 109 of the double row rolling bearing 107 which supports the driving shaft 100 . A stick-slip noise is generated at the abutting surfaces between the outer joint member 108 and the inner ring 109 due to radical slip therebetween when a large amount of torsion exist in the driving shaft 100 .
[0006] A bearing apparatus for a vehicle driving wheel is known for example from Japanese Laid open publication No. 5404/1999. The bearing apparatus has a wheel hub 110 on which the inner ring 109 is fitted. The inner wheel 109 is axially secured by a caulked portion 111 formed on the inner end portion of the wheel hub 110 . The wheel hub 110 and the outer joint member 108 are united by a nut 113 . The outer joint member 108 is fitted in the wheel hub 110 via the serration 112 . The shoulder of the outer joint member 108 is abutted to the inner end surface of the caulked portion 111 .
[0007] Accordingly, the pre-load of the double row rolling bearing 107 can be easily controlled and maintained without strongly fastening the nut 113 as in a conventional manner and also without strictly controlling the fastening torque. In addition, the wheel hub 110 and the outer joint member 108 can be united by lightly tightening the nut 113 . Therefore it is possible to prevent generation of the stick-slip noise at the abutting surfaces between the inner ring 109 and the outer joint member 108 although the torsion would be caused on the outer joint member 108 . However, in such a bearing apparatus for a driving wheel, noise generation or loosening of the nut 113 is sometimes caused during rapid acceleration and deceleration times when circumferential backlash occurs in the fitted portion of the serration 112 . In order to resolve this problem, a helix angle is provided in the serration 112 of the outer joint member 108 . The serration 112 is press fit into the serration 114 of the wheel hub 110 to eliminate the circumferential backlash in the fitted portion. In such a construction, a problem exists in that a machine, such as a press or the like, is required to assemble or disassemble the wheel hub 110 and the outer joint member 108 . This reduces the working efficiency.
[0008] While this structure can maintain the pre-load of the rolling bearing 107 lightly tightened to the nut 113 , another problem is created. A small gap is created at the abutted portion between the wheel hub 110 and the outer joint member 108 . This lowers the sealing performance. If rain water penetrates into the bearing, the serration fitted portion will be rigidly seized by rust, which also reduces the working efficiency.
[0009] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
SUMMARY OF THE INVENTION
[0010] It is an object of the present invention to provide a bearing apparatus for a vehicle driving wheel which has high reliability and an excellent maintenance ability. Thus, a high working efficiency exist in assembling and disassembling the bearing apparatus.
[0011] To achieve the objects of the present invention, a bearing apparatus for a vehicle driving wheel is provided with a double row rolling bearing. A wheel hub is integrally formed with a wheel mounting flange at one end of the double row rolling bearing. A cylindrical stepped portion of smaller diameter axially extends from the other end of the wheel hub. An inner ring is fitted on the stepped portion of smaller diameter of the wheel hub. The inner ring is secured on the wheel hub through a caulked portion formed by plastically deforming the end of the stepped portion radially outwardly. An outer joint member has a shoulder adapted to be abutted to the end surface of the caulked portion. A stem portion axially extends from the shoulder. The outer joint member is inserted in the wheel hub, via a serration fitted portion, to attain a detachable engagement with the wheel hub. The bearing apparatus further comprises a pre-loading mechanism formed in the serration fitted portion between the stem portion of the outer joint member and the wheel hub. A fastening mechanism combines the wheel hub and the outer joint member. A releasing mechanism is adapted to be arranged on the wheel hub to remove the fastening mechanism.
[0012] According to the provision of the pre-loading mechanism formed in the serration fitted portion between the stem portion of the outer joint member and the wheel hub, it is possible to eliminate circumferential backlash and prevent noise generation at rapid acceleration and deceleration times of the vehicle as well as the loosening of the bolt due to the circumferential backlash. In addition it is possible to easily disassemble the bearing apparatus although the serration of the stem portion and the wheel hub is fitted in the pre-load condition. This is due to the provision of the releasing mechanism adapted to be arranged on the wheel hub to remove the fastening mechanism.
[0013] According to the present invention, the serration fitted portion is pre-loaded by providing a helix angle on the serration of the stem portion of the outer joint member. The helix angle has a predetermined angle relative to the axis of the stem portion. This structure provides the pre-load in the serration fitted portion in order to prevent circumferential backlash. This, in turn, prevents noise generation at rapid acceleration and deceleration times of vehicle as well as the loosening of the bolt due to the circumferential backlash. In addition, it is possible to improve sealing performance by preventing fretting abrasion at the caulked portion and the shoulder of the outer joint member.
[0014] According to the present invention, the outer end surface of the wheel hub is formed with an internal thread. The wheel hub and the outer joint member are united by a plate. The plate has a circular aperture formed at a position corresponding to the internal thread. A central aperture is formed with an internal thread. The plate abuts the outer end surface of the wheel hub. A securing bolt is screwed into an internal thread formed in the shaft of the outer joint member through the central aperture of the plate. This structure makes it possible to reduce the weight of the bearing apparatus as well as to easily disassemble the bearing apparatus. This improves the working efficiency in assembling and disassembling the bearing apparatus even though the serration of the stem portion and the wheel hub is fitted in the pre-load condition.
[0015] According to the present invention, the releasing mechanism includes a releasing jig formed with an external thread. An internal thread, which engages the external thread of the releasing jig, is formed on a pilot portion of the wheel hub. Accordingly, it is possible to separate the wheel hub and only mount the releasing jig on the wheel hub by screwing the bolt into the internal thread formed in the center of the releasing jig. Thus, it is possible to improve the working efficiency of assembly and disassembly of the bearing apparatus even though the serration of the stem portion and the wheel hub is fitted in the pre-load condition.
[0016] According to the present invention, the outer end portion of the wheel hub is formed with an annular recess with a tapered internal circumferential surface. The annular recess receives a fastening member formed with a serration on its inner circumferential surface. The diameter of the fastening member is reduced by screwing a securing bolt into an internal thread formed in the stem portion of the outer joint member. Since the fastening member applies the pre-load at the serration fitted portion, it is possible to unite and to pre-load the stem portion and the wheel hub without providing the pre-loading mechanism between the serration fitted portion.
[0017] According to the present invention, the fastening member is a split ring formed with slits arranged along its circumference. Alternatively, the fastening member is formed as a plurality of circumferentially separated parts. This structure reduces the diameter of the fastening member.
[0018] More particularly, according to the present invention, a plurality of slits are formed on either the inner or outer circumferential surface of the fastening member. This structure reduces the diameter of the fastening member and thus also improves the working efficiency during assembly and disassembly of the bearing apparatus.
[0019] According to the present invention, an elastic ring is fitted in an annular space formed between the end surface of the inner ring and the shoulder of the outer joint member. One end of a pulsar ring is arranged on the shoulder of the outer joint member engaging the elastic ring. This structure prevents the plastic ring from falling off as well as remarkably improving the sealing performance between the end surface of the inner ring and the shoulder of the outer joint member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0021] [0021]FIG. 1 is a longitudinal section view showing a first embodiment of the bearing apparatus for a driving wheel of the present invention;
[0022] [0022]FIG. 2 is a cross section view showing a releasing jig of the present;
[0023] [0023]FIG. 3 is an enlarged partial cross section view of FIG. 1 of the bearing apparatus for a driving wheel of the present invention;
[0024] [0024]FIG. 4 is a longitudinal section view of the bearing apparatus for a driving wheel of the present invention of the first embodiment for explaining a method of disassembling;
[0025] [0025]FIG. 5 is a longitudinal section view showing a second embodiment of the bearing apparatus for a driving wheel of the present invention;
[0026] [0026]FIG. 6 is a longitudinal section view of the bearing apparatus for a driving wheel of the present invention of the second embodiment for explaining a method of disassembling;
[0027] [0027]FIG. 7( a ) is a front elevation view showing an another releasing jig of the present, and FIG. 7( b ) is a cross section view;
[0028] [0028]FIG. 8 is a longitudinal section view showing a third embodiment of the bearing apparatus for a driving wheel of the present invention;
[0029] [0029]FIG. 9( a ) is a front elevation view showing one embodiment of the fastening member of the present invention, and FIG. 9( b ) is a cross section view thereof;
[0030] FIGS. 10 ( a ), ( b ) and ( c ) are front elevation views showing other embodiments of the fastening members;
[0031] [0031]FIG. 11 is a longitudinal section view showing a bearing apparatus for a driving wheel of the prior art;
[0032] [0032]FIG. 12 is a longitudinal section view showing another bearing apparatus for a driving wheel of the prior art;
[0033] [0033]FIG. 13 is a longitudinal section view showing one example of power transmission apparatus into which a bearing apparatus for a driving wheel is incorporated.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] Preferred embodiments of the present invention will be hereinafter described with reference to the accompanied drawings. FIG. 1 is a longitudinal section view showing a first embodiment of a bearing apparatus for a vehicle driving wheel of the present invention.
[0035] The apparatus has a wheel hub 1 , a double row rolling bearing 2 and an constant velocity universal joint 3 which are assembled as a unit. In the description below, the term “outboard side” of the apparatus denotes a side which is positioned outside of the vehicle body. The term “inboard side” of the apparatus denotes a side which is positioned inside of the body when the apparatus is mounted on the vehicle body.
[0036] The wheel hub 1 is formed integrally with a wheel mounting flange 4 at the outboard side of the wheel hub 1 on which a wheel (not shown) is mounted. The wheel hub 1 has an inner raceway surface 1 a at the outboard side of the double row rolling bearing 2 . A cylindrical stepped portion 1 b of smaller diameter axially extends from the inner raceway surface 1 a . The outer circumferential surface of the wheel hub 1 , from the inner raceway surface 1 a to the cylindrical stepped portion 1 b , is formed with a hardened layer having a surface hardness of HRC 54˜64. It is preferable to use a high frequency induction heating as a heat treatment which can easily carry out a local heating and setting of the depth of a hardened layer. The end of the stepped portion is not hardened and has a surface hardness less than HRC 25 to enable the end to be plastically deformed to form caulked portion 6 .
[0037] The stepped portion 1 b of small diameter of the wheel hub 1 is press fit with an inner ring 7 to form a so-called “third generation” structure. The inner ring 7 is immovably secured in an axial direction. The outer circumferential surface of the inner ring 7 is formed with inner raceway surface 7 a at the inboard side of the double row rolling bearing 2 to form a double row inner raceway surface of the bearing 2 .
[0038] The double row rolling bearing 2 has an outer member 8 , inner member 9 and a double row rolling elements 10 and 10 . The outer member 8 is integrally formed on its outer circumferential surface with a body mounting flange 8 a . On its bore surface, the outer member 8 has a double row outer raceway surfaces 8 b and 8 b . On the other hand, the inner member 9 has the wheel hub 1 and the inner ring 7 . The double row rolling elements 10 and 10 are contained between the outer raceway surfaces 8 b and 8 b and the inner raceway surfaces 1 a and 7 a . The rolling elements 10 are freely rotatably held by cages 11 and 11 . Seals 12 and 13 are arranged at the ends of the bearing 2 to prevent leakage of grease contained within the bearing 2 as well as ingress of rain water or dusts. The illustrated ball rolling elements 10 and 10 may be replaced for example by conical rolling elements.
[0039] The constant velocity universal joint 3 has an outer joint member 14 , a joint inner ring 15 , a cage 16 and torque transmitting balls 17 . The outer joint member 14 has a cup-shaped mouth portion 14 a , a shoulder 14 b that forms the bottom of the mouth portion 14 a , and a stem portion 18 which axially extends from the shoulder 14 b . The outer circumferential surface of the stem portion 18 is formed with a serration (or a spline) 18 a . An external thread 18 b is formed on the inner circumferential surface of the stem portion 18 . The serration 18 a of the stem portion 18 is formed with a helix angle of a predetermined angle relative to the axis of the stem portion 18 .
[0040] The serration 18 a of the stem portion 18 is fitted into the serration 5 of the wheel hub 1 by inserting the stem portion 18 into the wheel hub 1 until the shoulder 14 b of the outer joint member 14 abuts the inner end surface of the caulked portion 6 . Thus a pre-load is caused at the fitted portion of the serrations of the wheel hub 1 and the stem portion 18 in order to eliminate circumferential backlash. Finally the wheel hub 1 and the outer joint member 14 are axially united by screwing a securing bolt 20 into the internal thread 18 b via a plate 19 abutting onto the outer end surface 1 c of the wheel hub 1 . In this case, the stem 18 can be easily fitted into the serration 5 of the wheel hub 1 if the fitted length is less than ½˜⅓ the whole length of the serration 18 a of the stem portion 18 . Accordingly, the stem portion 18 of the outer joint member 14 can be inserted into the wheel hub 1 by fastening the bolt 20 .
[0041] Alternatively, the serration 18 a of the stem portion 18 , with the helix angle, in order to apply the pre-load to the fitted portion with the serration 5 of the wheel hub, it is possible to appropriately set the tooth thickness of the serrations 18 a and 5 of the stem portion 18 and the wheel hub 1 , respectively, to apply the pre-load at their fitted portions.
[0042] One embodiment of the releasing jig 19 ′ used for disassembling the bearing apparatus to repair it is formed as a plate shaped configuration as shown in FIG. 2. The jig 19 ′ has an internal thread 19 a to engage the securing bolt 20 at the center. The jig 19 ′ also has a plurality of circular apertures 19 b near its periphery. Internal threads Id are formed on the outer end surface of the wheel hub 1 at positions corresponding to those of the circular apertures 19 b of the releasing jig 19 ′.
[0043] An elastic ring 21 is inserted around the caulked portion 6 of the wheel hub 1 in an annular space formed between the inner ring 7 and the shoulder 14 b . The elastic ring 21 is pressed down by a pulsar ring 22 for ABS (Anti-lock Brake System) press fit onto the outer circumferential surface of the shoulder 14 b to prevent the elastic ring 21 from coming out of the annular space. The pulsar ring 22 is formed by press forming a steel plate and is formed with a plurality of irregularities 22 a to detect the rotation speed using an oppositely arranged sensor. The pulsar ring may be integrally heat bonded to the elastic ring or may be inserted into an annular recess 21 a formed in the elastic ring 21 ′ as shown in FIG. 3.
[0044] According to this embodiment, the rolling bearing adopts a so-called “self-retain structure” in which the inside gap of the rolling bearing 2 is a negative gap to improve the rigidity of the bearing. The inner ring 7 is axially secured by the caulked portion to maintain the negative gap. Accordingly, this structure makes it possible, not only to sub-unitize the bearing portion, but to easily incorporate a bearing portion to a vehicle because it is unnecessary to control the pre-load by setting the fastening torque. In addition it is possible to prevent loosening of bolt 20 because of the application of the pre-load at the serrations 5 and 18 a to eliminate the circumferential backlash. Also, it is possible to prevent ingress of rain water or dusts through a gap between the caulked portion 6 and the shoulder 14 b . Furthermore, it is possible to remarkably improve the sealing performance between the caulked portion 6 and the shoulder 14 b because of the presence of the elastic ring 21 inserted in the annular space formed between the inner ring 7 and the shoulder 14 b.
[0045] A method for disassembling the bearing apparatus of the first embodiment will be described with reference to FIG. 4. First, the bolt 20 and the plate 19 fastened onto the outer end surface 1 c of the wheel hub 1 are removed. The bolt 23 is screwed into the stem portion 18 of the outer joint member 14 in order to plug the internal threaded aperture 18 b . Any member may be used in place of the bolt 23 so as to plug the aperture 18 b . The releasing jig 19 ′ is abutted onto the outer end surface 1 c of the wheel hub 1 and aligning the circular aperture 19 b with the internal thread 1 d formed on the outer end surface 1 c . The bolt 24 is screwed into the internal thread 1 d so as to secure the releasing jig 19 ′ on the outer end surface 1 c . Finally, the securing bolt 20 is screwed into the internal thread 19 a of the releasing jig 19 ′. Continuing the screwing operation, the tip end of the bolt 20 abuts on the head of bolt 23 and thus the outer joint member 14 will be gradually pushed out from the wheel hub 1 . Thus, according to the bearing apparatus of the present invention, it is possible to reduce its weight and to assure its reliability compared with the bearing apparatus of the prior art. In addition it is possible to easily assemble and disassemble the bearing apparatus and thus to improve the maintenance working efficiency.
[0046] [0046]FIG. 5 is a longitudinal section view showing a second embodiment of the bearing apparatus for a driving wheel of the present invention. The only difference between this embodiment and the first embodiment is in the structure of the stem portion of the outer joint member and therefore like numerals are used to designate like structure also in FIG. 5.
[0047] The stem portion 26 of the outer joint member 25 in the constant velocity universal joint 3 ′ is formed with a serration (or spline) 26 a at the circumferential surface. A threaded portion 26 b is formed at the end. Similarly to the first embodiment, the helix angle is applied to the serration 26 a inclined at a predetermined angle relative to the axis of the stem portion 26 . In order to apply the pre-load to the fitted portion of the serrations 5 and 26 a and thus eliminate circumferential backlash, the stem portion 26 is fitted into the wheel hub 1 ′ with the serration 26 a of the stem portion 26 press fit into the serration 5 of the wheel hub 1 ′ until the shoulder 14 b abuts the inner end surface of the caulked portion 6 of the wheel hub 1 ′. Finally the wheel 1 ′ and the outer joint member 25 are axially united by screwing the securing nut 27 into the threaded portion 26 b of the stem portion 26 . A numeral 27 a denotes a caulked portion to engage notched portions formed at the tip end of the stem portion 26 to form a detent of the securing nut 27 .
[0048] A method for disassembling the bearing apparatus of the second embodiment will be described with reference to FIG. 6. First, the securing nut 27 fastened onto the outer end surface 1 c of the wheel hub 1 ′ is removed. The caulked portion 27 a of the securing nut 27 is deformed. A releasing jig 28 is inserted within a pilot portion le of the wheel hub 1 ′. The inner circumferential surface is formed with an internal thread 29 and the outer circumferential surface of the releasing jig 28 is formed with an external thread 28 a to engage with the internal thread 29 . FIG. 7( a ) is a front elevation view of the releasing jig 28 . FIG. 7( b ) is a cross section view. The releasing jig 28 has a generally cup-shaped configuration and is formed with a flat chamfered surface 28 b on its bottom and a internal thread 28 c at its center.
[0049] The bolt 30 is screwed into the internal thread 28 c of the releasing jig 28 . The tip end of the bolt 30 abuts the stem portion 26 . Thus, the outer joint member 25 is pushed out from the wheel hub 1 ′ so as to secure the releasing jig 19 ′ on the outer end surface 1 c.
[0050] [0050]FIG. 8 is a longitudinal section view showing a third embodiment of the bearing apparatus for a driving wheel of the present invention. The only difference between this embodiment and the first embodiment is in the structure of the stem portion of the outer joint member. Thus, like numerals are used to designate like structure in FIG. 8.
[0051] The stem portion 26 of the outer joint member 25 is formed with a serration (or spline) 26 a at the circumferential surface. A threaded portion 26 b is at the end. On the other hand, the outer end portion of the wheel hub 31 is formed with an annular recess 33 to receive a fastening member 32 . The inner circumferential surface of the annular recess 33 is formed with a tapered surface 33 a . The tapered surface has a taper angle larger than the wedge angle. The outer circumferential surface of the fastening member 32 is also formed with a tapered surface 32 a corresponding to the tapered surface 33 a . As shown in FIG. 9, the fastening member 32 is a split-ring having one slit on its circumference. The fastening member 32 has a serration 32 c formed on its inner circumferential surface. The serration 32 c engage a serration 26 a of the stem portion 26 .
[0052] As shown in FIG. 8, the securing nut 27 is screwed on the threaded portion 26 b formed on the end portion of the stem portion 26 . The fastening member 32 is moved axially inward and thus reduces its diameter by the tapered surface 33 a of the wheel hub 31 . Thus the serration 32 c of the fastening member 32 is strongly fastened onto the serration 26 a of the stem portion 26 to apply the pre-load to the fitted portion of the serrations 32 c and 26 a . Accordingly, circumferential backlash at the fitted portion can be eliminated.
[0053] The power from the constant velocity universal joint 3 ′ is transmitted to the serration 32 c of the fastener 32 , via the serration 26 a of the outer joint member 25 , and then to the wheel hub 31 , via the friction between the tapered surfaces 32 a and 33 a . If the power is large enough to overcome the friction, it can be transmitted to the wheel hub 31 , via the serrations 26 a and 5 . In disassembling the bearing apparatus, the fastening member 32 can be easily removed from the wheel hub 31 by only removing the securing nut 27 . This is due to the tapered surfaces 32 a and 33 a of the fastening member 32 and the wheel hub 31 being formed to have a tapered angle larger than the wedge angle.
[0054] The fastening member 32 may be formed in many other configuration for example as shown in FIG. 10. It is of course that each of these fastening members has a tapered surface similar to that shown in FIG. 9.
[0055] A fastening member 34 shown in FIG. 10( a ) has a two-piece structure in which a serration 34 a and a plurality of slits 34 b are formed on its inner circumferential surface. A fastening member 35 shown in FIG. 10( b ) is also a two-piece structure with serration 35 a formed on its inner circumferential surface and a plurality of slits 35 b formed on its outer circumferential surface. A fastening member 36 shown in FIG. 10( c ) is a simple two-piece structure with only a serration 36 a formed on its inner circumferential surface. Other structure for example that separate into more than three pieces may be adopted.
[0056] As described above, since it is possible to obtain the pre-loaded fitted condition between the serration 26 a of the stem portion 26 and the serration 32 c of the fastening member 32 by fastening the securing nut 27 and reducing the diameter of the fastening member 32 , it is possible to dispense with the helix angle on the serration 26 a of the stem or to make the helix angle small. This further improves the working efficiency in the assembling or disassembling operation.
[0057] It is intended that the present invention is construed as including all alternations and modifications insofar as they come within the scope of the appended claims or their equivalent. | A bearing apparatus for a vehicle driving wheel has a pre-loading mechanism formed in the serration fitted portion between the stem portion of the outer joint member and the wheel hub. A fastening member combines the wheel hub and the outer joint member. A releasing member, adapted to be arranged on the wheel hub, enables removal of the fastening mechanism. | 5 |
FIELD OF THE INVENTION
This invention relates generally to screened enclosures for creating a bug-free environment and more particularly to a screen room having roof panels that can be made to pivot between an enclosure-covering roof position and a vertical disposition.
DISCUSSION OF THE PRIOR ART
During summer months in many areas, it is difficult to enjoy being out-of-doors because of mosquitoes and other flying and biting insects. So-called screen houses or screen rooms have been designed for use in a patio or in the yard to provide an environment where evening breezes can be enjoyed, but insects are blocked from entering the screened space.
Screen rooms of the prior art typically comprise a plurality of individual screened wall panels mounted on a framework to define a rectangular or other polygonal interior space with a screened entry door. A roof structure commonly comprises a water-impervious fabric overlaying the wall arrangement. This design offers the advantage of sheltering the occupants and/or furniture from rain, but it renders the structure vulnerable to strong winds. For this reason, screen rooms have also been designed to have the roof structure also comprise screened panels which are effective to preclude insect entry, but also are significantly less vulnerable to damage from strong winds than a water impervious fabric roof.
The use of screened roof panels on screen rooms has created a different problem in climates where winter snow can be expected to fall. Screen rooms of practical size necessarily incorporate screened roof panels of appreciable area and the weight of wet snow thereon can readily distort and even collapse the frame structure of the screen room. This has necessitated the disassembly of such screen rooms in the fall of the year and erection again the following spring.
The present invention employs a simple, yet highly novel and non-obvious technique for obviating this problem.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a screen room with a framework defining an enclosure to which is mounted a plurality of vertical, screened side walls and supporting a plurality of screened roof panels where the screened roof panels are pivotally joined to the framework for movement between an enclosure-covering disposition and a vertical orientation. When in the vertical orientation, only a miniscule surface area is exposed to snow loads.
DESCRIPTION OF THE DRAWINGS
The foregoing features, objects and advantages of the invention will become apparent to those skilled in the art from the following detailed description of a preferred embodiment, especially when considered in conjunction with the accompanying drawings in which like numerals in the several views refer to corresponding parts.
FIG. 1 is an exterior, perspective view of a screen room incorporating the present invention;
FIG. 2 is a partial interior view of the screen room of FIG. 1 showing a corner portion of the room with the roof panel in its enclosure covering disposition; and
FIG. 3 is an interior view of the screen room like that of FIG. 2 , but with one of the roof panels in its vertical (winter) orientation.
DESCRIPTION OF THE PREFERRED EMBODIMENT
This description of the preferred embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description of this invention. In the description, relative terms such as “lower”, “upper”, “horizontal”, “vertical”, “above”, “below”, “up”, “down”, “top” and “bottom” as well as derivatives thereof (e.g., “horizontally”, “downwardly”, “upwardly”, etc.) should be construed to refer to the orientation as then described or as shown in the drawings under discussion. These relative terms are for convenience of description and do not require that the apparatus be constructed or operated in a particular orientation. Terms such as “connected”, “connecting”, “attached”, “attaching”, “join” and “joining” are used interchangeably and refer to one structure or surface being secured to another structure or surface or integrally fabricated in one piece, unless expressively described otherwise.
Referring to FIG. 1 , there is shown a perspective, exterior view of a screen room that incorporates the present invention. The screen room is identified generally by numeral 10 and is seen to comprise a generally rectangular enclosure having a front wall 12 , a rear wall 14 and opposed end walls 16 and 18 . Each of these side and end walls comprises a plurality of screened panels, as at 20 , disposed in side-by-side relationship and held in place by a framework comprising a plurality of extruded aluminum gable members 22 disposed in a parallel and spaced-apart relationship by elongated roof ridge divider bars 24 extending therebetween. The gable members 22 each comprise left and right vertical posts 26 and 28 with roof panel supporting rafters 30 and 32 connected at a predetermined slope angle to an upper end of the posts, the rafters 30 and 32 being joined together at their free ends along a roof ridge line 34 . Brackets 35 fastened to the roof supporting rafters at the junction where the ends come together are used to mount the ridge divider bars 24 in place between adjacent pairs of roof rafters.
Without limitation, the screen room may measure up to 40 feet wide by as long as the customer wants in five feet increments, where each of the walls comprise a plurality of screen panels 20 that are approximately 5 feet in width and 7 to 20 feet in height. One of the panels may comprise a screened entry door shown, at 37 in FIG. 1 .
Each of the screen panels 20 has a rectangular frame comprising extruded aluminum top rails 36 and bottom end rails 38 and left and right side rails 40 , 42 , respectively. The rails are joined to one another by screw fasteners (not shown) and supporting a mesh screening material, such as 0.013 in. yarn diameter fiberglass mesh covering the rectangular frame opening.
As seen in FIG. 1 , each of the opposed gabled end walls supports a pair of right angle triangular trusses 44 , 46 with their vertical legs in abutting relationship. Aluminum ridge divider bars 24 extend between the triangular screened trusses at the room's opposed front and rear walls.
Roof screen panels, as at 48 , are pivotally supported between the triangular screen trusses and the roof panel supporting rafter 30 , 32 of an adjacent gable member, as well as between each of the roof panel supporting rafters of adjacent gable members that are disposed between the opposed end walls 16 and 18 by means of pivot pins 50 and 50 ′ joining the roof screen panels 48 to the rafters 30 , 32 on opposed sides of the roof screen panels 48 .
During summer months, the roof screen panels are pinned in place in linear alignment with the roof rafters of adjacent gable members to thereby create a pitch roof that blocks entry of insects into the interior of the assembled screen room 10 . In late fall, before a first snowfall is expected, the owner need only remove a retainer pin 49 ( FIG. 2 ) that extends through the side rails 40 and 42 of the roof screen panels and into an aligned bore in an adjacent gable rafter 30 , thereby allowing the roof screens to swing down about pivot pins 50 , 50 ′ into a vertical disposition, as shown in FIG. 3 , such that there can be no buildup of a snow load on the roof of the screen room. Again, the retainer pin 49 may now be inserted through aligned holes in screen rail 42 and the gable post 26 or 28 to releasably latch the now vertical screened panel to an adjacent vertical gable post to prevent it from swinging in the wind. In the spring, the owner can again elevate the roof screen panels 48 to their roof covering position by first removing the retainer pins 49 and rotating the roof covering screen panels about pivot pins 50 , 50 ′ and reinserting the pivot pins into holes in the rafters 30 , 32 .
Those skilled in the art can appreciate that the screen room needs not have a square base, but may comprise a rectangle or other polygonal shape. In the case of an octagonal-shaped gazebo structure, the roof panels are designed to be triangular in a plan view and would be pivotally mounted between an adjacent pair of roof panel supporting rafters.
This invention has been described herein in considerable detail in order to comply with the patent statutes and to provide those skilled in the art with the information needed to apply the novel principles and to construct and use such specialized components as are required. However, it is to be understood that the invention can be carried out by specifically different equipment and devices, and that various modifications, both as to the equipment and operating procedures, can be accomplished without departing from the scope of the invention itself. | An outdoor screen room for creating a bug-free environment comprises a plurality of upright screened sidewalls held in a framework that also supports a plurality of screened roof panels that are pivotally attached to the framework, allowing them to be shifted between an enclosure-covering disposition for summer use and a vertical disposition during winter months when snow loads on a horizontal or a slightly pitched roof may be a problem. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the priority of U.S. Provisional Patent Application Ser. No. 60/679,509, filed May 10, 2005, and entitled One-Piece, Tubular Member with an Integrated Welded Flange.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] Federal Regulators and Consumer Advocates are requesting higher performance in rollover, side, and frontal impacts. Their objectives are to increase buckling strength to 2.5 times vehicle weights to maintain the integrity of the passenger door apertures and passenger compartment during higher speed impacts.
[0004] The present invention relates to the manufacture of automotive impact and structural components. More, particularly, the invention discloses a front pillar structure of a vehicle adapted to reinforce the front pillar through stiffening or by way of a device for increasing the strength of a hollow shaped front pillar, which has a closed cross-section.
[0005] Typically, the automotive engineer strives to increase the strength of the roof rails, pillars, and bows while attaching this structure to a stiff foundation (e.g. frame or uni-body components). Traditional solutions usually included adding multiple sheet metal stampings of higher gage with strength, which were limited to the formability process. A tubular product always has been superior in torsional stiffness and strength; however, it could not be feasibly packaged, or attached to a non-cylindrical cavity in the vehicle, such as the pillars, which the present invention presumes to solve.
[0006] 2. Description of the Prior Art
[0007] Present construction of roof rails, roof headers, rocker reinforcements, front shot-gun structure, and radiator supports, are traditionally made of several stampings comprising a portion of a structural automotive body. Recently, roof structures and radiator supports have began replacing stampings as a one-piece component made by the hydroform process.
[0008] An example of a hydro-formed space frame exhibiting a pair of laterally spaced, and longitudinally extending side rail structures is set forth in U.S. Pat. No. 6,926,350, issued to Gabbianelli et al., and which also includes a pair of forward-most upright structures, each connected to a respective side rail structure, to thereby form a pair of A-pillars. A pair of roof rail structures are included, a forward end of each being connected to an upper end of an associated A-pillar, a rearward ring assembly connected at upper portions thereof with the roof rail structure and at bottom portions thereof with the side rail structures. The rearward ring assembly further includes a tubular hydroformed and inverted U-shaped upper member having a cross portion and a pair of leg portions extending downwardly from opposite ends of the cross portion, a pair of tubular hydroformed side members, and a cross structure rigidly connected in ring-forming relation between the second ends of the side members.
[0009] U.S. Patent Application Publication No. 2005/0088012, to Yoshida, teaches a vehicle front pillar with inner and outer frame members joined into a substantially tubular shape. A fore portion of the inner frame member is oriented toward the front of the vehicle and has at least one bent portion formed thereon so as to serve as a shock absorbing section. A rear portion of the inner frame member is oriented toward the back of the vehicle and has a reinforced member of a closed sectional structure attached thereto so as to serve as a high-rigidity section. The reinforcing member may have a circular or rectangular cross-sectional shape.
[0010] Finally, Yamamoto et al., U.S. Pat. No. 6,692,065, teaches a framing structure for arrangement around a vehicle door opening produced by a hydraulically tube-formed tubular framework disposed inside the vehicle door opening to form a basic framing. An outer panel us joined to the tubular framework by welding. The inner side of the tubular framework is an inner wall within the vehicle. The outer side of the tubular framework, facing the outer panel, is a stiffening wall. The stiffening wall is hidden within a closed spaced between the outer panel and the inner wall.
SUMMARY OF THE PRESENT INVENTION
[0011] The present invention discloses an elongated structural member and associated method for producing, and which is created according to any of a roll-forming, extrusion manufacturing, or hydroforming process, the structural member incorporating either an integrally formed or welded on flange hemmed over, providing a flange to spot-weld additional body panels, e.g., door, window mounting structure or other structure panels, to the structural member. The closed section rolled components, defining the elongated structural member, replace a multi-piece stamped construction with a simple single piece section and can either be rolled or extruded straight, or stretch bent into a curved or compound curved environment.
[0012] The present construction eliminates individual components or steps within the manufacturing process of automobile impact and structural component, such as, increases in steel gages, additional reinforcement members, and/or complex manufacturing operations. This in turn increases tooling and handling costs associated with conventional manufacturing processes as provided in the prior art.
[0013] Typical roof structures include an A-pillar, a roof rail, and B or C pillars for vehicle reinforcement. The present invention combines these commonly individual members by forming a one-piece structural member with integral weld flanges. Additional to pillar applications, the elongated structural member of the present invention may also be reconfigured for application to a lower rocker panel application.
[0014] The one-piece roll formed and stretch-bent component, (or otherwise fixture formed structural component), replaces (in the disclosed application) the following components of a roof rail system: 1) an inner A-pillar panel, 2) an outer A-pillar panel, 3) an A-pillar reinforcement, 4) an inner-side roof rail panel, 5) an outer-side roof rail panel, 6) an A-pillar extension, and 7) a C-pillar reinforcement, all used in typical body structure constructions. As a result, the present invention has a tooling advantage where it eliminates many stamped tool dies, weld machines, weld fixtures, and checking fixtures and also provides a weight advantage, if the martensitic alternative should it be required.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Reference will now be made to the attached drawings, when read in combination with the following detailed description, wherein like reference numerals refer to like parts throughout-the several views, and in which:
[0016] FIG. 1 is a side view of a one-piece, tubular member with an integrated welded flange;
[0017] FIG. 2 is a close-up of FIG. 1 showing a section of the one-piece, tubular member with an integrated welded flange;
[0018] FIG. 3 is a perspective view of a one-piece, single flanged, tubular pillar with a welded additional flange; and
[0019] FIG. 4 is a cross section, taken along line A-A in FIG. 1 , of the one-piece, single flanged, tubular pillar with a welded additional flange according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] Referring to accompanying drawings, a preferred embodiment of the present invention will now be described as follows. A roof structure, generally illustrated at 40 , ( FIG. 1 ), includes an A-pillar section 10 , a roof rail section 42 , and a B-pillar or C-pillar section 60 .
[0021] FIG. 2 presents an enlarge sectional view of that shown in FIG. 1 , of the A-pillar section 10 and which includes a one-piece tubular member 8 and a welded flange member 30 . The one-piece tubular member 8 replaces the inner and outer side panels associated with conventional A-pillars and roof rails and the additional A-pillar extension member, thereby reducing the manufacturing and assembly costs of additional parts and forming steps.
[0022] The tubular shape of the roof structure 40 increases the structural integrity of the entire member and as a result, the strengthened roof structure 40 eliminates the need of an additional A-pillar reinforcement insert. As was further previously described, the elongated structural member of the present invention is also suitable for incorporation into other applications, not limited to rocker panels, bumper configurations, and the like.
[0023] The one-piece tubular member is further not limited to being employed over the length of the entire roof structure 40 . In variations of the roof structure 40 , the one-piece tubular member 8 may be limited in length to the A-pillar section 10 , the roof rail section 42 , and/or the B or C pillar sections 60 . The above said, forming these sections separately requires additional welding and/or bonding subsequent steps to join the members together, and which may increase manufacturing costs.
[0024] Referring further to FIG. 4 (as well as also to the perspective view of FIG. 3 ), the cross-section of the A-pillar section 10 , taken across the A-A cross section of the roof structure 40 ( FIGS. 1-2 ), again illustrates the one-piece tubular member 8 and the welded flange member 30 , each which is formed of steel. The one-piece tubular member 8 ( FIG. 4 ) includes a top wall 24 , an outer panel 26 , and an inner panel 28 , these typically being formed as a one-piece member, and then subsequently bent to close the pillar structure. The outer panel 26 further includes a side wall 14 , a bottom wall 18 , and a flange wall 20 , whereas the inner panel 28 further includes side walls 14 ′ and 14 ″, a bottom wall 15 ′, and a flange wall 12 , with a top wall 16 joining the outer and inner panels.
[0025] After the subsequent bending of the roll-formed sheet metal, the one-piece tubular member 10 obtained exhibits a closed, and thereby polygonal shaped, e.g. such as any multi-sided article including triangular, rectangular, pentagonal, hexagonal, etc., section by, such as by welding as referenced at 22 , this further creating an integral flange between the respective outer and inner flange walls 20 and 12 for supporting a vehicular component. In doing so, the one-piece tubular member 10 forms a first selected and integrally formed (e.g. door seal) flange, see as further generally referenced at 50 . The door seal flange 50 includes a door seal 52 (see again FIG. 4 ) surrounding the outer flange wall 20 and inner flange wall 12 .
[0026] The top wall 16 of one-piece tubular member 8 , ( FIG. 4 ), is further joined to the bottom wall 32 of the welded flange member 30 through weld 24 , applied therebetween. As a result, an associated leg of the welded flange member 30 further extends upward from the one-piece tubular member 10 , this forming a side wall 34 upon which may be supported a glass window, (not illustrated), and which may further be added to the one-piece tubular member 8 in a subsequent manufacturing step.
[0027] The subsequent attachment step of the secondary (welded) flange member 30 can also be eliminated if the one-piece tubular member 8 is limited in length to the A-pillar section 10 or does not extend the full length of the roof structure 40 , ( FIG. 1 ). The above said, a preferred embodiment envisions that a single configured and integrated flange (such as illustrated at 50 and produced by configured portions 12 and 20 ) is capable of being created by the roll forming of the desired steel sheet material.
[0028] As further again referenced in FIG. 3 , a selected portion of either wall 12 or 20 (and referenced by wall portion 12 ′ defined by axially extending phantom line 23 ) is desirously sectioned along and outside of the weld location 22 . The purpose for doing this is to reduce the overall thickness of the flange wall (i.e. from a two-wall to a single wall thickness), this in order to provide improved structural integrity as it is found that a two layer welded assembly exhibits superior holding properties as compared to a three layer configuration.
[0029] Given further the limitations associated with roll forming techniques, it is typically understood that any additional flanges (e.g. such as that shown at 30 ) are separately installed such as by welding. However, the present invention does envision forming configurations and/or applications (roll forming, hydro-forming or the like) whereby more than flange may be integrally formed into an elongated structural member produced according to the present invention.
[0030] The polygonal cross-section of the one-piece tubular member 10 , (again FIG. 4 ), is again not limited to the preferred embodiment of the present invention. Due to ever changing demands for vehicle styling, the need for stronger vehicle members and smaller packaging is essential. As a result, in many situations, variable cross-sections and contrasting outer and inner pillar panels are highly desired. Roll-forming, among other desirable forming techniques, allows and enables variations in outer and inner pillar panel construction.
[0031] Given the above structural description, the method of forming of the roof structure 40 , (again FIG. 1 ), will now be briefly summarized. The one-piece tubular member and welded flange member are preferably formed from thin steel sheet, which during the roll forming process is a substantially continuous sheet supplied from a large coil. The width of the steel sheet is selected based on the desired finished dimension of the tubular and welded flange members to permit the creation of single or multiple members simultaneously. The initial width of the flat steel sheet, as provided in the coil, thus substantially corresponds to the width of the predetermined quantity of members if flattened out into a planar condition.
[0032] The flattened steel sheet is supplied from the coil into a roll-forming mill, which, in a conventional and known manner, progressively reforms the flat steel sheet as it passes through the mill so that, upon leaving the mill, the steel sheet is longitudinally formed. The continuous corrugated sheet is then fed to a cut-off press, which cuts the continuous corrugated sheet at desired spaced distances corresponding to the desired lengths of the finished roof structure(s).
[0033] In a further step, the roof structure(s) is heated at an elevated temperature, which is sufficient to bring about a metallurgical transformation in the metallic members loaded therein. In the preferred method, this metallurgical is an austenizing transition, and in that regard, the parts are heated to a temperature in excess of 900° C.
[0034] Following the appropriate heat treatment the roof structure(s) is quenched. The quench fluid is typically a liquid, and generally a water-based liquid, although other quenching media may be employed in the art. The quenching step hardens the metal and locks in the shape imposed thereupon by the forming (roll-forming) step. The resultant structural member consists of Ultra High Strength Steel (UHSS) and therefore has a smaller gage thickness and more importantly requires less package spacing. As a result, the UHSS pillar more efficiently meets vehicle impact standards while the conventional prior-art low-strength steel member requires a thicker gage and/or additional reinforcement structures to meet the same vehicle standards.
[0035] Although a particular preferred embodiment of the invention has been disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the present invention and without departing from that of the appended claims. | A structural supporting roof pillar for use in a vehicle including an elongated, interiorly hollowed and polygonal shaped body having a selected arcuate lengthwise configuration and corresponding in placement to at least one of an A, B, and C vehicle pillar. A first component supporting flange is integrally formed, such as by overlapping end portions of a roll formed body, and projecting in at least a partially lengthwise extending fashion from a given cross sectional location. A secondary component supporting flange is affixed to a further cross sectional location associated with the body, such as further by welding. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a fuel supply device for an internal combustion engine.
Fuel supply devices of this type are disclosed for example in the publication “Dieselmotor Management”, Verlag Vieweg, 2 edition 1999, pages 262-263. The fuel supply device has a feed pump which supplies the fuel from a supply container to a high pressure pump. With the high pressure pump, the fuel is supplied under high pressure at least indirectly to injection points on the internal combustion engine. The feed pump is driven mechanically by the internal combustion engine. During start of the internal combustion engine the feed pump is driven with a low rotary speed, so that the fuel quantity supplied by it in this condition is not sufficient to provide a reliable start of the internal combustion engine. In particular, at high fuel temperatures and low rotary speeds of the internal combustion engine, for example because of a not sufficient voltage of the board current source, the feed pump does not supply sufficient fuel quantity. The feed pump can be modified so that it supplies a greater fuel quantity, but in other operational conditions then the required fuel quantity will be too high and must be uselessly withdrawn.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a fuel supply device for an internal combustion engine, which avoids the disadvantages of the prior art.
In keeping with these objects and with others which will become apparent hereinafter, one feature of present invention resides, briefly stated, in a fuel supply device for an internal combustion engine which has a supply container, at least one feed pump for supplying a fuel from the supply container, a high pressure pump to which the fuel is supplied from the supply container by the feed pump, so that the fuel is supplied under high pressure at least indirectly to injection points of an internal combustion engine, the feed pump being driven mechanically by the internal combustion engine, and a further feed pump provided additionally to the mechanically driven feed pump and supplying the fuel from the supply container to the high pressure pump, the further feed pump having an electric drive and being operable independently from the mechanically driven feed pump.
When the fuel supply device is designed in accordance with the present invention, it has the advantage that by the electrically driven further feed pump, intentionally in the required operational conditions the fuel quantity supply by the high pressure pump is increased, so that a reliable start and a reliable operation of the internal combustion engine is guaranteed in all operational conditions.
In accordance with another feature of present invention, the mechanically driven feed pump and the further feed pump are assembled to form a feed module. Therefore a simple construction is provided.
In accordance with a further feature of present invention, the feed module has a suction connection to the supply container, through which both feed pumps aspirate fuel, a pressure connection to the high pressure pump through which both feed pumps supply fuel, and a check valve arranged between the pressure connection and the further feed pump and closing toward the further feed pump. With this construction a return flow of the fuel, which is supplied by the mechanically driven feed pump through the further feed pump into the supply container, is reliably prevented.
In accordance with another feature of present invention, the further feed pump is operated in the event of a failure of the mechanically driven feed pump. Therefore it is guaranteed that the internal combustion engine at least in an emergency situation can operate in the case of a failure of the mechanically driven feed pump.
Finally, in accordance with another feature of present invention, the further feed pump supplies a smaller fuel quantity than the maximum fuel quantity of the mechanically driven feed pump. Therefore a simple and cost favorable construction of both feed pumps can be provided.
The novel features which are considered as characteristic for the present invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view showing a fuel supply device for an internal combustion engine in a schematic illustration;
FIG. 2 is a view showing a feed module of the fuel supply device, on an enlarged scale; and
FIG. 3 is a view showing a characteristic field of the fuel quantity supplied by the feed pumps of the feed module, depending on a rotary speed.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a fuel supply device for an internal combustion engine 10 of a motor vehicle or a stationary internal combustion engine, which is a self-igniting internal combustion engine.
The fuel supply device has a feed pump 12 which supplies the fuel from a supply container 14 . The feed pump 12 can be formed as a gear pump and can be driven mechanically by the internal combustion engine 10 . The rotary speed of the feed pump 12 is proportional to the rotary speed of the internal combustion engine 10 . Downstream after the feed pump 12 , a high pressure pump 16 is arranged. Its suction side supplies the fuel which is displaced by the feed pump 12 . High pressure storage 18 is arranged downstream of the high pressure pump 16 .
Conduits 20 from the pressure storage 18 lead to injection points 22 at the cylinders of the internal combustion engine 10 . Injectors are arranged at the injection points 22 and inject fuel into the combustion chambers of the cylinders of the internal combustion engine 10 . Valves 21 are provided for controlling the injection of the injectors. They establish the connection of the injectors with the high pressure storage 8 or interrupt the connection. Alternatively, it can be provided that for each cylinder of the internal combustion engine 10 , a high pressure pump is provided. Its suction side is connected with the feed pump 12 .
In accordance with the present invention, in addition to the mechanically driven feed pump 12 , a further feed pump 30 is provided. It has an electrical drive 32 . The drive 32 is formed for example by a direct current electric motor, and the board current source of the motor vehicle serves as a current source. With the further feed pump 30 , during its operation parallel to the mechanically driven feed pump 12 , fuel is fed from the supply container 14 and supplied to the high pressure pump 16 . The mechanically driven feed pump 12 and the further feed pump 30 are assembled for example to form a feed module 34 . The feed module 34 is shown in FIG. 2 on an enlarged scale.
The feed module 34 has a housing 36 with a suction-side connection 38 . A suction conduit 39 to the supply container 14 is connected to the connection 38 . A pressure-side connection 40 is arranged moreover on the housing 36 . A pressure conduit 41 for the high pressure pump 16 is connected to the connection 40 . A pump chamber 42 is limited in the housing 36 for the feed pump 12 . Two toothed gears 44 which engage with one another over their outer periphery are arranged as components of the feed pump 12 in the pump chamber 42 . One of the toothed gears 44 is driven in a not shown manner by the internal combustion engine 10 . During the operation of the feed pump 12 fuel is supplied by its rotatable toothed gears 44 along supply passages 46 which extend over their periphery, from the suction side with the suction connection 38 to the pressure side with the pressure connection 40 .
The further feed pump 40 is formed for example as a diaphragm pump and has a diaphragm 50 arranged in the housing 36 in a further pump chamber 48 . The diaphragm 50 is connected with a plunger 52 which is driven by the electric motor 32 in a stroke movement. The electric motor 32 can be arranged in the housing 36 or, as shown in FIG. 2, outside of the housing 36 . A shaft 54 of the electric motor 32 extends in the housing 36 and is coupled with the plunger 52 by an eccentric 55 , so that during rotary movement of the shaft 54 the plunger 52 is driven in the stroke movement. The stroke movement of the plunger 52 is transmitted to the diaphragm 50 . A pump working chamber 56 is limited by the diaphragm 50 in the pump chamber 48 . It communicates with the suction connection 38 through the connection 57 extending in the housing 36 for example in form of an opening or a channel. A check valve 58 which opens into the pump working chamber 56 is arranged in the connection 57 and opens during a suction stroke of the diaphragm 50 , so that fuel can be supplied from the suction connection 38 into the pump work chamber 56 .
The pump work chamber 56 is also connected with the pressure connection 40 through a connection 60 which extends in the housing 36 , and can be also formed as an opening or a passage. A check valve 61 which opens toward the pressure connection 40 is arranged in the connection 60 . During the forward stroke of the diaphragm 50 the check valve 58 closes and the check valve 61 opens, so that fuel is displaced from the pump work 56 to the pressure connection 40 . The check valve 61 is preferably arranged in the connection 60 near the pump work chamber 56 . The plunger 52 , the diaphragm 50 as well as the check valves 58 and 61 together with a housing part which receives these elements, can form a structural unit which is insertable into the housing 36 of the feed module 34 . A further check valve 62 can be arranged in the connection 60 of the pump work chamber 56 with the pressure connection 40 near the pressure connection 40 , so as to open toward the pressure connection 40 and to close toward the pump work chamber 56 . The check valve 62 prevents that the fuel supplied by the feed pump 12 can be displaced by the connection 60 in the pump work chamber 56 to the further feed pump 30 .
The operation on the further feed pump 30 is controlled for example by an electronic control device 70 , by which for example also the injection of the fuel with the injectors is controlled. The control device 70 supplies signals about the operational condition of the internal combustion engine 10 , in particular its rotary speed, load, cooling medium temperature, fuel temperature and in some cases further parameters. With the control device 70 the further feed pump 30 , is set in operation, in particular at low rotary speed and or at high cooling medium and/or fuel temperature. A low rotary speed of the internal combustion engine 10 occurs for example during starts, so that the further feed pump 30 is driven by the control device 70 during starts of the internal combustion engine 10 when the feed pump 12 , because of the low rotary speed of the internal combustion 10 , is also driven with a low rotary speed.
It can be provided that the further feed pump 30 is set in operation by the control device 70 before the start of the internal combustion engine 10 , so that the high pressure pump 16 is supplied with fuel prematurely. Thereby a good lubrication of the high pressure pump 16 is provided. It can be for example provided that the control device 70 supplies a signal about closing of the doors of the motor vehicle, or about the insertion of the ignition key into the ignition lock, or about the rotation of the ignition key in an ignition position, or a seat occupation recognition, and in this case sets the further feed pump 30 in operation. When the internal combustion engine 10 reaches a sufficiently high rotary speed, for example the orderly idle running rotary speed, then the control device 70 switches off the further feed pump 10 so that when only the feed pump 12 supplies fuel to the high pressure pump 16 .
It can be also provided that in the case of a failure of the feed pump 12 , when the internal combustion engine 10 can no longer be operated, the control device 70 sets the further feed pump 30 in operation. Thereby a sufficient fuel quantity is supplied to the high pressure pump 16 , in order to provide at least an emergency operation of the internal combustion engine 10 with a low power. Moreover, it can be provided that the further feed pump 30 is set in operation after the supply container 14 is completely emptied and is subsequently again filled. Thereby a ventilation and filling of the conduits 39 and 41 of the high pressure pump 16 is provided, so that during a subsequent start of the internal combustion engine 10 they are filled with fuel and the starting process can be shortened.
FIG. 3 shows a characteristic field of a fuel supply quantity over the rotary speed of the feed pump 12 , wherein the numerical values are only exemplary. The high pressure pump 16 at a fuel temperature of approximately −20° C. has a fuel consumption marked with the point A, and at the fuel temperature of approximately +90° C. has the fuel consumption marked with the point B. In FIG. 3 a characteristic line of the feed pump 12 , or in other words the feed quantity V′ over the pump rotary speed np, at the fuel temperature of approximately −20° C. is plotted and identified with C. A further characteristic line for a fuel temperature of approximately +90° C. is plotted and identified with D. It can be seen from FIG. 3 that the fuel supply by the fuel pump 12 is first started from a predetermined minimum rotary speed np min of the fuel pump 12 and increases with increasing fuel temperature. With increasing rotary speed np the fuel pump 12 increases the fuel quantity V′. In FIG. 3 moreover a characteristic line of the further feed pump 30 is plotted, which is identified with E. The characteristic line E of the further fuel pump 30 extends approximately horizontally since the further feed pump 30 is driven with a constant rotary speed and not as the feed pump 12 with a rotary speed which is proportional to the rotary speed of the internal combustion engine 10 . When the feed pump 12 reaches such a high rotary speed np 1 that by it a sufficiently great fuel quantity V′ is supplied, the further feed pump 30 is switched off.
The fuel quantity supplied by the further feed pump 30 is substantially smaller than the maximum fuel quantity supplied by the feed pump 12 . The supply quantity of the further fuel pump 30 can amount to, for example, approximately between 3% and 20% of the maximum supply quantity of the feed pump 12 . The further feed pump 30 is operated correspondingly only for a short time period, so that it suffices to design it for a relatively short service life, which makes possible a cost-favorable manufacture. With the use of the further feed pump 30 , the feed pump 12 can be produced in a simple manner, since high manufacturing tolerances can be accepted for it. Such high manufacturing tolerances, in particular at low pump rotary speeds worsen the supply power, which however is compensated by the supply power of the further feed pump 30 . The further feed pump 30 can be formed also as a separate unit with respect to the feed pump 12 . Moreover, the further feed pump 30 can be arranged before the feed pump 12 and connected in series to the supply container 14 .
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
While the invention has been illustrated and described as embodied in fuel supply device for an internal combustion engine, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims. | A fuel supply device for an internal combustion engine has a supply container, at least one feed pump for supplying a fuel from the supply container, a high pressure pump to which the fuel is supplied from the supply container by the feed pump, so that the fuel is supplied under high pressure at least indirectly to injection points of an internal combustion engine, the feed pump being driven mechanically by the internal combustion engine, and a further feed pump provided additionally to the mechanically driven feed pump and supplying the fuel from the supply container to the high pressure pump, the further feed pump having an electric drive and being operable independently from the mechanically driven feed pump. | 5 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a remote operated tool string deployment apparatus (RODA) designed for use with a remote operated coil connector apparatus (ROCC) for deployment of coiled tubing within a well bore as part of a well intervention system.
[0002] The ROCC with which the RODA is employed enables the remote connection of intervention tool strings or bottom hole assemblies (BHA) to the coiled tubing where manually changing them is not feasible. A ROCC, particularly adapted for this purpose and for use with the RODA of the instant application, is described in Norris et al., U.S. Patent Application “Remote Operated Coil Connector Apparatus”, filed May 2, 2002, Ser. No. ______. The disclosure of this patent application is fully incorporated by reference in the instant application.
[0003] Where the overall length of the intervention tool string or BHA exceeds the capacity of the available lubricator section, it becomes necessary to make up the tool string in sections using the well as the lubricator. This requires a secondary RODA system for use with the ROCC system that enables the remote, sequential, staggered deployment of the intervention tool string or BHA into the well.
[0004] Specifically, the RODA system permits the sequential remote mechanical, hydraulic and electrical disconnection and reconnection of the upper part of the ROCC to and from a plurality of deployed RODA working tool string sections. It locates and houses a deployed tool string section via the provision of a RODA tool holder situated and spaced immediately above the well head blowout preventer (BOP). The RODA provides for a deployment bar on the lower part of each deployed tool string section, spaced to suit the configuration of the well head BOP, thus enabling the coiled tubing sealing rams to close around it. There is further provided by the RODA an internal double-barrier to the well in each tool string section during the duration of the deployment operation.
[0005] It is accordingly an object of the present invention to provide a RODA system having these features and functions for use with a ROCC system enabling the remote, sequential, staggered deployment of intervention tool strings or bottom hole assemblies into the well bore.
SUMMARY OF THE INVENTION
[0006] In accordance with the invention, there is provided a remote operated tool string deployment apparatus having means for sequentially engaging and removing a plurality of tool strings from a remote container. It further provides means for sequentially moving the tool strings away from the container and into the well bore and means within the well bore for sequentially receiving these tool strings and retaining the tool strings. Means are provided for sequentially disconnecting the tool strings from the engaging means within the well bore and means for activating the tool strings within the well bore to perform a tool operating function.
[0007] The apparatus may further include a coiled tubing as the means for sequentially engaging and removing a plurality of tool strings from a remote container.
[0008] With the apparatus, the means for sequentially engaging and removing may further include a remote tool string connector.
[0009] The means for sequentially receiving and retaining may include a plurality of tool holders.
[0010] The tool holders may include a profile portion for engagement with a latching mechanism of the tool string connector.
[0011] Each of the tool holders may further include a release mechanism for remotely releasing the coiled tubing from the tool string connector to separate the tool string connector from the tool string.
[0012] The release mechanism may include means for radially, sequentially expanding and retracting a profile out of and into engagement with a corresponding abutting surface on the tool string connector.
[0013] The release mechanism may further include hydraulic actuation means.
[0014] The remote operated tool string deployment apparatus in accordance with the invention preferably includes a coiled tubing and a remote tool string connector for sequentially engaging and removing a plurality of tool strings from a remote container. Means are further provided for moving the tool strings away from this container and into a well bore. A plurality of tool holders are provided within the well bore for sequentially receiving the tool strings and retaining the tool strings. Means are provided for sequentially disconnecting the tool strings from the tool string connector within the well bore. Means are provided for activating the tool strings within the well bore to perform a tool operating function.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 is an assembly view in vertical cross-section of one embodiment of a remote operated tool string deployment apparatus (RODA) for use with a remote operation coil connector (ROCC), as described in the aforementioned patent application;
[0016] [0016]FIG. 1 a is a view in vertical cross-section of the upper connector of the RODA shown in FIG. 1;
[0017] [0017]FIG. 1 b is a view similar to FIG. 1 a of the bulkhead section of the assembly of FIG. 1;
[0018] [0018]FIG. 1 c is a view in partial cross-section of the deployment bar of the assembly shown in FIG. 1;
[0019] [0019]FIG. 1 d is a view similar to FIG. 1 a of the lower connector of the assembly shown in FIG. 1; and
[0020] [0020]FIG. 2 is a sectional view of a tool holder for use with the assembly of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] With reference to the drawings, and for the present to FIG. 1 thereof, there is shown a RODA tool string section in accordance with a preferred embodiment of the invention. There is shown a RODA upper section designated as A and shown specifically in FIG. 1 a ; a TFCV bulkhead section designated as B and shown specifically in FIG. 1 b ; a deployment bar designated as C and shown specifically in FIG. 1 c ; and a RODA lower section designated as D and shown specifically in FIG. 1 d.
[0022] The RODA upper connector, designated as A in FIG. 1 and shown specifically in FIG. 1 a , is compatible with the upper portion of a ROCC tool string, such as that described in the aforementioned patent application. Specifically, it forms the upper connection to a working tool string section, thus enabling the next deployed tool string section to locate and latch. Further, it provides an internal receptacle for the mechanical connection to the mating RODA connector. Further, it houses single or multiple electrical “wet” connections to match those of the mating RODA connector. A sealing area is provided for the mated connector to enable continuity of fluid passage through the assembly. Externally, the RODA upper connector provides a mechanical anchor to locate the RODA tool holder, the specific embodiment of which is shown in FIG. 2.
[0023] Specifically, the RODA upper connector A includes a latch receptacle 1 to receive the mechanical latch connection of the upper ROCC. When the keys designated as 9 in FIG. 1 d of the upper ROCC are latched into this receptacle 1 , a joint is formed which can only be released by extraneous means provided by the tool holder which will be later described.
[0024] Internally, the latch receptacle 1 houses a bulkhead carrier 2 which in turn houses a pressure resistant multiple contact electrical “wet connect” stab connector 3 to mate with the connector in the upper ROCC designated in FIG. 1 d as 12 . With the assembly so connected, a seal bore 1 a is provided. This seal bore constitutes a chamber within the assembly that is pressure resistant to the well.
[0025] Externally, a series of spring-loaded, downward-facing anchor keys 4 are positioned to provide a positive, downward load-bearing seat against a mating shoulder 1 , as shown in FIG. 2A, housed within the tool holder and capable of holding the hanging weight of the tool string. Similarly, a set of upward facing anchor keys 4 a are positioned to provide a positive, upward load-bearing seat against a mating shoulder 2 , as shown in FIG. 2A, housed within the tool holder, thereby acting as a positive stop for the locating of the RODA tool string. The shoulder will enable an over-pull to be taken through the coiled tubing once the upper ROCC has latched.
[0026] With respect to the TFCV bulkhead, designated as B in FIG. 1 and shown particularly in FIG. 1 b , an offset twin flapper check valve 5 is housed within a bulkhead joint 6 . To provide for electrical feedthrough when required, the bulkhead joint has an offset “wet matable” pressure resistant multi-contact electrical connector 7 to maintain electrical continuity through the assembly.
[0027] With reference to FIG. 1 c , the deployment bar designated as 8 has a diameter corresponding to the size of the coiled tubing being used with the assembly. The length of the deployment bar is designed so that when the RODA tool string is located into the RODA tool holder, which will be described later with respect to FIG. 2, the deployment bar will be aligned with the BOP pipe rams designated as 8 a in FIG. 1 c . Upon closing of these pipe rams 8 a , an external seal is formed around the tool string.
[0028] With respect to FIG. 1 d , the RODA lower connector is shown for forming the lower connection of a working tool string section which locates and latches the next to be deployed tool string section. Specifically, it forms a mechanical latch connection for the mating RODA connector. In addition, it houses single or multiple electrical “wet” connectors to match with the mating RODA connector. It, likewise, provides a seal for the mating connector to enable continuity of fluid passage through the overall assembly of the RODA.
[0029] This RODA lower connector includes a series of spring loaded latch keys 9 designed to locate and latch into the receptacle 1 in the RODA upper connector. Once the keys 9 of the connector are latched into the receptacle 1 , a joint is formed which can only be released by extraneous means provided by the tool holder, which will be later described.
[0030] Internally, the body designated as 10 houses a bulkhead carrier 11 for a pressure resistant multiple electrical “wet” slab connector 12 which matches the connector 3 in the upper RODA shown in detail in FIG. 1 a . This body 10 , when in mated connection with the upper RODA, provides a sealed chamber that is pressure resistant to the well. The male fluid union 10 a in the lower RODA will be engaged into the seal receptacle provided in the upper RODA shown in FIG. 1 a to provide a continuous and pressure-containing chamber.
[0031] With reference to FIG. 2, there is shown a RODA tool holder for use with the remote operated tool string deployment apparatus in accordance with the instant invention. The tool holder of FIG. 2 differs from that shown and described in the aforementioned patent application in that it is a permanent fixture incorporated immediately above or close to the BOP of the well head. It provides a secondary locator and housing for the deployed tool string sections.
[0032] The tool holder includes a catcher sleeve compatible with the anchor keys of the RODA tool string. An upper and lower profile is provided to mechanically release the anchor keys. A remote operated profile is incorporated that may be energized in order to release the lower connector latch keys of the RODA tool string.
[0033] Specifically, within the body 13 of the tool holder, there is provided a spring-loaded catcher sleeve 14 . A preloaded spring 15 set to a selected force is likewise provided. At each end of the internal diameter of the catcher sleeve 14 , square, load-bearing shoulders 20 are formed into which the anchor keys 4 and 4 a of the upper RODA connector will locate. If these keys are pulled or pushed beyond a selected force, they will contact an upper or lower profile 16 in the body of the RODA tool holder and at this point be compressed and released from the catcher sleeve 14 .
[0034] Also housed within the body of the RODA tool holder is a normally retracted or “floating” series of lugs 17 that act as a release profile when energized. This release profile may be energized hydraulically through an external hydraulic control line port 18 . As the hydraulic pressure is applied through the port 18 , a spring-loaded piston sleeve 19 moves down and over the profile, thereby locking it into the internal bore 13 a of the tool holder to form a reduced-neck internal diameter portion. This will serve to release the lower connector latch keys designated as 9 in FIG. 1 d of the RODA tool string. When the lugs 17 forming the release profile have served their purpose, the hydraulic pressure supply is reduced and the spring-loaded piston sleeve 19 will thus move back to its original position. This allows the release profile lug 17 to retract so that the tool string may pass through the internal bore 13 a of the tool holder without obstruction.
[0035] Description of Operation
[0036] The ROCC connector provides the first connection to the RODA tool string. When its connection is completed, the RODA tool string can be moved to the RODA tool holder. Once the RODA tool string is so located, which an upward overpull of the coiled tubing will confirm, the pipe rams of the BOP are operated to close around the deployment section 8 of the RODA tool string. The RODA tool string is now constrained by this operation.
[0037] To release the ROCC from the RODA tool string, the tool holder, remote operated release profile 17 is energized. This is achieved hydraulically via control line 18 . The energized release profile 17 provides a reduced neck portion, as shown in FIG. 2B. If the RODA tool string is pulled beyond a preset force, the latch keys 9 of the ROCC will contact this reduced neck portion. As this pulling is continued, the ROCC latch keys 9 will be compressed, thereby releasing the ROCC from the upper connector of the RODA tool string which will remain in situ. The ROCC is then free to return to its start position in order to pick up the next required RODA tool string for the deployment cycle to be continued. In order to introduce the deployed RODA tool string into the well, the BOP pipe rams must be opened. The RODA tool string is then pushed down against the catcher sleeve 14 via the anchor keys 4 and 4 a beyond a preselected force so that they will contact the lower profile 16 in the body of the RODA tool holder to compress and be released from the catcher sleeve 14 . The tool string is now free to enter the well bore.
[0038] When this operation is completed and the RODA tool string is removed from the well bore, each deployed section must be dismantled to be stored for subsequent use. To achieve this, the last deployed tool string section must be pulled through the RODA tool holder catcher sleeve 14 , as shown in FIG. 2. An overpull load will result as this occurs.
[0039] Once the next RODA tool string has been located into the RODA tool holder, the BOP pipe rams are closed. Again, the RODA tool holder remote operated release profile must be energized. The RODA lower tool string connection can then be released by over-pulling as previously described, leaving the upper RODA tool string connection of the next section and remainder of the tool string BHA in situ.
[0040] The ROCC connector, providing the connection to the released RODA tool string section, can now move upward to locate it into the ROCC tool holder from where it was originally located and now will be released. The ROCC tool holder, now housed in a released RODA tool string section, can then be stored and replaced with another empty tool holder ready for the next RODA tool string section. | A remote operated tool string deployment apparatus (RODA) is provided for use with a remote operation coil connector (ROCC) in a well intervention system. The ROCC enables the remote connection of intervention tool strings or bottom hole assemblies (BHA) to the coiled tubing where manually changing them is not possible. | 4 |
The Government has rights in this invention pursuant to Contract No. N62269-77-C-0025 awarded by the Department of the Navy.
This application is a continuation of application Ser. No. 152,921, filed June 3, 1980 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to gas generators of a compact size and light weight for supplying a gas to inflate an inflatable safety cushion apparatus that is attachable to passive belt type restraints used in various vehicles including aircraft.
2. Description of the Prior Art
Various forms of restraints have been proposed in the prior art for the protection of vehicle occupants. Specifically, there have been provided inflatable seat belt-shoulder harness systems, and inflatable air bag systems. Inflatable belt and harness systems and inflatable air bag systems are designed to provide a greater degree of protection than the conventional seat belt and shoulder harness systems are capable of for the vehicle occupants.
The inflatable restraint systems of the prior art are complex and expensive, and are characterized by their longer than desirable "reaction time", that is the length of time required for inflation and effective constraining action on the user upon a crash impact. Additionally, the prior art inflatable restraint systems depend on the surrounding structure for functional support and are best suited for installation at the time of manufacture of the vehicle. Among the reasons for this is that the inflatable belt systems require, in addition to the use of a special inflatable belt, the mounting in the vehicle, of a pressurized gas supply or inflator that is connected to the inflatable belt by an elongated tube or pipe. The inflatable air bag systems involve mounting in the steering wheel hub and/or in the dashboard of the vehicle of a folded and compacted air bag that is inflatable to a relatively large volume, and a pressurized gas supply or gas generator.
With prior art inflatable belt-type restraint systems, the time required to transport the inflation gas from a remote source results in an undesirable delay in the inflation of the inflatable belt. This extends the reaction time of the system beyond a value that is optimum for protection of the user in the most comfortable manner. The relatively larger volume of the air bag, and the relatively large distance between the folded and compacted bag and the user that must be traversed by the inflated bag, upon a crash impact, to constrain the user also cause the reaction time of the inflatable air bag restraint systems to be longer than desirable. As a consequence, for both the inflatable belt and the inflatable air bag restraint systems of the prior art as proposed for use in automotive vehicles, the longer than desirable reaction time upon a crash impact tends to allow some movement of the user to occur, thus exposing the user to an undesirable shock of sudden, hard constraint.
There thus exists a need in the art for not only an improved restraint for the protection of the occupants of vehicles involved in crashes, but a need for an improved gas generator for supplying the gas to such a device in a rapid and direct manner.
There further exists a need for a compact, lightweight and effective gas generator to be used inside a safety cushion of the type described in commonly owned, co-pending patent application Ser. No. 152,922 filed on even date with the present application by Bliss W. Law, et al, now U.S. Pat. No. 4,348,037. Some gas generators which are located in their entirety within the inflatable bladder of an inflatable body and head restraint are shown in U.S. Pat. No. 3,905,615 to Schulman issued Sept. 16, 1975 and in U.S. Pat. No. 3,948,541 to Schulman issued Apr. 6, 1976. These do not however, solve the problem of compactness, lightness of weight and of a shape to provide maximum comfort and safety to the user.
Gas generators in the art have generally been cylindrical with the propellant about some central core in either a doughnut shape, concentric cylinders or discs. Such an arrangement tends to make them too bulky and too thick for use with safety cushions applied to safety harnesses.
The gas generator or inflator of the present invention inflates the safety cushion with an innocuous gas such as nitrogen and is entirely enclosed in the safety cushion. The inflator is attached to suitable sensor apparatus that detects and responds to crash impacts of the vehicle in which it is installed. In order to achieve a desirable compactness, and in particular, a flat, slim configuration suitable for attachment to the safety harness between it and the occupant, the inflator has dual side by side combustion chambers having longitudinal axes that lie in a common plane. The combustion chambers are filled with gas generant material that is ignitable by a central igniter located between them and also in side by side relationship with them thus providing a very flat, compact and safely shaped package for the gas generator which is at the same time capable of efficient and quick gas generation in sufficient quantity but in minimum size. The inflator contains appropriate filters and cooling means, and is capable of inflating the safety cushion within about 15 milliseconds. Such rapid inflation of the safety cushion apparatus contributes importantly to the attainment of a desirably short reaction time.
OBJECTS OF THE INVENTION
It is, therefore, an object of the present invention to provide a gas generator capable of inflating a safety cushion in an acceptably rapid time wherein the generator comprises a compact flat unit without protrusions which might be uncomfortable or dangerous to the user of the cushion.
It is also an object of the present invention to provide a gas generator of the foregoing type wherein gas generation chambers and an igniter are arranged in a side by side coplanar relationship.
It is also an object of the present invention to provide a gas generator of the foregoing type wherein a maximum of gas is generated by minimum size and dimension of the gas generator housing.
It is also an object of the present invention to provide a gas generator of the foregoing type wherein the generated gas released from the generating unit is cool and clean enough so as not to create a hazard to the person using the equipment and to the equipment itself.
It is also an object of the present invention to provide a gas generator of the foregoing type which is lightweight.
It is also an object of the present invention to provide a gas generator of the foregoing type wherein the generator can be disassembled easily and recharged for further use.
Other objects and advantages of the present invention will become apparent from the description and claims which follow.
THE DRAWINGS
FIG. 1 is a longitudinal cross section of the gas generator showing its interior and the location of the gas generating material and filters;
FIG. 2 is a transverse cross section of the gas generator taken on lines 2--2 of FIG. 1 looking in the direction of the arrows;
FIG. 3 is a view of a restraining harness showing the location of an inflated safety cushion and the location of the gas generator with respect to it;
FIG. 4 is a cross sectional view of the safety cushion in its uninflated, folded condition taken on lines 4--4 of FIG. 3 looking in the direction of the arrows and showing the gas generator inside the bag;
FIG. 5 is a side external view of a portion of the restraining harness showing the location of the gas generator within the safety cushion.
DETAILED DESCRIPTION OF THE INVENTION
With particular reference to FIGS. 1 and 2 of the drawings, the gas generator includes a solid body 10 which is provided with two longitudinal chambers or cavities 11, 12 having longitudinal axes that lie in a common plane and that extend substantially parallel to the sides of the body 10 having the longer dimension. The chambers 11 and 12 are closed at their right hand end in FIG. 1 except for outlet ports 13, 14 which are sealed by aluminum foil seals 13a, 14a. In between chambers 11, 12 is a third chamber or cavity 15 having an opening 16 at its right hand end in FIG. 1. Chamber 15 is open at its left hand end in FIG. 1, is of somewhat smaller diameter than the bores 11, 12 and has large elongated ports 17, 18 through its sides corresponding with in contiguous relation to similar ports 19, 20, respectively, through the side walls of chamber 11, 12 to afford communication from chamber 15 into chambers 11, 12. All three chambers are arranged in coplanar side-by-side relationship as shown in the drawings in order to afford as thin and compact a package as possible suitable for use between a person's body and a safety harness as mentioned previously in this specification and to provide a minimum size for a maximum gas output. A cover or end plate 21 is provided which covers the open end of the chamber bores 11, 12 and 15 and is held tightly in place by means of screws 22 which also provide an attachment means for a mounting bracket 22a. The mating surfaces of body 10 and cover 21 are each machined to provide a substantially flat surface and a coating of an epoxy compound is applied between them at the time of assembly to prevent any leakage of gases.
Before cover 21 is put in place, however, chamber 11, 12 are both filled with filtering material and gas-generating propellant in the following manner. A spacer ring 23 is placed in each chamber 11, 12 followed by disclike stainless steel filter screens 24, 25, screen 25 being of a fine mesh and screen 24 of a coarser mesh with screen 24 to the right of screen 25 in FIG. 1 in a position downstream of the flow of gases from chambers 11 and 12. To the left of screen 25 (upstream) is a porous layer or layered screen 26 of pH adjusting material such as ferrous sulfate. Just upstream of layer 26 (to its left in FIG. 1) is another stainless steel filter screen 27 which is spirally wrapped on a pin 28 and inserted as a unit during assembly of the gas generator. Still another stainless steel filter screen 29 is provided about the inner wall of each chamber 11, 12 with a suitable opening 30 provided in each as shown to provide easy communication with the igniter cavity 15 through ports 19, 20 and 17, 18. Screen 29 is several layers thick but leaves most of the volume of chambers 11, 12 open to receive gas generant. This gas generant comprises pellets 38 which substantially fill the remaining space in each of chambers 11, 12 with the pellets 38 made of a typical formulation for gas generants such as about 70 percent sodium azide (NaN 3 ), 28 percent molybdenum disulfide (MoS 2 ) and 2 percent sulfur. Both chambers 11, 12 are filled with these pellets 38 after igniter 31 is put in place in cavity 15. Its connecting wires 32 pass out of the gas generator through opening 16 from where they are connected to an inflation initiator or sensor (not shown) associated with the harness and the vehicle to which it is attached and which responds to crash impacts.
The igniter 31 is of a type customarily employed in the ignition of gas generators and comprises a tubular shell 33 which contains an electrically operated squib 34 and fast burning igniter material 35. Shell 33 is perforated as shown at 36 to afford communication with chambers 11, 12 and the perforations are covered with easily destructible tape 37 on its exterior to protect the contents during handling and installation into cavity 15.
The gas generator is then ready to be closed and end plate or cover 21 is fastened in place by means of screws 22 which also pass through bracket 22a to hold it in place. Epoxy compound is applied, as mentioned previously in this specification, to the mating surfaces of body 10 and end plate 21 to act as a sealing compound. The gas generator unit is then put in place inside the safety cushion 39 with the whole assembly attached to the harness and enclosed in a protective cover 42 with the safety cushion 39 folded inside of it. The cover 42 is closed and fastened by a suitable pull-apart fastener.
OPERATION OF THE INVENTION
As mentioned previously in this specification, the gas generator is made to function on receipt of a signal from a sensor (not shown) which detects that the vehicle with which it is associated has been involved in a collision. This signal to the gas generator is in the form of an electric impulse to the igniter 31 which causes ignition of squib 34. This action in turn causes ignition of the igniter material 35 which burns very rapidly and destroys or blows off tape 37 after which its flame and high temperature gases pass out through perforations 36 into chambers 11, 12 and ignite the gas generant pellets 38. As these burn, gas is generated which, because of its high pressure, forces its way through the various filter screens, ruptures the aluminum foil seals 13a, 14a, and flows to outlet openings 13, 14 from which it enters directly into the surrounding inflatable bag or can be conducted to such an inflatable located nearby. The generated gas first encounters screen 29 where cooling of the gas takes place to some extent and some relatively large pieces of gas generating material become trapped before they enter, or interfere with the operation of, the remaining screens. Next the gas passes through spirally wrapped screen 27 where additional material is filtered out and additional cooling of the gas occurs. The gas then passes through the porous layer 26 of pH adjusting material which changes the pH value of the gas to neutralize it to an acceptable value after which the gas passes through screens 25, 24 to the outlets 13, 14. The spacer ring 23 serves to keep the filter screen 24 off the end walls of chambers 11, 12 so that outlets 13, 14 will not become blocked. This entire action takes place very rapidly so that the safety cushion 39 becomes totally inflated within about 15 milliseconds.
The entire gas generator is located within a safety cushion 39 applied to a safety harness 40 as shown in FIGS. 3, 4 and 5 in the manner shown in the commonly owned and co-pending application for patent of Bliss W. Law, et al bearing Ser. No. 152,922, filed on even date herewith and mentioned earlier in this specification. As gas is generated, it flows directly into cushion 39 as stated above, and fully inflates it within about 15 milliseconds with the overall reaction time of the whole system including operation of the sensor taking not more than about 20 to 25 milliseconds.
A gas generator is ordinarily used for each safety cushion. In connection with the safety harness 40 shown in FIG. 3, a second identical gas generator 41 is used to inflate a matching safety cushion for the second upright strap of a shoulder harness 40a (the left hand strap in FIG. 3). Others could be used in other locations between the strap and the body of the occupant where an additional cushion is needed.
While there have been shown and described and pointed out the fundamental novel features of the invention as applied to a preferred embodiment, it will be understood that various omissions and substitutions and changes in the form and details of the device illustrated and in its operation may be made by those skilled in the art, without departing from the spirit of the invention. It is the intention, therefore to be limited only as indicated by the scope of the following claims. | An inflator or gas generator is provided for inflating a protective cushion associated with a safety harness used in a vehicle including an aircraft. The generator is of a structure which provides a maximum quantity of inflating gases for a minimum size, weight, shape and general compactness of the generating unit. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a divisional application of U.S. Ser. No. 14/177,097, filed on Feb. 10, 2014, now U.S. Pat. No. 9,273,437, which is a divisional application of U.S. patent application Ser. No. 13/686,756, filed on Nov. 27, 2012, now U.S. Pat. No. 8,657,525, which is a divisional application of U.S. patent application Ser. No. 12/347,467, filed on Dec. 31, 2008, now U.S. Pat. No. 8,322,945. The present application claims the benefits of U.S. Provisional Application Ser. No. 61/061,567, filed Jun. 13, 2008, entitled “MOBILE BARRIER”, and 61/091,246, filed Aug. 22, 2008, entitled “MOBILE BARRIER”, and 61/122,941, filed Dec. 16, 2008, entitled “MOBILE BARRIER” each of which is incorporated herein by this reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of trailers and other types of barriers used to shield road construction workers from traffic. More specifically, the present invention discloses a safety and construction trailer having a fixed safety wall and semi tractor hookups at both ends.
BACKGROUND
[0003] Various types of barriers have long been used to protect road construction workers from passing vehicles. For example, cones, barrels and flashing lights have been widely used to warn drivers of construction zones, but provide only limited protection to road construction workers in the event a driver fails to take heed. Some construction projects routinely park a truck or other heavy construction equipment in the lane between the construction zone and on-coming traffic. This reduces the risk of worker injury from traffic in that lane, but does little with regard to errant traffic drifting laterally across lanes into the construction zone. In addition, conventional barriers require significant time and effort to transport to the work site, and expose workers to significant risk of accident while deploying the barrier at the work site. Therefore, a need exists for a safety barrier that can be readily transported to, and deployed at the work site. In addition, the safety barrier should protect against lateral incursions by traffic from adjacent lanes, as well as traffic in the same lane.
SUMMARY
[0004] These and other needs are addressed by the various embodiments and configurations of the present invention. In contrast to the prior art in the field, the present invention can provide a safety trailer with a fixed safety wall and semi tractor hookups at one or both ends.
[0005] In a first embodiment, a safety trailer includes:
[0006] (a) first and second removably interconnected platforms, at least one of the first and second platforms being engaged with an axle and wheels, the first and second platforms defining a trailer; and
[0007] (b) a plurality of wall sections supported by the trailer, the wall sections, when deployed to form a barrier wall, are positioned between the first and second interconnected platforms
[0008] (c) wherein at least one of the following is true:
[0009] (c1) the trailer supports a ballast member, the ballast member being positioned near a first side of the trailer and the ballast member near a second, opposing side of the trailer, the ballast member offsetting, at least partially, a weight of the plurality of wall sections, and
[0010] (c2) the axle of the trailer is engaged with a vertical adjustment member, the vertical adjustment member selectively adjusting a vertical position of a surface of the trailer.
[0011] In a second embodiment, a safety trailer includes:
[0012] (a) first and second platforms;
[0013] (b) a plurality of interconnected wall sections positioned between and connected to the first and second platforms, the plurality of wall sections defining a protected work area on a side of the trailer;
[0014] (c) wherein each wall section has at least one of the following features:
[0015] (c1) a plurality of interconnected levels, each level comprising first and second longitudinal members, a plurality of truss members interconnecting the first and second longitudinal members, and being connected to an end member;
[0016] (c2) a longitudinal member extending a length of the wall section, the longitudinal member being positioned at the approximate position of a bumper of a vehicle colliding with the wall section;
[0017] (c3) a plurality of full height and partial height wall members, the full height wall members extending substantially the height and width of the wall section and the partial height wall members extending substantially the width but less than the height of the wall section, the full height and partial height members alternating along a length of the wall section; and
[0018] (c4) first and second end members, each of the first and second end members comprising an outwardly projecting alignment member and an alignment-receiving member, the first and second end members having the alignment and alignment-receiving members positioned in opposing configurations.
[0019] In a third embodiment, a trailer includes:
[0020] (a) a trailer body;
[0021] (b) a removable caboose engageable with the trailer body, the caboose having a nose portion and at least one axle and wheels; and
[0022] (c) a caboose receiving member, the caboose receiving member comprising an alignment device, wherein, in a first mode when the caboose is moved into engagement with the trailer body, the alignment device orients the caboose with a king pin mounted on the trailer body and, in a second mode when the caboose is engaged with the trailer body, the alignment device maintains a desired orientation of the caboose with the trailer.
[0023] In a fourth embodiment, a safety system includes:
[0024] (a) a vehicle;
[0025] (b) first and second platforms;
[0026] (c) a barrier engaged with the first and second platforms, the barrier and first and second platforms forming a protected work space; and
[0027] (d) a caboose, wherein the vehicle and caboose are engaged with the first and second platforms, respectively, wherein the vehicle has a movable king pin plate engaged with a first king pin on the first platform, and wherein the caboose has a fixed king pin plate engaged with a second king pin on the second platform.
[0028] In a fifth embodiment, a safety system includes:
[0029] (a) a vehicle;
[0030] (b) first and second platforms;
[0031] (c) a barrier engaged with the first and second platforms, the barrier and first and second platforms forming a protected work space; and
[0032] (d) a caboose, wherein the vehicle and caboose are engaged with the first and second platforms, respectively, wherein the vehicle and caboose have braking systems that operate independently.
[0033] In a sixth embodiment, a trailer includes:
[0034] (a) first and second platforms;
[0035] (b) a barrier engaged with the first and second platforms, the barrier and first and second platforms forming a protected work space, wherein the barrier is formed by a plurality of interconnected wall sections and wherein the interconnected wall sections slidably engage one another.
[0036] In a seventh embodiment, a trailer includes:
[0037] (a) first and second platforms;
[0038] (b) a barrier engaged with the first and second platforms, the barrier and first and second platforms forming a protected work space, wherein the barrier is formed by a plurality of interconnected wall sections and wherein the interconnected wall sections telescopically engage one another.
[0039] In an eighth embodiment, a trailer includes:
[0040] (a) first and second platforms;
[0041] (b) a barrier engaged with the first and second platforms, the barrier and first and second platforms forming a protected area, wherein the barrier is formed by a plurality of interconnected wall sections, and wherein at least one of the following is true:
[0042] (b1) a bottom of the barrier is positioned at a distance above a surface upon which the trailer is parked and wherein the distance ranges from about 10 to about 14 inches;
[0043] (b2) a height of the barrier above the surface is at least about 3.5 feet; and
[0044] (b3) a height of the barrier from a bottom of the barrier to the top of the barrier is at least about 2.5 feet.
[0045] The present invention can provide a number of advantages depending on the particular configuration.
[0046] In one aspect, the barrier (and thus the entire trailer) is of any selected length or extendable, but the wall is “fixed” to the platforms on one side of the trailer. That side, however, can be changed to the right or left side of the road, depending on the end to which the semi tractor attaches. This dual-ended, fixed-wall design thus can eliminate the need for complex shifting or rotating designs, which are inherently weaker and more expensive, and which cannot support the visual barriers, lighting, ventilation and other amenities necessary for providing a comprehensive safety solution. The directional lighting and impact-absorbing features incorporated at each end of the trailer and in the caboose can combine with the fixed wall and improved lighting to provide increased protection for both work crews and the public, especially with ever-increasing amounts of night-time construction. End platforms integral to the trailer's design can minimize the need for workers to leave the protected zone and eliminate the need for separate maintenance vehicles by providing onboard hydraulics, compressors, generators and related power, fuel, water, storage and portable restroom facilities. Optional overhead protection can be extended out over the work area for even greater environmental relief (rain or shine). The fixed wall itself can be made of any rigid material, such as steel. Lighter weight materials having high strength are typically disfavored as their reduced weight is less able to withstand, without significant displacement, the force of a vehicular collision. The trailer can carry independent directional and safety lighting at both ends and will work with any standard semi tractor. Optionally, an impact-absorbing caboose can be attached at the end of the trailer opposite the tractor to provide additional safety lighting and impact protection.
[0047] In one aspect, the trailer is designed to provide road maintenance personnel with improved protection from ongoing, oncoming and passing traffic, to reduce the ability of passing traffic to see inside the work area (to mitigate rubber-necking and secondary incidents), and to provide a fully-contained, mobile, enhanced environment within which the work crews can function day or night, complete with optional power, lighting, ventilation, heating, cooling, and overhead protection including extendable mesh shading for sun protection, or tarp covering for protection from rain, snow or other inclement weather.
[0048] Platforms can be provided at both ends of the trailer for hydraulics, compressors, generators and other equipment and supplies, including portable restroom facilities. The trailer can be fully rigged with direction and safety lighting, as well as lighting for the work area and platforms. Power outlets can be provided in the interior of the work area for use with construction tools and equipment, with minimal need for separate power trailers or extended cords. Both the caboose and the center underside of both end platforms can provide areas for fuel, water and storage. Additional fuel, water and miscellaneous storage space can be provided in an optional extended caboose of like but lengthened design.
[0049] In one aspect, the trailer is designed to eliminate the need for separate lighting trucks or trailers, to reduce glare to traffic, to eliminate the need for separate vehicles pulling portable restroom facilities, to provide better a brighter, more controlled work environment and enhanced safety, and to, among other things, better facilitate 24-hour construction along our nation's roadways. Other applications include but are not limited to public safety, portable shielding and shelter, communications and public works. Two or more trailers can be used together to provide a fully enclosed inner area, such as may be necessary in multi-lane freeway environments.
[0050] With significant shifts to night construction and maintenance, the trailer, in one aspect, can provide a well-lit, self-contained, and mobile safety enclosure. Historical cones can still be used to block lanes, and detection systems or personnel can be used to provide notice of an errant driver, but neither offers physical protection or more than split second warning for drivers who may be under the influence of alcohol or intoxicants, or who, for whatever reason, become fixated on the construction/maintenance equipment or lights and veer into or careen along the same.
[0051] The trailer can provide an increased level of physical protection both day and night and workers with a self-contained and enhanced work environment that provides them with basic amenities such as restrooms, water, power, lighting, ventilation and even some possible heating/cooling and shelter. The trailer can also be designed to keep passing motorists from seeing what is going on within the work area and hopefully facilitate better attention to what is going on in front of them. Hopefully, this will reduce both direct and secondary incidents along such construction and maintenance sites.
[0052] Embodiments of this invention can provide a safety trailer with semi-tractor hookups at both ends and a safety wall that is fixed to one side of the trailer. That side, however, can be changed to the right or left side of the road, depending on the end to which the semi-tractor attaches. A caboose can be attached at the end of the trailer opposite the tractor to provide additional lighting and impact protection. Optionally, the trailer can be equipped with overhead protection, lighting, ventilation, onboard hydraulics, compressors, generators and other equipment, as well as related fuel, water, storage and restroom facilities and other amenities.
[0053] These and other advantages will be apparent from the disclosure of the invention(s) contained herein.
[0054] As used herein, “at least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.
[0055] It is to be noted that the term “a” or “an” entity refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. It is also to be noted that the terms “comprising”, “including”, and “having” can be used interchangeably.
[0056] The preceding is a simplified summary of the invention to provide an understanding of some aspects of the invention. This summary is neither an extensive nor exhaustive overview of the invention and its various embodiments. It is intended neither to identify key or critical elements of the invention nor to delineate the scope of the invention but to present selected concepts of the invention in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other embodiments of the invention are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0057] FIGS. 1A-1E show a loaded trailer, in accordance with embodiments of the present invention;
[0058] FIGS. 2A-2C show a deployed protective wall, in accordance with embodiments of the present invention;
[0059] FIGS. 3A-3C show a wall section in accordance with embodiments of the present invention;
[0060] FIGS. 4A-4H show a platform and its components in accordance with embodiments of the present invention;
[0061] FIGS. 5A-5B show a caboose, in accordance with embodiments of the present invention;
[0062] FIGS. 6A-6G show a truck mounted attenuator attached to the caboose shown in FIGS. 5A-5B ;
[0063] FIG. 7 shows an interconnection member between a platform and a truck mounted attenuator;
[0064] FIG. 8 shows a forced air system, in accordance with embodiments of the present invention;
[0065] FIG. 9 shows the loaded trailer, including a storage compartment;
[0066] FIG. 10 is a flow chart illustrating a method of deploying a protective barrier;
[0067] FIG. 11 is a flow chart illustrating a method of balancing the weight of a protective barrier;
[0068] FIG. 12 is a flow chart illustrating a method of changing the orientation of a protective barrier/trailer;
[0069] FIG. 13 is a flow chart illustrating a method of disassembling a protective barrier and loading the component parts for transport;
[0070] FIGS. 14A-C are illustrations of a fixed wall protective barrier in accordance with alternative embodiments of the present invention;
[0071] FIG. 15A-C are illustrations of a fixed wall protective barrier in accordance with another alternative embodiment of the present invention;
[0072] FIG. 16 shows a configuration of the caboose according to an embodiment;
[0073] FIG. 17 shows a configuration of the caboose according to an embodiment; and
[0074] FIG. 18 shows a configuration of the caboose according to an embodiment.
DETAILED DESCRIPTION
[0075] Embodiments of the present invention are directed to a mobile traffic barrier. In one embodiment, the mobile traffic barrier includes a number of inter-connectable wall sections that can be loaded onto a truck bed. The truck bed itself includes two (first and second) platforms. Each platform includes a king pin (not shown); the king pin providing a connection between the selected platform and either a caboose or a tractor. By enabling the tractor to hook at either end, the trailer can incorporate a rigid fixed wall that is open to the right or left side of the road, depending on the end to which the tractor is connected. The side wall and the ends of the trailer define a protected work area for road maintenance and other operations. The tractor and caboose may exchange trailer ends to change the side to which the wall faces. The dual-hookup, fixed-wall design can enable and incorporate compartments (in the platforms) for equipment and storage, onboard power for lighting, ventilation, and heating and/or cooling devices and power tools, and on-board hydraulics for hydraulic tools. The design can also provide for relatively high shielding from driver views, and in general, a larger and better work environment, day or night.
[0076] Referring initially to FIG. 1A , a trailer in accordance with an embodiment is generally identified with reference numeral 100 . The trailer 100 includes two (first and second) platforms 104 a,b and a number of wall sections 108 a - c . As described in greater detail below, the wall sections 108 a - c are adapted to interconnect to each other and to the platforms 104 a,b to form a protective wall. In FIG. 1A , the wall sections 108 a,b are disconnected from each other and secured in a stored position on top of the interconnected platforms 104 a,b . In this position, the trailer 100 is configured so that it may be transported to a work site. In the transport configuration illustrated in FIG. 1A , the platforms 104 are bolted to each other to form a truck bed that is operable to carry the wall sections 108 and other components.
[0077] In addition to the wall sections 108 a - c , the platforms 104 a,b carry two rectangular shaped ballast members 112 a,b , which are shown as boxes of sand. As will be appreciated, the ballast members can be any other heavy material. The weights of ballast boxes 112 a,b counter balance the weights of the wall sections 108 a - c , when the wall sections 108 a - c are deployed to form a protective barrier and when being transported atop the platforms. The ballast boxes 112 a,b hold between about 5,000 and 8,000 lbs. of weight, particularly sand. At 8,000 lbs., the ballast boxes 112 a,b counter balance three wall sections 108 a - c , when the wall sections are deployed or being transported. In one configuration, the wall sections 108 a - c weigh approximately 5,000 lbs. each.
[0078] The truck bed formed by the interconnected platforms 108 a,b is connected at one end to a standard semi-tractor 116 and at the other end to an impact-absorbing caboose 120 . Both of the platforms 108 a,b include a standard king pin connection to the tractor 116 or caboose 120 , as the case may be. The caboose 120 may include an impact absorbing Track Mounted Attenuator (“TMA”) 136 , such as the SCORPION™ manufactured by TrafFix Devices, Inc. In accordance with alternative embodiments, the caboose 120 and/or tractor 116 may include a rigid connection to the rear platform 104 .
[0079] FIG. 1B shows a reverse side of the trailer 100 shown in FIG. 1A . Each platform 104 a,b includes at least one storage compartment 124 . The doors 128 to the storage compartment 124 are shown in FIG. 1A . The reverse perspective of FIG. 1B shows a rigid wall 132 forming the rear of the storage compartment 124 .
[0080] FIG. 1C shows a rear view of the trailer 100 . In FIG. 1C , the TMA 136 is shown in its retracted position. FIG. 1D shows a rear view of the trailer 100 with the TMA 136 in a deployed position.
[0081] FIG. 1E shows a top plan view of the trailer 100 . As can also be seen in FIGS. 1D and 1E , the trailer 100 includes three wall sections 108 stored on top of the platforms 104 a,b . Two of the wall sections 108 a,b nearest the right side of the trailer are positioned end-to-end, with one being positioned on top of each platform. The third wall section 108 c is positioned between the wall sections 108 a,b and the ballast boxes 112 and is approximately bisected by the longitudinal axis A of the trailer (or the first and second platforms). Effectively, by substantially co-locating the longitudinal axis of the third wall section 108 c with the longitudinal axis A of the trailer, the weight of the third wall section 108 c is effectively counter-balanced. The weight of ballast box 112 a therefore counterbalances effectively the first wall section 104 a and ballast box 112 b counterbalances effectively the second wall section 104 b . The platforms 104 a,b are asymmetrical with respect to the longitudinal axis A. Accordingly, the weights of the ballast boxes can be greater than the weights of the wall sections to counter balanced the asymmetrical portion of the platforms. The loading of the trailer shown in FIG. 1E thus serves to balance the weight of the various trailer components with respect to the longitudinal axis A.
[0082] Referring now to FIG. 2A , the trailer 100 is shown in its unloaded or deployed configuration. As can be seen in FIG. 2A , the wall sections 108 a - c have been removed from their loaded positions on top of the platforms 104 a,b and connected between the platforms 104 a,b to form a protective barrier 200 . This is accomplished by removing the wall sections 108 a - c , such as for example through the use of cranes or a forklift, and then disconnecting the two platforms 104 a,b from each other. After the platforms 104 a,b have been disconnected, the platforms 104 a,b are spatially separated and the wall sections 108 a - c are then inserted there-between. As can be seen in FIG. 2A , the two ballast boxes 112 a,b remain in place on top of the platforms 104 a,b . The ballast boxes provide a counter-balance to the weight of the wall sections 108 a - c , which are disposed on the opposite side of the platforms 104 a,b.
[0083] FIG. 2A shows a view of the protective barrier 200 from the perspective of the protected work zone area. From the protected work zone, the storage compartment doors 128 and other equipment are accessible. The protected work zone area 204 can seen in FIG. 2B , which shows a top plan view of the protective barrier 200 shown in FIG. 2A . As can be seen, the protective barrier creates a protected work area 204 , which includes a space adjacent to the wall sections 108 a - c and between the platforms 104 a,b . The road or other work surface is exposed within the work zone area 204 . The work zone area 204 is sufficiently large for heavy equipment to access the work surface.
[0084] FIG. 2C shows the traffic-facing side of the protective barrier 200 . As can be seen in FIG. 2C , the protective barrier 200 presents a protective wall 208 proximate to the traffic zone. The protective wall 208 includes the rigid wall 132 and number of wall sections 108 a - c , which are interconnected to the two platforms 104 a,b . The bottoms of the wall sections 108 a - c are elevated a distance 280 above the roadway 284 . FIGS. 5A-B additionally show a portion of the caboose 120 , which interconnects to and is disposed underneath a selected one of the platforms 104 a,b . The wheels of the caboose 120 , in the deployed position of the trailer 100 shown in FIG. 2C , are covered with a piece of sheet metal 212 . During transport, this piece of sheet metal 212 can be disconnected from the platform 104 and positioned in a stowed manner on top of one of the platforms 104 .
[0085] Although stands 290 are shown in place at either end of the protective barrier 200 and may be used to support individual wall sections 108 of the barrier 200 , it is to be understood that no stands are required to support the barrier 200 . The barrier 200 has sufficient structural rigidity to act as a self-supporting elongated beam when supported on either end by the tractor 116 and caboose 120 . This ability permits the barrier 200 to be located simply by locking the tractor and caboose brakes and relocated simply by unlocking the brakes, moving the barrier 200 to the desired location, and relocking the brakes of the tractor and caboose. Requiring additional supports or stands to be lowered as part of barrier 200 deployment can not only immobilize the barrier 200 but also increase barrier rigidity to the point where it may cause excess damage and deflection to a colliding vehicle and excess ride down and lateral G forces to the occupant of the vehicle.
[0086] The wall section height is preferably sufficient to prevent a vehicle colliding with the barrier 200 from flipping over the wall section into the work area and/or the barrier 200 from cutting into the colliding vehicle, thereby increasing vehicle damage and lateral and ride-down G forces to vehicular occupants. Preferably, the height of each of the wall sections is at least about 2.5 feet, more preferably at least about 3.0 feet, even more preferably at least about 3.5 feet, and even more preferably at least about 4.0 feet. Preferably, the height of the top of each wall section above the surface of the ground or pavement 284 is at least about 3.5 feet, more preferably at least about 4 feet, even more preferably at least about 4.5 feet, and even more preferably at least about 5 feet.
[0087] The protective wall or barrier 200 may additionally include attachment members 216 operable to interconnect a visual barrier 220 to the protective wall 200 . A visual barrier 220 in accordance with embodiments is mounted to the protective wall 200 and extends from the top of the protective wall 200 to approximately four feet above the wall 200 . The visual barrier 220 is interconnected to attachment members 216 , such as poles, which are interconnected to the wall 200 . In accordance with an embodiment, the attachment members 216 comprise poles which extend 10 feet upwardly from the wall section 200 . Each pole may support a 6 lb. light head at the top which generates over 3,000 alums of light. The poles may additionally provide an attachment means for the visual barrier 220 . While attached to the poles, the visual barrier 220 extends approximately 4 feet upwardly from the protective wall 200 .
[0088] The visual barrier 220 provides an additional safety factor for the work zone 204 . Studies have shown that a major cause of highway traffic accidents in and around work zone areas is the tendency for drivers to “rubber-neck” or look into the work zone from a moving vehicle. In this regard, it is found that such behavior can lead to traffic accidents. In particular, the “rubber-necking” driver may veer out of his or her traffic lane and into the work zone, resulting in a work zone incursion. The present invention can provide a structurally rigid wall 200 that prevents incursion into the work zone 204 , as well as a visual barrier 220 which discourages this, so called, “rubber necking” behavior.
[0089] Studies have indicated that people are drawn to lights and distractions, and that they tend to steer and drive into what they are looking at. This is particularly hazardous for construction workers, especially where cones and other temporary barriers are being deployed on maintenance projects. Studies also indicate that lighting and equipment movement within a work zone are important factors in work site safety. Significant numbers of people are injured not only from errant vehicles entering the work zone, but also simply by movement of equipment within the work area. The trailer can be designed not only to keep passing traffic out of the work area, but also to reduce the amount of vehicles and equipment otherwise moving around within the work area.
[0090] In terms of lighting, research indicates more is better. Current lighting is often somewhat removed from the location where the work is actually taking place. Often, the lighting banks are on separate carts which themselves contribute to equipment traffic, congestion and accidents within the job site.
[0091] These competing considerations of motorists, at night, steering towards lights and roadside workmen being safer at night with more lighting can be satisfied by the trailer. The trailer can use the light heads 270 to provide substantial lighting where it is needed. If the work moves, the lighting moves with the work area, rather than the work area moving away from the lighting. Most importantly, the safety barrier—front, back and side—can move along too, providing simple but effective physical and visual barriers to passing traffic. Referring to FIGS. 2B and 2C , the light heads 270 positioned along the barrier 200 have a direction of illumination that is approximately perpendicular or normal to the direction of oncoming traffic. This configuration provides not only less glare to oncoming motorists but also less temptation for motorists to steer towards and into the barrier 200 .
[0092] FIGS. 2A-2C show the protective barrier 200 deployed for use in connection with a work-zone area. The design of the support members and the traffic facing portion of the protective barrier 200 , serve to provide a safe means for mitigating the effects of such a collision. In particular, the barrier 200 can re-direct the impacted moving car down the length of the protective wall 208 . Here, the moving car is not reflected back into traffic. Further incidents are prevented by not reflecting the moving car back from the mobile barrier into other cars, thereby enhancing safety not only of the driver of the vehicle colliding with the barrier but also of other drivers in the vicinity of the incident. The inherent rock/roll movement in the tractor 116 and trailer (caboose) springs and shocks assist dissipation of shock from vehicular impact. In addition, by deflecting the moving vehicle down the length of the protective wall 208 , the work zone 200 is prevented from sustaining an incursion by the moving vehicle, thereby enhancing safety of workers.
[0093] A number of factors are potentially important in maintaining this desirable effect. Firstly, the protective barrier 204 is maintained in a substantially vertical position. This is accomplished through a ballasting system and method in accordance with an embodiment. In particular, the wall sections 108 are balanced in a first step with the ballast boxes 112 . In a following step, a more precise balancing of the protective barrier 200 position is achieved through a system of movable pistons associated with the caboose 120 . This aspect of the invention is described in greater detail below. Second, the structural design of the wall sections 108 serve to provide optimal deflection of an incoming car. Finally as shown in FIG. 2B , the protective wall or barrier 200 is substantially planar and smooth (and substantially free of projections) along its length to provide a relatively low coefficient of friction to an oncoming vehicle. As will be appreciated, projections can redirect the vehicle into the wall and interfere with the wall's ability to direct the vehicle in a direction substantially parallel to the wall.
[0094] Turning now to FIG. 3A , an individual wall section 108 is shown in perspective view from the traffic side of the wall section 108 . As can be seen in FIG. 3A , the wall section 108 includes a wall skin portion 300 , which faces the traffic side of the protective barrier 200 and is smooth to provide a relatively low coefficient of friction to a colliding vehicle. The wall skin 300 is adapted to distribute the force of the impact along a broad surface, thereby absorbing substantially the impact. As additionally can be seen in FIG. 3A , the wall section 108 includes a first end portion or wall end member 304 a . The first end portion 304 a includes a conduit box 308 , a number of bolt holes 312 , a protruding alignment member, which is shown as a large dowel 316 a , and an alignment receiving member, which is shown as a small dowel receiver hole 320 a . As will be appreciated, the alignment member can have any shape or length, depending on the application. The first end portion 304 a of the wall section 108 is adapted to be interconnected to a second end portion 304 b of an adjacent wall section 108 or platform 104 . A second end portion 304 b can be seen in FIG. 3B , which shows the opposite end 304 b of the wall section 108 shown in FIG. 3A , including a protruding small dowel 316 b and a large dowel receiver hole 320 b . For each wall section 108 , the large dowel 316 a disposed on the top of the first end portion 304 a is operatively associated with a large dowel receiver hole 320 b in the second end portion 304 b of an adjacent wall section 108 or platform 104 . Similarly, the small dowel 316 b on the second end portion 304 b is operatively associated with the small dowel receiver hole 320 a in the first end portion 304 a of an adjacent wall section 108 or platform 104 . Additionally, the wall sections 108 are interconnected through a screw-and-bolt connection using the bolt holes 312 associated with the wall ends 304 . The conduit box 308 is additionally aligned with an adjacent conduit box 308 , providing a means for allowing entry and pass-through of such components as electrical lines, air hoses, hydraulic lines, and the like.
[0095] In FIG. 3B , a portion of the wall skin 300 is not shown in order to reveal the interior of the wall section 108 . As can be appreciated, such a partial wall skin 300 is shown here for illustrative purposes. As can be seen in FIGS. 3B and 3C , the wall section 108 includes three bracing sections 324 a - c vertically spaced equidistant from one another. Each of the bracing sections 324 includes two opposing horizontal beams 328 a - b , with the free ends being connected to the adjacent wall end member 304 a,b . The two horizontal beams 328 a - b are interconnected with angled steel members 332 to form a truss-like structure. The wall section 108 includes three bracing sections: the first bracing section 324 a being at the top, the second bracing section 324 b being at the middle and the third bracing section 324 c being at the bottom. Additionally, the wall section 108 includes a number of full-height vertical wall sections 336 a,b , the wall end members 304 a,b , and a number of partial-height vertical wall sections 340 a - c . As shown in FIG. 3A , the full-height wall sections 336 a,b and partial-height wall sections 340 a - c alternate. Additionally, it can be seen that the angled steel members 332 intersect at points where the partial-height wall 340 or full height wall 336 section, as the case may be, meets the horizontal beam 328 a,b , which, on one side, faces the traffic side of the wall section 108 . Additionally, the wall section includes a fourth horizontal member 344 . Unlike the structural members 328 and 336 which are preferably configured as rectangular steel beams, this fourth horizontal member 344 is configured as a steel C-channel beam. The C-channel is preferably positioned substantially at the height of a car or SUV bumper. In use, the bottom of the wall section 108 sits approximately eleven inches off of the ground, and the fourth horizontal member 344 sits approximately twenty inches off of the ground.
[0096] The wall sections 108 constructed as described and shown herein are specifically adapted to prevent gouging of the wall as a result of an impact from a moving car. In particular, gouging as used herein refers to piercing or tearing or otherwise drastic deformation of the wall section, which results in transfer of energy from a moving car into the mobile barrier 200 . As described herein, by deflecting the car down the length of the protective wall 200 , a desirable amount of energy is absorbed by the wall and therefore not transferred to other portions of the protective wall 200 . It is additionally noted that the floating king pin plate of the standard trailer 116 provides a shock absorbing effect for impacts which are received by the protective wall 200 . The shock absorbing effect of the trailer's 116 floating king pin plate 500 is complemented by fixed king pin plate associated with the caboose 120 (which is discussed below).
[0097] In accordance with an embodiment, the dimensions of the various trailer and wall components vary. By way of example, the length of each wall section 108 preferably ranges from about 10 to 30 feet in length, more preferably from about 15 to 25 feet in length, and more preferably from about 18 to 22 feet in length. The width of each of the wall sections preferably ranges from about 18 to 30 inches, more preferably from about 22 to 28 inches, and more preferably from about 23 to 25 inches. The height of each of the wall sections 108 preferably ranges from about 3 to 4.5 feet, more preferably from about 3.75 to 4.25 feet, and more preferably from about 3.9 to 4.1 feet. It should be noted that these height ranges and distances measure from the base of a wall section 108 to the top of the wall section 108 and do not include the wall section's height when it is displaced with respect to the ground. In use, the wall section 108 typically is disposed at a predetermined distance from the ground. In particular, this distance preferably ranges from about 10 to 14 inches, more preferably from about 11 to 13 inches, and more preferably from about 11.5 to 12.5 inches. In accordance with an embodiment, a wall section is approximately 20 feet long, 24 inches wide, 4 feet high as measured from the base of the wall section to the top of the wall section and, when deployed, disposed at a distance of 12 inches from the ground.
[0098] The beams 328 a and 328 b span the length of the entire wall section. In accordance with an embodiment, the horizontal beams 328 a and 328 b measure from about 3-5 inches by about 5-7 inches, more preferably from about 3.5 inches to 4.5 inches by 5.5 inches to 6.5 inches, and even more preferably are about 4 inches by 6 inches. In accordance with an embodiment, the longer dimension of the beam is disposed in the horizontal direction. For example, with 4.times.6 beams, the 4-inch dimension is disposed in the vertical direction and the 6-inch dimension in the horizontal direction. In this embodiment with three sets of horizontal beams, the bottom and middle beams are separated by about 18 inches and the middle and the top beams also by about 18 inches. In this configuration, the total height of the wall section is 4 feet. In other portions of the mobile barrier 200 , the orientations of the horizontal beams may differ. In particular, the longer 6 inch dimension may be in the vertical direction, and the shorter 4 inch dimension may be in the horizontal direction. In accordance with an embodiment, this orientation for the horizontal beams is implemented in connection with the platforms 104 .
[0099] The wall skin 300 may be comprised of a single homogeneous piece of steel that is welded to the wall section 108 . The wall skin 300 is preferably between about 0.1 and 0.5 inch thick, more preferably between about 0.2 and 0.4 inch, and even more preferably approximately 0.25 inches thick. These dimensions are also applicable to the partial-height and full height wall members 340 , 336 . The wall end portions or plates 304 b and 304 a are preferably between about 0.25 and 1.25 inch thick, more preferably between about 0.5 and 1 inch thick, and even more preferably are about 0.75 inch thick.
[0100] In accordance with a preferred embodiment where the wall sections 108 are approximately 20 feet in length, a work space area 204 is defined when these wall sections are deployed that measures approximately 80 feet in length. In particular, the three wall sections total 60 feet in addition to 10 feet on each side of additional space provided by the interior portions of the platforms 104 .
[0101] Referring again to FIG. 3C , a wall section 108 may include a number of attaching devices, which provide a means for interconnecting various auxiliary components to the wall section 108 . In particular, a wall section 108 may include an attachment member mounting 348 , operable to mount an attachment member 216 , such as a pole. The attachment member mounting shown in FIG. 3C includes a lever which, through a quarter turn, is operable to lock the light pole in place. A pole may be used to mount a light in connection with using the wall barrier during night-time hours. As can be appreciated in such conditions, the work area will be required to be illuminated. Such illumination can be accomplished by light poles and corresponding lights which are mounted to the wall section. The light poles, lights and other auxiliary components may be stored in the storage compartments 124 .
[0102] The wall section 108 additionally may include attachments for jack stands 352 . The jack stands 352 provide a means for supporting the wall section 108 at the above-mentioned height of approximately eleven inches from the ground.
[0103] The wall section 108 may additionally include, so called, “glad hand boxes” (not shown), which provide means for accessing 12, 110, 120, 220, and/or 240 volt electricity. In accordance with the embodiments, the protective barrier 200 includes an electric generator and/or one or more batteries (which may be recharged by on-board solar panels) providing electricity which is accessible through the glad hand box and is additionally used in connection with other components of the protective barrier 200 described herein. The generator and/or the batteries may additionally be stored the storage compartments 124 , and the batteries used to start the generator and support electronics when the generator is turned off or is not operational.
[0104] The wall section 108 may be comprised of, or formed from, any suitable material which provides strength and rigidity to the wall section 108 . In accordance with embodiments, the beams of the wall section are made of steel and the outer skin of the wall section is made from sheets of steel. In accordance with alternative embodiments, the wall section 108 is made from carbon fiber composite material.
[0105] Referring now to FIG. 4A , a side perspective view of a platform 104 is shown. In FIG. 4A the platform is resting on a jack stand 352 . Additionally, the outline of the caboose 120 is shown in FIG. 4A . With the caboose 120 attached, the platform 104 shown in FIG. 4A would correspond to the rear of the protective barrier 200 and/or the rear of the loaded trailer 100 . As can be seen in FIG. 4A , the platform includes a king pin 400 . The king pin 400 provides an interconnection between the platform 104 and the caboose 120 . The king pin 400 is disposed on the underside of the platform 104 in a position that allows the king pin 400 to connect with a standard floating king pin plate associated with a semi-tractor 116 or a fixed king pin plate associated with the caboose 120 . In this way, either the caboose 120 or the semi-tractor 116 may be connected to the platform 104 using the king pin 400 . A nose receiver 404 portion of the platform 104 provides a means for receiving the end, or nose portion of the caboose 120 . This aspect of the invention is described in greater detail below.
[0106] In FIG. 4B and FIG. 4C , two opposed platforms 104 are shown with a central external cover plate of the central portions of the platforms being removed to show the structural members while the ballast box external support plates are in position, in FIG. 4D , a platform is shown with all exterior cover plates removed, and in FIG. 4G a platform is shown with all external cover plates in position. As can be seen, the first end 408 of the platform 104 is wider than the second end 412 of the platform 104 . Here, the platform 104 includes support members 421 for supporting the king pin (not shown), a sloping plate 428 for receiving the nose portion of the caboose, a flat plate assembly 422 positioned above and supporting the jack stands 423 , and a sloped or narrowing section 416 , which slopes from the larger, first-end 408 width, to the smaller, second-end 412 width. This sloped portion 416 of the platforms 104 includes the storage compartment 124 . The two second-ends 412 of the platform 104 are adapted to be interconnected to each other. The two first-ends 408 of the platform 104 are adapted to interconnect to either the tractor 116 or the caboose 120 , as described above. As can be seen in FIG. 4D , the platform 104 includes two side channels 420 a - b . Typically, the channel 420 a proximate to the work zone is adapted to receive a ballast box 112 , both in the mobile and the deployed positions.
[0107] FIGS. 4D, 4E, and 4F further show the structural members of each of the platforms. The platforms are identically constructed but are mirror images of one another. The traffic-facing, or elongated, side 460 of the platform 104 includes upper, middle, and lower horizontal structural members 464 , 468 , and 472 . The upper, middle, and lower horizontal structural members are at the same heights as and similar dimensions to the upper, middle, and lower horizontal beams 328 , respectively. The members 464 , 468 , and 472 , unlike the beams 328 , are oriented with the long dimension vertical and the shorter dimension horizontal. By orienting the members differently from the beams, the need for a member similar to the fourth horizontal member 344 is obviated. The upper structural member 464 is part of an interconnected framework of interconnected members 476 , 480 , 484 , 488 , 490 , and 492 defining the upper level of the platform. Lateral structural members 494 provide structural support for the ballast boxes, depending on where they are positioned, and lateral members 496 provide further structural support for the upper level and for the king pin and other caboose interconnecting features discussed below. The first end of the lower structural member attaches to a corner member 497 and second ends of the upper and lower structural members to the second end member 498 . At the level of the lower structural member 472 , lower structural members 473 , 474 , 475 , and 477 define the lower level of the platform. Additional vertical and corner members 478 , 479 , and 481 attach the lower and upper levels of the platform and horizontal support member 483 interconnects corner members 497 and 481 and vertical members 478 and 479 . The lower level further includes lateral members 475 and elongated member 477 to provide further structural support for the lower level and provide support for the bottom of the storage compartment.
[0108] In FIGS. 4G and 4H , portions of the platform 104 are shown, which include the underside of a platform 104 . As can be seen in FIG. 4E , the platform 104 includes a king pin 400 disposed substantially in alignment with a longitudinal axis 405 bisecting a space 407 defined by the nose receiver portion 404 . The nose receiver portion 404 includes two angled components 424 a,b as well as a downwardly facing deflection plate 428 . FIG. 4H shows, in plan view, the components 424 a,b , each of which includes a straight portion 409 a,b and angled portion 411 a,b . The space 407 between the angled portions is in substantial alignment with the king pin 400 .
[0109] As the caboose 120 is backed into the space underneath the platform 104 , the king pin 400 is received in a king pin receiver channel 524 ( FIG. 5 ) in a fixed king pin plate on the caboose 120 , and the nose of the caboose is received in the nose receiver 404 portion of the platform 104 . The nose receiver portion 404 , namely the angled portions of the components 424 a,b and sloped deflection plate 428 , guide the an angled front-nose portion 520 ( FIG. 5 ) of the caboose as the caboose is brought into position underneath the platform 104 to align the king pin with the king pin receiver channel 524 ( FIG. 5 ). In particular, the two angled components 424 operate to provide lateral guidance for the position of the caboose 120 . Here, the two angled components 424 ensure that the king pin 400 is received in the king pin receiver channel 524 associated with the caboose 120 . The downwardly facing deflection plate 428 exerts a downward force on the nose 520 of the caboose that results in the rear of the caboose 120 raising up to engage the rear of the platform 104 . The interconnection between the caboose 120 and the rear of the platform 104 is described in greater detail below.
[0110] In FIG. 5A , a side perspective view of the caboose 120 is shown. As shown in FIG. 5A , the caboose 120 includes the fixed king pin plate 500 . The king pin plate 500 includes a king pin receiver channel 524 provided at the end of the plate 500 . This pin receiver channel 524 is adapted to receive the king pin 400 and provides a locking mechanism for locking the caboose 120 to the end of the platform 104 . In addition, the caboose 104 includes a vertical adjustment member, which is shown as movable pneumatically or hydraulically actuated piston 508 (as can be seen in FIG. 4A ), disposed on each side between the two wheels of the caboose 120 . Although a piston is shown, it is to be understood that any suitable adjustment member may be used, such as a mechanical lifting device (e.g., a jack or crank). The movable piston 508 is associated with a piston cylinder and is interconnected to a top 512 portion and a bottom portion 516 of the caboose 120 . The bottom portion 516 provides a mounting for the wheel axles as well as the wheel suspension. The movable piston 508 , as described in greater detail below, is operable to be inflated, thereby adjusting the height of the selected, adjacent side of mobile barrier 200 . More specifically, the movable piston 508 moves the caboose 120 off of its suspension or leaf springs.
[0111] In FIG. 5A , a side perspective view of the caboose 120 is shown. As can be seen in FIG. 5B , the fixed king pin plate 500 includes the king pin receiver channel 524 . The king pin receiver channel 524 includes a front, wide portion 528 , which leads into a rear, narrow portion 532 , as this king pin receiver channel 524 allows the caboose 120 to be positioned properly while the caboose is being backed into and underneath the platform 104 . In this regard, the nose 520 of the caboose 120 is additionally received in the nose receiver portion 404 , disposed on the underside of the platform 104 . This aspect of the present invention is described in greater detail below.
[0112] Referring now to FIG. 58B , an additional side perspective view of the caboose 120 is shown. In FIG. 5B , the king pin plate 500 is shown removed from the caboose 120 . As can be seen in FIG. 5B , underneath the king pin plate 500 , the caboose 120 includes a number of air cylinders 536 . These air cylinders 536 are associated with a standard ABS braking system and operate independently of the braking system of the tractor 116 . As described in greater detail below, the air cylinders 536 can be locked by an auxiliary mechanism associated with the caboose 120 to hold the caboose 120 in place. The auxiliary mechanism may be adjusted to allow the brakes to be engaged and the caboose 120 held in place even if the caboose 120 is disconnected from the platform 104 . This mechanism additionally provides a means for inflating and deflating the movable piston 508 disposed on either side of the caboose 120 .
[0113] FIGS. 5A, 5B, and 8 depict the removable attachment mechanism between the caboose and the platform. The caboose includes permanently attached first and second pairs 580 a,b of opposing attachment members 584 a,b . Each attachment member 584 a,b in the pair 580 a,b has matching and aligned holes extending through each attachment member. In FIG. 8 , first and second pairs 804 a,b of attachment members 808 a,b are permanently attached to the platform. Each attachment member 808 a,b in the pair includes matching and aligned holes extending through the attachment member 808 . When the caboose is in proper position relative to the platform, the holes in the attachment members 584 a,b and 808 a,b are aligned and removably receive a pin 802 having a cotter pin or key 810 to lock the dowell 802 in position in the aligned holes of each set of engaged pairs of attachment members 580 and 804 .
[0114] An embodiment includes a truck mounted crash attenuator, or equivalently, a Truck Mounted Attenuator (TMA). Referring again to FIG. 1A , a truck mounted attenuator 136 is shown interconnected to the trailer 100 at the caboose 120 . In FIG. 1A , the truck mounted attenuator 136 is shown in a retracted position. The truck mounted attenuator 136 includes a first portion 140 and a second portion 144 . In the retracted position, the first portion 140 is positioned substantially vertically and supports the weight of the second portion 144 , which is held in a substantially horizontal position over the caboose 120 . A movable electronic billboard 148 and light bar 150 (which can provide a selected message to oncoming traffic) is located underneath the second portion 144 of the truck mounted attenuator 136 .
[0115] The deployment of the truck mounted attenuator 136 and the electronic billboard and light bar 148 is illustrated in FIGS. 6A-6G . As shown in FIG. 6A through FIG. 6F , the truck mounted attenuator 136 is extended and lowered into a position wherein both the first portion 140 and the second portion 144 are substantially horizontal and proximate to the ground. As shown in FIG. 6G , the electronic billboard 148 and light bar 150 are then raised. Referring to FIG. 7 , the TMA 136 is typically bolted by a bracket 700 to the caboose 120 . The TMA is thus readily removable simply by unbolting the TMA from the vertical plate of the bracket 700 . Additionally, the bracket 700 and associated components provide a means for attaching the electronic billboard 148 and light bar 150 to the caboose 120 . The bracket 700 is mounted to provide a desirable height for the truck mounted attenuator in its deployed position, more specifically, approximately ten to eleven inches off of the ground. The bracket 700 is additionally mounted to provide visibility of the caboose brake lights and other warning lights associated with the trailer 100 . In FIG. 1C , a rear view of the loaded trailer 100 is illustrated. As shown herein, the truck mounted attenuator 136 is raised into its tracked position. As can be seen, the brake lights 152 of the caboose 120 are visible underneath the truck mounted attenuator 136 . A beacon 156 is also visible, despite the presence of the truck mounted attenuator 136 . The beacon 156 provides a visual indication of an end portion of the trailer 100 . As with the caboose 120 , the truck mounted attenuator 136 may be associated with either of the two platforms 104 and thereafter either end of the trailer.
[0116] Turning now to FIG. 8 , a forced air system 800 in accordance with an embodiment is shown. The forced air system 800 includes two lever attenuators 804 operable to lock the brakes of the caboose 120 independently of the brakes of the tractor 116 . As used herein, locking the brakes includes disconnecting or disabling the automatic brake system, typically associated with the caboose 120 . Here, the brakes are forced into a locked position, thereby locking or preventing movement of the caboose 120 . Also shown in FIG. 8 is a knob 808 operable to control the inflation and/or deflation of the moveable pistons 508 . As described above, the pistons 508 are used to provide a finer grade vertical adjustment of the balancing of the protective barrier 200 by vertically lifting or lowering a selected side of the caboose and interconnected platform. In other words, inflating the piston on a first side of the caboose lifts the first side of the platform relative to the second side of the platform and vice versa. In accordance with embodiments, the air provided to the pistons 508 is delivered from an air supply associated with the trailer 116 and not from an air compressor.
[0117] The interconnection between the platform 104 and the king pin plate 500 is illustrated in FIG. 8 . A removable pin interconnects the platform to the caboose. The pin is removable, and may be locked in place with attachment member 802 .
[0118] Turning now to FIG. 9 , a loaded trailer 100 is shown from the work area-side of the trailer 100 . As shown herein, the wall sections 108 are loaded on top of the platforms 104 and the platforms 104 are interconnected. As described above, this loaded position corresponds to an arrangement of the various components, which can be used to transport the entire system. As shown in FIG. 9 , the platform includes a storage compartment. Various auxiliary components described herein are stored in this storage compartment 124 . As can be seen in FIG. 9 , such components, as the light poles 900 , the corresponding lights themselves 904 , the visual barrier 220 , as well as various electrical components, are shown inside of the compartment. For example, FIG. 9 includes an onboard computer 908 and a generator 912 . In this configuration or in the deployed configuration, various lines 916 , such as electrical lines or air lines, may run along the length of a wall section 108 through the various adjacent conduit boxes 308 .
[0119] Referring now to FIG. 10 , a flow chart is shown which illustrates the steps in a method of deploying a mobile barrier in accordance with an embodiment. Initially at step 1004 , the trailer arrives at a worksite. At step 1008 , the wall sections 108 are unloaded from the trailer bed. This may be done with the use of cranes, a fork lift, and/or other heavy equipment operable to remove and manipulate the weight associated with the wall sections 108 . At step 1012 , the platforms 104 are disconnected from each other. More particularly, the bolt connections that interconnect the platforms 104 are removed. At step 1016 , the platforms 104 are separated. Here, the brakes of the caboose 120 may be locked and the disconnected platform portion of the trailer 116 attached to the tractor 116 may be driven away from the location of the caboose 120 and its attached platform. A dolly or castor wheel may be connected to the end of the platform 104 to provide mobility for the portion of the platform 104 attached to the tractor 116 , thereby allowing the platform to move into position to be engaged with the end wall section. Alternatively, a first platform connected to the tractor 116 is positioned at the desired location before disconnection of the platforms. Jacks attached to the first platform are lowered into position with the roadway. The platforms are then disconnected, with the second platform being supported by the caboose. A forklift or other vehicle is used to move the second platform into position for connection with the wall sections. In any event at step 1020 , the platforms 104 and wall sections 108 are interconnected to form a protective barrier 200 . At this point a continuous protective barrier 200 is formed from the various components of the trailer. Next, a number of steps or operations may be employed. At step 1024 , it may be determined that the protective barrier 200 must be balanced. More particularly, the weight of the protective barrier 200 must be adjusted such that the protective barrier 200 wall comes into a substantially vertical alignment. If no balancing of the protective barrier 200 is needed, work may be commenced within the protected area 204 of the protective wall 200 . At step 1028 , it may be determined that the direction or orientation of the protective barrier 200 may need to be changed. This may be done by jacking the second platform, disconnecting the caboose, and reversing the positions of the tractor 116 and caboose 120 . Alternatively, the jack stands may be retracted and the truck, while the wall sections are deployed, driven, while attached to the barrier, to a new location. At step 1032 , work may be completed and the protective barrier 200 may then be disassembled for transport.
[0120] Turning now to FIG. 11 , a method of balancing a protective barrier 200 (step 1024 ) is illustrated. This method assumes that the ballast boxes are not adequate to counter-balance completely the deployed barrier. At step 1104 , the protective barrier 200 or wall is inspected to determine whether or not the wall is disposed at a substantially vertical orientation. This can be done using a manual or automatic level detection device. If at decision 1108 the wall is substantially vertical, step 1112 follows. At step 1112 the process may end. If at decision 1108 , it is determined that the wall is not substantially vertical, step 1116 follows. At step 1116 , one or more of the piston cylinders 508 are inflated or deflated to provide a counter balance to the weight of the protective barrier 200 and desired barrier 200 orientation.
[0121] FIG. 12 illustrates a method of changing directions for the protective barrier 200 . Initially, at step 1204 , the caboose-engaging platform is placed on jack stands and thereafter the caboose is disconnected from the platform to which it is attached. At step 1208 , the caboose is towed out from underneath the platform 104 . Here, the caboose 120 may be connected to or otherwise attached to a tractor, forklift, or pickup truck, which is operable to tow the caboose 120 . At step 1220 , the tractor-engaging platform is placed on jack stands and the tractor 116 is disconnected from the platform 104 to which it is attached. At step 1216 , the tractor 116 is driven out from underneath the platform 104 . At step 1220 , the positions of the caboose 120 and tractor 116 are interchanged. At 1224 , the caboose 120 is positioned underneath and connected to the platform 104 to which the tractor 104 was formally attached. As described above, this includes a nose receiver portion 404 , providing guidance to the caboose 120 in order to guide the king pin 400 into the king pin receiver channel 532 associated with the king pin plate. At step 1228 , the tractor 116 is positioned with respect to and connected to the platform 104 to which the caboose 120 was formally attached.
[0122] Referring now to FIG. 13 , a method of loading a trailer in accordance with embodiments is illustrated. Initially at step 1304 , the platforms 104 and wall sections 108 are placed on jack stands and disconnected from one another. This includes removing the bolt connections which interconnect the opposing faces of the platforms 104 and/or wall sections 108 . At step 1308 , the platforms 104 are brought together. As described above, this includes interconnecting a castor or dolly wheel to at least one platform end and driving the platform 104 in the direction of the opposing platform. Alternatively, the platform engaging the caboose is taken off of its jack stands and maneuvered by a vehicle to mate with the other, stationary platform. At step 1312 , the platforms 104 are interconnected by such means as bolting the platforms together. At step 1316 , the wall sections 108 are loaded onto the truck bed. Because the ballast boxes typically do not counter-balance precisely the loaded wall sections and vice versa, the piston cylinders 508 are inflated or deflated, as desired, to provide a level ride of the trailer. Finally, at step 1320 , the trailer 100 departs from the worksite. In one configuration, castor or dolly wheels may be put on each of the two platforms so that, when they are disconnected from end wall sections of the barrier, the first and second platforms may be moved into engagement with and connected to one another. The wall sections may then be disconnected from one another and loaded onto the connected platforms.
[0123] The above discussion relates to a mobile barrier in accordance with an embodiment that includes a number of interconnectable wall sections, which are, in one configuration placed on the surface of a truck bed. In a second configuration, these wall sections are removed from the truck bed and interconnected with portions of the trailer to form a protective barrier. In this way, a fixed wall is formed that provides protection for a work area. The present invention can provide a non-rotating wall that is deployed to form the protective barrier. Alternative embodiments of a fixed wall mobile barrier are illustrated in FIGS. 14A-C and FIGS. 15A-C .
[0124] FIGS. 14A-C illustrate a “sandwich” type extendable protective wall. As shown in FIG. 14A , the mobile barrier 1400 includes two platforms 104 and three interconnected wall sections 1404 a , 1404 b and 1404 c . FIG. 14A illustrates a contracted or retracted position wherein the wall sections 1404 a - c are disposed adjacent to one another in a “sandwich position”. FIG. 14B illustrates an intermediate step in the deployment of the mobile barrier 1400 . Here, the platforms 104 are moved away from each other and the sandwiched wall sections extended. From this intermediate position, the sections 1404 a and 1404 c move forward to a position adjacent to the forward position of the wall section 1404 a . In accordance with embodiments, the wall sections 1404 a - c are disposed on sliding rails which allow the displacement shown in FIG. 14B-C . Additionally between wall sections 1404 a and 1404 a (similarly 1404 b and 1404 c ) an articulating mechanism is provided, which allows motion between the adjacent wall sections. FIG. 14C shows the final position of the mobile barrier 1400 . Here, the various wall sections 1404 a - c and the platforms 104 provide a continuous mobile barrier included a protected work space.
[0125] FIGS. 15A-15C illustrate a telescoping type protective wall system 1500 . FIG. 15A shows a retracted, or closed, position of the protective barrier 1500 . The protective barrier includes opposing platforms 104 . The protective barrier in this embodiment includes two wall sections, the first wall section 1504 encloses the second wall section 1508 in the contracted position shown in FIG. 15A . In the intermediate position shown in FIG. 15B , the second wall section 1508 is extended outward from the first wall section 1504 in a telescopic manner. In the final position shown in FIG. 15C , the second wall section 1508 moves forward to a position adjacent to the first wall section 1504 . In the final position shown in FIG. 15C , the first wall section 1504 , second wall section 1508 and portions of the two platforms 104 form a continuous protective barrier including protective interior space.
[0126] A number of alternative caboose embodiments will now be discussed.
[0127] Referring to FIG. 16 , the caboose 1600 has one or more steerable or articulating axles 1604 a,b or wheels 1608 a - d to avoid a selected area 1612 , such as a work area containing wet concrete. The wheels 1608 a - d are turned to a desired orientation, which is out of alignment with the tractor 116 tires, so that, when the trailer is pulled forward by the tractor 116 , the trailer moves both forward and laterally out of alignment with the path of movement of the tractor 116 . This may be effected in many ways. In one configuration, steering arms (not shown) are attached to the axles 1604 , and the arms are controlled by electrically operated hydraulic cylinders incorporated into the caboose frame assembly. The caboose axles are turned out when pulling ahead to more quickly move the rear of the trailer out and away from the area 1612 . Once the tractor and trailer are out of alignment with the area 1612 , the axles are returned, such as by the hydraulics, to their original positions in alignment with the tractor wheels. The electronics controlling the hydraulics are controlled from the tractor cab or a special switch assembly located in the caboose or on the trailer near the caboose. Alternatively, the axles or wheels may be steered manually, such as by a steering wheel mounted on the platform or caboose. The nose portion of the caboose remains stationary in the members 404 a,b , or the caboose does not rotate about the kingpin but remains aligned with the longitudinal axis of the trailer throughout the above sequence.
[0128] Referring to FIG. 17 , the caboose 1700 articulates or rotates about the king pin 400 . One or more electrically driven hydraulic cylinders at the front of the caboose laterally displaces the nose 1704 in a desired orientation relative to the longitudinal axis of the trailer. When the caboose is rotated to place the wheels 1708 a - d in a desired orientation, which is out of alignment with the tractor 116 tires, the tractor pulls the trailer forward. The trailer moves both forward and laterally out of alignment with the path of movement of the tractor 116 . The hydraulics then push the nose of the caboose to the aligned, or normal, orientation in which the wheels of the caboose are in alignment with the wheels of the tractor. The hydraulic cylinder(s) can be connected directly to a front pivot (not shown) or incorporated into the nose portion or the current “V” wedge assembly, which includes the members 404 a,b . In the latter design, the members 404 a,b are mounted on a movable plate, and the hydraulic cylinder(s) move the plate to a desired position while the nose portion 1704 is engaged by, or sandwiched between, the members 404 a,b . Unlike the prior caboose embodiment, the caboose rotates about the kingpin and does not remain aligned with the longitudinal axis of the trailer throughout the above sequence.
[0129] Referring to FIG. 18 , the caboose 1800 has an elongated frame with articulated steering on one or more axles 1804 a - c , with the rear axle 1804 a being preferred. When only the rear axle is steerable, the axle 1804 a is steered, as noted above, to place the wheels 1808 a,b in the desired orientation. After the caboose is rotated to place the wheels 1808 a,b in a desired orientation, which is out of alignment with the tractor 116 tires, the tractor pulls the trailer forward. The trailer rotates about the king pin 400 and moves both forward and laterally out of alignment with the path of movement of the tractor 116 . The wheels 1808 are then moved back into alignment with the wheels of the tractor. Like the prior embodiment, the caboose rotates about the kingpin and does not remain aligned with the longitudinal axis of the trailer throughout the above sequence. To make this possible, the nose portion of the caboose may need to be removed from engagement with the members 404 a,b , such as by moving a movable plate, to which the members are attached, away from the nose portion.
[0130] In another embodiment, the caboose is motorized independently of the tractor. An engine is incorporated directly into the caboose to provide self-movement and power. In one configuration made possible by this embodiment, the platforms could engage simultaneously two cabooses with a TMA positioned on each caboose to provide crash attenuation at both ends of the trailer. One or both of the cabooses is motorized. This is particularly useful where the trailer may be on site for longer periods and needs only nominal movement from time-to-time, such as at gates, for spot inspection stations, or for security and/or military applications where unmanned and/or more protected movement is desired.
[0131] In other embodiments, the caboose is attached permanently to the platform. In this embodiment, different tractor/trailers, that are mirror images of one another, are used to handle roadside work areas at either side of a roadway.
[0132] The present invention, in various embodiments, includes components, methods, processes, systems and/or apparatus substantially as depicted and described herein, including various embodiments, sub combinations, and subsets thereof. Those of skill in the art will understand how to make and use the present invention after understanding the present disclosure. The present invention, in various embodiments, includes providing devices and processes in the absence of items not depicted and/or described herein or in various embodiments hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease and/or reducing cost of implementation.
[0133] The foregoing discussion of the invention has been presented for purposes of illustration and description. The foregoing is not intended to limit the invention to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the invention are grouped together in one or more embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the invention.
[0134] Moreover, though the description of the invention has included description of one or more embodiments and certain variations and modifications, other variations and modifications are within the scope of the invention, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative embodiments to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter. | In one embodiment, a safety trailer has semi-tractor hitches at both ends and a safety wall that is fixed to one side of the trailer. That side, however, can be changed to the right or left side of the road, depending on the end to which the truck attaches. A caboose can be attached at the end of the trailer opposite the tractor to provide additional lighting and impact protection. Optionally, the trailer can be equipped with overhead protection, lighting, ventilation, onboard hydraulics, compressors, generators and other equipment, as well as related fuel, water, storage and restroom facilities and other amenities. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of U.S. Provisional Application No. 61/262,883, filed on Nov. 19, 2009, in the United States Patent and Trademark Office, the entire content of which is incorporated herein by reference.
BACKGROUND
[0002] 1. Field
[0003] One or more embodiments of the present invention relate to an energy management system, and more particularly, to a grid-connected energy storage system including an energy management system.
[0004] 2. Description of the Related Art
[0005] Interest in harnessing renewable or green energy resources has been increasing recently. Various forms of renewable energy resources (e.g., solar, wind or geothermal power) are harnessed to generate electricity. The generated electricity is supplied to the power grid to reach homes and businesses. Prior to being supplied to the power grid, the generated electricity may be stored in a storage device. Further, systems need to be put into place to accommodate interruptions in the supply of power from the renewable energy resource. Also, it is necessary to convert the power into a form that may be appropriately stored or utilized.
SUMMARY OF THE INVENTION
[0006] An aspect of an embodiment of the present invention is directed toward a grid-connected energy storage system including an energy management system.
[0007] An embodiment of the present invention provides an energy management system including: a first interface configured to receive a first power from a power generation system; a second interface configured to couple to the power generation system, a power grid, and a storage device, and to receive at least one of the first power from the power generation system, a second power from the power grid, or a third power from the storage device, and to supply a fourth power to at least one of the power grid or a load; and a third interface configured to receive the third power from the storage device, and to supply a fifth power to the storage device for storage.
[0008] The second interface may be configured to receive the second power and the first power converted by the first interface concurrently or at different times.
[0009] The third interface may be further configured to receive at least one of the first power converted by the first interface or the second power converted by the second interface.
[0010] The third interface may be configured to receive the third power, the first power converted by the first interface, and the second power converted by the second interface, concurrently or at different times.
[0011] The system may be configured to store the first power in the storage device via the third interface as the fifth power, or to transfer the first power via the second interface to at least one of the power grid or the load as the fourth power.
[0012] The system may be further configured to supply the first power or the third power to the load as the fourth power even if the power grid is in a normal operating state.
[0013] The system may be configured to store the second power from the power grid in the storage device via the second and third interfaces as the fifth power, or to supply the second power to the load.
[0014] The system may be configured to supply the third power from the storage device via the second interface to the power grid or the load as the fourth power.
[0015] The first interface may include a first power converter configured to convert the first power from DC or AC power to a DC sixth power.
[0016] The first power converter may be further configured to perform maximum power point tracking control to obtain a maximum power generated by the power generation system.
[0017] The second interface may include a second power converter and the third interface may include a third power converter, wherein the second power converter is configured to: convert the DC sixth power to the fourth power, which is an AC power; convert a seventh power from the third power converter from DC power to the fourth power; and convert the second power from AC power to an eighth power, which is a DC power, and wherein the third power converter is configured to: convert the sixth power or the eighth power to the fifth power; and convert the third power to the seventh power.
[0018] The second power converter may be further configured to control a power conversion efficiency.
[0019] The third power converter may be further configured to control a power conversion efficiency.
[0020] The energy management system may further include: a first switch between the second power converter, and the power grid and the load; and a second switch between the first switch and the power grid wherein the first and second switches are configured to be controlled in accordance with a control signal from a controller.
[0021] The controller may be configured to turn the first switch on and the second switch off to supply the fourth power to the load.
[0022] The energy management system may further include a controller configured to: receive at least one of a voltage sensing signal, a current sensing signal or a temperature sensing signal from at least one of the first, second and third power converters; output a pulse width modulation control signal to at least one of the first, second or third power converters; monitor a status of at least one of the storage device, the power grid, or the load; determine a driving mode; and control conversion operations and/or efficiencies of at least one of the first, second, and third converters or the first and second switches.
[0023] The energy management system may further include a DC stabilizer between the first and third power converters and the second power converter, and configured to maintain a constant DC voltage level at an input of the second power converter and at an input of the third power converter.
[0024] The DC stabilizer may include a capacitor.
[0025] The first interface may include a maximum power point tracking converter configured to: convert the AC or DC first power to a sixth power, which is a DC power; and perform a maximum power point tracking control for tracking the maximum output voltage from the power generation system.
[0026] The second interface may include a bi-directional inverter and the third interface may include a bi-directional converter, wherein the bi-directional inverter is configured to: convert the DC sixth power to the fourth power, which is an AC power; convert a seventh power from the bi-directional converter from DC power to the fourth power; and convert the second power from AC power to an eighth power, which is a DC power, and wherein the bi-directional converter is configured to: convert the sixth power or the eighth power to the fifth power; and convert the third power to the seventh power.
[0027] The energy management system may further include a DC link capacitor between the bi-directional inverter, and the MPPT converter and the bi-directional converter, and configured to: supply the sixth power to the bi-directional inverter or the bi-directional converter; and stabilize the DC voltage level at an input of the bi-directional converter and at an input of the bi-directional inverter.
[0028] The energy management system may further include a battery management system between the third interface and the storage device, and configured to control charging and discharging operations of the storage device.
[0029] The battery management system may further be configured to perform at least one of an over-charge protection function, an over-discharging protection function, an over-current protection function, an overheat protection function, or a cell balancing operation, by determining voltage, current, and temperature of the storage device.
[0030] The storage device may include a battery.
[0031] Another embodiment of the present invention provides an energy storage system including the energy management system and the storage device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] The accompanying drawings, together with the specification, illustrate exemplary embodiments of the present invention, and, together with the description, serve to explain the principles of the present invention.
[0033] FIG. 1 is a block diagram of a grid-connected energy storage system according to an embodiment of the present invention;
[0034] FIG. 2 is a detailed block diagram of the grid-connected energy storage system of FIG. 1 ;
[0035] FIG. 3 is a block diagram of a grid-connected energy storage system according to another embodiment of the present invention;
[0036] FIG. 4 is a diagram illustrating flows of a power signal and a control signal in the grid-connected energy storage system of FIG. 3 ;
[0037] FIG. 5 is a flowchart illustrating operations of a grid-connected energy storage system according to an embodiment of the present invention; and
[0038] FIG. 6 is a flowchart illustrating operations of a grid-connected energy storage system according to an embodiment of the present invention.
EXPLANATIONS OF CERTAIN REFERENCE NUMERALS
[0039]
[0000]
100, 200: grid-connected energy
storage system
110, 210: energy management system
120: storage device
130, 230: power generation system
140, 240: grid
150, 250: load
111: first power converter
112: second power converter
113: third power converter
114: controller
116, 216: first switch
117, 217: second switch
118: DC link portion
211: MPPT converter
212: bi-directional inverter
213: bi-directional converter
214: integrated controller
215: BMS
220: battery
DETAILED DESCRIPTION
[0040] In the following detailed description, only certain exemplary embodiments of the present invention have been shown and described, simply by way of illustration. As those skilled in the art would realize, the described embodiments may be modified in various different ways, all without departing from the spirit or scope of the present invention. Accordingly, the drawings and description are to be regarded as illustrative in nature and not restrictive. Like reference numerals designate like elements throughout the specification.
[0041] Embodiments of the present invention will be described in more detail with reference to accompanying drawings. Certain parts for comprehension of operations according to the embodiments of the present invention are described below, and certain other parts may be omitted in order not to complicate understanding of the present invention.
[0042] FIG. 1 is a block diagram of a grid-connected energy storage system 100 according to an embodiment of the present invention.
[0043] Referring to FIG. 1 , the grid-connected energy storage system 100 of the present embodiment includes an energy management system 110 and a storage device 120 , and the grid-connected energy storage system 100 is connected to a power generation system 130 , a grid 140 , and a load 150 .
[0044] The energy management system 110 receives power from the power generation system 130 ; and transfers the power to the grid 140 or stores the power in the storage device 120 or supplies the power to the load 150 . The generated power may be direct current (DC) power or alternating current (AC) power.
[0045] The energy management system 110 stores the power generated in the power generation system 130 in the storage device 120 or transfers the generated power to the grid 140 or supplies the generated power to the load 150 . In addition, the energy management system 110 may transfer the power stored in the storage device 120 to the grid 140 , may supply the stored power to the load 150 , or may store the power supplied from the grid 140 in the storage device 120 . Also, the energy management system 110 performs an uninterruptible power supply (UPS) operation in an abnormal state, for example, during a power failure of the grid 140 , the energy management system 110 may be configured to supply the power to the load 150 . Otherwise, the energy management system 110 may supply the power generated by the power generation system 130 and the power stored in the storage system 120 to the load 150 even when the grid 140 is in a normal state.
[0046] The energy management system 110 performs a power conversion operation for storing the generated power in the storage device 120 , a power conversion operation for storing the generated power to the grid 140 or the load 150 , a power conversion operation for storing the power of the grid 140 in the storage device 120 , and a power conversion operation for supplying the power stored in the storage device 120 to the grid 140 or the load 150 . In addition, the energy management system 110 monitors states of the storage device 120 , the grid 140 , and the load 150 in order to distribute the power generated by the power generation system 130 , the power supplied from the grid 140 , or the power stored in the storage device 120 to the storage device 120 , the grid 140 , and/or the load 150 .
[0047] The storage device 120 is a large capacity storage device for storing the power supplied from the energy management system 110 . The supplied power is converted from the power generated by the power generation system 130 , or is converted from the utility power supplied from the grid 140 . The power stored in the storage device 120 may be supplied to the grid 140 or to the load 150 according to control of the energy management system 110 . The storage device 120 includes a secondary rechargeable battery, for example, a nickel-cadmium battery, a lead acid battery, a nickel metal hydride (NiMH) battery, a lithium ion battery, and/or a lithium polymer battery.
[0048] In the present embodiment, the grid-connected energy storage system 100 is configured to include the energy management system 110 and the storage system 120 . However, the present invention is not limited thereto, and the grid-connected energy storage system may include the energy management system formed integrally with the storage device.
[0049] The power generation system 130 includes a system for generating electrical energy by using renewable energy, for example, an energy source such as solar energy, wind power, or tidal power. For example, when the power generation system 130 is a photovoltaic power generation system, a solar array converts solar light into electrical energy. In addition, the photovoltaic power generation system includes a plurality of modules which are connected in series and/or in parallel to each other and a supporter. However, the power generation system 130 may alternatively include a system for generating electrical energy by using some other suitable type of energy and/or power source.
[0050] Structures of the energy management system 110 and the grid-connected energy storage system 100 including the energy management system 110 will be described in more detail with reference to FIG. 2 .
[0051] FIG. 2 is a detailed block diagram of the grid-connected energy storage system 100 of FIG. 1 .
[0052] Referring to FIG. 2 , the energy management system 110 includes a first power converter 111 , a second power converter 112 , a third power converter 113 , a controller 114 , a first switch 116 , a second switch 117 , and a DC link portion 118 . The energy management system 110 is connected (or coupled) to the power generation system 130 , the storage device 120 , the grid 140 , and the load 150 . Flows of the power between the components of FIG. 2 are denoted by solid lines, and flows of control signals are denoted by dotted lines.
[0053] The first power converter 111 is connected (or coupled) between the power generation system 130 and a first node N 1 , and converts the power (or first power) generated by the power generation system 130 to transfer the power to the first node N 1 . The power generated by the power generation system 130 may be DC power or AC power, and accordingly, the first power converter 111 converts the AC power or the DC power respectively to DC power of different voltages. The first power converter 111 may perform a rectification operation to convert the AC power to DC power (or sixth power), or may operate as a converter to convert the DC power to DC power (or sixth power) of different voltages. In addition, the first power converter 111 performs maximum power point tracking (MPPT) control in order to obtain the maximum power generated by a photovoltaic power generation system 131 , a wind power generation system 132 , or a tidal power generation system 133 , according to a control (or control signal) of the controller 114 .
[0054] The second power converter 112 is connected (or coupled) between the first node N 1 and the grid 140 , and operates as an inverter to convert the DC power converted by the first power converter 111 to AC power (or fourth power) for the grid 140 or converts the DC power converted by the third power converter 113 to AC power (or fourth power) for the grid 140 . In addition, the second power converter 112 performs a rectification operation, that is, converts the utility AC power (or second power) supplied from the grid 140 to DC power (or eighth power) to transfer the DC power to the first node N 1 . Also, the second power converter 112 controls a conversion efficiency of power according to control of the controller 114 .
[0055] The third power converter 113 is connected (or coupled) between the first node N 1 and the storage device 120 , and converts the DC power supplied via the first node N 1 to DC power (or fifth power) of different voltages to transfer the converted DC power to the storage device 120 . In addition, the third power converter 113 converts the DC power (or third power) stored in the storage device 120 to DC power (or seventh power) of different voltages to transfer the converted DC power to the first node N 1 . That is, the third power converter 113 operates as a converter which converts the DC power to DC power of different voltages. Also, the third power converter 113 controls a conversion efficiency according to the control of the controller 114 .
[0056] The first switch 116 is connected (or coupled) between the second power converter 112 and a second node N 2 . The second switch 117 is connected between the second node N 2 and the grid 140 . The first switch 116 and the second switch 117 are configured to block the power(s) flowing between the second power converter 112 , the grid 140 , and the load 150 (e.g., the second power and/or fourth power), according to the control of the controller 114 . The first switch 116 and the second switch 117 may be circuit breakers. Switching operations of the first and second switches 116 and 117 are controlled by the controller 114 .
[0057] The DC link portion 118 maintains a DC voltage level at the first node N 1 to be at a DC link level. The voltage level at the first node N 1 may be unstable due to an instantaneous voltage sag of the power generation system 130 or the grid 140 , or a peak load of the load 150 . However, the voltage at the first node N 1 should be stabilized in order for the second power converter 112 and the third power converter 113 to operate normally. Therefore, the DC link portion 118 maintains the DC voltage level at the first node N 1 at a constant DC link voltage level.
[0058] The controller 114 controls overall operation of the grid-connected energy storage system 110 . The controller 114 receives voltage sensing signals, current sensing signals, and temperature sensing signals sensed by the first, second, and third power converters 111 , 112 , and 113 , and then outputs pulse width modulation (PWM) control signals to switching devices of the first through third power converters 111 , 112 , and 113 to control the conversion efficiencies. In addition, the controller 114 monitors states of the storage device 120 , the grid 140 , and the load 150 , and determines a driving mode, for example, a power supply mode for supplying the power generated by the power generation system 130 to the grid 140 , a power storage mode for storing the power in the storage device 120 , and a power supply mode for supplying the power to the load 150 , according to the monitored states of the storage device 120 , the grid 140 , and the load 150 . The controller 114 controls the conversion operations and efficiencies of the first to third converters 111 , 112 , 113 and turning on/off operations of the first and second switches 116 and 117 , according to the determined driving mode.
[0059] The power generation system 130 generates power (or first power) and outputs the generated power to the energy management system 110 . The power generation system 130 may be the photovoltaic system 131 , the wind power generation system 132 , or the tidal power generation system 133 . Otherwise, the power generation system 130 may be a power generation system generating power from renewable energy, such as geothermal energy. In particular, a solar battery generating power by using the photovoltaic energy may be easily installed in a house or a plant, and thus, may be suitable for the grid-connected energy storage system 100 which is distributed in each house.
[0060] The grid 140 may include a power plant, a substation, and power transmission cables. When the grid 140 is in a normal state, the grid 140 supplies the power to the storage device 120 or to the load 150 according to the turning on/off of the first and second switches 116 and 117 , and receives the power supplied from the storage device 120 or the power generated from the power generation system 130 . When the grid 140 is in an abnormal state caused by, for example, electric failure or electric repair work, the power supply from the grid 140 to the storage device 120 or to the load 150 is stopped, and the power supply from the storage device 120 to the grid 140 is also stopped.
[0061] The load 150 consumes the power generated by the power generation system 130 , the power stored in the storage device 120 , and/or the power supplied from the grid 140 . The load 150 may be, for example, a house or a plant.
[0062] FIG. 3 is a block diagram of a grid-connected energy storage system 200 according to another embodiment of the present invention.
[0063] Referring to FIG. 3 , an energy management system 210 includes an MPPT converter 211 , a bi-directional inverter 212 , a bi-directional converter 213 , an integrated controller 214 , a battery management system (BMS) 215 , the first switch 216 , the second switch 217 , and a DC link capacitor 218 . The energy management system 210 is connected to a battery 220 , a photovoltaic (PV) system 230 including a solar panel 231 , the grid 240 , and the load 250 .
[0064] The MPPT converter 211 converts a DC voltage (or first power) output from the solar battery 231 to a DC voltage of the first node N 1 . Since an output of the solar panel 231 varies depending on weather conditions, such as solar radiation and temperature, and a load condition, the MPPT converter 211 controls the solar panel 231 to generate the maximum amount of power. That is, the MPPT converter 211 operates as a boost DC-DC converter, which boosts the DC voltage output from the solar battery 231 and outputs the boosted DC voltage, and as an MPPT controller. For example, the MPPT converter 211 may output a DC voltage in the range of about 300 V to about 600 V. In addition, the MPPT converter 211 performs the MPPT control for tracking the maximum output voltage from the solar battery 231 . The MPPT control may be executed by a perturbation and observation (P&O) control method, an incremental conductance (IncCond) control method, or a power versus voltage control method. The P&O control method increases or reduces a reference voltage by measuring a current and a voltage of the solar panel 231 . The IncCond control method is to control the output DC voltage by comparing an output conductance with an incremental conductance of the solar panel 231 , and the power versus voltage control method is to control the output DC voltage by using a slope of a power versus voltage characteristic. Other MPPT control methods may also be used.
[0065] The DC link capacitor 218 is connected (or coupled) between the first node N 1 and the bi-directional inverter 212 in parallel. The DC link capacitor 218 supplies the DC voltage (or sixth power) output from the MPPT converter 211 to the bi-directional inverter 212 or the bi-directional converter 213 while maintaining the DC voltage level at the DC link level, for example, DC 380 V. The DC link capacitor 218 may be an aluminum electrolytic capacitor, a polymer capacitor, or a multi layer ceramic capacitor (MLC). The voltage level at the first node N 1 may be unstable due to variation in the DC voltage output from the solar battery 231 , the instantaneous voltage sag of the grid 240 , or the peak load occurring at the load 250 . Therefore, the DC link capacitor 218 provides the bi-directional converter 213 and the bi-directional inverter 212 with the stabilized DC link voltage for normally operating the bi-directional converter 213 and the bi-directional inverter 212 . In the present embodiment illustrated in FIG. 3 , the DC link capacitor 218 is separately formed, however, the DC link capacitor 218 may be included in the bi-directional converter 213 , the bi-directional inverter 212 , or the MPPT converter 211 .
[0066] The bi-directional inverter 212 is connected (or coupled) between the first node N 1 and the grid 240 . The bi-directional inverter 212 converts the DC voltage (or sixth power) output from the MPPT converter 211 and the DC voltage (or seventh power) output from the bi-directional converter 213 to an AC voltage (or fourth power) of the grid 240 or the load 250 , and converts the AC voltage (or second power) supplied from the grid 240 to the DC voltage (or eighth power) to transfer the DC voltage to the first node N 1 . That is, the bi-directional inverter 212 operates both as an inverter for converting the DC voltage to the AC voltage and as a rectifier for converting the AC voltage to DC voltage.
[0067] The bi-directional inverter 212 rectifies the AC voltage (or second power) input from the grid 240 via the first and second switches 216 and 217 to the DC voltage (or eighth power) which is to be stored in the battery 220 , and converts the DC voltage output from the battery 220 to AC voltage (or fourth power) for the grid 240 . The AC voltage output to the grid 240 should match a power quality standard of the grid 240 , for example, a power factor of 0.9 or greater and a total harmonic distortion (THD) of 5% or less. To this end, the bi-directional inverter 212 synchronizes a phase of the AC voltage with a phase of the grid 240 to prevent reactive power from being generated (or reduce the likelihood of reactive power being generated), and adjusts the AC voltage level. In addition, the bi-directional inverter 212 may include a filter for removing a harmonic from the AC voltage output to the grid 240 , and the filter may have functions such as restriction of a voltage changing range, power factor improvement, removal (or reduction) of DC component, and protection of transient phenomena. The bi-directional inverter 212 of the present embodiment performs both as an inverter which converts the DC power of the power generation system 230 or the battery 220 to AC power to be supplied to the grid 240 or the load 250 , and a rectifier which converts the AC power supplied from the grid 240 to DC power to be supplied to the battery 220 .
[0068] The bi-directional converter 213 is connected between the first node N 1 and the battery 220 , and converts the DC voltage (or sixth power or the eighth power) at the first node N 1 to the DC voltage (or fifth power) to be stored in the battery 220 . In addition, the bi-directional converter 213 converts the DC voltage (or third power) stored in the battery 220 to a suitable DC voltage (or seventh power) level to be transferred to the first node N 1 . For example, when the DC power (or first power) generated by the photovoltaic power generation system 230 is charged in the battery 220 or the AC power (or second power) supplied from the grid 240 is charged in the battery 220 , that is, in a battery charging mode, the bi-directional converter 213 functions as a converter which decompresses (or reduces) the DC voltage level at the first node N 1 or the DC link voltage level maintained by the DC link capacitor 218 , for example, a DC voltage of 380 V, down to a battery storing voltage, for example, a DC voltage of 100V. In addition, when the power (or third power) charged in the battery 220 is supplied to the grid 240 or to the load 250 , that is, in a battery discharging mode, the bi-directional converter 213 functions as a converter which boosts the battery storing voltage, for example, a DC voltage of 100 V, to the DC voltage level at the first node N 1 or the DC link voltage level, for example, a DC voltage of 380 V. The bi-directional converter 213 of the present embodiment converts the DC power generated by the photovoltaic power generation system 230 or the DC power converted from the AC power supplied from the grid 240 to DC power to be stored in the battery 220 , and converts the DC power stored in the battery 220 to DC power to be input into the bi-directional inverter 212 for supplying the DC power to the grid 240 or to the load 250 .
[0069] The battery 220 stores the power supplied from the photovoltaic power generation system 230 or the grid 240 . The battery 220 may include a plurality of battery cells which are connected in series or in parallel with each other to increase a capacity and an output thereof, and charging and discharging operations of the battery 220 are controlled by the BMS 215 or the integrated controller 214 . The battery 220 may include various suitable kinds of battery cells, for example, a nickel-cadmium battery, a lead-acid battery, an NiMH battery, a lithium ion battery, and/or a lithium polymer battery. The number of battery cells configuring the battery 220 may be determined according to a power capacity required by the grid-connected energy storage system 200 and/or conditions of designing the battery 220 .
[0070] The BMS 215 is connected to the battery 220 , and controls the charging/discharging operations of the battery 220 , according to the control of the integrated controller 214 . The power discharged from the battery 220 to the bi-directional converter 213 and the power charged in the battery 220 from the bi-directional converter 213 are transferred via the BMS 215 . In addition, the BMS 215 may have functions such as an over-charging protection, an over-discharging protection, an over-current protection, an overheat protection, and a cell balancing operation. To this end, the BMS 215 detects the voltage, current, and temperature of the battery 220 to determine a state of charge (SOC) and a state of health (SOH) of the battery 220 , thereby monitoring remaining power and lifespan of the battery 220 .
[0071] The BMS 215 may include a micro-computer which performs a sensing function for detecting the voltage, current, and temperature of the battery 220 and determines the over-charging, the over-discharging, the over-current, the cell balancing, the SOC, and the SOH, and a protection circuit, which protects the charging/discharging, fusing, and cooling of the battery 220 according to a control signal of the micro-computer. In FIG. 3 , the BMS 215 is included in the energy management system 210 and is separated from the battery 220 , however, a battery pack including the BMS 215 and the battery 220 as an integrated body may be formed. In addition, the BMS 215 controls the charging and discharging operations of the battery 220 , and transfers status information of the battery 220 , for example, information about charged power amount obtained from the determined SOC, to the integrated controller 214 .
[0072] The first switch 216 is connected between the bi-directional inverter 212 and the second node N 2 . The second switch 217 is connected between the second node N 2 and the grid 240 . The first and second switches 216 and 217 are turned on or turned off by the control of the integrated controller 214 , and supply or block the power of the photovoltaic power generation system 230 or the battery to the grid 240 or to the load 250 , and supply or block the power from the grid 240 to the load 250 or the battery 220 . For example, when the power generated by the photovoltaic power generation system 230 or the power stored in the battery 220 is supplied to the grid 240 , the integrated controller 214 turns the first and second switches 216 and 217 on. In addition, when only the power from the grid 240 is supplied to the load 250 , the integrated controller 214 turns the first switch 216 off and turns the second switch 217 on.
[0073] The second switch 217 blocks the power supply to the grid 240 and makes the grid-connected energy storage system 200 solely operate according to the control of the integrated controller 214 , when an abnormal situation occurs in the grid 240 , for example, an electric failure occurs or distribution lines need to be repaired. At this time, the integrated controller 214 separates the energy management system 210 from the grid 240 to prevent (or reduce the likelihood of) an accident, such as an electric shock applied to a worker working on the line management or repair from occurring, and to prevent the grid 240 from (or reduce the likelihood of the grid 240 ) negatively affecting electrical equipment due to the operation in the abnormal state. In addition, when the grid 240 recovers to the normal state from the operation in the abnormal state, that is, the power generated by the photovoltaic power generation system 230 or the power stored in the battery 220 is supplied to the load 250 , a phase difference is generated between the voltage of the grid 240 and the output voltage of the battery 220 which is in the sole operating state, and thus, the energy management system 210 may be damaged. The integrated controller 214 performs a sole operation preventing control in order to address the above problem.
[0074] The integrated controller 214 controls overall operations of the energy management system 210 . The control operations of the integrated controller 214 will be described with reference to FIG. 4 in more detail.
[0075] FIG. 4 is a diagram illustrating flows of the power and control signals in the grid-connected energy storage system 200 of FIG. 3 .
[0076] Referring to FIG. 4 , the flow of power between the internal components in the grid-connected energy storage system 200 of FIG. 3 and the control flow of the integrated controller 214 are illustrated. As shown in FIG. 4 , the DC level voltage converted by the MPPT converter 211 is supplied to the bi-directional inverter 212 and the bi-directional converter 213 . In addition, the DC level voltage supplied to the bi-directional inverter 212 is converted to the AC voltage by the bi-directional inverter 212 to be supplied to the grid 240 , or the DC level voltage supplied to the bi-directional converter 213 is converted to the DC voltage by the bi-directional converter 213 to be charged in the battery 220 and is charged in the battery 220 via the BMS 215 . The DC voltage charged in the battery 220 is converted to an input DC voltage level of the bi-directional inverter 212 by the bi-directional converter 213 , and then, is converted to the AC voltage suitable for the standard of the grid by the bi-directional inverter 212 to be supplied to the grid 240 .
[0077] The integrated controller 214 controls overall operations of the grid-connected energy storage system 200 , and determines an operating mode of the system 200 , for example, determines whether the generated power will be supplied to the grid, to the load, or stored in the battery, and whether the power supplied from the grid will be stored in the battery.
[0078] The integrated controller 214 transmits control signals for controlling switching operations of the MPPT converter 211 , the bi-directional inverter 212 , and the bi-directional converter 213 . The control signals may reduce a loss of power caused by the power conversion executed by the converter 211 or 213 , or the inverter 212 by controlling a duty ratio with respect to the input voltage of the each converter or the inverter. To this end, the integrated controller 214 receives signals for sensing the voltage, the current, and the temperature at an input terminal of each of the MPPT converter 211 , the bi-directional inverter 212 , and the bi-directional converter 213 , and transmits the converter control signal and the inverter control signal based on the received sensing signals.
[0079] The integrated controller 214 receives grid information including information about the grid status and information about the voltage, the current, and the temperature of the grid from the grid 240 . The integrated controller 214 determines whether or not the abnormal situation occurs in the grid 240 and whether or not the power of the grid is returned, and performs a sole operation prevention control through a controlling operation for blocking the power supply to the grid 240 and a controlling operation of matching the output of the bi-directional inverter 212 and the supplied power of the grid 240 after returning the power of the grid 240 .
[0080] The integrated controller 214 receives a battery status signal, that is, a signal indicating the charging/discharging states of the battery, through communication with the BMS 215 , and determines the operating mode of the system 200 based on the received signal. In addition, the integrated controller 214 transmits a signal for controlling charging/discharging of the battery to the BMS 215 according to the operating mode, and the BMS 215 controls the charging and discharging operations of the battery 220 according to the transmitted signal.
[0081] FIG. 5 is a flowchart illustrating a method of operating a grid-connected energy storage system according to an embodiment of the present invention.
[0082] Referring to FIG. 5 , a renewable energy generation system generates power in operation 500 . The renewable energy generation system may be, but is not limited to, a photovoltaic energy generation system, a wind power generation system, and/or a tidal power generation system, and the generated power may be DC power or AC power. In operation 502 , a voltage of the generated power is converted to a DC link voltage. The DC link voltage is a DC voltage having a constant DC voltage level to be input to an inverter or a converter from the power having an unstable voltage level generated in operation 500 .
[0083] In operation 504 , it is determined whether the power generated in operation 500 will be supplied to a grid or to a load, or will be stored in a battery. The above determination of operation 504 is based on a current power selling price to the system, the generated power amount, required load's power consumption amount, and/or the power charged in the battery. As a result of the determination of operation 504 , if it is determined that the generated power is to be stored in the battery, the DC link voltage converted in operation 502 is converted to the battery charging voltage and charged in the battery in operations 506 and 508 .
[0084] As a result of the determination of operation 504 , if the generated power is to be supplied to the grid or to the load, the DC link voltage converted in operation 502 is converted to an AC voltage which corresponds to AC voltage standard of the grid or the load in operation 510 . In operation 512 , it is determined whether the AC voltage will be supplied to the grid or to the load. In operation 514 , the AC voltage is supplied to the grid, and in operation 516 , the AC voltage is supplied to the load.
[0085] FIG. 6 is a flowchart illustrating a method of operating a grid-connected energy storage system according to another embodiment of the present invention.
[0086] Referring to FIG. 6 , a grid condition is monitored in operation 600 . The grid condition may include information about whether an electric failure occurs or not in the grid, whether the power is returned in the grid, whether distribution lines are repaired, and information about voltage, current, and temperature of the grid. In operation 602 , it is sensed whether an abnormal state occurs in the grid. In operation 604 , the power supply to the grid is blocked. When the power supply to the grid is blocked, the grid-connected energy storage system may solely operate in a stabilized state. In operation 606 , a battery discharging mode is selected. At this time, if the power is sufficiently generated by the renewable energy generation system, the power generated by the renewable energy generation system may be supplied to the load. In operation 608 , the power stored in the battery is supplied to the load. In operation 610 , it is determined whether the abnormal situation of the grid is finished. If it is determined that the abnormal situation of the grid is finished, the blockage of the grid is released in operation 612 . Before releasing the blockage of the grid, a current status of the power in the grid may be checked, and then, it may be tested whether the voltage of the grid and a grid connected voltage of the energy storage system, that is, the power supplied to the grid, match each other. In operation 614 , a battery charging mode is selected, and in operation 616 , the power generated by the renewable energy generation system or the power of the grid is stored in the battery. The charging is executed to a level at which the battery may supply the power sufficiently in the above abnormal situation, and after that, the power generated by the renewable energy generation system is supplied to the battery, the load, or the grid if necessary.
[0087] While the present invention has been described in connection with certain exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, and equivalents thereof. | An energy management system includes: a first interface configured to receive a first power from a power generation system; a second interface configured to couple to the power generation system, a power grid, and a storage device, and to receive at least one of the first power from the power generation system, a second power from the power grid, or a third power from the storage device, and to supply a fourth power to at least one of the power grid or a load; and a third interface configured to receive the third power from the storage device, and to supply a fifth power to the storage device for storage. | 8 |
TECHNICAL FIELD
[0001] The present invention relates to a stereo signal encoding apparatus, a stereo signal decoding apparatus, a stereo signal encoding method, and a stereo signal decoding method.
BACKGROUND ART
[0002] In mobile communication systems, in order to make effective use of radio spectrum resources and the like, there is a need to compress a speech signal to a low bit rate for transmission thereof. There is also a desire for a telephone service with improved speech quality and a good feeling of naturalness, and the achievement thereof makes desirable the high-quality encoding of not only monaural signals, but also multichannel audio signals, and in particular stereo audio signals.
[0003] A known method for encoding a stereo audio signal at low bit rate is the intensity stereo method. In the intensity stereo method, a monaural signal is multiplied by scaling coefficients to generate an L-channel signal (left-channel signal) and an R-channel signal (right-channel signal). A method such as this is called amplitude panning.
[0004] The most basic method of amplitude panning is that of multiplying a monaural signal in the time domain by gain coefficients for amplitude panning (panning gain coefficient) to determine the L-channel signal and the R-channel signal (refer, for example, to the Non-Patent Literature 1). Another method is that of multiplying a monaural signal by panning gain coefficients for each frequency component (or each frequency group) in the frequency domain to determine the L-channel signal and the R-channel signal (refer to, for example, Non-Patent Literature 2).
[0005] If panning gain coefficients are used as encoding parameters of parametric stereo, scalable encoding (monaural-stereo scalable encoding) of a stereo signal can be done (refer to, for example, Patent Literatures 1 and 2). The panning gain coefficients are described in Patent Literature 1 as balance parameters and are described in Patent Literature 2 as ILDs (level differences).
[0006] In a mobile communication system, in order to make effective use of radio spectrum resources, a technique exists as intermittent transmission (DTX: discontinuous transmission) exists (refer to, for example, Non-Patent Literature 3). The DTX technique is a technique that, when speech is not emitted, information representing background noise is intermittently transmitted at an ultra-low bit rate. This enables reduction of the average bit rate during a conversation, and also accommodation of more mobile terminals with the same frequency band.
[0007] For example, in Non-Patent Literature 3, at a rate of one time every eight frames in a frame that is judged to be a non-speech section (inactive speech section, background noise section), LPC (linear prediction coding) coefficients are quantized by 29 bits (for example, by converting LPC coefficients to LSF (line spectral frequency) coefficients, and the frame energy is quantized by 6 bits, making a total of 35 bits (bit rate: 1.75 kbits/s). In the decoding section, ten pulses per frame generated based on random numbers are multiplied by the decoded frame energy, and the result is passed through a synthesis filter constituted by the decoded LPC coefficients to generate a decoded signal. This decoding processing is performed, while updating the LPC coefficients and the frame energy every eight frames.
CITATION LIST
Patent Literature
PTL 1
[0000]
Japanese Translation of a PCT Application Laid-Open No. 2004-535145
PTL 2
[0000]
Japanese Translation of a PCT Application Laid-Open No. 2005-533271
Non-Patent Literature
NPL 1
[0010] V. Pulkki and M. Karjalainen, “Localization of amplitude-panned virtual sources I: Stereophonic panning,” Journal of the Audio Engineering Society, Vol. 49, No. 9, September 2001, pp. 739-752.
NPL 2
[0000]
B. Cheng, C. Ritz and I. Burnett, “Principles and analysis of the squeezing approach to low bit rate spatial audio coding,” proc. IEEE ICASSP2007, pp. 1-13-1-16, April 2007.
NPL 3
[0000]
3GPP TS 26.092 V4.0.0, “AMR Speech Codec: Comfort noise aspects (Release 4),” May 2001.
SUMMARY OF INVENTION
Technical Problem
[0013] Consider the case of applying an intermittent transmission technique to a stereo signal. In the above-noted conventional art, when panning coefficients are used with respect to the spectral profile of a background noise signal, because sub-hands are multiplied by panning coefficients, there is a problem that energy steps occurring in the spectra between sub-bands reduce the quality. This problem becomes prominent with a simple background noise signal, compared with a speech spectral profile. Although narrowing the width of the sub-bands to suppress the occurrence of energy steps can be envisioned as a method of solving this problem, the number of panning coefficients that must be transmitted from the encoder side to the decoder side increases, resulting in an increase in the bit rate.
[0014] In contrast, if the spectral profile of the background noise signal is represented by LPC coefficients, the above-noted energy steps do not occur in the spectrum. However, it is necessary to encode the LPC coefficients for both the L channel and the R channel, this resulting in the problem of an increased bit rate.
[0015] An object of the present invention is to provide a stereo signal encoding apparatus, a stereo signal decoding apparatus, a stereo signal encoding method, and a stereo signal decoding method that enable a reduction of the bit rate, without reducing the quality when an intermittent transmission technique is applied to a stereo signal.
Solution to Problem
[0016] A stereo signal encoding apparatus according to an embodiment of the present invention encodes a stereo signal having a first channel signal and a second channel signal; the stereo signal encoding apparatus adapts a constitution of comprising: a first encoding section that generates first encoded stereo data by encoding the stereo signal when the stereo signal of the current frame is a speech part; a second encoding section that encodes the stereo signal when the stereo signal of the current frame is a non-speech part and that generates second encoded stereo data by encoding each of: monaural signal spectral parameters that are spectral parameters of a monaural signal generated using the first channel signal and the second channel signal; first channel signal information regarding the amount of variation between the spectral parameters of the monaural signal and the spectral parameters of the first channel signal; and second channel signal information regarding the amount of variation between the spectral parameters of the monaural signal and the spectral parameters of the second channel signal; and a transmitting section that transmits the first encoded stereo data or the second encoded stereo data.
[0017] A stereo signal decoding apparatus adapts a constitution of comprising: a receiving section that obtains first encoded stereo data to be generated when a stereo signal having a first channel signal and a second channel signal is a speech part in an encoding apparatus or second encoded stereo data to be generated when the stereo signal is a non-speech part in the encoding apparatus; a first decoding section that obtains a first decoded stereo signal by decoding the first encoded stereo data; and a second decoding section that decodes the second encoded stereo data, obtaining a second decoded stereo signal having a first decoded channel signal and a second decoded channel signal, using monaural signal spectral parameters that are spectral parameters of a monaural signal obtained from encoded data generated using the first channel signal and the second channel signal, the first channel signal and the second channel signal being obtained from encoded data included in the second encoded stereo data, first channel signal information regarding the amount of variation between the spectral parameters of the monaural signal and the spectral parameters of the first channel signal, and second channel signal information regarding the amount of variation between the spectral parameters of the monaural signal and the spectral parameters of the second channel signal.
[0018] A stereo signal encoding method according to an embodiment of the present invention encodes a stereo signal having a first channel signal and a second channel signal; the stereo signal encoding method has a first encoding step of generating first encoded stereo data by encoding the stereo signal when the stereo signal of the current frame is a speech part; a second encoding step of encoding the stereo signal when the stereo signal of the current frame is a non-speech part and of generating second encoded stereo data by encoding each of: monaural signal spectral parameters that are spectral parameters of a monaural signal generated using the first channel signal and the second channel signal; first channel signal information regarding the amount of variation between the spectral parameters of the monaural signal and the spectral parameters of the first channel signal; and second channel signal information regarding the amount of variation between the spectral parameters of the monaural signal and the spectral parameters of the second channel signal; and a transmitting step of transmitting the first encoded stereo data or the second encoded stereo data.
[0019] A stereo signal decoding method according to an embodiment of the present invention has a receiving step of obtaining first encoded stereo data to be generated when a stereo signal having a first channel signal and a second channel signal is a speech part in an encoding apparatus or second encoded stereo data to be generated when the stereo signal is a non-speech part in the encoding apparatus; a first decoding step of obtaining a first decoded stereo signal by decoding the first encoded stereo data; and a second decoding step of decoding the second encoded stereo data. obtaining a second decoded stereo signal having a first decoded channel signal and a second decoded channel signal, using monaural signal spectral parameters that are spectral parameters of a monaural signal generated using the first channel signal and the second channel signal, the first channel signal and the second channel signal being obtained from encoded data included in the second encoded stereo data, first channel signal information regarding the amount of variation between the spectral parameters of the monaural signal and the spectral parameters of the first channel signal, and second channel signal information regarding the amount of variation between the spectral parameters of the monaural signal and the spectral parameters of the second channel signal.
Advantageous Effects of Invention
[0020] According to the present invention, in applying an intermittent transmission technique to a stereo signal, the bit rate can be reduced, without reducing the quality.
BRIEF DESCRIPTION OF DRAWINGS
[0021] FIG. 1 is a block diagram showing the constitution of a stereo signal encoding apparatus according to Embodiment 1 of the present invention;
[0022] FIG. 2 is a block diagram showing the constitution of a stereo signal decoding apparatus according to Embodiment 1 of the present invention;
[0023] FIG. 3 is a block diagram showing the internal constitution of a stereo DTX encoding section according to Embodiment 1 of the present invention;
[0024] FIG. 4 is a block diagram showing the internal constitution of a stereo DTX decoding section according to Embodiment 1 of the present invention;
[0025] FIG. 5 is a block diagram showing the constitution of a stereo DTX encoding section according to Embodiment 2 of the present invention;
[0026] FIG. 6 is a block diagram showing the constitution of a stereo DTX decoding section according to Embodiment 2 of the present invention;
[0027] FIG. 7 is a drawing showing the relationship of correspondence of the frame energy difference between the channels and deformation coefficients for each channel according to Embodiment 2 of the present invention;
[0028] FIG. 8 is a block diagram showing the constitution of a stereo DTX encoding section according to Embodiment 3 of the present invention; and
[0029] FIG. 9 is a block diagram showing the constitution of a stereo DTX decoding section according to Embodiment 3 of the present invention.
DESCRIPTION OF EMBODIMENTS
[0030] Embodiments of the present invention will now be described in detail, with reference to the accompanying drawings.
Embodiment 1
[0031] FIG. 1 is a block diagram showing the constitution of stereo signal encoding apparatus 100 according to Embodiment 1 of the present invention.
[0032] Stereo signal encoding apparatus 100 is mainly constituted by VAD (voice active detector) section 101 , switching sections 102 and 105 , stereo encoding section 103 , stereo DTX encoding section 104 , and multiplexing section 106 . Stereo signal encoding apparatus 100 forms frames of a stereo signal at a prescribed time interval (for example, 20 ms), and encodes the stereo signal in units of the frames. Each of the constituent elements will be described in detail below.
[0033] VAD section 101 analyzes an input signal (a stereo signal formed by an L-channel signal and an R-channel signal) and judges whether the input signal of the current frame is a speech part or a non-speech part. A non-speech part corresponds to an inactive speech part, which, because the signal amplitude value is extremely small, is sensed as inactive speech by the sense of hearing, a background noise part or the like, which is typified by environmental sounds that are perceived in everyday life (operation sounds of ducts or the traveling sounds of vehicles), or the like. In the following, a background noise part will be described as a typical non-speech part. In this analysis, at least the signal energy is used. As a result of the analysis, if VAD section 101 judges the input signal of the current frame to be a speech part, it generates VAD data indicating that the input signal of the current frame is a speech part, and if VAD section 101 judges the input signal of the current frame to be a background noise part, it generates VAD data indicating that the input signal of the current frame is a background noise part. VAD section 101 outputs the generated VAD data to switching sections 102 and 105 and to multiplexing section 106 .
[0034] Switching section 102 , in accordance with the VAD data input from VAD section 101 , switches the output destination of the input signal (stereo signal) between stereo signal encoding section 103 and stereo DTX encoding section 104 . Specifically, if the VAD data indicates a speech part, switching section 102 switches the output destination to stereo encoding section 103 and outputs the input signal to stereo encoding section 103 . If, however, the VAD data indicates a background noise part, switching section 102 switches the output destination to stereo DTX encoding section 104 and outputs the input signal to stereo DTX encoding section 104 .
[0035] Stereo encoding section 103 encodes the input signal (speech part) input from switching section 102 . Specifically, stereo encoding section 103 uses the correlation between the L-channel signal and the R-channel signal that constitute the stereo signal to encode the stereo signal. The method indicated in Non-Patent Literature 1, for example, is used as the method of encoding the above-noted stereo signal. Stereo encoding section 103 outputs the encoded stereo data generated by encoding processing to switching section 105 .
[0036] Stereo DTX encoding section 104 encodes the input signal (background noise part) input from switching section 102 . For example, stereo DTX encoding section 104 performs encoding processing one time for each prescribed number of frames (for example, eight frames). This is because it is assumed that there is little time variation of the characteristics of background noise. As a result, the bit rate can be further reduced. Stereo DTX encoding section 104 outputs the encoded stereo data generated by encoding processing to multiplexing section 106 , via switching section 105 . For frames for which encoding processing does not operate, stereo DTX encoding section 104 outputs to switching section 105 an SID that is a specific code (for example, silence description) indicating that encoding processing has not been done as encoded stereo data. The encoding processing in stereo DTX encoding section 104 will be described later in detail.
[0037] Switching section 105 , similar to switching section 102 , in accordance with the VAD data input from VAD section 101 , switches the input source of the encoded stereo data between stereo encoding section 103 and stereo DTX encoding section 104 . Specifically, if the VAD data indicates a speech part, switching section 105 switches the input source to stereo encoding section 103 , and outputs the encoded stereo data generated by the stereo encoding section 103 to multiplexing section 106 . If, however, the VAD data indicates a background noise part, switching section 105 switches the input source to stereo DTX encoding section 104 , and outputs the encoded stereo data generated by the stereo DTX encoding section 104 to multiplexing section 106 .
[0038] Multiplexing section 106 multplexes the VAD data input from VAD section 101 and the encoded stereo data input from switching section 105 to generate multiplexed data. By doing this, the multiplexed data is transmitted to the stereo signal decoding apparatus.
[0039] The above completes the description of the constitution of stereo signal encoding apparatus 100 .
[0040] Next, a stereo signal decoding apparatus 200 according to the present embodiment will be described, using FIG. 2 , which is a block diagram showing the constitution of stereo signal decoding apparatus 200 .
[0041] Stereo signal decoding apparatus 200 is mainly constituted by demultiplexing section 201 , switching sections 202 and 205 , stereo decoding section 203 , and stereo DTX decoding section 204 . Each of the constituent elements will be described in detail below.
[0042] Demultplexing section 201 receives the input multiplexed data, and demultiplexes it into VAD data and encoded stereo data. Demultipexing section 201 outputs the VAD data to switching sections 202 and 205 and outputs the encoded stereo data to switching section 202 .
[0043] In accordance with the VAD data (data indicating that the input signal of the current frame is either a speech part or a background noise part) input from demultipexing section 201 , switching section 202 switches the output destination of the encoded stereo data between stereo decoding section 203 and stereo DTX decoding section 204 . Specifically, if the VAD data indicates a speech part, switching section 202 switches the output destination to stereo decoding section 203 and outputs the encoded stereo data to stereo decoding section 203 . If, however, the VAD data indicates a background noise part, switching section 202 switches the output destination to stereo DTX decoding section 204 and outputs the encoded stereo data to stereo DTX decoding section 204 .
[0044] Stereo decoding section 203 decodes the encoded stereo data input from switching section 202 (that is, the encoded stereo data generated in stereo signal encoding apparatus 100 when the stereo signal is a speech part) to generate a decoded stereo signal (decoded L-channel signal and decoded R-channel signal). Stereo decoding section 203 then outputs the generated decoded stereo signal to switching section 205 .
[0045] Stereo DTX decoding section 204 decodes the encoded stereo data input from switching section 202 (that is, the encoded stereo data generated in stereo signal encoding apparatus 100 when the stereo signal is a background noise part) to generate a decoded stereo signal (decoded L-channel signal and decoded R-channel signal). Stereo DTX decoding section 204 then outputs the generated decoded stereo signal to switching section 205 . As described above, because stereo DTX encoding section 104 ( FIG. 1 ) performs encoding processing at a rate of one time each prescribed number of frames (for example, eight frames), stereo DTX decoding section 204 receives the encoded stereo data at a rate of one time every prescribed number of frames (for example, eight frames), and receives SID (silence description) for other frames, that is, frames for which the encoding processing did not operate. Upon receiving the SID, stereo DTX decoding section 204 uses the recently received encoded stereo data to perform decoding processing to generate a decoded stereo signal. That is, stereo DTX decoding section 204 uses the received encoded stereo data continuously for a prescribed number of frames (for example, eight frames). The decoding processing in stereo DTX decoding section 204 will be described later in detail.
[0046] Switching section 205 , similar to switching section 202 , in accordance with the VAD data input from demultipexing section 201 , switches the input source of the decoded stereo signal between stereo decoding section 203 and stereo DTX decoding section 204 . Specifically, if the VAD data indicates a speech part, switching section 205 switches the input source to stereo decoding section 203 and outputs the decoded stereo signal generated by the stereo decoding section 203 . If, however, the VAD data indicates a background noise part, switching section 205 switches the input source to stereo DTX decoding section 204 and outputs the decoded stereo signal generated by stereo DTX decoding section 204 .
[0047] The above completes the description of the constitution of stereo signal decoding apparatus 200 .
[0048] Next, the constitution of stereo DTX encoding section 104 in stereo signal encoding apparatus 100 will be described, using FIG. 3 . In the following description, LSP (line spectral pair) parameters are assumed to be used as the spectral parameters for each signal. For example, the LSP parameters of the signals are determined by converting the LPC coefficients obtained by LPC analysis of the signals. However, the spectral parameters that are used are not restricted to being the LSP parameter, and may be LSF (line spectral frequency) parameters, ISF (immitance spectral frequency) parameters, or the like.
[0049] FIG. 3 is a block diagram showing the internal constitution of stereo DTX encoding section 104 .
[0050] Stereo DTX encoding section 104 is mainly constituted by frame energy encoding sections 301 and 302 , spectral parameter analysis sections 303 and 304 , average spectrum parameter calculation section 305 , average spectral parameter quantization section 306 , average spectral parameter decoding section 307 , error spectral parameter calculation sections 308 and 309 , error spectral parameter quantization sections 310 and 311 , and multiplexing section 312 . Each of the constituent elements will be described in detail below.
[0051] Frame energy encoding section 301 determines the frame energy of the input L-channel signal and generates quantized L-channel signal frame energy information by performing scalar quantization (encoding) of the frame energy. Frame energy encoding section 301 then outputs the quantized L-channel signal frame energy information to multiplexing section 312 .
[0052] Frame energy encoding section 302 determines the frame energy of the input R-channel signal and generates quantized R-channel signal frame energy information by performing scalar quantization (encoding) of the frame energy. Frame energy encoding section 302 then outputs the quantized R-channel signal frame energy information to multiplexing section 312 .
[0053] Spectral parameter analysis section 303 performs LPC analysis of the input L-channel signal to generate LSP parameters indicating the spectral characteristics of the L-channel signal. Spectral parameter analysis section 303 then outputs the L-channel signal LSP parameters to average spectral parameter calculation section 305 and error spectral parameter calculation section 308 .
[0054] Spectral parameter analysis section 304 , similar to spectral parameter analysis section 303 , performs LPC analysis of the input R-channel signal to generate LSP parameters indicating the spectral characteristics of the R-channel signal. Spectral parameter analysis section 304 then outputs the R-channel signal LSP parameters to average spectral parameter calculation section 305 and error spectral parameter calculation section 309 .
[0055] Average spectral parameter calculation section 305 calculates the average spectral parameters, using the L-channel signal LSP parameters and the R-channel signal LSP parameters. Average spectral parameter calculation section 305 then outputs the average spectral parameters to average spectral parameter quantization section 306 .
[0056] For example, average spectral parameter calculation section 305 calculates the average spectral parameters LSP m (i) in accordance with the following Equation (1).
[0000]
[
Eq
.
1
]
LSP
m
(
i
)
=
1
2
(
LSP
L
(
i
)
+
LSP
R
(
i
)
)
i
=
0
,
…
,
N
LSP
-
1
(
1
)
[0057] In the above, LSP L (i) indicates the LSP parameters of the L-channel signal, LSP R (i) indicates the LSP parameters of the R-channel signal, and N LSP indicates the order of the LSP parameters.
[0058] Average spectral parameter calculation section 305 may calculate the average spectral parameters based on the L-channel signal energy and the R-channel signal energy, as shown in the following Equation (2).
[0000]
[
Eq
.
2
]
LSP
m
(
i
)
=
1
2
(
w
·
LSP
L
(
i
)
+
(
1
-
w
)
LSP
R
(
i
)
)
i
=
0
,
…
,
N
LSP
-
1
(
2
)
[0059] In the above, w indicates weighting that is determined based on the L-channel signal energy E L and the R-channel signal energy E R , and set with respect to the calculated average spectral parameters LSP m (i) so that the influence of LSP parameters for the channel having a large energy becomes large. For example, w is calculated by the following Equation (3).
[0000] [Eq. 3]
[0000] w=E L /( E L +E R ) (3)
[0060] Stated differently, average spectral parameter calculation section 305 calculates the average of the L-channel signal LSP parameters and the R-channel signal LSP parameters as the LSP parameters of a monaural signal generated from the L-channel signal and the R-channel signal. Average spectral parameter calculation section 305 may down-mix the L-channel signal and the R-channel signal to generate a monaural signal and take the LSP parameters calculated from this monaural signal (monaural signal LSP parameters) as the average spectral parameters.
[0061] Average spectral parameter quantization section 306 , based on vector quantization, scalar quantization, or a quantization method that is a combination thereof, quantizes (encodes) the average spectral parameters. Average spectral parameter quantization section 306 outputs the quantized average spectral parameter information determined by quantization processing to average spectral parameter decoding section 307 and multiplexing section 312 .
[0062] Average spectral parameter decoding section 307 decodes the quantized average spectral parameter information (that is, the encoded data of the average spectral parameters) to generate decoded average spectral parameters. Average spectral parameter decoding section 307 then outputs the decoded average spectral parameters to error spectral parameter calculation sections 308 and 309 .
[0063] Error spectral parameter calculation section 308 subtracts the decoded average spectral parameters from the L-channel signal LSP parameters to calculate the L-channel signal error spectral parameters. Error spectral parameter calculation section 308 then outputs the L-channel signal error spectral parameters to error spectral parameter quantization section 310 .
[0064] Error spectral parameter calculation section 309 subtracts the decoded average spectral parameters from the R-channel signal LSP parameters to calculate the R-channel signal error spectral parameters. Error spectral parameter calculation section 309 then outputs the R-channel signal error spectral parameters to error spectral parameter quantization section 311 .
[0065] Error spectral parameter quantization section 310 , based on vector quantization, scalar quantization, or a quantization method that is a combination thereof, quantizes (encodes) the L-channel signal error spectral parameters. Error spectral parameter quantization section 310 then outputs the quantized L-channel signal error spectral parameter information to multiplexing section 312 .
[0066] Error spectral parameter quantization section 311 , similar to the error spectral parameter quantization section 310 , quantizes (encodes) the R-channel signal error spectral parameters. Error spectral parameter quantization section 311 then outputs the quantized R-channel signal error spectral parameter information to multiplexing section 312 .
[0067] Multiplexing section 312 multiplexes the quantized L-channel signal frame energy information, the quantized R-channel signal frame energy information, the quantized average spectral parameter information, the quantized L-channel signal error spectral parameter information, and the quantized R-channel signal error spectral parameter information to generate encoded stereo data. Multiplexing section 312 then outputs the encoded stereo data to switching section 105 ( FIG. 1 ). In stereo DTX encoding section 104 , the multiplexing section 312 is not an essential constituent element. For example, quantized L-channel signal frame energy information, the quantized R-channel signal frame energy information, the quantized average spectral parameter information, the quantized L-channel signal error spectral parameter information, and the quantized R-channel signal error spectral parameter information may be directly output as encoded stereo data to switching section 105 ( FIG. 1 ) from the constituent elements that generate each of the data.
[0068] The above completes the description of the constitution of stereo DTX encoding section 104 .
[0069] Next, the constitution of stereo DTX decoding section 204 in stereo signal decoding apparatus 200 will be described, using FIG. 4 , which is a block diagram showing the internal constitution of stereo DTX decoding section 204 .
[0070] Stereo DTX decoding section 204 is mainly constituted by demultiplexing section 401 , frame gain decoding sections 402 and 403 , average spectral parameter decoding section 404 , error spectral parameters decoding sections 405 and 406 , spectral parameter generation sections 407 and 408 , excitation generation sections 409 and 412 , multiplication sections 410 and 413 , and synthesis filter sections 411 and 414 . Each of the constituent elements will be described in detail below.
[0071] Demultiplexing section 401 demultiplexer the encoded stereo data input from switching section 202 ( FIG. 2 ) into the quantized L-channel signal frame energy information, the quantized R-channel signal frame energy information, the quantized average spectral parameter information, the quantized L-channel signal error spectral parameter information, and the quantized R-channel signal error spectral parameter information. Demultiplexing section 401 then outputs the quantized L-channel signal frame energy information to frame gain encoding section 402 , the quantized R-channel signal frame information to frame gain encoding section 403 , the quantized average spectral parameter information to average spectral parameter decoding section 404 , the quantized L-channel signal error spectral parameter information to error spectral parameter decoding section 405 , and the quantized R-channel signal error spectral parameter information to error spectral parameter decoding section 406 .
[0072] In stereo DTX decoding section 204 , demultiplexing section 401 is not an essential constituent element. For example, by the demultiplexing processing in demultiplexing section 201 shown in FIG. 2 , the quantized L-channel signal frame energy information, the quantized R-channel signal frame energy information, the quantized average spectral parameter information, the quantized L-channel signal error spectral parameter information, and the quantized R-channel signal error spectral parameter information may be obtained and each of these data may be directly output to frame gain decoding section 402 and 403 , average spectral parameter decoding section 404 , and error spectral parameter decoding section 405 and 406 , respectively.
[0073] Frame gain decoding section 402 decodes the quantized L-channel signal frame energy information and outputs the obtained decoded L-channel signal frame energy to multiplication section 410 .
[0074] Frame gain decoding section 403 decodes the quantized R-channel signal frame energy information and outputs the obtained decoded R-channel signal frame energy to multiplication section 413 .
[0075] Average spectral parameter decoding section 404 decodes the quantized average spectral parameter information and outputs the obtained decoded average spectral parameters to spectral parameter generation sections 407 and 408 .
[0076] Error spectral parameter decoding section 405 decodes the quantized L-channel signal error spectral parameter information and outputs the obtained decoded L-channel signal error spectral parameters to spectral parameter generation section 407 .
[0077] Error spectral parameter decoding section 406 decodes the quantized R-channel signal error spectral parameter information and outputs the obtained decoded R-channel signal error spectral parameters to spectral parameter generation section 408 .
[0078] Spectral parameter generation section 407 uses the decoded average spectral parameters and the decoded L-channel signal error spectral parameters to generate the decoded L-channel signal spectral parameters. Spectral parameter generation section 407 then converts the generated decoded L-channel signal spectral parameters to decoded L-channel signal LPC coefficients and outputs the obtained decoded L-channel signal LPC coefficients to synthesis filter section 411 .
[0079] For example, spectral parameter generation section 407 , in accordance with the following Equation (4), uses the decoded average spectral parameters LSP qm (i) and the decoded L-channel signal error spectral parameters ELSP qL (i) to generate the decoded L-channel signal spectral parameters LSP qL (i).
[0000] [Eq. 4]
[0000] LSPq L ( i )= LSPq m ( i )+ ELSPq L ( i ) i= 0 , . . . ,N LSP −1 (4)
[0080] Spectral parameter generation section 408 uses the decoded average spectral parameters and the decoded R-channel signal error spectral parameters to generate the decoded R-channel signal spectral parameters. Spectral parameter generation section 408 then converts the generated decoded R-channel signal spectral parameters to decoded R-channel signal LPC coefficients and outputs the obtained decoded R-channel signal LPC coefficients to synthesis filter section 414 .
[0081] For example, spectral parameter generation section 408 , in accordance with the following Equation (5), uses the decoded average spectral parameters LSP qm (i) and the decoded R-channel signal error spectral parameters ELSP qR (i) to generate the decoded R-channel signal spectral parameters LSP qR (i).
[0000] [Eq. 5]
[0000] LSPq R ( i )= LSPq m ( i )+ ELSPq R ( i ) i= 0 , . . . ,N LSP −1 (5)
[0082] Excitation generation section 409 , multiplication section 410 , and synthesis filter 411 are constituent elements corresponding to the L-channel signal.
[0083] Excitation generation section 409 generates an excitation signal represented by a random signal or a limited number of pulses and outputs the excitation signal to multiplication section 410 . Normalization is done so that the frame energy of the excitation signal is 1.
[0084] Multiplication section 410 multiplies the excitation signal by the decoded L-channel signal frame energy and outputs the multiplication result to synthesis filter section 411 .
[0085] Synthesis filter section 411 has a synthesis filter constituted by the decoded L-channel signal LPC coefficients input from spectral parameter generation section 407 and passes the multiplication result input from the multiplication section 410 (the excitation signal multiplied by the decoded L-channel signal frame energy) through the synthesis filter to generate a decoded L-channel signal. This decoded L-channel signal is output as the output signal.
[0086] Excitation generation section 412 , multiplication section 413 , and synthesis filter 414 are constituent elements corresponding to the R-channel signal.
[0087] Excitation generation section 412 generates an excitation signal represented by a random signal or a limited number of pulses and outputs the excitation signal to multiplication section 413 . Normalization is done so that the frame energy of the excitation signal is 1.
[0088] Multiplication section 413 multiplies the excitation signal by the decoded R-channel signal frame energy and outputs the multiplication result to synthesis filter section 414 .
[0089] Synthesis filter section 414 has a synthesis filter constituted by the decoded R-channel signal LPC coefficients input from spectral parameter generation section 408 and passes the multiplication result input from the multiplication section 413 (the excitation signal multiplied by the decoded R-channel signal frame energy) through the synthesis filter to generate a decoded R-channel signal. This decoded R-channel signal is output as the output signal.
[0090] In this manner, when the stereo signal of the current frame is a background noise part, stereo signal encoding apparatus 100 generates, as encoded stereo data, encoded average spectral data, which is the average of spectral parameters of the L-channel signal and the spectral parameters of the R-channel signal (that corresponds to the encoded data of the LPC coefficients of a monaural signal); encoded data of the varying component (error) between the average spectral parameters and the LSP parameters of the L-channel signal; and encoded data of the varying component (error) between the average spectral parameters and the LSP parameters of the R-channel signal.
[0091] That is, even if the spectral profile of the background noise signal is represented by LPC coefficients, rather than encoding the LPC coefficients of the L-channel signal and the LPC coefficients of the R-channel signal, in addition to the encoded data of the LPC coefficients of a monaural signal, stereo signal encoding apparatus 100 adds, as information added to the LPC coefficients of the monaural signal, the difference (amount of variation) between the LSP parameters of the monaural signal and the LSP parameters of the L-channel signal (information regarding the L-channel signal) and the difference (amount of variation) between the LSP parameters of the monaural signal and the LSP parameters of the R-channel signal (information regarding the R-channel signal). Stated differently, stereo signal encoding apparatus 100 uses the correlation between the LPC coefficients of the monaural signal and the LPC coefficients of the L-channel signal and the correlation between the LPC coefficients of the monaural signal and the LPC coefficients of the R-channel signal to encode the stereo signal.
[0092] Because it is sufficient to encode only the LPC coefficients of the monaural signal and added information regarding the monaural signal and each channel signal, the bit rate can be reduced, compared to the case of encoding LPC coefficients for two channels (L channel and R channel).
[0093] Also, when the stereo signal of the current frame is a background noise part, stereo signal decoding apparatus 200 obtains a decoded stereo signal that is made up of a decoded L-channel signal and a decoded R-channel signal, using encoded data of the average spectral parameters (that corresponds to the encoded data of the LPC coefficients of a monaural signal); encoded data of the varying component (error) between the average spectral parameters and the LSP parameters of the L-channel signal; and encoded data of the varying component (error) between the average spectral parameters and the LSP parameters of the R-channel signal, which are included in the encoded stereo data.
[0094] As a result, using the LPC coefficients of the monaural signal and the information added to the LPC coefficients of the monaural signal (varying component of LSP parameters of the monaural signal and the LSP parameters of each channel signal), the LPC coefficients of the L-channel signal and the LPC coefficients of the R-channel signal are obtained. This enables the achievement of the same quality as the case of receiving the LPC coefficients for two channels (L channel and R channel).
[0095] Thus, according to the present embodiment, in applying an intermittent transmission technique to a stereo signal, the bit rate can be reduced, without reducing the quality.
Embodiment 2
[0096] FIG. 5 is a block diagram showing the internal constitution of stereo DTX encoding section 104 of stereo signal encoding apparatus 100 ( FIG. 1 ) according to Embodiment 2 of the present invention.
[0097] Stereo DTX encoding section 104 shown in FIG. 5 is mainly constituted by frame energy encoding sections 301 and 302 , monaural signal generation section 501 , spectral parameter analysis section 502 , spectral parameter quantization section 503 , and multiplexing section 312 . Each of the constituent elements will be described below in detail. In FIG. 5 , parts having the same constitution as in FIG. 3 are assigned the same reference signs, and the description thereof will be omitted.
[0098] Monaural signal generation section 501 down-mixes the L-channel signal and the R-channel signal making up a stereo signal to generate a monaural signal. Monaural signal generation section 501 then outputs the generated monaural signal to spectral parameter analysis section 502 .
[0099] Spectral parameter analysis section 502 performs LPC analysis of the monaural signal to generate LSP parameters that indicate the spectral characteristics of the monaural signal. The LSP parameters of a monaural signal can be determined, for example, by converting the LPC coefficients obtained by analysis with respect to the monaural signal. Spectral parameter analysis section 502 then outputs the LSP parameters of the monaural signal to spectral parameter quantization section 503 .
[0100] Spectral parameter quantization section 503 , based on vector quantization, scalar quantization, or a quantization method that is a combination thereof, quantizes (encodes) the LSP parameters of the monaural signal. Spectral parameter quantization section 503 outputs the quantized monaural signal spectral parameter information determined by quantization processing to multiplexing section 312 .
[0101] The above completes the description of the constitution of stereo DTX encoding section 104 .
[0102] Next, the constitution of stereo DTX decoding section 204 of stereo signal decoding apparatus 200 ( FIG. 2 ) of Embodiment 2 of the present invention will be described, using FIG. 6 , which is a block diagram of the internal constitution of stereo DTX decoding section 204 according to Embodiment 2 of the present invention.
[0103] Stereo DTX decoding section 204 shown in FIG. 6 is mainly constituted by demultiplexing section 401 , frame gain decoding sections 402 and 403 , spectral parameter decoding section 601 , frame gain comparison 602 , spectral parameter generation sections 603 and 604 , excitation generation sections 409 and 412 , multiplication sections 410 and 413 , and synthesis filter sections 411 and 414 . Each of the constituent elements will be described below in detail. In FIG. 6 , parts having the same constitution as in FIG. 4 are assigned the same reference signs, and the description thereof will be omitted.
[0104] Spectral parameter decoding section 601 decodes the quantized monaural signal spectral parameter information to obtain the monaural signal spectral parameters, and outputs the monaural signal spectral parameters to spectral parameter generation sections 603 and 604 .
[0105] Frame gain comparison section 602 compares the decoded L-channel signal frame energy and the decoded R-channel signal frame energy and, in according to the comparison result, determines deformation coefficients for deforming at least one of the decoded L-channel signal LPC coefficients and the decoded R-channel signal LPC coefficients.
[0106] Spectral parameter generation section 603 converts the monaural signal spectral parameters to monaural signal LPC coefficients and calculates the decoded L-channel signal LPC coefficients (deformed LPC coefficients) to be used in the synthesis filter section 411 , using the monaural signal LPC coefficients and the deformation coefficients corresponding to the L-channel signal.
[0107] Similar to spectral parameter generation section 603 , spectral parameter generation section 604 converts the monaural signal spectral parameters to monaural signal LPC coefficients, and calculates the decoded R-channel signal LPC coefficients (deformed LPC coefficients) to be used in synthesis filter section 414 , using the monaural signal LPC coefficients and the deformation coefficients corresponding to the R-channel signal.
[0108] In this manner, spectral parameter generation sections 603 and 604 calculate the decoded L-channel signal LPC coefficients and the decoded R-channel signal LPC coefficients to be used, respectively, in the synthesis filter sections 411 and 414 , using the deformation coefficients obtained based on the comparison result at frame gain comparison section 602 and the monaural signal spectral parameters.
[0109] In this case, the description has been for the case in which it is the frame gain comparison section 602 that determines the deformation coefficients in accordance with the comparison result. This is not a restriction, however; for example, spectral parameter generation sections 603 and 604 may determine the deformation coefficients in accordance with the comparison result input from the frame gain comparison section 602 .
[0110] For example, let the deformation coefficients for deforming the decoded L-channel signal LPC coefficients LPC L (i) be α L and let the deformation coefficients for deforming the decoded R-channel signal LPC coefficients LPC R (i) be α R . In this case, it is assumed that 0.0≦α L ≦1.0 and 0.0≦α R ≦1.0. In this case, the synthesis filters H L (Z) and H R (Z) that correspond, respectively, to the L-channel signal and the R-channel signal are represented by the following Equation (6) and Equation (7).
[0000]
[
Eq
.
6
]
H
L
(
z
)
=
1
1
-
∑
i
=
1
N
LPC
LPC
L
(
i
)
·
α
L
i
·
z
-
i
[
Eq
.
7
]
(
6
)
H
R
(
z
)
=
1
1
-
∑
i
=
1
N
LPC
LPC
R
(
i
)
·
α
R
i
·
z
-
i
(
7
)
[0111] In the above, N LPC is the order of the LPC coefficients. That is, the LPC coefficients of the signals of each channel are deformed by the deformation coefficients α, as shown in Equations (6) and (7).
[0112] The deformation coefficients α L and α R may be formed, for example, by the method of using the following Equations (8).
[0000]
[
Eq
.
8
]
{
α
L
=
1.0
,
α
R
=
0.8`
if
log
10
E
L
E
R
>
1.0
α
L
=
1.0
,
α
R
=
1.0
if
-
1.0
≤
log
10
E
L
E
R
≤
1.0
α
L
=
0.8
,
α
R
=
1.0
if
log
10
E
L
E
R
<
-
1.0
(
8
)
[0113] The intention of this is to make the LPC coefficients of the channel having the smaller frame energy approach (flatten to) white noise.
[0114] Specifically, if the decoded L-channel signal frame energy E L is 10 dB larger than the decoded R-channel signal frame energy E R (upper line in Equation (8)), the decoded L-channel signal LPC coefficients LPC L (i) are not deformed (α L =1.0), and the decoded R-channel signal LPC coefficients LPC R (i) are made smaller (α R =0.8). That is, deformation is applied in the direction that increases the degree of making the decoded R-channel signal LPC coefficients LPC R (i) white.
[0115] If, however, the decoded R-channel signal frame energy E R is 10 dB larger than the decoded L-channel signal frame energy E L (lower line in Equation (8)), the decoded R-channel signal LPC coefficients LPC R (i) are not deformed (α R =1.0), and the decoded L-channel signal LPC coefficients LPC L (i) are made smaller (α L =0.8). That is, deformation is applied in the direction that increases the degree of making the decoded L-channel signal LPC coefficients LPC L (i) white.
[0116] That is, if the difference between the decoded L-channel signal frame energy and the decoded R-channel signal frame energy exceeds a threshold (in this case, 10 dB), stereo DTX decoding section 204 applies deformation to the LPC coefficients of the channel signal having the smaller frame energy between the decoded L-channel signal LPC coefficients and the decoded R-channel signal coefficients in the direction that increases the degree of making those LPC coefficients white.
[0117] In cases other than the above (that is, if the energy difference is within 10 dB, shown by the middle line in Equation (8)), the LPC coefficients of neither channel signal are deformed (α L =α R =1.0).
[0118] The method of determining the above-noted deformation coefficients α L and α R is based on the following idea.
[0119] It is possible to judge that, compared to the channel having a large frame energy, the channel having a small frame energy is farther away from the source of the background noise. When the distance from the source of background noise becomes large, there is a tendency to be influenced by external perturbation (for example, reflection from a wall or other noise) from the source up until reaching the microphone, so that the spectrum approaches white noise. Thus, even if added information representing the L-channel signal LPC coefficients and the R-channel signal LPC coefficients is not encoded at the encoder side, by making the LPC coefficients of the channel having small frame energy (the channel that is distant from the source of the background noise) approach white (flatten), high-quality background noise can be generated.
[0120] Finer setting can be made of this correspondence between the frame energy and the LPC coefficients (deformation coefficients). FIG. 7 shows an example of the correspondence between the frame energy and the LPC coefficients (deformation coefficients). In FIG. 7 , the broken line shows the value of the deformation coefficients α L (the range from 0.0 to 1.0) and the solid line shows the value of the deformation coefficients α R (the range from 0.0 to 1.0).
[0121] As shown in FIG. 7 , the larger the decoded L-channel signal frame energy E L is with respect to the decoded R-channel signal frame energy E R (the larger log 10 (E L /E R ) is), the greater is the deformation that increases making the decoded R-channel signal LPC coefficients white (that is, the smaller the deformation coefficients α R are made).
[0122] In contrast, the larger the decoded R-channel signal frame energy E R is with respect to the decoded L-channel signal frame energy E L (the smaller log 10 (E L /E R ) is), the greater is the deformation that increases making the decoded L-channel signal LPC coefficients white (that is, the smaller the deformation coefficients α L are made).
[0123] That is, the larger is the difference between the decoded L-channel signal frame energy and the decoded R-channel signal frame energy, the stereo DTX decoding section 204 applies greater deformation to the LPC coefficients of the channel signal having the smaller frame energy between the decoded L-channel signal LPC coefficients and the decoded R-channel signal LPC coefficients, in the direction that increases the degree of making those LPC coefficients white.
[0124] Further, if the difference between the decoded L-channel signal frame energy E L and the decoded R-channel signal frame energy E R exceeds 50 dB, the LPC coefficients of the channel signal with the smaller frame energy becomes completely flat.
[0125] In this manner, in the present embodiment, stereo signal encoding apparatus 100 encodes the monaural signal LPC coefficients, the L-channel signal frame energy, and the R-channel signal frame energy. Then, based on the relationship between the frame energies of the received L-channel signal and R-channel signal, stereo signal decoding apparatus 200 deforms the LPC coefficients of the monaural signal so as to generate the decoded L-channel signal LPC coefficients and the decoded R-channel signal LPC coefficients.
[0126] That is, even if the spectral profile of the background noise signal is represented by LPC coefficients, rather than encoding the LPC coefficients of the L-channel signal and the LPC coefficients of the R-channel signal, in addition to the encoded data of the LPC coefficients of a monaural signal, stereo signal encoding apparatus 100 adds, as information added to the LPC coefficients of the monaural signal, the frame energy of the L-channel signal (information regarding the L-channel signal) and the frame energy of the R-channel signal (information regarding the R-channel signal).
[0127] If the present embodiment is compared to Embodiment 1, the encoded data of the frame energies of each channel signal are transmitted from the encoder side to the decoder in both embodiments. In the present embodiment, however, the encoded data of the frame energies of each channel signal is further used as information added to the monaural signal LPC coefficients. As a result, in the stereo signal decoding apparatus 100 , it is not necessary to encode added information that is required to express the LPC coefficients of the channel signals (in Embodiment 1, varying components between the monaural signal LPC coefficients and LPC coefficients of each of the channel signals).
[0128] Stereo signal encoding apparatus 200 applies deformation to the LPC coefficients of the channel signal having the smaller frame energy between the channel signals constituting the stereo signal, in the direction that increases the degree of making those coefficients white. This enables generation of high-quality background noise, even if only the LPC coefficients of the monaural signal are received.
[0129] Thus, in the present embodiment, even when only the LPC coefficients of a monaural signal are transmitted, high-quality background noise can be generated, and also the bit rate can be reduced further, relative to Embodiment 1.
Embodiment 3
[0130] FIG. 8 is a block diagram showing the internal constitution of stereo DTX encoding section 104 of stereo signal encoding apparatus 100 ( FIG. 1 ) according to Embodiment 3 of the present invention.
[0131] Stereo DTX encoding section 104 shown in FIG. 8 is mainly constituted by frame energy encoding sections 301 and 302 , monaural signal generating section 501 , spectral parameter analysis section 502 , spectral parameter quantization section 503 , spectral parameter analysis sections 701 and 702 , spectral parameter decoding section 703 , frame gain decoding sections 704 and 705 , frame gain comparison section 706 , spectral parameter estimation section 707 , error spectral parameter calculation sections 708 and 709 , error spectral parameter quantization sections 710 and 711 , and multiplexing section 312 . Each of the constituent elements will be described in detail below. In FIG. 8 , parts having the same constitution as in FIG. 5 are assigned the same reference signs, and the description thereof will be omitted.
[0132] Spectral parameter analysis section 701 performs LPC analysis of the input L-channel signal, generates and outputs to error spectral parameter calculation section 708 LSP parameters indicating the spectral characteristics of the L-channel signal.
[0133] Spectral parameter analysis section 702 performs LPC analysis of the input R-channel signal, generates and outputs to error spectral parameter calculation section 709 LSP parameters indicating the spectral characteristics of the R-channel signal.
[0134] Spectral parameter decoding section 703 decodes the quantized monaural signal spectral parameter information input from spectral parameter quantization section 503 , generates the monaural signal spectral parameters, and outputs the monaural signal spectral parameters to spectral parameter estimation section 707 .
[0135] Frame gain decoding section 704 decodes the quantized L-channel signal frame energy information input from frame energy encoding section 301 and outputs the obtained decoded L-channel signal frame energy to frame gain comparison section 706 .
[0136] Frame gain decoding section 705 decodes the quantized R-channel signal frame energy information input from frame energy encoding section 302 and outputs the obtained decoded R-channel signal frame energy to frame gain comparison section 706 .
[0137] Frame gain comparison section 706 compares the decoded L-channel signal frame energy and the decoded R-channel signal frame energy. Then, frame gain comparison section 706 , in accordance with the comparison result, determines the deformation coefficients for deforming at least one of the decoded L-channel signal LPC coefficients and the decoded R-channel signal LPC coefficients. Frame gain comparison section 706 outputs the determined deformation coefficients to spectral parameter estimation section 707 . Because the method of determining the deformation coefficients has been described in Embodiment 2, the description thereof will be omitted.
[0138] Spectral parameter estimation section 707 , using the monaural signal spectral parameters and the deformation coefficients, calculates the estimated L-channel signal spectral parameter and the estimated R-channel signal spectral parameters. Spectral parameter estimation section 707 outputs the calculated estimated L-channel signal spectral parameters to error spectral parameter calculation section 708 and outputs the estimated R-channel signal spectral parameters to error spectral parameter calculation section 709 .
[0139] Spectral parameter estimation section 707 calculates the estimated L-channel signal spectral parameters and the estimated R-channel signal spectral parameters as indicated, for example, below.
[0140] First, spectral parameter estimation section 707 converts the monaural signal spectral parameters to determine monaural signal LPC coefficients. Then, spectral parameter estimation section 707 imparts deformation to the monaural signal LPC coefficients, using the L-channel deformation coefficients, to determine the deformed L-channel LPC coefficients. Because the method of deformation has already been described in Embodiment 2, the description thereof will be omitted. Spectral parameter estimation section 707 converts the deformed L-channel LPC coefficients determined in this manner to spectral parameters such as LSP parameters or LSF parameters, and outputs these as the estimated L-channel signal spectral parameters to error spectral parameter calculation section 708 .
[0141] Spectral parameter estimation section 707 performs the same type of processing as the L channel with respect to the R channel as well. That is, spectral parameter estimation section 707 imparts deformation to the monaural signal LPC coefficients using the deformation coefficients for the R channel to determine the deformed R-channel LPC coefficients. Spectral parameter estimation section 707 converts the R-channel LPC coefficients to determine and output to error spectral parameter calculation section 709 the estimated R-channel signal spectral parameters.
[0142] Error spectral parameter calculation section 708 subtracts the estimated L-channel signal spectral parameters from the spectral parameters of the L-channel signal (LSP parameters of a L-channel signal) to calculate and output to error spectral parameter quantization section 710 the L-channel signal error spectral parameters.
[0143] Error spectral parameter calculation section 709 subtracts the estimated R-channel signal spectral parameters from the spectral parameters of the R-channel signal (LSP parameters of a R-channel signal) to calculate and output to error spectral parameter quantization section 711 the R-channel signal error spectral parameters.
[0144] Error spectral parameter quantization section 710 , based on vector quantization, scalar quantization, or a quantization method that is a combination thereof, quantizes (encodes) the L-channel signal error spectral parameters. Error spectral parameter quantization section 710 outputs the quantized L-channel signal error spectral parameter information determined by quantization processing to multiplexing section 312 .
[0145] Error spectral parameter quantization section 711 , based on vector quantization, scalar quantization, or a quantization method that is a combination thereof, quantizes (encodes) the R-channel signal error spectral parameters. Error spectral parameter quantization section 711 outputs the quantized R-channel signal error spectral parameter information determined by quantization processing to multiplexing section 312 .
[0146] FIG. 9 is a block diagram showing the internal constitution of stereo DTX decoding section 204 of stereo signal decoding apparatus 200 ( FIG. 2 ) according to Embodiment 3 of the present invention.
[0147] Stereo DTX decoding section 204 shown in FIG. 9 is mainly constituted by demultiplexing section 401 , frame gain decoding sections 402 and 403 , spectral parameter decoding section 601 , error spectral parameter decoding sections 801 and 802 , frame gain comparison section 602 , spectral parameter generation sections 803 and 804 , excitation generation sections 409 and 412 , multiplication sections 410 and 413 , and synthesis filter sections 411 and 414 . Each of the constituent elements will be described in detail below. In FIG. 9 , parts having the same constitution as in FIG. 6 are assigned the same reference signs, and the description thereof will be omitted.
[0148] Error spectral parameter decoding section 801 decodes the quantized L-channel signal error spectral parameter information and outputs the obtained decoded L-channel signal error spectral parameters to spectral parameter generation section 803 .
[0149] Error spectral parameter decoding section 802 decodes the quantized R-channel signal error spectral parameter information and outputs the obtained decoded R-channel signal error spectral parameters to spectral parameter generation section 804 .
[0150] Spectral parameter generation section 803 converts the monaural signal spectral parameters to monaural signal LPC coefficients and uses the deformation coefficients for the L channel with respect to the monaural signal LPC coefficients, to determine the deformed L-channel LPC coefficients. Because the method of the deformation has been described in Embodiment 2, the description thereof will be omitted. After conversion of the deformed L-channel LPC coefficients to spectral parameters, the decoded L-channel signal error spectral parameters are added and conversion is done again to LPC coefficients. Spectral parameter generation section 803 outputs the LPC coefficients to synthesis filter section 411 as the decoded L-channel LPC coefficients.
[0151] Spectral parameter generation section 804 converts the monaural signal spectral parameters to monaural signal LPC coefficients and uses the deformation coefficients for the R channel with respect to the monaural signal LPC coefficients, to determine the deformed R-channel LPC coefficients. Because the method of deformation has been described in Embodiment 2, the description thereof will be omitted. After conversion of the deformed R-channel LPC coefficients to spectral parameters, the decoded R-channel signal error spectral parameters are added and conversion is done again to LPC coefficients. Spectral parameter generation section 804 outputs the LPC coefficients to synthesis filter section 414 as the decoded R-channel LPC coefficients.
[0152] In this manner, in the present embodiment, stereo signal encoding apparatus 100 , similar to Embodiment 2, estimates the L-channel signal LPC coefficients and the R-channel signal LPC coefficients from the relationship between the L-channel signal frame energy and the R-channel signal frame energy, and then encodes the error signal between these estimated values and the original signals (in this case, the L-channel signal LPC coefficients and the R-channel signal LPC coefficients). Stereo signal decoding apparatus 200 compares the frame energy of the L-channel signal with the frame energy of the R-channel signal and, using the comparison result, the monaural signal spectral parameters, the decoded L-channel signal error spectral parameters, and the decoded R-channel signal error spectral parameters, calculates the decoded L-channel signal LPC coefficients and the decoded R-channel signal LPC coefficients.
[0153] That is, if spectral profile of the background noise signal is represented by LPC coefficients, similar to Embodiment 2, in addition to the encoded data of the LPC coefficients of a monaural signal, stereo signal encoding apparatus 100 adds, as information added to the LPC coefficients of the monaural signal, the frame energies of each of the L-channel signal and the R-channel signal (information regarding the L-channel signal and the R-channel signal). Additionally, in the present embodiment, stereo encoding apparatus 100 adds the difference between the L-channel signal spectral parameters (L-channel signal LPC coefficients) and the estimated L-channel signal spectral parameters (deformed L-channel LPC coefficients) (information regarding the L-channel signal) and the difference between the R-channel signal spectral parameters (R-channel signal LPC coefficients) and the estimated R-channel signal spectral parameters (deformed R-channel LPC coefficients) (information regarding the R-channel signal).
[0154] In this manner, by encoding the error components of the LPC coefficients after estimation, stereo signal encoding apparatus 100 encodes efficiently with a small number of bits, and can reduce the bit rate.
[0155] Stereo signal encoding apparatus 100 deforms the LPC coefficients of the channel signal having the smaller frame energy between the channel signals constituting the stereo signal, in the direction that increases the degree of making those coefficients white. As a result, even if stereo signal decoding apparatus 200 receives only the LPC coefficients for a monaural signal, high-quality background noise can be generated.
[0156] Thus, in the present embodiment, even when only the LPC coefficients of a monaural signal are transmitted, high-quality background noise can be generated, and also the bit rate can be reduced.
[0157] The above completes the description of the embodiments of the present invention.
[0158] The present invention may be applied regardless of whether a speech signal or an audio signal is used as the input signal.
[0159] The above-noted embodiments have been described for the case in which VAD data indicates a background noise part, with the switching section connecting to the stereo DTX encoding section in the stereo signal encoding apparatus and connecting to the stereo DTX decoding section in the stereo signal decoding apparatus. However, even if the VAD data indicates a non-speech part other than a background noise part (for example, an inactive speech part or the like), it is obvious that the same type of operation and effect can be exhibited.
[0160] The present invention is not restricted to the above-noted embodiments, and can be subjected to various modifications.
[0161] The stereo signal decoding apparatus in the above-noted embodiments performs processing using encoded data transmitted from the stereo signal encoding apparatus in the above-noted embodiments. The present invention is, however, not restricted in this manner, and as long as the encoded data includes the required parameters and data, processing is possible even if the data is not the encoded data from the stereo signal encoding apparatus in the above-noted embodiments.
[0162] Also, even for the case in which a signal processing program for operation is recorded by writing it into a machine-readable recording medium such as a memory, a disk, a tape, a CD, a DVD, or the like, the present invention can be applied, and the same operation and effect as the present embodiments can be obtained.
[0163] Although in the above-noted embodiments the description has been for the case of constituting the present invention with hardware, the present invention may be implemented by software in concert with hardware.
[0164] Each of the functional blocks used in the descriptions of the above-noted embodiments is typically implemented by an LSI device, which is an integrated circuit. These may be made into a single separate chip, and one chip may be made to include a part or all thereof. In this case, although an LSI device is cited, depending upon the level of integration, this may be called an integrated circuit, a system LSI device, a super LSI device, or an ultra LSI device.
[0165] The method of integrated circuit implementation is not restricted to large-scale integration, and implementation may be done by dedicated circuitry or a general-purpose processor. A programmable FPGA (field programmable gate array) or a reconfigurable processor, in which circuit cell connections or settings within an LSI device can be reconfigured after manufacture of an LSI device, may be used.
[0166] Additionally, in the event of the appearance of integrated circuit technology taking the place of large-scale integration, either by advances in semiconductor technology or other, derivative technology, the functional blocks may be, of course, integrated using that technology. Biotechnology may also be applied.
[0167] The disclosure of Japanese Patent Application No. 2010-256915, filed on Nov. 17, 2010, including the specification, drawings and abstract, is incorporated herein by reference in its entirety.
INDUSTRIAL APPLICABILITY
[0168] The present invention is particularly suitable for use in an encoding apparatus that encodes a speech signal or an audio signal that is made up of a L-channel signal and a R-channel signal, and in a decoding apparatus that decodes the encoded signal.
REFERENCE SIGNS LIST
[0000]
100 Stereo signal encoding apparatus
101 VAD section
102 , 105 , 202 , 205 Switching section
103 Stereo encoding section
104 Stereo DTX encoding section
106 Multiplexing section
200 Stereo signal decoding apparatus
201 , 401 Demultiplexing section
203 Stereo decoding section
204 Stereo DTX decoding section
301 , 302 Frame energy encoding section
303 , 304 , 502 , 701 , 702 Spectral parameter analysis section
305 Average spectral parameter calculation section
306 Average spectral parameter quantization section
307 Average spectral parameter decoding section
308 , 209 , 708 , 709 Error spectral parameter calculation section
310 , 311 , 710 , 711 Error spectral parameter quantization section
312 Multiplexing section
402 , 403 , 704 , 705 Frame gain decoding section
404 Average spectral parameter decoding section
405 , 406 , 801 , 802 Error spectral parameter decoding section
407 , 408 , 603 , 604 , 803 , 804 Spectral parameter generation section
409 , 412 Excitation generation section
410 , 413 Multiplication section
411 , 414 Synthesis filter section
501 Monaural signal generation section
503 Spectral parameter quantization section
601 , 703 Spectral parameter decoding section
602 , 706 Frame gain comparison section
707 Spectral parameter estimation section | Provided is a stereo signal encoding device that enables a lower bitrate without decreasing quality when applying an intermittent transmission technique to a stereo signal. A stereo encoding unit ( 103 ) generates first stereo encoded data by encoding the stereo signal when the stereo signal of the current frame is an audio section A stereo DTX encoding unit ( 104 ) is a means for encoding the stereo signal when the stereo signal of the current frame is a non-audio section, and generates second stereo encoded data by encoding each of: a monaural signal spectral parameter that is a spectral parameter of a monaural signal generated using the first channel signal and the second channel signal; first channel signal information relating to the first channel signal; and second channel signal information relating to the second channel signal. | 6 |
FIELD OF THE INVENTION
The present invention relates to an improved method for attaching rigidized surface insulation to a spacecraft.
BACKGROUND OF THE INVENTION
Attaching or fastening rigidized surface insulation to a spacecraft such as an orbiter shuttle vehicle presents a number of problems. The technique presently in use provides for bonding of the insulation to a rigid strain arrestor plate which, in turn, is bonded to a strain isolator pad, the pad being bonded directly to the skin structure of the spacecraft. This technique suffers serious disadvantages. For example, the strain induced in adjacent components must be compatible in order for the insulation to remain in place. However, with the technique outlined above, large compatability stresses are induced in the various components due to thermally and mechanically induced strains. Further, the orbiter skin cannot be allowed to buckle since transverse stresses would be induced in the rigidized surface insulation tending to cause separation, and this is a problem with the technique in question. In addition, this technique requires that the external fastener heads be flush with the outer surface of the skin. The foregoing problems dictate a relatively heavy design thereby adding to the overall weight. Yet another problem concerns the use of bonding as a means of attaching the insulation since such bonding degrades the overall system reliability.
SUMMARY OF THE INVENTION
In accordance with the invention, an auger device or mechanism is utilized to fasten rigidized surface insulation to a spacecraft. The auger can be screwed into an insulation tile or included therein when the tile is fabricated, and the combination of the auger and tile is fastened to the skin of the spacecraft through suitable means such as an attachment screw which penetrates the skin, and an associated fastener. The rigidized surface insulation is weak in tension and shear, and thus applying the loads required to keep the insulation in place on the spacecraft (effectively at a point) presents a problem. An auger, because of the large shear and bearing area employed thereby, permits the application of relatively large loads to the insulation.
Among a number of major advantages of the attachment method of the invention over the present "baseline" method of attachment described is the reduction in weight of the attachment device as compared with the attachment device currently used. Further, since the auger arrangement provides for attachment of the structure to the orbiter skin at only one point, the orbiter structure is free to deform, due, e.g., to thermally or mechanically induced loads, without inducing compatability stresses. Further in this regard, the orbiter structure can be designed so as to permit the skin to buckle thus providing the possibility of large weight savings. In addition, the attachment method of the invention eliminates the need for flush external fastener heads as was required in the fastening technique described above, thus providing a more lightweight design. Further, elimination of the need for the series bonding of the various components as described above, eliminates the unreliability associated with such bonding. Thus, to briefly summarize, the method of the invention eliminates compatibility stresses, reduces weight, and improves reliability as compared with the attachment method presently in use.
Other features and advantages of the invention will be set forth in or apparent from, the detailed description of a preferred embodiment found hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view, partly in section and partly broken away, illustrating the auger attachment method of the invention;
FIG. 2 is a side elevational view of a rigid surface insulation member which has been predrilled in accordance with initial steps in the attachment method of the invention;
FIG. 3 is a side elevational view illustrating the screwing of the auger into a rigid surface insulation member; and
FIG. 4 is a plan view of a rigid surface insulation member with an auger screwed thereinto.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, an insulation attachment auger according to the invention is generally denoted 10. The auger 10 is used to attach a rigidized surface insulation (RSI) member or tile 12 to the body or base structure 14 of a spacecraft such as an orbiter shuttle vehicle. The auger 10 is installed from the side of the RS1 member 12 which ultimately goes next to orbiter skin, i.e., auger 10 is screwed in from the side adjacent the base structure 14. The base structure 14 includes a spacecraft skin 14a and a support arrangement therefor indicated by support elements 14b.
The auger 10 includes a hollow, substantially cylindrical stem 16 and a helical blade 18 which extends laterally outward from stem 16 as shown. Auger 10 is attached to the spacecraft base structure 14 by means of an attachment screw 22 which extends through a hole or aperture 14c in spacecraft skin 14a. Attachment screw 22 is mounted within auger stem 16 by means of an arrangement including a plurality of preloaded "Belleville" washers or springs 24 which are disposed between the head 22a of attachment screw 22 and an annular insulating washer 26 which is seated at the base of auger stem 16. A generally annular, inwardly extending flange or abutment 16a supports washer 26 and screw 22 extends through central opening in washer 26 and flange 16a as illustrated. A blind fastener 28 is used to affix or fasten attachment screw 22 to the spacecraft skin 14a.
A lightweight fibrous pad 30 is located between the insulating tile 12 and the spacecraft skin 14a.
As is illustrated in FIGS. 1 and 2, in accordance with a preferred emodiment, a tool hole 20, a portion of which is shown at the top of FIG. 1, is drilled into insulation tile 12 prior to the installation of the auger. In addition to the tool hole 20, a second hole 21 is predrilled on the opposite side of RSI tile 12 which receives the auger stem 16. The required depth for hole 21 is only enough to clear the head of attachment screw 22 and the Belleville washers 24. However, the RSI tile 12 may be predrilled to depth corresponding to the entire auger stem 16. If the RSI tile 12 is predrilled to the minimum depth, the portion of the auger stem 16 above the head 22 a of attachment screw 22 and the Belleville washers will be filled with insulation material from the tile 12 since that portion of the auger stem 16 operates much in the manner of a cookie cutter.
Considering the various steps in the attachment method of the invention, as mentioned above and as can best be seen in FIG. 2, the insulating tile 12 is first predrilled at 20 to provide a clearance hole for a tool to be described hereinbelow, and at 21 to provide a clearance for the auger stem 16. The auger 10 is then screwed into the rigidized surface insulation tile 12 as illustrated in FIG. 3. Installation of auger 10 is effected through the utilization of a special tool which is indicated at 40 in FIG. 3. As shown in FIG. 4, the closed outer end of auger 10 includes a diametric slot 42 and a central hole 44 that corresponds to the hole through which attachment screw 22 extends in FIG. 1. Tool 40 includes female threading (not shown) for receiving attachment screw 22 and a diametric land, indicated at 46 in FIG. 4, which mates with slot 42, similar to the operation of a spanner wrench. When the special tool 40 and the auger 10 are properly mated, the mated assembly is placed into the chuck 50 of a device such as a drill press (not shown). The drill press is used only to hold and align the auger 10 and the turning force, indicated by the arrow in FIG. 3, is provided, for example, by an end wrench or by a "cheater" bar inserted through a diametric hole 48 drilled into tool 40. When auger 10 is properly installed in RSI tile 12, tool 40 is removed by loosening attachment screw 22. Access to attachment screw 22 is provided through tool hole 20. It is noted that auger 10 is screwed into tile 12 below the surface of the latter by 1/32 to 1/8 in. in an exemplary embodiment. This allows the auger 10 to be isolated from the spacecraft skin 14a thereby preventing relative vibration between the auger and the RSI tile. The auger-tile combination and associated pad are held in position relative to the spacecraft skin 14a and the end attachment screw 22 is secured in place by use of blind end fastener. Attachment screw 22 is tightened by means of a suitable tool such as an Allen wrench inserted through tool hole 20. At this stage the fibrous pad 30 is preloaded.
As indicated above, rather than screwing the auger 10 into tile 12, the auger 10 may be encased in the tile when the latter is fabricated. It is also noted that while the use of the blind fastener 28 is the preferred method of attaching the screw 22 to the spacecraft skin, the blind fastener can be replaced by any other suitable arrangement for attaching the screw to the skin, such as, for example, the use of a "nut plate" bonded to the skin.
Although the present invention has been described relative to exemplary embodiment thereof, it will be understood by those skilled in the art that variations and modifications can be effected in these embodiments without departing from the scope and spirit of the invention. | An auger device is used to attach rigidized surface insulation to a spacecraft. The auger is preferably screwed into an insulation tile which has been predrilled. The augertile combination is then fastened to the spacecraft using an attachment screw which penetrates the spacecraft skin and which is secured by a blind end fastener. In an alternate method, the auger is incorporated in the insulation tile when the latter is fabricated. | 8 |
TECHNICAL FIELD
[0001] The present invention relates to ubiquitous/universal processes for establishing cells capable of stable high yield expression of a recombinant gene with human glycosylation pattern, and for establishing stable universal precursor cells available for insertion of arbitrary target genes. The invention further relates to the cells obtainable by said processes.
BACKGROUND OF THE INVENTION
[0002] Recombinant protein production is of central importance for different applications. Structural studies of proteins (rational drug design and drug optimisation are based thereon (Antivir. Chem. Chemother., 12 Suppl. 1, 43-49 (2001))), industrial applications of proteins (enzymes) and clinical use of recombinant proteins have increased the need for their efficient production. As of February 2000, according to a survey by the Pharmaceutical Research and Manufacturers of America, 122 biologics, including 20 monoclonal antibodies were either in phase III trials or awaiting FDA approval (K. Garber, 2001, Nature Biotech. 19, 184-185).
[0003] Depending on the application, native conformation and correct posttranslational modifications (such as glycosylation) of the recombinant protein are essential. Prokaryots such as the biotechnology “pet” organism Escherichia coli ( E. coli ) lack the ability to introduce posttranslational modification. Only eukaryotic cells possess the cell machinery necessary for co-translational and post-translational modifications as they are often required to produce functionally active proteins. Various eukaryotic systems for the production of a variety of heterologous proteins exist, Fungal expression systems, using e.g. derived from the genus Saccharomyces, Candida, Pichia, Hansenula, Aspergillus or Kluyveromyces are well established (Hollenberg and Gelissen (1997), Current Opinion in Biotechnology 8, 554-560). To circumvent the problem of plasmid instability sometimes encountered in fungi, sequences coding for heterologous proteins are ideally integrated into the fungal chromosome via homologous recombination. Further problems encountered with fungal expression systems are overglycosylation of heterologous proteins and incorrect folding such as incorrect oligomerisation and insufficient ligand incorporation. Expression of heterologous proteins in insect cells—the DNA encoding the heterologous protein can also become integrated into the chromosome via recombination—gets around these problems. However, insect cells lack the ability to produce sialic acid and sialic glycans. Terminal sialic acid residues play divers biological roles in many glycoconjugates. Plants can also be used for the production of recombinant proteins. However, in these heterologous expression system difficulties in extraction and purification prove real bottlenecks.
[0004] Mammalian expression system, cultured cells as well as transgenic animals have none of these disadvantages. Recombinant proteins can be produced in cultured mammalian cells either transiently or constitutively (stably). For transient expression of recombinant a vector DNA encoding the recombinant protein is introduced into the cell and in general is not integrated into the cellular DNA. Expression titers of the recombinant protein are at the beginning high. However, since the vector DNA is generally not replicated, the vector DNA becomes diluted with each cell proliferation and hence the expression titer drops. Only rarely a vector DNA or part of the vector DNA illegitimedly recombines with the cellular genomic DNA and the gene encoding recombinant protein is stably integrated into the genome. If the gene encoding the recombinant protein is associated with a selection marker, cells carrying this cassette can be identified and isolated as stably transformed cells. Stable transformants have the advantage that the heterologous proteins are continuously produced. The expression titer is mainly determined by the strength of the promoter construct, the site of integration into the chromosome, the copy number and the type of recombinant protein in question. Many strong promoters are commercially available, however, their transcriptional activity varies depending on the cellular level of the relevant transcription factors and on the chromatin structure at the integration site. For example integration within the scaffod- or matrix attachment regions (S/MAR elements) of chromosomal DNA can augment the activity of promoters—and hence the expression of heterologous genes—and protect them from inactivation by the flanking chromatin. Therefore, it is highly desirable to chose a promoter highly active in a specific cell and to direct integration into an active part of the chromosome. Preferentially a single integration event is desirable, since heterologous genes at low copy number are in general expressed more stable than multicopy genes.
[0005] Integration at a single preselected highly active locus can be achieved via homologous recombination. This method, although typically applied to mouse embryonic stem cells, is extremely inefficient in somatic cells of human origin and requires a large scale screening effort. Moreover it is not applicable for most human permanent cell lines when it is desired to completely shut off the expression of a given target gene, because these cell lines are usually polyploid and targeting more than 2 identical loci is hardly feasible. Site specific recombination using recombinases, eg. Cre, flp, C13 and their respective target site (RRS) are a viable alternative (Feng, Y. Q. et al., Journal of Molecular Biology, vol. 292(4), p. 779-785 (1999); Schlake, T. et al., Biochemistry, Am. Chem. Soc., vol. 244(1-2), p. 185-193 (October 2000); Fussenegger, M. et al., Trends in Biotechnology, vol. 17(1), p. 35-42 (January 1999); Groth, A. C. et al., Proceedings of the National Academy of Sciences of USA, vol. 97(11), p. 5995-6000 (May 2000)). With this approach, a plasmid carrying a single RRS can be used to target a single RRS in the chromosome. This method, however, has certain limitations: Namely, it is quite inefficient because the reverse reaction, excision of the plasmid, is an intermolecular recombination and takes place at much higher speed than the integration. Secondly, the whole plasmid including bacterial genes are integrated. To solve the first problem unidirectional was established, e.g. by meains of hetero-specific target sites for both flp and cre. These RRS are recognised by the respective recombinase but a successful recombination requires identical sites and the excision reaction is precluded (Karreman S. et al., Nucleic Acids Res., vol 24(9), p. 1616-1624 (1996); Trinh, K. R. et al., J. of Immunol. Methods, vol. 244, p. 185-193 (2000)). However, the targeting plasmid still has to be integrated into a single favourable position of the chromosome. A large scale screening effort is required to find such rare integrates. These clones often contain more than one copy of the plasmid, the may contain incomplete copies and bacterial sequences care not precluded from integration. These bacterial sequences are recognized by the mammalian cell often leading to inactivation of the targeted region. Alternatively, the targeting cassette may be integrated via retroviral vectors (Karreman S. et al., Nucleic Acids Res., vol 24(9), p. 1616-1624 (1996)). These vectors target active sites within chromosome, only full length cassettes are integrated and the infection dose can be adjusted to create single integration sites. However, expression units flanked by ITRs may also be subject to inactivation. In addition, the use of this system may be restricted by the governmental release agencies to exclude t therapeutic applications of the expressed protein.
SUMMARY OF THE INVENTION
[0006] In view of the above, there is still a need for a method allowing the transformation/conversion of a cell line with an arbitrary gene coding for a product of interest to obtain a high yield recombinant human glycoprotein producing cell, especially for a method without or only little cumbersome screening procedures. It was surprisingly found that cells expressing recombinant glycoproteins with features of human posttranslational modification at high yield are obtainable by first identifying a non-essential highly expressed cellular gene (hereinafter shortly referred to as “starting gene”) in a human or essentially human hybrid cell (hereinafter shortly referred to as “starting cell”); secondly directly replacing the starting gene via homologous recombination with a first functional DNA sequence (e.g. by utilizing an appropriate targeting cassette) containing recombinase recognition sites (RRSs) for site-directed integration and optionally a “place-holder” gene comprising various functional sequences and selecting/isolating a stable clone of this precursor expression cell (functionalized cell); thirdly introducing the gene of interest (from here on called “target gene”) coding for the target gene product (protein) by site-directed integration using a recombinase recognizing the RRSs incorporated with the first targeting cassette; and finally selecting/isolating a stable expression cell capable of producing large amounts of the recombinant protein. Direct replacement of the starting gene with a functional DNA sequence containing a DNA sequence coding for the target gene product is also applicable.
[0007] It was moreover found that suitable starting cells for the above method are specific mammalian cells such as human myeloma and hybridoma cells and human heterobybridoma cells (including human-mouse hetero-hybridoma cells such as H-CB-P1), which allow the production of proteins having an essentially human glycosylation pattern.
[0008] Using the present invention it is possible to introduce stably any gene encoding a recombinant protein of interest into the specific mammalian cells set forth above. Using the present invention the gene of interest encoding the recombinant protein will become integrated into the locus of a highly expressed cellular gene and preferably in close proximity to a highly active cellular promoter residing in an active part of the chromosome. Using the present invention precursor cell lines of various origin can be created carrying a place holder gene surrounded by RRSs. Using the present invention the place holder gene can be exchanged with the gene of interest, encoding the recombinant protein, by site-specific recombination at the RRSs catalyzed by a suitable recombinase, giving rise to the final high-yield expression cell.
[0009] Finally, it was found that the human-mouse heterohybridoma provides for a very distinct human glycosylation pattern.
[0010] More specifically, the present invention provides
[0000] (1) a process for preparing cells capable of stable high yield expression of a target gene product having essentially human glycosylation pattern which method comprises
[0000] (a) selecting a human cell or human hybrid cell (hereinafter “starting cell” capable of stable high yield expression of a starting gene product being non-essential to the starting cell;
[0000] (b) screening for the locus of the starting gene product within the genome of the starting cell;
[0000] (c1) replacing the gene coding for the starting gene product with a first functional DNA sequence containing one or more recombinase recognition sites (RRS) to obtain a functionalized precursor cell; and
[0011] (d) integrating a second functional DNA sequence containing a DNA sequence coding for the target gene product into the functionalized precursor cell obtained in step (c1) by use of a recombinase recognizing the RRSs incorporated with the first functional sequence, or
[0000] (c2) directly replacing the gene coding for the starting gene product with a functional DNA sequence containing a DNA sequence coding for the target gene product;
[0012] (2) in a preferred embodiment of the method of (1) above the starting cell is an immortalized cell derived from B lymphocytes (preferably is a human-mouse hetero-hybridoma such as hetero hybridoma H-CB-P1 (DSM ACC 2104)) and integration of the functional DNA sequence(s) is effected at a Ig locus (preferably at a rearranged human Ig locus of said cell);
[0000] (3) a cell capable of high yield expression of a target gene product obtainable by the method of (1) or (2) above;
[0000] (4) a method for preparing a functionalized cell comprising the steps (a) to (c1) as defined in (1) or (2) above;
[0000] (5) a precursor cell as defined in (4) above;
[0000] (6) a method for high yield expression of a target gene product which comprises cultivating a cell as defined in (3) above; and
[0000] (7) a target gene product obtainable by cultivating a cell derived from H-CB-P1.
DESCRIPTION OF THE FIGURES
[0013] FIG. 1 : Concept overview, multistep process to create high yield expression cell lines comprising site-specific integration of genes into an IgH locus at frt sites. The IgH locus of H-CB-P1 is represented in the upper graph of FIGS. 1 a and 1 b . It contains the variable gene promoter followed by a protein leader sequence and specific V, D, and J genes rearranged and positioned next to the enhancer Eμ, the MAR and the Cμ coding sequences. Target sequences for homologous recombination are shown marmorate. Via homologous recombination between the flanking sequence elements “Vhprom” and “Cμ” of vector 1 (targeting vector) and the genomic DNA, first functionalized sequences located between the flanking sequences are introduced into the genomic DNA and a recombinant PBG03 genome is the result. The first functionalized sequence contains frt sites (frtF5 frtF3 and frt wt), an artifical strong promoter CES ( FIG. 1 a ) or no additional promoter ( FIG. 1 b ) upstream of the first expressed gene(hobFc). In addition a blasticidine or hygromycin resistance gene and an ATG deleted neomycin gene are part of the first functionalized sequence. The recombinant genome carries the first functional sequences integrated in the chromosomal DNA.
[0014] FLP recombinase catalyses recombination at frtF5 and frtF3 or at frt wt and frtF3 sites of the recombinant H-CB-P1 genome and vector 2, the actual gene of interest is introduced and expressed from the artificial or the endogenous VH promoter ( FIGS. 1 a and 1 b , respectively). Parts of the first functionalized sequence located between frtwt and frt F3 sites are replaced by a weak promoter followed by an ATG which after recombination is positioned in the same open reading frame as the ATG-deleted neomycin gene. The resulting genome has lost the hobFc gene and the blasticidin or hygromycin resistence genes and instead has the gene of interest (target gene) and a functional neo gene.
[0015] FIG. 2 : The endogenous cassette (CEShobFcblas) of the targeting vector. The detailed structure of the endogenous cassette containing an CES promoter, a hobFC fusion gene, a blasticidin resistance gene and a start codon (ATG) deficient neomycin gene is shown. In more detail, the endogenous sequence contains a modified frt site (frtF5) followed by a hybrid promoter structure comprising the early CMV promoter/enhancer elements as well as the first intron of the elongation factor alpha gene. The next element is a frt wildtype site followed by the hobFC fusion gene (hobFC), and the SV40 polyadenylation signal (SV40PA). A weak SV40 promoter controlling the expression of the blasticidin resistance gene follows. The last elements are a modified frt site (frtF3) and next to it the ATG deficient neo gene. Modified frt sites F3 and F5 allow recombination with identical sites but not with wildtype frt sites and F5 or F3 sites respectively. The frt F3 site is positioned to upstream of the neo gene to form a contiguous open reading frame lacking the ATG.
[0016] FIG. 3 : Cloning strategy for the intermediate vector pVCμ containing the flanking regions Vhprom and Cμ.
[0017] The 2 kb VH promoter sequence was amplified from PBG03 cell genomic DNA using forward primer VHpromF (SEQ ID NO:1) and reverse primer VHpromR (SEQ ID NO:2). The PCR product VHprom was cloned into the pCR 4BluntTOPO vector (Invitrogen) and the resulting vector named pVH. The 7.4 kb Cμ region was amplified from genomic H-CB-P1 DNA as two overlapping fragments, namely CμMitteR and CμMitteF. The primers CμintV (SEQ ID NO:3) and CμMitteR (SEQ ID NO:5) give rise to the product CμMitteR and the primers CμMitteF (SEQ ID NO:6) and the reverse primer CμintR (SEQ ID NO:4) produce the fragment CμMitteF. Both fragments were cloned into a pCR 4BluntTOPO vector (Invitrogen) and the resulting vectors called pCμMitteR and pCμMitteF. The full length Cμ sequence was re-established by opening both vectors with the restriction enzyme SpeI and DraIII, and ligating the SpeI-DraIII fragment from pCμMitteR into the opend pCμMitteF. The resulting vector pCμ carries the full-length Cμ region (Cμ intron). The VH promoter sequence and the Cμ sequence were combined in one vector pVHCμ, by digesting both pVH and pCμ with the restriction SpeI and PmeI, and inserting the isolated Vhprom PmeI-SpeI fragment into the phosphatase treated opend vector pCμ.
[0018] FIG. 4 : Cloning strategy for the targeting vectors pCESHhobFc and pVHCμHhobFc. The targeting vector pVHCμCESHhobFc containging the highly active promoter CES and the hobFC fusion gene was created by ligating an end-filled SwaI-BstBI fragment isolated from pCESHhobFc into the pVHCμ vector that had been digested with PmeI and dephosphorylated. The targeting vector pVHCμHhobFc that has the hobFC fusion gene but no CES promoter, was prepared by ligating an endfilled Bst1107-BstBI fragment isolated from pCESHhobFc into an PmeI digested and dephosphorylated vector pVHCμ.
[0019] FIG. 5 : Cloning strategy for targeting vectors carrying a blasticidin resistant gene, pVHCμCEShobFcblas and pVHCμhobFcblas.
[0020] The plasmid pcDNATRD was used as donor for the blasticidin gene. To delete the hygromicin gene sequences as well as the FRT5 and neomycin sequences from the vector pCESHhobFc, the vector was digested with EcoRI and SalI and dephosphorylated. An EcoI-SalI fragment from pCDNATRD containing the blasticidin resistant gene sequence was ligated into the previously opened pCESHhobFc vector and the resulting plasmid named pCEShobFcblasdeleted. The Frt F5 sequence and the ATG-deleted neomycin sequence were isolated from pCESHhobFc as a SalI SalI fragment and re-inserted into the SalI site of pCEShobFcblasdeleted. ShobFcblasdeleted. The resulting plasmid pCEShobFcblas was used together with pVHCμCESHhobFc to create pVHCμCEShobFcblas. The BamHI-SalI fragment comprising the hobFc sequence and the blasticidin gene was isolated from pCEShobFcblas and inserted into vector pVHCμCESHhobFc opened with BamHI and SalI, giving rise to pVHCμCEShobFcblas. The vector pVHCμhobFcblas was created by ligating a BamHI-SalI fragment containing the hobFc gene and the blasticidin gene into vector pVHCμHhobFc digested with BamHI and SalI.
[0021] FIG. 6 : Immunostaining of H-CB-P1 clones
[0022] H-CB-P1 clones obtained through transfection of H-CB-P1 cells with pVHCμ CESHhobFcblas were immunostained with a Texas Red conjugated anti-human IgG, F y fragments specific antibody isolated from goats or an AMCA conjugated anti-human IgM, Fc 5μ specific antibody isolated from goats. The left column shows two H-CB-P1 clones stained with the Texas Red conjugated antibody and visualized with an UV WG filter. In the right column the same clones are shown after staining with the AMCA conjugated anti-IgM antibody and visualized under UV filter WU. Whereas for the clone in the upper panel only IgG staining is evident, staining with both antibodies is present for the clone in the lower panel. The first clone may result from homologous recombination whereas the other clone contains an illegitimate insertion of the functional sequences.
[0023] FIG. 7 : Direct immunostaining of H-CB-P1 clones and further expansion of clones. It is demonstrated that H-CB-P1 clones could be immunostained without jeopardizing the cells viability and that subsequent expansion of the stained clone was possible. A H-CB-P1 clone cultured for ten days in a 96 well plate was immuno-stained with an Texas Red conjugated anti-IgG antibody. A picture of the clone prior to immunostaining visualized with normal light microscopy, is shown in the top left panel. The same clone immunostained with the Texas Red conjugated anti-IgG antibody is shown in the top right hand panel. The bottom panels show pictures of the well post trypsinisation. No cells can be seen when the picture was taken under a normal light microscope, as shown in the bottom left hand panel. The right hand panel shows the same well examined under UV filter WU. The cells are completely removed from the well and the fluorescent antibody precipitate remained in the well and is not attached to the cell surface.
[0024] FIG. 8 : Ant-IgM dot blot of cell culture supernatants from induvidual clones Supernatant of the following clones
[0000] 1: pVHCμhobFcblas-D6; 2: pVHCμhobFcblas-G8;
[0000] 3: pCEShobFcblas-A3; 4: pVHCμCEShobFcblas-B4;
[0025] 5: pVHCμCEShobFcblas-D3; 6: pVHCμCEShobFcblas-G8 were spotted onto a membrane and subjected to the ECR staining method. Since the starting cell population homogenously produces IgM, clones with no detectable IgM expression result from inactivation of the IgM H gene mediated by the targeting vector. The clone A3 generated by transfection of pCESHhobFcblas which lacks homologous flanking sequences was unable to target the IgM locus and expresses IgM.
[0026] FIG. 9 : Anti-IgG dot blot of cell culture supernatants from individual clones. Supernatant from the following clones
[0000] 1: pVHCμhobFcblas D6; 2: pVHCμhobFcblas D6 (1:2 diluted); 3: pVHCμhobFcblas-G8; 4: pVHCμhobFcblas G8 (1:2 diluted); 5: pCEShobFcblas A3; 6: pVHCμCEShobFcblas B4; 7: pVHCμCEShobFcblas D3; 8: pVHCμCEShobFcblas D3 (1:2 diluted);
[0000] 9: pVHCμCEShobFcblas D3 (1:10 diluted); 10: pVHCμCEShobFcblas G8;11:hobFc standard 500 ng/ml; 12: hobFc standard 50 ng/ml IgG
[0027] were spotted onto a membrane and subjected to the ECR staining procedure using an anti-IgG antibody.
[0028] FIG. 10 : Detection of homologue recombination via PCR
[0029] To test whether a homologue recombination event had occurred between the (targeting) vector and the Ig locus of H-CB-P1 cells, a PCR strategy was applied. Upon recombination the endogenous cassette of the vector containing the CES promoter, the hobFc gene and a resistance gene (hygromycin or blasticidin) followed by the ATG-deleted neomycin gene becomes integrated between the genomic V gene promoter sequences and the enhancer Eμ. The forward primer V5 (SEQ ID NO:7) which binds to the genomic V gene promoter sequences outside of the fragment Vhprom was combined, with primers V6 or V7 (SEQ ID NOs:8 and 9, respectively), which bind specifically within the first functional sequence. The occurrence of PCR products is strictly dependent on co-localisation of both primer binding sequences and hence homologous recombination. To confirm any positives the putative positiv PCR product was used in a nested PCR reaction with the primers VHpromF and VHpromR (SEQ ID NOs:1 and 2, respectively).
[0000] a: primer position, b: electrophoretic analysis of PCR products
[0000] left: first PCR V5, V7
[0000] lane 1: 1 kb ladder (Invitrogen); lane 2: clone pVHCμhobFcblas H6;
[0000] lane 3: clone pVHCμCEShobFcblas B10; lane 4: clone pVHCμhobFcblas D4;
[0000] lane 5: clone pVHCμhobFcblas D8; lane 6: clone pVHCμhobFcblas E11;
[0000] lane 7: neg control H-CB-P1
[0000] right: nested PCR
[0000] lane 1: 1 kb ladder (Invitrogen); lane 2: neg control H-CB-P1;
[0000] lane 3: clone pVHCμCEShobFcblas H6; lane 4: clone pVHCμhobFcblas D4;
[0000] lane 5 clone pVHCμhobFcblas E11
[0030] FIG. 11 : hobFc expression In the absence of selction pressure.
[0031] Cells were cultivated for 3 month in the absence of selection pressure. To determine expression cells were seeded at a density of 10 5 cells/ml. After 24 h cell culture supernatants were harvested and subjected to a westen blot (dot blot) using an anti human Fc antibody. Supernatants were applied to the filter from left to right: undiluted, 1:2 dilution and 1:10 dilution.
[0032] Left: clone pCEShobFcblas A3 (random insertion),
[0033] Center top pVHCμhobFcblas G8; Center bottom pVHCμhobFcblas G8;
[0034] Right pVHCμCEShobFcblas D3.
[0035] Expression is stable in clones resulting from homologous insertion of the functionalised sequences including the hobFc gene.
[0036] FIG. 12 : Generation of a target cell clone using GFP as a model target gene. Clone pVHCμCEShobFcblas D3 (renamed PBG04) was transfected with vector 2 comprising a second fuctional sequence (frtwt, GFP open reading frame and polyadenylation signal, minimal promoter followed by ATG and frtF5) and plasmid pflp comprising a functional expression unit for the flp recombinase (Note: the vector is unable to express GFP in a naive cell because it lacks a functional promoter driving expression). After two weeks of selection with G418 individual stable clones strongly expressing GFP are detectable. GFP expression as well as G418 resistance depends on the homologous recombination event.
[0037] FIG. 13 : Identification of the rearrangements in the heterohybridoma H-CB-P1 The cDNA for the light and heavy chain genes form H-CB-P1 was sequenced and compared to database sequences. Genomic genes constituting the heavy gene genes were identified by homology with unrearranged genomic sequences. Based on the identification of V1-2, D1, J6 and μ a genomic map of the rearranged locus was constructed. PCR primers were designed using this information, respective fragments extending 5′ to the variable gene V1-2 promoter and containing the D,J, and μ Intron sequences but leaving out the variable gene ATG were amplified and used to construct the targeting vector.
[0038] The lambda light chain variable gene V3-19 was identified via homology search as well. This approach was not suitable to identify the constant gene because the locus contains 100% identical gene copies. A PCR based on primers in the intervening sequences between constant region genes allowed to identify J2 and H2 as the genes constituting the rearranged lambda gene of H-CB-P1
[0039] FIG. 14 : Chromosome analysis of H-CB-P1. GTG Banding, left panel 68-94 chromosomes were fond. The majority were identified as mouse chromosomes Spectral Karyotype Analysis, middle and right panels. Human chromosomes within H-CB-P1 were identified by hybridisation with specifically labeled humanchromosome libraries. 8 intact human chromosomes 4, 5, 7, 10, 14, 17, 18, 22 In addition Chromosome fragments of ch. 4, 8, 9, 10, 11, 14, 16 were identified A hybridization with a probe specific for the human Ig H locus revealed a single IgH locus on the intact chromosome 14
[0040] FIG. 15 : Schematic representation of a N linked oligosacharide structure of a mammalian glycoprotein.
[0041] The leptin-Fc molecule contains two N linked oligosacharides, one on each chain of the Fc domain.
[0042] FIG. 16 : Aminophase-HPLC of leptinFc
[0043] LeptinFc from PBG-04 was generated in roller bottle culture and purified by a generic process including affinity chromatography, gel filtration and membrane filtration. The protein was digested with trypsin and the resulting peptides were deglycosylated by PNGase F digestion. The glycans were labeled with 2-aminobenzamide and separated by HPLC on a Phenomenex Hypersil APS-2-column. Peak numbers represent the fractions which were used in MALDI-TOF-MS analysis.
DETAILED DESCRIPTION OF THE INVENTION
[0044] The present invention provides a method to transform a mammalian starting cell, in particular a human cell or human hybrid cell into a stable high yield expressing cell. To achieve continuous recombinant expression, the gene encoding the recombinant product becomes integrated into the genomic cellular DNA. Expression levels are highly determined by the site of integration of the recombinant gene into the cellular DNA. Therefore, the here presented method comprises the integration of a recombinant gene into a transcriptionally highly active part of the genome of a cell. The gene of interest coding for the recombinant protein can either be under the control of very strong recombinant promoter, or be placed under the control of a highly active cellular promoter by integrating it downstream of the highly active cellular promoter.
[0045] In a preferred embodiment of the method (1) of the invention the starting cell secretes the starting gene product, preferably in an amount of at least 0.3 fmol/cell/d of a polypeptide chain (which equals 30 pg/cell/day for a protein of approximately 90 kd) and more preferably in an amount of more than 1 fmol/cell/d (which equals 100 pg/cell/day for a protein of approximately 90 kd). Alternatively, in case the starting cell does not secrete the starting gene product a gene coding for a highly expressed preferably nonessential intracellular or membrane protein or a highly expressed noncoding RNA is selected.
[0046] In another preferred embodiment, the starting cell is a primary, immortalized or fusionated cell or a genetic modification thereof. Thus, the starting cell may be selected from primary cells, immortalized cells (e.g. immortalized cells derived from B lymphocytes) or tumor cells or genetic modifications thereof, cell hybrids, cell lines used generally in protein manufacturing such as HEK293, PER.C6 human cell lines created from primary cells via genetic immortalization or fusion with immortal cell lines, preferably it is a human hybridoma or hetero-hybridoma cell (e.g. human-mouse, human-rat or the like) and most preferably is human-mouse hetero-hybridoma H-CB-P1 (DSM ACC 2104; previously referred to as ZIM517).
[0047] If the starting cell is a human cell or human heterohybridoma (e.g. as defined above), it is preferred that said hybrid cell or heteor-hybridoma comprises at least one human chromosome and/or is capable of human post-translational modification. It is particularly preferred that the starting gene product is a human gene.
[0048] The starting gene product is preferably selected from secreted proteins such as antibodies, cytokines, hormones, enzymes, transport proteins storage proteins, structural proteins, etc. The starting gene product is either known a main product of the chosen starting cell. So stable expression of IgM has been observed for H-CB-P1 or selected in a screening procedure. Screening may be based on individual or combined methods comprising microarray expression analysis, 2D protein gel electrophoresis, quantitative PCR, RNAse protection, northern blot, ELISA and western blot. The power and sensitivity of these individual methods is known to those skilled in the art.
[0049] The method of the invention allows the production of any recombinant protein. Preferred target gene products include, but are not limited to, enzymes, in particular proteases, protease inhibitors, hormones, cytokines, receptors or soluble forms thereof (e.g. receptors lacking transmembrane or intracellular domains), full-length antibodies or antibody domains and fusion proteins combining domains of these protein classes.
[0050] In a first option of embodiment (1) comprising steps (a), (b), (c1) and (d), the replacement of the starting gene is effected by an one step replacement strategy, wherein the starting cell is contacted with a vector construct containing the first functional sequence, said first functional sequence inactivating and partially or completely replacing the gene coding for the starting gene product. Alternatively, the replacement is effected in a two or multistep strategy, wherein the gene coding for the starting gene product is deleted or inactivated and subsequently contacted with a vector containing the first functional sequence, said first functional sequence being incorporated at the site of the deleted/inactivated starting gene product.
[0051] Specific incorporation of the first functional sequence at the location of the starting genes is facilitated by sequences flanking the first functional sequence in the vector which are homologous to the target gene or adjacent sequences. These flanking sequences are obtained either from lambda, cosmid, pac or bac libraries of the starting cell or generated by PCR using starting cell DNA as a template. The percentage of cell clones resulting from specific incorporation of the first functional sequence at the location of the target gene may be further increased by employing a dual selection strategy, where a positive selection marker is contained as part of the first functional sequence and a negative selection marker separated from the first functional sequence by a homologous flank. Homologous exchange allows incorporation of the positive selection marker in the absence of the negative selection marker. Examples for positive selection markers are the hygromycin, blasticidin, neomycin, or glutamin synthetase genes and the HSV tk or the Cytosine desaminase gene are negative selection markers. Markers and methods for their application are known to those skilled in the art.
[0052] Cell clones resulting from homologous exchange are identified by the presence of elements of or gene products expressed from the first functional sequence and the inactivation of at least one allele of the starting gene. These cell clones represent the functionalised precursor cell.
[0053] The first functional sequence comprises one or more RRS(s) selected from loxP, frt, att L and attR sites of lambdoid phages, recognition sites for resolvases or phage C31 integrase. It is preferred that said recognition sites provide for unidirectional integration, which is achieved, e.g. by modified loxP and frt sites as well as by the (wild-type) recognition sites of ΦC31 integrase. The first functional sequence may further comprise sequences selected from marker sequences, secreted protein genes, promoters, enhancers, splice signals, polyadenylation signals, IRES elements, etc.
[0054] To create a producer cell for the target gene product, the functionalized precursor cell (if not already a producer as obtained in step (c2) of second option of embodiment (1), see below), e.g. the PBG03 clone D3 (DSM ACC2577), is subsequently contacted with a second vector containing the second functional sequence. The second functional sequence comprises the target gene and RRS(s) for said recombinases present in the first functional sequence. The second functional sequence further comprises functional sequences selected from promoter sequences, marker sequences, splice donor and acceptor sequences, recombinase recognition sequences differing from RRS of the first functional sequence, etc.
[0055] The integration of the second functional DNA sequence is effected by recombinases recognising the RRS with or without accessory proteins (e.g., Cre, Flp, φC31 integrase, resolvase and the like). These recombinase and accessory proteins, mRNA coding for these proteins or viral or nonviral vectors allowing there transient expression are delivered together with, shortly before or after delivery of the second functional sequence.
[0056] A pure population of clones containing the second functional sequence at the location of the starting gene is achieved by selection using a reconstituted functional selection marker gene. As an example an inactive ATG deleted selection marker gene introduced with the first functional sequence may be reconstituted by delivery of an active promoter and an in frame-ATG codon with the second functional sequence.
[0057] In a second option of embodiment (1) of the invention (comprising steps (a), (b) and (c2)) the gene coding for the starting gene product may directly (i.e. without the provision of the precursor cell) be replaced with a functional DNA sequence containing a DNA sequence coding for the target gene product (hereinafter shortly referred as “third DNA sequence”). Said third DNA sequence may be incorporated by a one- or multi-step strategy as described herein before. The third DNA sequence may further contain functional sequences (such as promoters, markers etc.) as the first and second DNA sequence described herein before. This second option of embodiment (1) of the invention is particularly preferred, if only one target gene product is to be produced so that the generation of the precursor cell is not necessary.
[0058] In preferred embodiment (2) of the invention, the starting cell preferably is a human-mouse hetero-hybridoma cell, preferably is hetero-hybridoma cell H-CB-P1 (DSM ACC2104). The integration of the functional DNA sequence is effected at a Ig locus, preferably at one of the human rearranged Ig loci (e.g. heavy chain or light chain (λ or κ)) of the hybridoma cell. The rearranged immunoglobin locus is the genomic sequence surrounding the functional Ig gene (heavy chain λ or κ) modified from the germ line chromosomal configuration during maturation of the B-lymphocyte which gave rise to the hybridoma. The IgH locus Is located at chromosome 14q32.33. In H-CB-P1 this locus is formed by the rearranged and affinity matured VH1-2 gene linked via a D-gene to the J H 6-gene linked via the μ-intron to the Cμ sequences (DD 296 102 B3). The sequence of the rearranged VDJ region of the H-CB-P1-IgH locus is provided in SEQ ID NO:12.
[0059] It is preferred that the cells of embodiments (3) and (5) of the invention are derived from H-CB-P1 (DSM ACC2104). Furthermore, it is preferred in embodiment (3) of the invention that the target gene product is an antibody. In such case the cell is preferably PBG04 (DMS ACC2577). In the above cells in particular utilized for the expression of antibodies it is feasible that its light chains are inactivated (disrupted) or replaced with a gene coding for same or different target gene product.
[0060] Moreover, as indicated before, the target gene products obtainable by expression of a cell line derived from H-CB-P1 possesses a unique essentially human glycosylation pattern.
[0061] Glycoproteins for therapeutic application, in particular antibodies are typically manufactured in mammalian cells because posttranslational modifications such as N linked glycans are generated only in mammals and they have a substantial impact on pharmacological features of these proteins. A fully processed N glycan forms a biantennary structure with core fucose and terminal sialic acids ( FIG. 15 ). The majority of proteins, under physiologic conditions, carries only truncated versions of the full structure. The degree at which glycosylation is driven to completion depends on the cell type as well as on culture conditions.
[0062] So the degree of sialinisation the addition of the terminal sialic acid to the glycan varies and does rich only 30-40% for antibodies in human blood. However, a high percentage of sialinated proteins increases the half life of a therapeutic protein in blood. The cell lines derived from H-CB-P1, such as PBG04 generate highly sialinated glycoproteins in comparison to CHO and NS0 cells widely used in the manufacture of glycoproteins as can be seen from Example 5. For therapeutic glycoproteins a low content of glycans terminated before the addition of galactose (G0 structures) is advantageous. So G0 Glycoproteins tend to dimerize and the ability of antibodies to mediate complement dependent cytotoxicitly is diminished. The genetic composition of PBG04 allows a more complete processing with a low degree of G0 structures (4.3% on leptin-Fc In a roller bottle process)
[0063] Whereas the general biantennary structure is formed by all mammals, some specific structures (linkages between individual sugars) are either specific to, or completely excluded in humans. These structures affect biological features as well. Therefore, it is of advantage to use cells to manufacture glycoproteins for therapeutic applications which provide the necessary enzymes to generate human specific modifications and lack enzymes which are not present in human cells are responsible for atypical linkages. Such cells may be entirely human or contain a subset of human chromosomes. In the latter cells it is important that the human specific glycosylation enzymes dominate over those, not present in humans.
[0064] So neuraminic acid may be added as N acetylneuraminic acid or N glycolylneuraminic acid, the latter being the major structure in mouse cells. N glycolylneuranminic acid is absent on glycans form old word monkeys and man. They are immunogenic and may lead to the formation of antibodies against the therapeutic protein.
[0065] In addition, mouse cells contain an additional glycosylation enzyme, the alpha 1,3 galactosysltransferase. It mediates the transfer of gal residues to exposed gal residues of the glycan. Such linkage is also found in yeast and as a protection humans have pre-existing antibodies against this structure. Recognition may lead to the formation of immune complexes and kidney damage as a result of treatment. Only 1.3% PBG04 derived leptin-Fc contains alpha 1,3 gal.
[0066] A small percentage of human proteins contains bisecting N-acetylglycoseamine. It does not, per se, influence biologic features but the enzyme complex interferes with another one mediating core fucosylation. Often, in proteins with bisecting N-acetylglycoseamine, core fucose is missing, resulting in more efficient binding of the Fc-gamma Receptor and in enhancement of antibody dependent cellular cytotoxicity (ADCC). Therefore cells have been engineered to express (1,4)-N-acetylglucosaminyl transferase III to increase the percentage of non-core-fuccosylated proteins. (U.S. Pat. No. 6,602,684)
[0067] A high content of glycoproteins without core fucose can also be achieved in mouse cells. However, these proteins contain the disadvantageous features typical for mouse proteins. A specific hybrid cell of a human a and a mouse with the right chromosomal composition cell can combine the advantageous features of both. Cell lines derived from H-CB-P1 such as PBG04 are such cell lines.
[0068] The present invention is further explained by the following examples which are, however, not to be construed to limit the invention.
[0069] The cell line H-CB-P1 was deposited at the “Zentralinstitut für Molekularbiologie, Akademie der Wissenschaften der DDR”, Robert-Rössle-Str. 10, Berlin Buch, DDR-1115 as ZIM-0517 on Mar. 16, 1990 and was transferred to the DSMZ, Deutsche Sammlung von Mikroorganismen und Zellkulturen GmbH, Maschroder Weg 13, 38124 Braunschweig, Germany, on Dec. 12, 2000 and here given the depositary number DSM ACC2104. The PBG03 clone D3 (pVHCμCES hobFcblas) was renamed PBG04 and was deposited at the DMSZ as DSM ACC2577 on Sep. 18, 2002.
EXAMPLES
[0000] Materials and Methods
[0000] Materials:
[0000] DNA Cloning Techniques
[0070] Isolation of Genomic DNA: Cells from a T25 cm 2 flask were trypsinized (see chapter “Trypsinisation” below), the resuspended cell pellet transferred into a 1.5 ml Eppendorf tube and 200 μl PBS added. The tube was centrifuged for 5 min at 13,200 rpm, the supernatant discarded and the pellet re-suspended in 2 ml of solution A. After transfer of the suspension into a Falcon tube (15 ml), 133 μl 10% SDS and 333 μl protease K were added. Either a 3 h incubation at 55° C., or an over night incubation at room temperature followed. The suspension was mixed with 607 μl, 6 M NaCl and vortexed for 15 s before centrifuging it (4300 rpm, 4° C., 20 min). The supernatant was transferred into a Falcon tube (15 ml) and mixed with 2.5 ml 100% Ethanol. A threadlike DNA precipitate formed at the interface and was removed with a pipette tip and re-suspended in ½ TE buffer. The DNA was allowed to completely dissolve at 56° C. before it was stored at 4° C.
[0071] PCR: The PCR method was used to isolate genomic DNA sequences (preparative PCR) or to detect certain DNA sequences (analytical PCR).
[0072] Preparative PCR: Preparative PCR reactions (50 μl) were set up with the Expand High Fidelity PCR kit (Roche) according to the manufacturer's Instruction (20-30 ng of template, 5 μl of 15 mM Mg Cl 2 buffer (10×), 5 μl dNTP mix, 0.5 μl of each primer (30 nM), 0.5 μl polymerase and filled to 50 μl with water). The PCR products were purified using a QIAquick PCR purification kit (QIAGEN).
[0073] Analytical PCR: Analytical PCR reactions (10 μl) were prepared with Taq polymerase kit (QIAGEN) following the manufacturer's instruction (10 ng of template, 1 μl 10× buffer, 0.5 μl dNTP mix, 0.1 μl of each primer (30 μM), 0.1 μl Taq polymerase and filled to 10 μl with water).
[0074] The PCR cycling program varied for each product according to the annealing temperature of the primer (see Table 2) and the length of the expected PCR products (determined elongation time and temperature; see Table 1).
TABLE 1 Length of the amplified fragment determines elongation time parameter length, time length, time length, time length, time length, time temperature temperature temperature temperature temperature length of <750 bp 1.5 kb <3 kb >3 kb 6 kb fragment elongation 45 s 1 min 2 min 3 min + 15 s 4 min + 15 s time after each step after each step temperature 72° C. 72° C. 72° C. 68° C. 68° C.
[0075]
TABLE 2
Annealing temperature for primers
Primer/SEQ ID NO:
Sequence (annealing temperature [° C.])
Producer
VHpromF/1
ATACTAGTCGGCCG CAGGCACATCCACAGTCAC (55)
GIBCO BRL
VHpromR/2
TCCCGGGTATCGA TGGAGCTCTCAGGGGATTC (55)
GIBCO BRL
CμintV/3
CATCGA TCCGCTACTACTACTACATGG (55)
GIBCO BRL
CμintR/4
CGGCCACGCTGCTCGTAT (55)
GIBCO BRL
CμMitteR/5
AGCTCACCTGGTGCAACT (54)
GIBCO BRL
CμMitteF/6
GACCTAAGCTGACCTAGAC (54)
GIBCO BRL
V5/7
TCCCTC-CAAAAGCTGTAG (52)
TIB
V6/8
ATGGCGGTAATGTTGGAC (52)
TIB
V7/9
CACAAGAATCCGCACAGG (54)
TIB
EBVtestR/10
CCTGATATTGCAGGTAGG (52)
GIBCO BRL
EBVtestF/11
TACCGACGAAGGAACTTG (52)
GIBCO BRL
[0076] In bold: restriction sites
[0077] Amplification, isolation and quantification of plasmid DNA: E. coli transformants were grown in a 1 ml, 30 ml or 100 ml culture and plasmid DNA isolated using Mini-, Midi- or Maxi-plasmid purification kits (QIAGEN), respectively. The instruction of the manufacturer were followed. The DNA concentration was determined via spectroscopy, measuring the absorbance at 260 and 280 nm.
[0078] Restriction Enzyme Digestion: Plasmid DNA was digested with 1 unit of the appropriate restriction enzyme for 1 μg of DNA, using the buffer and temperature recommended by the supplier (see Table 3). If the analysis required the use of two or more restriction enzymes, the reactions were carried out simultaneous digestion if possible. Otherwise, sequential single digestions were performed with an intervening column purification step (QIAGEN) of the reaction mix.
TABLE 3 Used Restriction Enzymes Enzyme Conc. Temp. Buffer Inact. Producer Art. No. BamHI 20 U/μl 37° C. 2 a 65° C. BioLabs R0136L BgIII 40 U/μl 37° C. M 65° C. Boehringer 1175068 BsaBI 10 //μl 60° C. 2 80° C. BioLabs R0556S BsiWI 10 U/μl 55° C. 3 80° C. BioLabs R0136L Bst11071 5 U/μl 37° C. 3 + BSA 80° C. BioLabs R0553S BstBI 20 U/μl 65° C. 4 + BSA 80° C. BioLabs R0519S ClaI 10 U/μl 37° C. H 65° C. Roche 404217 DraIII 20 U/μl 37° C. 3 + BSA 65° C. BioLabs R0510L EagI 10 U/μl 37° C. 3 + BSA 65° C. BioLabs R0505S EcoRI 40 U/μl 37° C. H 65° C. Roche 200310 HincII 10 U/μl 37° C. 3 + BSA 65° C. BioLabs R0103S HindIII 40 U/μl 37° C. B 5° C. Roche 798983 KpnI 10 U/μl 37° C. L 65° C. Roche 899186 Mfel 10 U/μl 37° C. 4 65° C. BioLabs R0589S NotI 10 U/μl 37° C. 3 + BSA 65° C. BioLabs R0189L PmeI 10 U/μl 37° C. 4 + BSA 65° C. BioLabs R0560L PstI 10 U/μl 37° C. H 80° C. Roche 621633 PvuII 5 U/μl 37° C. 3 + BSA 65° C. BioLabs R0150S SacII 20 U/μl 37° C. 4 + BSA 65° C. BioLabs R0157S SalI 10 U/μl 37° C. H 65° C. Boehringer 567663 ScaI 10 U/μl 37° C. H 80° C. Roche 775266 SmaI 20 U/μl 37° C. 4 + BSA 65° C. BioLabs R0141S SpeI 10 U/μl 37° C. 2 + BSA 65° C. BioLabs R0133L SspI 5 U/μl 37° C. 2 + BSA 65 BioLabs R0182L StyI 10 U/μl 37° C. H 65° C. Roche 85111023 SwaI 10 U/μl 25° C. 3 + BSA 65° C. BioLabs R0604L XbaI 10 U/μl 37° C. H 65° C. Boehringer 674265 a specific buffer
[0079] End repair of DNA with 5′ protruding termini: To “blunt” 5′ overhangs such as those produced by EcoRI, the digested DNA was treated with the Klenow fragment (Roche) according to the manufacturer's instruction. The endfilling reaction was stopped by a heat inactivation step (65° C., 20 min) and the DNA ethanol precipitated or directly subjected to gel purification.
[0080] Dephosphorylation of vector DNA: To prevent self-ligation of linearised vector DNA (see passage “Ligation” below) with compatible ends, DNA was dephosphorylated using alkaline phosphatase (AP) (Roche) according to the manufacturer's instruction. The AP was heat inactivated (65° C., 15 min) and the DNA gel purified (for electrophoresis see passage “Agarose Gel Electrophoresis” below) prior to use in a ligation reaction.
[0081] TOPO Cloning: PCR amplification products were cloned into TOPO vectors from Invitrogen. According to the instruction of the TOPO cloning kit, the purified PCR product (0.25-2 μl) was mixed with the salt solution (0.5 μl), water added to reach a volume of 2.5 μl and then the TOPO vector (0.5 μl) added. Following a 30 min incubation at room temperature, the reaction tube was transferred onto ice, 2 μl of the reaction added to “one shot chemically competent E. coli ” and the cells incubated for 30 min on ice. The cells were heat-shocked (42° C., 30 s), immediately transferred back onto Ice and 250 μl of room temperature SOC medium added. The transformation reaction was incubated for 1 h at 37° C. with shaking (300 rpm) before the mixture was plated on LB plates containing either Kanamycin or ampicillin. The plates incubated of overnight at 37° C.
[0082] Ligation: All ligation reactions were carried out in 10 μl volumes with 0.1-1 μg of dephosphorylated vector and an excess of insert. The reaction contained 2 μl T4 ligation buffer (Gibco BRL) and 1 μl T4 ligase (Roche), and were incubated for two hours at 16° C. or overnight at 4° C. The ligation reaction was transformed into bacteria.
[0083] To reduce the level of unwanted non-recombinants, ligations could be postdigested with a suitable restriction enzyme if there was a unique restriction site in the self-ligated vector. Following the digestion, the ligation reaction was ethanol precipitated in the presence of acrylamide (centrifugation at 4° C., 14,000 rpm, 15 min) before the re-dissolved DNA was used again in a transformation reaction
[0084] Transformation of competent bacteria: Competent E. coli XL2 (stored at −70° C.) were thawed on ice, mixed with either the ligation reaction (also kept on ice, see passage “Ligation” above) or with 1-100 ng plasmid DNA (re-transformation) and incubated on ice for 20 min. Subsequently the transformation reaction was heat-shocked (30-60 s, 42° C.), the tube returned onto ice and 205 μl SOC medium (free of any antibiotic) added and the reaction incubated shaking (300 rpm) at 37° C. for 45 min. The transformation reaction was plated on LB plates containing an antibiotic (either kanamycin (40-60 μg/ml) or ampicillin (50-100 μg/ml)) and incubated overnight at 37° C. The bacterial colonies were counted and the efficiency of the transformation reaction calculated.
[0085] Agarose Gel Electrophoresis: DNA fragments were separated according to their length on 0.7-1.5% agarose gels. The agarose was dissolved in 1×TAE buffer and 2 μl ethidiumbromide/100 ml agarose added. When the agarose had dissolved, it was poured into a tray and allowed to set. The DNA sample was mixed with the loading buffer Orange G, loaded onto a horizontal gel and run at 40-90 V with 1×TAE as running buffer. The DNA/ethidium bromide complexes were visualized under UV light.
[0086] Gel Purification of DNA Fragments: The DNA was separated on an agarose gel (40-80 V) and DNA bands (visualised under UV light) of interest excised with a scalpel. Using a QIAquick gel extraction kit (QIAGEN), the DNA was extracted from the agarose block according to the manufacturer's instructions.
[0000] Cell Culture
[0087] Trypsinisation: Adhesive cells were harvested using trypsin. First the culture medium was removed and the cell monolayer washed with citrate buffer (pre-warmed to 37° C.). A small amount of trypsin was added directly to the cell monolayer and incubated for 3-5 min at 37° C. Trypsinisation was stopped by addition of PBG 1.0 medium supplemented with 5% FCS (see Table 4). The cell suspension was transferred into a Falcon tube (50 ml) and centrifuged for 10 min (800 rpm, 30° C.). The cell pellet was re-suspended in fresh medium and the cells used for electroporation or for further passaging.
TABLE 4 Volumes of citrate, trypsin and PBG 1.0 supplemented with 5% FCS used for the trypsinisation of the cells growing in different flasks Tissue culture Citrate Trypsin PBG 1.0/5% flask buffer (ml) (ml) FCS (ml) T25 1.0 0.5 4.5 T85 2.0 1.0 9.0 T180 5.0 2.0 8.0
Counting of Cells
[0088] After the cells had been trypsinized they were counted in a Neubauer chamber (haematocytometer). A small volume of the cell suspension was introduced into the chamber and the chamber placed under a microscope. Only cells within one of the four squares of the chamber were counted, the cell number multiplied with the factor 10 4 to obtain the number of cells per ml. To differentiate between vital and dead cells, the cells were stained with trypan blue prior to counting. Dead cells appeared blue whereas vital cells did not take up the dye.
[0000] Transformation
[0089] Electroporation of H-CB-P1 Cells: In a standard electroporation reaction 10 μg of linearised plasmid DNA were used. The culture medium was removed and the H-CB-P1 monolayer washed with citrate buffer and trypsinised (see passage “Trypsinisation” above). The cell pellet was re-suspended in Opti-MEM (pre-warmed to 37° C.) to obtain 3×10 6 cells per ml. A volume of 700 μl of the cell suspension was transferred into the electroporation cuvette (peqLab; EQUBIO 4 mm) and the linearised DNA (10 μg) added. The cells were electroporated at 250 V, 1500 μF and immediately afterwards transferred into T75 bottles containing pre-warmed PBG 1.0 medium supplemented with 5% FCS, and incubated at 37° C. and 5% CO 2 .
[0000] Selection
[0090] Selection of H-CB-P1 Cells: The electroporated H-CB-P1 cells were cultured for two days at 37° C. and 5% CO 2 . On day 2, the culture medium was removed and non-adhesive cells harvested by centrifugation of the culture medium. 1 ml of the culture medium (supernatant) was frozen for later examination of transient expression. The trypsinized cell monolayer and the cells harvested from the culture medium by centrifugation were combined and pelleted. Cells were re-suspended in PBG 1.0 medium supplemented with 5% FCS to obtain dilutions of 1×10 6 , 1×10 5 and 1×10 4 cells/ml. Each dilution was supplemented with 5 μg/ml or 10 μg/ml blasticidin or with 200 μg/ml or 400 μg/ml hygromycin. The selection medium was changed on days 4, 7 and 10, and the growth of the H-CB-P1 clones controlled via microscopy. Between days 8 and 10 vital clones were visible by eye. On day 13 clones were harvested by trypsinisation, the cell pellet suspended in PBG 1.0 medium so that when cells were seeded into 96 well plates, a well contained either 5 cell or 1 cell. The selection pressure (either 5 or 10 μg/ml blasticidin or 200 or 400 μg/ml hygromycin) was maintained throughout. On day 10 the cells were immuno-stained to differentiate between positive and negative cell clones. The cell culture medium was removed and replaced with standard medium supplemented with a fluorecently labeled antibody (2 μg/ml) recognizing the recombinant protein produced by the cells. The antibody suspension was left for 4 h on the cell monolayer before it was replaced with OptiMem 1 supplemented with 5% FCS. The cell monolayers were examined under a fluorescent microscope. When Texas red conjugated antibodies were used, the microscopy was done with a UV filter (WG) that is transmissible for 470-480 nm spectra. The excited Texas red labeled antibodies emit light in the spectra of 590 nm. A UV filter (WU) transmissible for spectra of 330-355 nm was used for visualization of antibodies conjugated to AMCA. Emission of excited AMCA occurred in the blue spectra (420 nm). Only clones that were large and strongly fluorescent were considered. Was there only a single clone in one well, the cells were further expanded. Was there more than only one clone in a well, the individual clones (cells) were picked with a microcapillar and transferred into a new 96 well plate for further expansion (see the following passage “Mircopillary Picking”).
[0091] Microcapillary Picking: The microcapillary picking device used a capillary attached to a movable arm that was controlled via a joystick. The microcapillar and the arm were inside the hood wheras the joystick was controlled from outside. When an interesting clone was identified via the immunostaining technique (described in section “Selection of H-CB-P1” above), the microcapillary was placed over the clone, negative pressure induced within the capillary through a vacuum pump and the cell pile of interest sucked into the microcapillary. The arm was moved over the fresh well of a 96 well plate and the cells therein ejected.
[0092] Cryoconservation: For long term storage cells trypsinized cells were re-suspended at 1×10 6 to 1×10 7 cells/ml. The cells were pelleted by centrifugation (700 rpm, 10 min) and the supernatant removed. The cells re-suspended in cold pre-conditioned medium (900 μl), a cryo-vial filled with 180 μl DMSO and 720 μl FCS, and the 900 μl cell suspension transferred into the DMSO/FCS solution. The cryo-vial was stored for 24 h in a special freezing container to freeze the cells gently. For long term storage the cryo-vials were transferred into liquid nitrogen tanks (storage at −196° C.).
[0000] Detection of Protein Products
[0093] EC-Western-Blot (Enhanced Chemiluminscence): For detection of hobFC antibodies 20 μl of cell culture supernatant were mixed with 10 μl 5% SDS and incubated for 2 min at 97° C. Was the cell culture medium expected to contain IgM antibodies, the culture medium was not treated. A membrane (Amersham-Pharmacia; Hybond-P) was first rinsed in methanol (1 min), washed three times in water (1 min), and then soaked in plot transfer buffer before placing it on a piece of 3 MM paper also soaked with plot transfer buffer. 5 μl of the pre-treated (hobFC antibodies) or 5 μl of the untreated (IgM antibodies) culture medium were spotted onto the membrane and incubated for 1 min. The membrane was placed in blocking buffer, incubated for half an hour under shaking and three-times washed for 5 min in T-PBS. The blocked membrane was placed in a detecting antibody solution (for IgG 1:2000 and for IgM 1:5000) and incubated for 2 h. Three more washes, of 2, 5 and 10 min in T-PBS buffer followed. The membrane was placed in developer (Amersham-Pharmacia, ECL) and incubated for 1 min. Finally it was drained and placed onto 3 MM paper and wrapped in cellophane to prevent drying. The light emission was observed in a dark room.
Example 1
Preparation of a Targeting Vector Specific for the IgM Region of H-CB-P1 Cells
[0094] The recombinant gene was to be inserted into the IgM sequence region because it is well-known that antibodies are highly expressed and secreted proteins. The final targeting vector hence required sequences that had 100% homology to the targeted genomic IgM sequences. For the basic targeting vector pVHCμ the VH region of 2 kb and the Cμ intron region of 7.4 kb in length were chosen (see FIG. 3 ). Both regions were isolated as PCR fragments using polymerases with proofreading activity (proofstart polymerase (Qiagen)), subcloned into a pCR 4BluntTOPO vector (Invitrogen) and finally combined in one vector named pVHCμ (see FIG. 3 ).
[0095] Preparation of plasmids pVHCμCESHhobFc and pVHCμHhobFc: The basic targeting vector pVHCμ does not have an endogenous cassette yet. The endogenous cassette containing the CE promoter, the place holder gene hobFc, three FRT recombination sites as well as a hygromycin resistance gene and an ATG deleted neomycin gene was isolated from the vector pCESHhobFc as a BstDI-SwaI fragment. The fragment was then endfilled with Klenow polymerase and ligated into the basic targeting vector pVHCμ that had been digested with PmeI and dephosphorylated. The resulting targeting vector was called pVHCμCESHhobFc.
[0096] A second vector pVHCμHhobFc that lacked the CES promoter construct but contained all the other parts of the endogenous cassette was also constructed. A BstBI-Bstl107I fragment was isolated from pCESHhobC and endfilled. The Bstl107I restriction site in pCESHhobFc is immediately upstream of the frt wt site followed by the hobFc gene and thus the Isolated Bstl107I-Bstb1 fragment lacks the promoter. The fragment was ligated into a pVHCμ vector previously digested with PmeI and the resulting vector was pVHCμHhobFc. In both vectors pVHCμCSHHobFc and pVHCμHhobFc the active resistance marker gene of the endogenous cassette was the hygromycin resistance gene. An alternative set of vectors that contained a blasticidin gene instead of the hygromycin gene was also created.
[0097] Construction of pVHCμCSHhobFcblas and pVHCμhobFcblas: To create targeting vectors with the blasticidin gene as marker gene in the endogenous cassette, the vector pcDNATRD was used as donor for the blasticidin gene. The first step involved the exchange of the hygromycin gene with the blasticidin gene. To this end the blasticidin gene was Isolated from pcDNATRD as an EcoRI-SalI fragment. The endogenous cassette vector pcESHhobFc was also opened with EcoRI-SalI and thereby the hygromycin gene was removed as well as part of the ATG-deleted neomycin gene. The fragment containing the blastidin gene was ligated into the opened pCESHhobFc and the resulting vector named pCEShobFcblas deleted.
[0098] The second step was the re-insertion of the coincidentally removed ATG-deleted neomycin gene. For that a fragment encompassing the ATG-deleted neomycin gene was Isolated from pCESHhobFc and inserted into the opened vector pCEShobFcblasdeleted. The resulting vector was named pCEShobFcblas. This vector now served as donor vector for the blasticidin gene for plasmids pVHCμCSHhobFc and pVHCμHhobFc. A BamHI-SalI fragment was Isolated from pCESHhobFcblas and inserted into a BamHI-SalI opened vector pVHCμCESHhobFc, giving rise to pVHCμCEShobFcblas. To create the control vector pVHCμhobFcblas lacking the CES promoter, the vector pVHCμHhobFc was also digested with BamHI-SalI and again the BamHI-SalI fragment isolated from pCEShobFcblas ligated into it.
Example 2
Selection of hobFc Clones
[0099] Electroporation: H-CB-P1 cells were electroporated with plasmids pVHCμCshobFcblas, pVHCμhobFcblas, pVHCμHhobFc and pCShobFcblas. In order to determine the transfection efficiency, cells were transfected with plasmid pGFPN1VA and as mock control, cells were electroporated with a water sample. The transfection efficiency was found to be at approximately 20%. On day 2 post-electroporation depending on the transfected plasmid either hygromycin or blasticidin was added to the culture medium. When mock-transfected cells were all dead, cells from the other transfection reactions were harvested and re-seeded at a density of either 1 cell or 5 cells per well into a 96 well plate. Cells were continued to be cultured with medium supplemented with the appropriate antibiotic.
[0100] To optimise the selection conditions cells were seeded at 10 4 , 10 5 or 10 6 cells/20 ml into T75 flasks two days post-electroporation. The medium was supplemented with either 5 or at 10 μg/m blasticidin, or 200 or 400 μg/ml hygromycin. On day 14 the number of clones per cm 2 was determined. The highest number of clones was obtained in flasks seeded with at 1×10 6 cells that had been transfected with the plasmids lacking the CES promoter (pVHCμhobFcblas). Three times fewer clones were obtained when cells had been transfected with plasmids carrying the CES promoter. Furthermore these clones did grow less well as those without the CES promoter.
[0101] The effect antibiotics have on the selection of protein producing clones: Following the expansion of the clones in T75 flasks, the clones were trypsinized and re-seeded into 96 well plates at 5 cells/well. The culture medium contained either 5 or 10 μg/ml blasticidin or 200 or 400 μg/ml hygromycin. On day 10 post-seeding, cells were stained with Anti IgG antibodies conjugated with Texas red and AMCA labeled antibodies against IgM. The results obtained with cells cultured with blasticidin showed that with the higher antibiotic concentration far fewer positive clones were obtained. When 10 μg/ml blasticidin were used, 100% more hobFC negative clones were observed compared to 5 μg/ml. However, only the first three rows of the 96 well plate containing cells cultured with 10 μg/ml blasticidin were counted and the result for the entire plate was extrapolated wheras all rows of the 96 well plate containing cells cultured with 5 μg/ml blasticidin where counted.
[0102] Advantage of selection with fluorescently labeled antibodies: Using the immunofluorescent staining technique large numbers of clones can be screened rapidly. The results obtained with the direct immuno-technique were a first indication for correct integration of the targeting sequence into the genomic DNA. Non-expressing clones were easily detected with this technique. The immunofluorescent staining method is technically easy, lower concentrations of antibodies are required than with the methyl-cellulose staining technique, and the proliferation of cells is not impaired. Without any noticeable damages, cells could be immuno-stained before subsequent trypsinization or microcapillary picking to transfer cells into new culture vessels.
Example 3
Detection of Homologous Insertion into the IgM Locus
[0103] For the design of the targeting vector the rearranged immunoglobulin heavy chain locus was assembled based on the cDNA sequence of the antibody and human genome sequence information. To ensure that the production of IgM was disrupted by the targeting approach, the complete leader sequence including the ATG, the V, D and J genes were omitted from the targeting vector and deleted from the genome via a single homologous recombination event. Hence the replacement type targeting vector contained isogenic sequences from the IgM locus to allow the directed cross over as well as the hobFc gene, blasticidin and ATG deleted neomycin resistance genes. Since only one rearranged active IgM locus on chromosome 14 is present in the starting cell line H-CB-P1, the homologous recombination event completely abolishes IgM expression which is detected by fluorescent antibody staining and supernatant immunoblotting using an anti-IgM antibody.
[0104] Western Blot (Dot Blot) for IgM and IgG: The dot blot technique was used to verify the results obtained with the direct immuno-staining technique. The supernatant (medium) of these clones was examined for presence of IgM and IgG. If supernatant was found to be IgM negative as well as IgG positive, it was concluded that a homologous recombination event had taken place.
[0105] PCR for detection of integrated targeting sequences: To verify that the targeting cassette had become integrated at the IgM locus PCR reactions were set up with the forward primer V5 (SEQ ID NO:7) and reverse primers V6 (SEQ ID NO:8) or V7 (SEQ ID NO:9), and genomic DNA isolated from cell clones as template. Primer V5 binds to the genomic V gene promoter sequences outside of the fragment Vhprompresent in the targeting vector, reverse primer V6 binds within the CES promoter sequences (and hence was only used for cells transfected with plasmids carrying the CES promoter) and primer V7 bind within the hobFc gene. Using the described primer combinations the occurrence of PCR products is strictly dependent on co-localisation of both primer binding sequences and hence homologous recombination. To increase the sensitivity of this PCR assay, first-round PCR products were used as templates in nested PCR reactions with primers VHpromF (SEQ ID NO:1) and VHpromR (SEQ ID NO:2). Finally nested PCR products were subjected to an enzyme restriction digest with HincII and DraI to confirm that obtained sequences were correct. Passing on all these assays, PBG03 clones H6 (pVHCμhobFcblas), D4 (pVHCμhobFcblas), E11 (pVHCμhobFcblas) D3 (pVHCμCEShobFcblas) and G8 (pVHCμhobfcblas) had integrated the targeting sequence correctly. Clone D3 (pVHCμCEShobFcblas) was renamed PBG04 and deposited at the German Collection of Microorganism and Cell Cultures (DSMZ).
Example 4
Recombination to Generate a Target Cell Clone
[0106] Clone pVHCμCEShobFcblas D3 (PBG04) was transfected with vector 2 comprising a second functional sequence (frtwt, GFP ORF and polyadenylation signal, minimal promoter followed by ATG and frt5) and plasmid pflp comprising a functional expression unit for flp recombinase using the transfection reagent effectene (Qiagen). Vector 2 does not contain a promoter driving the GFP expression unit. The functionalised cell (PBG04) is sensitive to Geneticin selection from 200 μg/ml. Vector 2 misses a neomycin resistance gene sequence which could confer resistance to Geneticin. As expected no green fluorescence was detectable 1-4 days after transfection. After two weeks of selection with Geneticin individual stable clones strongly expressing GFP were detectable. GFP expression depends on integration in direct proximity to a functional promoter. Geneticin resistance is dependent on reconstitution of the neo resistance gene present in the cell line by the ATG from vector 2. We conclude that in all cases vector 2 has replaced sequences between the frtw and frt F5 sites and functionally linked the CES promoter and GFP as well as the ATG deleted neomycin gene with the ATG.
Example 5
Studies of the Glycosylation Pattern of Leptin Fc
[0107] Leptin Fc from PB604 was generated in roller bottle culture and purified by a generic process including affinity chromatography, gel filtration and membrane filtration. The protein was digested with trypsin and the resulting peptides were deglycosylated by PNGase F digestion. The glycans were labeled with 2-aminobenzamide and separated by HPLC on a Phenomenex Hypersil APS-2-column ( FIG. 16 ). MALDI-TOF-MS (BRUKER BIFLEX™) was used with the desialylated, labelled samples to further characterize the respective fractions shown in Table 5.
[0108] The single N-glycosylation site on Fc carries complex oligosaccharide structures which are sialylated at 37%, a rate close to average sialylation on antibodies in human blood. Sialic acids were further characterized by sialidase treatment, DMB labelling and separation on a Bischoff Hypersil-ODS-column and compared with the Sialic Acid Reference Panel (Oxford GlycoSciences). Typically, N-acetylneuraminic acid was found. Only 2% were represented by N-glycolylneuraminic acid, the dominating form in mouse myeloma cells, which was shown to be immunogenic (Noguchi, A. et al., J. Biochem, 17(1):p. 59-62 (1995)). Alpha 1,3 Gal structures, which are not made in human cells and are known to increase clearence via preexisting antibodies, were only found in 1.3% of the glycans. The above findings are summarized in Table 6.
TABLE 5 Identified oligosacharides as the result of Results of MALDI-TOF-MS analysis of fractions from the Phenomenex Hypersil APS-2-column Peak Area (%) Monoisotopic mass (m/z) Proposed structure 1 1.2 1256.9 Man3HexNAc1 2 1.4 1402.9 Man3HexNAc1Fuc 3 8.0 1378.4 Main High Man5 4 1.6 1377.9 High Man5 1419.0 Man3HexNAc1Hex1 5 4.3 1606.5 Man3HexNAc2Fuc 6 3.1 1565.5 Man3HexNAc1Hex1Fuc 7 2.7 1540.7 Trace HighMan6 1581.7 Main Man5HexNAc 8 4.7 1540.5 HighMan6 1581.5 Main Man5HexNAc 1622.7 Man3HexNAc2Hex1 9 9.3 1768.8 Man3HexNAc2Hex1Fuc 10 6.6 1743.8 Main Man5HexNAc1Hex1 1784.9 Trace Man3HexNAc2Hex2 11 8.7 1784.7 Man3HexNAc2Hex2 12 1.6 1784.5 Man3HexNAc2Hex2 1889.7 Man5HexNAc1Hex1Fuc 1930.7 Trace Man3HexNAc2Hex2Fuc 13 10.9 1930.8 Man3HexNAc2Hex2Fuc 14 3.0 1664.5 Bi − 2AB 1946.9 Trace Man3HexNAc2Hex3 2093.0 (Bi + Gal*) Man3HexNAc2Hex3Fuc (Bi + Fuc + Gal*) 15 25.7 2150.0 Man3HexNAc3Hex3 16 3.2 N.D. 17 2.8 N.D. 18 0.9 2031.2 Tri − 2AB 2514.2 Man3HexNAc4Hex4
[0109]
TABLE 6
Summary of specific features of N linked Oligosacharides from proteins isolated
from human blood, hamster CHO, mouse NS0 cells or the heterohybridoma PBG-04
Feature
Impact
PBG-04
CHO
NS0
human
Sialylation
↓ proteol. Sens./Clearence
37%
variable
variable
35-40
N acetyl-
wanted
98%
high
low
100%
N glycolyl-
immunogenic
2%
low
high (>50%)
no
2-6 linkage
unknown
no
no
no
variable
1-3 alpha gal.
Preexist. Ab: clearence
1.3%
variable
high
no
Bisecting GlcNAc
? → ↓ core fucosylation
no
no
no
10%
No core fucose
↑ ADCC, Fcγ-binding
60%
5%
10-50%
5%
G0-structures
↑Dimerisation, G2→↑CDC
4.3%
variable
variable
low
Example 6
Preparation of a Targeting Vector for the Light Chain Lambda Locus of PBG04
[0110] The structure of the rearranged lambda chain locus was identified by alignment of the known cDNA of the lambda gene with human genomic sequences. The gene consists of a variable gene, J and H segment already joined together. V3-19 was identified as the variable gene.
[0111] This approach was not suitable to identify the constant gene because the locus contains 100% identical gene copies. A PCR based on primers in the known leader sequence and in the unique intervening sequences between constant region genes. Primers V81, V83 (SEQ ID NOs:13 and 14, respectively) gave a correctly sized PCR product which showed the expected restriction pattern and therefore allowed to identify J2 and H2 as the genes constituting the rearranged lambda gene of H-CB-P1 (SEQ ID NO:21). Based on this information the sequence of the rearranged locus was proposed and a targeting vector was constructed.
[0112] A 5′ flank upstream of the coding sequences of the variable gene V3-19 was created with Primers V89 and V94 (SEQ ID NOs:15 and 18, respectively) using Provestart Polymerase (Qiagen). A 4 kb fragment was cloned in pPCR4blunttopo (Invitrogen). A 3 prime flank was amplified in two steps: overlapping PCR products were created using Primers V90 V91 and V115 V116 (SEQ ID NOs:16, 17, 19 and 20, respectively) and lined via a unique SphI site present in both fragments. The flanking sequences were cloned into a single vector PVLCL (SEQ ID NO: 22).
[0113] To allow the Insertion of genes independent from those in the heavy chain locus analogous but hetero-specific frt based replacement system was designed. It contains in the 5′3′ direction a frt F3 site, the CMV EF1alpha hybrid promoter followed by the human alpha (1) antitrypsin gene, the hygromycin resistance marker, an wt frt site and an ATG deleted histidinol resistance marker. These elements were cloned into pVLCL to create pVLCLaathyg.
[0114] Since frt wt and F5 sites do not allow recombination, specific replacement vectors can exclusively target the heavy and light chain loci, providing a promoter and a start codon to the neomycin and histidinol resistance markers respectively. To increase selectivity, the replacement vectors contain start condons in different open reading frames relative to the frt site. As a result, incorporation of the vector into the wrong frt site does not result in resistance to the respective antibiotic.
[0115] PVLCLaathyg was transfected into PBG-04 using electroporation. Cells were seeded into a T75 flask and subjected to selection at 200 μg/ml Hygromycin. For 3 weeks. Resulting clones were isolated by dilution cloning and clones resulting from homologous exchange were identified by the absence of an immunoflourescence signal using a fluorescence-labelled anti human-lambda-chain antibody. The resulting cell clones are analyzed for the expression of alpha 1 antitrypsin. These clones are suitable for the coexpression of two independent transgenes which have to be expressed at high level. Preferably these genes are the heavy and light chain genes of an antibody. Within a single exchange reaction using flp recombinase, heavy and light chain genes can be directed to their respective locations. | The invention relates to ubiquitous/universal processes for establishing cells capable of stable high yield expression of a recombinant gene with human glycosylation pattern, and for establishing stable universal precursor cells available for insertion of arbitrary target genes. The invention further relates to cells obtainable by said processes | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13/407,835, filed Feb. 29, 2012, which is a continuation of U.S. patent application Ser. No. 11/136,398, filed May 25, 2005, both of which are expressly incorporated herein by reference in their entireties.
FIELD
[0002] The invention generally relates to a system and method for delivering and deploying a medical device within a vessel, more particularly, it relates to a system and method for delivering and deploying an endoluminal therapeutic device within the vasculature of a patient to embolize and occlude aneurysms, particularly cerebral aneurysms.
BACKGROUND
[0003] Walls of the vasculature, particularly arterial walls, may develop areas of pathological dilatation called aneurysms. As is well known, aneurysms have thin, weak walls that are prone to rupturing. Aneurysms can be the result of the vessel wall being weakened by disease, injury or a congenital abnormality. Aneurysms could be found in different parts of the body with the most common being abdominal aortic aneurysms and brain or cerebral aneurysms in the neurovasculature. When the weakened wall of an aneurysm ruptures, it can result in death, especially if it is a cerebral aneurysm that ruptures.
[0004] Aneurysms are generally treated by excluding the weakened part of the vessel from the arterial circulation. For treating a cerebral aneurysm, such reinforcement is done in many ways including: (i) surgical clipping, where a metal clip is secured around the base of the aneurysm; (ii) packing the aneurysm with small, flexible wire coils (micro-coils); (iii) using embolic materials to “fill” an aneurysm; (iv) using detachable balloons or coils to occlude the parent vessel that supplies the aneurysm; and (v) intravascular stenting.
[0005] Intravascular stents are well known in the medical arts for the treatment of vascular stenoses or aneurysms. Stents are prostheses that expand radially or otherwise within a vessel or lumen to provide support against the collapse of the vessel. Methods for delivering these intravascular stents are also well known.
[0006] In conventional methods of introducing a compressed stent into a vessel and positioning it within in an area of stenosis or an aneurysm, a guiding catheter having a distal tip is percutaneously introduced into the vascular system of a patient. The guiding catheter is advanced within the vessel until its distal tip is proximate the stenosis or aneurysm. A guidewire positioned within an inner lumen of a second, inner catheter and the inner catheter are advanced through the distal end of the guiding catheter. The guidewire is then advanced out of the distal end of the guiding catheter into the vessel until the distal portion of the guidewire carrying the compressed stent is positioned at the point of the lesion within the vessel. Once the compressed stent is located at the lesion, the stent may be released and expanded so that it supports the vessel.
SUMMARY
[0007] Aspects of the present invention include a system and method of deploying an occluding device within a vessel. The occluding device can be used to remodel an aneurysm within the vessel by, for example, neck reconstruction or balloon remodeling. The occluding device can be used to form a barrier that retains occlusion material such as a well known coil or viscous fluids, such as “ONYX” by Microtherapeutics, within the aneurysm so that introduced material will not escape from within the aneurysm. Also, during deployment, the length of the occluding device can be adjusted in response to friction created between the occluding device and an inner surface of a catheter. When this occurs, the deployed length and circumferential size of the occluding device can be changed as desired by the physician performing the procedure.
[0008] An aspect of the present invention includes a system for supporting and deploying an occluding device. The system comprises an introducer sheath and an assembly for carrying the occluding device. The assembly includes an elongated flexible member having an occluding device retaining member for receiving a first end of the occluding device, a proximally positioned retaining member for engaging a second end of the occluding device and a support surrounding a portion of the elongated flexible member over which the occluding device can be positioned.
[0009] Another aspect of the present invention includes a system for supporting and deploying an occluding device. The system comprises an assembly for carrying the occluding device. The assembly comprises an elongated member including a flexible distal tip portion, a retaining member for receiving a first end of the occluding device, and a support surrounding a portion of the elongated flexible member for supporting the occluding device.
[0010] A further aspect of the present invention comprises a method of introducing and deploying an occluding device within a vessel. The method includes the steps of introducing an elongated sheath including an introducer sheath carrying a guidewire assembly into a catheter and advancing the guidewire assembly out of the sheath and into the catheter. The method also includes the steps of positioning an end of the catheter proximate an aneurysm, advancing a portion of the guidewire assembly out of the catheter and rotating a portion of the guidewire assembly while deploying the occluding device in the area of the aneurysm.
BRIEF DESCRIPTION OF THE FIGURES
[0011] FIG. 1 is a cross section of an occluding device delivery assembly and occluding device according to an aspect of the invention;
[0012] FIG. 2 illustrates a catheter and introducer sheath shown in FIG. 1 ;
[0013] FIG. 3 is a partial cut away view of the introducer sheath of FIG. 2 carrying a guidewire assembly loaded with an occluding device;
[0014] FIG. 4 is a cross section of the guidewire assembly illustrated in FIG. 3 ;
[0015] FIG. 5 is a schematic view of the guidewire assembly of FIG. 4 ;
[0016] FIG. 6 is a second schematic view of the guidewire assembly of FIG. 4 ;
[0017] FIG. 7 illustrates the occluding device and a portion of the guidewire assembly positioned outside the catheter, and how a proximal end of the occluding device begins to deploy within a vessel;
[0018] FIG. 8 illustrates a step in the method of deploying the occluding device;
[0019] FIG. 9 illustrates the deployment of the occluding device according to an aspect of the present invention;
[0020] FIG. 10 is a schematic view of a guidewire assembly according to another embodiment of the present invention; and
[0021] FIG. 11 is a schematic view of the deployed occluding device after having been deployed by the guidewire assembly of FIG. 10 .
DETAILED DESCRIPTION
[0022] An occluding device delivery assembly having portions with small cross section(s) and which is highly flexible is described herein. FIG. 1 illustrates an introducer sheath 10 according to an aspect of the present invention that receives, contains and delivers an occluding device 100 to a flexible micro-catheter 1 for positioning within the vasculature of an individual. The occluding device 100 can include those embodiments disclosed in copending U.S. patent application Ser. No. 11/136,395, titled “Flexible Vascular Occluding Device”, filed on May 25, 2005, which is expressly hereby incorporated by reference in its entirety.
[0023] A distal end 12 of the introducer sheath 10 is sized and configured to be received within a hub 2 of the micro-catheter 1 , as shown in FIGS. 1 and 2 . The hub 2 can be positioned at the proximal end of the micro-catheter 1 or at another location spaced along the length of the micro-catheter 1 . The micro-catheter 1 can be any known micro-catheter that can be introduced and advanced through the vasculature of a patient. In an embodiment, the micro-catheter has an inner diameter of 0.047 inch or less. In another embodiment, the micro-catheter has an inner diameter of about 0.027 inch to about 0.021 inch. In an alternative embodiment, the micro-catheter could have an inner diameter of about 0.025 inch. However, it is contemplated that the catheter 1 can have an inner diameter that is greater than 0.047 inch or less than 0.021 inch. After the introducer sheath 10 is positioned within the catheter hub 2 , the occluding device 100 can be advanced from the introducer sheath 10 into the micro-catheter 1 in preparation for deploying the occluding device 100 within the vasculature of the patient.
[0024] The micro-catheter 1 may have at least one fluid introduction port 6 located adjacent the hub 2 or at another position along its length. The port 6 is preferably in fluid communication with the distal end of the micro-catheter 1 so that a fluid, e.g., saline, may be passed through the micro-catheter 1 prior to insertion into the vasculature for flushing out air or debris trapped within the micro-catheter 1 and any instruments, such as guidewires, positioned within the micro-catheter 1 . The port 6 may also be used to deliver drugs or fluids within the vasculature as desired.
[0025] FIG. 3 illustrates the introducer sheath 10 , an elongated flexible delivery guidewire assembly 20 that is movable within the introducer sheath 10 and the occluding device 100 . As shown, the guidewire assembly 20 and the occluding device 100 , carried by the guidewire assembly 20 , have not been introduced into the micro-catheter 1 . Instead, as illustrated, they are positioned within the introducer sheath 10 . The introducer sheath 10 may be made from various thermoplastics, e.g., PTFE, FEP, HDPE, PEEK, etc., which may optionally be lined on the inner surface of the sheath or an adjacent surface with a hydrophilic material such as PVP or some other plastic coating. Additionally, either surface may be coated with various combinations of different materials, depending upon the desired results.
[0026] The introducer sheath 10 may include drainage ports or purge holes (not shown) formed into the wall near the area covering the occluding device 100 . There may be a single hole or multiple holes, e.g., three holes, formed into introducer sheath 10 . These purge holes allow for fluids, e.g., saline, to readily escape from in between the introducer sheath 10 and the guidewire assembly 20 when purging the sheath prior to positioning the introducer sheath 10 in contact with the catheter hub 2 , e.g., to remove trapped air or debris.
[0027] As shown in FIG. 4 , the guidewire assembly 20 includes an elongated flexible guidewire 21 . The flexibility of the guidewire 21 allows the guidewire assembly to bend and conform to the curvature of the vasculature as needed for positional movement of the occluding device 100 within the vasculature. The guidewire 21 may be made of a conventional guidewire material and have a solid cross section. Alternatively, the guidewire 21 can be formed from a hypotube. In either embodiment, the guidewire 21 has a diameter D 5 ranging from about 0.010 inch to about 0.020 inch. In an embodiment, the largest diameter of the guidewire is about 0.016 inch. The material used for the guidewire 21 can be any of the known guidewire materials including superelastic metals, e.g., Nitinol. Alternatively, the guidewire 21 can be formed of metals such as stainless steel. Length L 4 of the guidewire can be from about 125 to about 190 cm. In an embodiment, the length L 4 is about 175 cm.
[0028] The guidewire assembly 20 can have the same degree of flexion along its entire length. In an alternative embodiment, the guidewire assembly 20 can have longitudinal sections, each with differing degrees of flexion/stiffness. The different degrees of flexions for the guidewire assembly 20 can be created using different materials and/or thicknesses within different longitudinal sections of the guidewire 21 . In another embodiment, the flexion of the guidewire 21 can be controlled by spaced cuts (not shown) formed within the delivery guidewire 21 . These cuts can be longitudinally and/or circumferentially spaced from each other. The cuts can be formed with precision within the delivery guidewire 21 . Different sections of the delivery guidewire 21 can include cuts formed with different spacing and different depths to provide these distinct sections with different amounts of flexion and stiffness. In any of the above embodiments, the guidewire assembly 20 and the guidewire 21 are responsive to torque applied to the guidewire assembly 20 by the operator. As discussed below, the torque applied to the guidewire assembly 20 via the guidewire 21 can be used to release the occluding device 100 from the guidewire assembly 20 .
[0029] The size and shape of the cuts formed within the delivery guidewire 21 may be controlled so as to provide greater or lesser amounts of flexibility. Because the cuts can be varied in width without changing the depth or overall shape of the cut, the flexibility of the delivery guidewire 21 may be selectively altered without affecting the torsional strength of the delivery guidewire 21 . Thus, the flexibility and torsional strength of the delivery guidewire 21 may be selectively and independently altered.
[0030] Advantageously, longitudinally adjacent pairs of cuts may be rotated about 90 degrees around the circumference of the delivery guidewire 21 from one another to provide flexure laterally and vertically. However, the cuts may be located at predetermined locations to provide preferential flexure in one or more desired directions. Of course, the cuts could be randomly farmed to allow bending (flexion) equally, non-preferentially in all directions or planes. In one embodiment, this could be achieved by circumferentially spacing the cuts.
[0031] The flexible delivery guidewire 21 can include any number of sections having the same or differing degrees of flexion. For example, the flexible delivery guidewire 21 could include two or more sections. In the embodiment illustrated in FIG. 4 , the flexible delivery guidewire 21 includes three sections, each having a different diameter. Each section can have a diameter of about 0.005 inch to about 0.025 inch. In an embodiment, the diameter of one or more sections can be about 0.010 inch to about 0.020 inch. A first section 22 includes a proximal end 23 that is located opposite the position of the occluding device 100 . The first section 22 can have a constant thickness along its length. Alternatively, the first section 22 can have a thickness (diameter) that tapers along its entire length or only a portion of its length. In the tapered embodiment, the thickness (diameter) of the first section 22 decreases in the direction of a second, transition section 24 . For those embodiments in which the guidewire 21 has a circular cross section, the thickness is the diameter of the section.
[0032] The second, transition section 24 extends between the first section 22 and a third, distal section 26 . The second section 24 tapers in thickness from the large diameter of the first section 22 to the smaller diameter of the third section 26 . As with the first section 22 , the second section 24 can taper along its entire length or only a portion of its length.
[0033] The third section 26 has a smaller thickness compared to the other sections 22 , 24 of the delivery guidewire 21 . The third section 26 extends, away from the tapered second section 24 that carries the occluding device 100 . The third section 26 can taper along its entire length from the second section 24 to the distal end 27 of the delivery guidewire 21 . Alternatively, the third section 26 can have a constant diameter or taper along only a portion of its length. In such an embodiment, the tapering portion of the third section 26 can extend from the second section 24 or a point spaced from the second section 24 to a point spaced from distal end 27 of the delivery guidewire 21 . Although three sections of the delivery guidewire 21 are discussed and illustrated, the delivery guidewire 21 can include more than three sections. Additionally, each of these sections can taper in their thickness (diameter) along all or only a portion of their length. In any of the disclosed embodiments, the delivery guidewire 21 can be formed of a shape memory alloy such as Nitinol.
[0034] A tip 28 and flexible tip coil 29 are secured to the distal end 27 of the delivery guidewire 21 as shown in FIGS. 4 and 5 . The tip 28 can include a continuous end cap or cover as shown in the figures, which securely receives a distal end of the tip coil 29 . Flexion control is provided to the distal end portion of the delivery guidewire 21 by the tip coil 29 . However, in an embodiment, the tip 28 can be free of the coil 29 . The tip 28 has a non-percutaneous, atraumatic end face. In the illustrated embodiment, the tip 28 has a rounded face. In alternative embodiments, the tip 28 can have other non-percutaneous shapes that will not injure the vessel in which it is introduced. As illustrated in FIG. 4 , the tip 28 includes a housing 45 that securely receives the distal end of the guidewire 21 within an opening 46 in the interior surface of the housing 45 . The guidewire 21 can be secured within the opening by any known means.
[0035] As shown in FIG. 4 , the tip coil 29 surrounds a portion of the guidewire 21 . The tip coil 29 is flexible so that it will conform to and follow the path of a vessel within the patient as the tip 28 is advanced along the vessel and the guidewire 21 bends to follow the tortuous path of the vasculature. The tip coil 29 extends rearward from the tip 28 in the direction of the proximal end 23 , as shown.
[0036] The tip 28 and coil 29 have an outer diameter D 1 of about 0.010 inch to about 0.018 inch. In an embodiment, their outer diameter D 1 is about 0.014 inch. The tip 28 and coil 29 also have a length L 1 of about 0.1 cm to about 3.0 cm. In an embodiment, they have a total length L 1 of about 1.5 cm.
[0037] A proximal end 30 of the tip coil 29 is received within a housing 32 at a distal end 24 of a protective coil 35 , as shown in FIGS. 1 and 4 . The housing 32 and protective coil 35 have an outer diameter D 2 of about 0.018 inch to about 0.038 inch. In an embodiment, their outer diameter D 2 is about 0.024 inch. The housing 32 and protective coil 35 have a length L 2 of about 0.05 cm to about 0.2 cm. In an embodiment, their total length L 2 is about 0.15 cm.
[0038] The housing 32 has a non-percutaneous, atraumatic shape. For example, as shown in FIG. 5 , the housing 32 has a substantially blunt profile. Also, the housing 32 can be sized to open/support the vessel as it passes through it. Additionally, the housing 32 can include angled sidewalls sized to just be spaced just off the inner surface of the introducer sheath 10 .
[0039] The housing 32 and protective coil 35 form a distal retaining member that maintains the position of the occluding device 100 on the flexible guidewire assembly 20 and helps to hold the occluding device 100 in a compressed state prior to its delivery and deployment within a vessel of the vasculature. The protective coil 35 extends from the housing 32 in the direction of the proximal end 23 of the delivery guidewire 21 , as shown in FIG. 4 . The protective coil 35 is secured to the housing 32 in any known manner. In a first embodiment, the protective coil 35 can be secured to the outer surface of the housing 32 . In an alternative embodiment, the protective coil 35 can be secured within an opening of the housing 32 so that the housing 32 surrounds and internally receives the distal end 51 of the protective coil 35 ( FIG. 4 ). As shown in FIGS. 3 and 4 , the distal end 102 of the occluding device 100 is retained within the proximal end 52 so that the occluding device 100 cannot deploy while positioned in the sheath 10 or the micro-catheter 1 .
[0040] At the proximal end of the occluding device 100 , a bumper coil 60 and cap 62 prevent lateral movement of the occluding device 100 along the length of the guidewire 21 in the direction of the proximal end 23 , see FIG. 3 . The bumper coil 60 and cap 62 have an outer diameter D 4 of about 0.018 inch to about 0.038 inch. In an embodiment, their outer diameter D 4 is about 0.024 inch. The cap 62 contacts the proximal end 107 of the occluding device 100 and prevents it from moving along the length of the guidewire 21 away from the protective coil 35 . The bumper coil 60 can be in the form of a spring that contacts and pressures the cap 62 in the direction of the protective coil 35 , thereby creating a biasing force against the occluding device 100 . This biasing force (pressure) aids in maintaining the secured, covered relationship between the distal end 102 of the occluding device 100 and the protective coil 35 . As with any of the coils positioned along the delivery guidewire 21 , the bumper coil 60 can be secured to the delivery guidewire 21 by soldering, welding, RF welding, glue, and/or other known adhesives.
[0041] In an alternative embodiment illustrated in FIG. 10 , the bumper coil 60 is not utilized. Instead, a proximal end 107 of the occluding device 100 is held in position by a set of spring loaded arms (jaws) 104 while positioned within the introducer sheath 10 or the micro-catheter 1 . The inner surfaces of the micro-catheter 1 and the introducer sheath 10 limit the radial expansion of the arms 104 . When the proximal end of the occluding device passes out of the micro-catheter 1 , the arms 104 would spring open and release the occluding device as shown in FIG. 11 .
[0042] In an alternative embodiment, the bumper coil 60 and cap 62 can be eliminated and the proximal end of the occluding device 100 can be held in position relative to the protective coil 35 by a tapered section of the guidewire 21 . In such an embodiment, the enlarged cross section of this tapered section can be used to retain the occluding device 100 in position along the length of the delivery guidewire 21 and prevent movement of the occluding device 100 in the direction of the proximal end 23 .
[0043] As shown in FIG. 4 , the guidewire assembly 20 includes a support 70 for the occluding device 100 . In a first embodiment, the support 70 can include an outer surface of the delivery guidewire 21 that is sized to contact the inner surface of the occluding device 100 when the occluding device 100 is loaded on the guidewire assembly 20 . In this embodiment, the outer surface of the delivery guidewire 21 supports the occluding device 100 and maintains it in a ready to deploy state. In another embodiment, illustrated in the Figures, the support 70 comprises a mid-coil 70 that extends from a location proximate the protective coil 35 rearward toward the bumper coil 60 . The mid-coil 70 extends under the occluding device 100 and over the delivery guidewire 21 , as shown in FIG. 1 . The mid-coil 70 can be coextensive with one or more sections of the delivery guidewire 21 . For example, the mid-coil 70 could be coextensive with only the second section 24 of the delivery guidewire 21 or it could extend along portions of both the third section 26 and the second section 24 of the delivery guidewire 21 .
[0044] The mid-coil 70 provides the guidewire assembly 20 with an outwardly extending surface that is sized to contact the inner surface of the occluding device 100 in order to assist in supporting the occluding device and maintaining the occluding device 100 in a ready to deploy state. Like the other coils discussed herein and illustrated in the figures, the coiled form of the mid-coil 70 permits the mid-coil 70 to flex with the delivery guidewire 21 as the delivery guidewire 21 is advanced through the vasculature of the patient. The mid-coil 70 provides a constant diameter along a length of the delivery guidewire 21 that is covered by the occluding device 100 regardless of the taper of the delivery guidewire 21 beneath the occluding device 100 . The mid-coil 70 permits the delivery guidewire 21 to be tapered so it can achieve the needed flexibility to follow the path of the vasculature without compromising the support provided to the occluding device 100 . The mid-coil 70 provides the occluding device 100 with constant support regardless of the taper of the delivery guidewire 21 prior to the occluding device 100 being deployed. The smallest diameter of the occluding device 100 when in its compressed state is also controlled by the size of the mid-coil 70 . Additionally, the diameter of the mid-coil 70 can be chosen so that the proper spacing, including no spacing, is established between the occluding device 100 and the inner wall of the micro-catheter 1 prior to deployment of the occluding device 100 . The mid-coil 70 can also be used to bias the occluding device 100 away from the delivery guidewire 21 during its deployment.
[0045] In either embodiment, the support 70 can have an outer diameter D 3 of about 0.010 inch to about 0.018 inch. In an embodiment, the outer diameter D 3 is about 0.014 inch. The support 70 can also have a length L 3 of about 2.0 cm to about 30 cm. In an embodiment, the length L 3 of the support 70 is about 7 cm.
[0046] The occluding device 100 may also be placed on the mid-coil 70 between an optional pair of radio-opaque marker bands located along the length of the guidewire assembly 20 . Alternatively, the protective coil 35 , bumper coil 60 and or mid-coil 70 can include radio-opaque markers. In an alternative embodiment, the guidewire assembly 20 may include only a single radio-opaque marker. The use of radio-opaque markers allows for the visualization of the guidewire assembly 20 and the occluding device 100 during placement within the vasculature. Such visualization techniques may include conventional methods such as fluoroscopy, radiography, ultra-sonography, magnetic resonance imaging, etc.
[0047] The occluding device 100 can be delivered and deployed at the site of an aneurysm A according to the following method and variations thereof. The delivery of the occluding device 100 includes introducing the micro-catheter 1 into the vasculature until it reaches a site that requires treatment. The micro-catheter 1 is introduced into the vasculature using a conventional technique such as being advanced over or simultaneously with a conventional vascular guidewire (not shown). The positioning of the micro-catheter 1 can occur before it receives the guidewire assembly 20 or while it contains the guidewire assembly 20 . The position of the micro-catheter 1 within the vasculature can be determined by identifying radio-opaque markers positioned on or in the micro-catheter 1 .
[0048] After the micro-catheter 1 is positioned at the desired location, the guidewire is removed and the distal end of the introducer sheath 10 is inserted into the proximal end of the micro-catheter 1 , as shown in FIG. 1 . In an embodiment, the distal end of the introducer sheath 10 is introduced through the hub 2 at the proximal end of the micro-catheter 1 . The introducer sheath 10 is advanced within the micro-catheter 1 until a distal tip of the introducer sheath 10 is wedged within the micro-catheter 1 . At this position, the introducer sheath 10 cannot be advanced further within the micro-catheter 1 . The introducer sheath 10 is then securely held while the delivery guidewire assembly 20 carrying the occluding device 100 is advanced through the introducer sheath 10 until the occluding device 100 is advanced out of the introducer sheath 10 and into the micro-catheter 1 .
[0049] The guidewire assembly 20 and the occluding device 100 are advanced through the micro-catheter 1 until the tip coil 29 is proximate the distal end of the micro-catheter 1 . At this point, the position of the micro-catheter 1 and guidewire assembly 20 can be confirmed. The guidewire assembly 20 is then advanced out of the micro-catheter 1 and into the vasculature of the patient so that the proximal end 107 of the occluding device 100 is positioned outside the distal end of the micro-catheter 1 and adjacent the area to be treated. At any point during these steps, the position of the occluding device 100 can be checked to determine that it will be deployed correctly and at the desired location. This can be accomplished by using the radio-opaque markers discussed above.
[0050] When the distal end 102 of the occluding device 100 is positioned outside the micro-catheter 1 , the proximal end 107 will begin to expand, in the direction of the arrows shown in FIG. 7 , within the vasculature while the distal end 102 remains covered by the protective coil 35 . When the occluding device 100 is in the proper position, the delivery guidewire 21 is rotated (See FIG. 8 ) until the distal end 102 of the occluding device 100 moves away from the protective coil 35 and expands within the vasculature at the desired location. The delivery guidewire 21 can be rotated either clockwise or counter clockwise as needed to deploy the occluding device 100 . In an embodiment, the delivery guidewire 21 may be rotated, for example, between two and ten turns in either or both directions. In another example, the occluding device may be deployed by rotating the delivery guidewire 21 clockwise for less than five turns, for example, three to five turns. After the occluding device 100 has been deployed, the delivery guidewire 21 can be retracted into the micro-catheter 100 and removed form the body.
[0051] In an alternative or additional deployment step shown in FIG. 9 , friction between the occluding device 100 and inner surface of the micro-catheter 1 cause the distal end of the occluding device 100 to separate from the protective coil 35 . The friction can be created by the opening of the occluding device 100 and/or the mid-coil 70 biasing the occluding device 100 toward the inner surface of the micro-catheter 1 . The friction between the micro-catheter 1 and the occluding device 100 will assist in the deployment of the occluding device 100 . In those instances when the occluding device 100 does not open and separate from the protective coil 35 during deployment, the friction between occluding device 100 and the inner surface of the micro-catheter 1 will cause the occluding device 100 to move away from the protective coil 35 as the delivery guidewire 21 and the micro-catheter 1 move relative to each other. The delivery guidewire 21 can then be rotated and the occluding device 100 deployed within the vessel.
[0052] After the occluding device 100 radially self-expands into gentle, but secure, contact with the walls of the vessel so as to occlude the neck of the aneurysm A, the micro-catheter 1 may be removed entirely from the body of the patient. Alternatively, the micro-catheter 1 may be left in position within vasculature to allow for the insertion of additional tools or the application of drugs near the treatment site.
[0053] Known materials can be used in the present invention. One common material that can be used with the occluding device 100 and the guidewire 21 is Nitinol, a nickel-titanium shape memory alloy, which can be formed and annealed, deformed at a low temperature, and recalled to its original shape with heating, such as when deployed at body temperature in the body. The radio-opaque markers can be formed of radio-opaque materials including metals, such as platinum, or doped plastics including bismuth or tungsten to aid in visualization.
[0054] The apparatus and methods discussed herein are not limited to the deployment and use within the vascular system but may include any number of further treatment applications. Other treatment sites may include areas or regions of the body such as organ bodies. Modification of each of the above-described apparatus and methods for carrying out the invention, and variations of aspects of the invention that are obvious to those of skill in the art are intended to be within the scope of the claims. Furthermore, no element, component or method step is intended to be dedicated to the public regardless of whether the element, component or method step is explicitly recited in the claims. | A system and method for deploying an occluding device that can be used to remodel an aneurysm within the vessel by, for example, neck reconstruction or balloon remodeling. The system comprises an introducer sheath and an assembly for carrying the occluding device. The assembly includes an elongated flexible member having an occluding device retaining member for receiving a first end of the occluding device, a proximally positioned retaining member for engaging a second end of the occluding device and a support surrounding a portion of the elongated flexible member over which the occluding device can be positioned. | 0 |
COPYRIGHT NOTICE
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for handling anaerobic digestion effluent. In particular, it relates to a method for treating the effluent in a high solids digestion to produce a biogas and a semi-solid secondary digestate.
2. Description of Related Art
The anaerobic digestion of organic material such as sewage sludge, municipal waste, industrial waste forest waste, agricultural waste, and especially animal waste is the fermentation of such material by bacteria in the absence of oxygen. The benefit of such digestion of waste material includes the stabilization of waste, odor control, solid reduction, energy production in the form of methane gas, elimination or reduction of pathogens, making the waste more environmentally neutral, producing a nutrient source, and the like. It has been generally used in many large scale treatments of animal wastes to control the disposal problem associated with such waste.
However, after the completion of the anaerobic digestion, the management of the effluent is a challenge. The volume of effluent is typically very large and large tracts of farm land are generally utilized to take the liquid for irrigation and fertilizer. Because of the high Biochemical Oxygen Demand (BOD)/Chemical Oxygen Demand (COD) and ammonium contents of this type of liquid waste, it is not generally allowed to be discharged into natural water streams or other bodies of water. Accordingly, management of the effluent is a constant concern and management problem and has even caused operations to shut down for lack of a management solution.
BRIEF SUMMARY OF THE INVENTION
The present invention relates to the discovery that anaerobic digestion effluent can be transformed into a semi-solid formulation by further fermentation with the addition of biomass to produce a semi-solid mixture which is digested at higher temperature to produce more biogas and a semi-solid which can be used as a fertilizer.
Accordingly, the present invention relates to a method of processing anaerobic digestion effluent comprising:
a) providing a quantity of anaerobic digestion effluent; b) adding the effluent to a biomass at at least about 50° C. in an insulated tank to form a mixture having a solids concentration of at least 20%; c) fermenting the mixture in the insulated tank for a time period of from at least about 5 to 10 days; and d) isolating the wet solids from the liquid.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is flow chart of the present invention.
FIG. 2 is a view of the system of the invention.
FIG. 3 is an example of the entire biogas production.
FIG. 4 is an example of a multiple sequential batch method of the present invention for producing biogas.
DETAILED DESCRIPTION OF THE INVENTION
While this invention is susceptible to embodiment in many different forms, there is shown in the drawings and will herein be described in detail specific embodiments, with the understanding that the present disclosure of such embodiments is to be considered as an example of the principles and not intended to limit the invention to the specific embodiments shown and described. In the description below, like reference numerals are used to describe the same, similar or corresponding parts in the several views of the drawings. This detailed description defines the meaning of the terms used herein and specifically describes embodiments in order for those skilled in the art to practice the invention.
DEFINITIONS
The terms “about” and “essentially” mean±10 percent.
The terms “a” or “an”, as used herein, are defined as one or as more than one. The term “plurality”, as used herein, is defined as two or as more than two. The term “another”, as used herein, is defined as at least a second or more. The terms “including” and/or “having”, as used herein, are defined as comprising (i.e., open language). The term “coupled”, as used herein, is defined as connected, although not necessarily directly, and not necessarily mechanically.
The term “comprising” is not intended to limit inventions to only claiming the present invention with such comprising language. Any invention using the term comprising could be separated into one or more claims using “consisting” or “consisting of” claim language and is so intended.
Reference throughout this document to “one embodiment”, “certain embodiments”, and “an embodiment” or similar terms means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of such phrases or in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments without limitation.
The term “or” as used herein is to be interpreted as an inclusive or meaning any one or any combination. Therefore, “A, B or C” means any of the following: “A; B; C; A and B; A and C; B and C; A, B and C”. An exception to this definition will occur only when a combination of elements, functions, steps or acts are in some way inherently mutually exclusive.
The drawings featured in the figures are for the purpose of illustrating certain convenient embodiments of the present invention, and are not to be considered as limitation thereto. Term “means” preceding a present participle of an operation indicates a desired function for which there is one or more embodiments, i.e., one or more methods, devices, or apparatuses for achieving the desired function and that one skilled in the art could select from these or their equivalent in view of the disclosure herein and use of the term “means” is not intended to be limiting.
As used herein “anaerobic digestion effluent” is a series of processes in which microorganisms break down biodegradable material in the absence of oxygen to produce a low solids liquid effluent. It is used for industrial or domestic purposes to manage waste and/or to release energy. The digestion process begins with bacterial hydrolysis of the input materials to break down insoluble organic polymers, such as carbohydrates, and make them available for other bacteria. Acidogenic bacteria then convert the sugars and amino acids into carbon dioxide, hydrogen, ammonia, and organic acids. Acetogenic bacteria then convert these resulting organic acids into acetic acid, along with additional ammonia, hydrogen, and carbon dioxide. Finally, methanogens convert these products to methane (biogas) and carbon dioxide. The methanogenic archaea populations play an indispensable role in anaerobic wastewater treatments.
It is used as part of the process to treat biodegradable waste and sewage sludge. As part of an integrated waste management system, anaerobic digestion reduces the emission of landfill gas into the atmosphere. Anaerobic digesters can also be fed with purpose-grown energy crops, such as maize.
Anaerobic digestion is widely used as a source of renewable energy. The process produces a biogas, consisting of methane, carbon dioxide and traces of other ‘contaminant’ gases. This biogas can be used directly as gaseous fuel for heat and power generation or upgraded to natural gas-quality biomethane for transportation fuel. The use of biogas as a fuel helps to replace fossil fuels. Also the nutrient-rich digestate produced can be used as fertilizer. The semi-solid material can be utilized for further or other uses within the skill of the art.
As used herein the term “quantity of anaerobic digestion effluent” refers to a measured quantity of effluent. As long as the quantity of effluent is known, that can be used to determine the conditions for the present invention.
As used herein the term “biomass”, refers to biological material from living, or recently living organisms. As an energy source, biomass can either be used directly, or converted into other energy products such as biofuel. Biomass is plant matter used to generate electricity with steam turbines and gasifiers or produce heat, usually by direct combustion. Examples include forest residues (such as dead trees, branches and tree stumps), yard clippings, wood chips, animal waste such as animal manure, and even municipal solid waste. Biomass also includes plant or animal matter that can be converted into fibers or other industrial chemicals, including biofuels. Industrial biomass can be grown from numerous types of plants, including miscanthus, switchgrass, hemp, corn, poplar, willow, sorghum, sugarcane, and a variety of tree species, ranging from eucalyptus to oil palm (palm oil). One embodiment of a hydrolytic degritter is shown herein and also in co-filed application, application no: SHIH001 filed on even date herewith and included herein by reference.
In the practice of the present invention a primary digester effluent of at least about 50° C. is added to biomass to a concentration of at least 20%. In one embodiment, the solids are about 20% to about 30%. The mixture of effluent and biomass is kept in an insulated tank for fermentation. In one embodiment, the temperature of the effluent is preheated to about 30-60° C. The mixture is not further heated and fermented for a period of from about at least 5 days and in one embodiment from about 5 to 10 days.
The mixture is usually carried out in a tank or in two or more tanks in series. As used herein the term “tank” refers to an insulated tank designed for holding the mixture and fermenting at an elevated temperature. The tank can be made of any material such as stainless steel, carbon steel, plastics, or fiber glass and in one embodiment the tank is insulated to better hold the elevated temperature. The tank is optionally fitted on the interior with a mixing apparatus to keep the contents of the tank mixing during the process of the invention. One skilled in the art could choose appropriate mixing apparatus. The type of tank could be also such that the same tank that can be used to complete the anaerobic digestion is used to make the composition of the present invention. This means the mixture never has to be transferred till the process is complete. In other embodiments the slurry can be removed to a different tank for fermentation. Where multiple tanks are utilized, they can be attached in series (see FIG. 4 ) and rather than waiting for a single tank to drain, the filling and draining can be accomplished in staggered fashion, e.g. five tanks done a day rather than one tank every five days.
The resulting product is very high solids of at least about 20% to about 40% or more. The remaining liquid from the fermentation can further have the liquid separated by leaching or pressing. The high solids material can then be utilized as a fertilizer or as desired.
Now referring to the drawings, FIG. 1 is a flow chart of the method of the invention. A low solids (e.g. 2%-5%) liquid effluent of an anaerobic digestion is measured and isolated 1 (e.g. transferred from an anaerobic digester). A biomass source 2 is then added to the effluent 1 to form a high solids mixture of about 20% to 30% solids 3 . The mixture is brought to a temperature of at least about 50 degrees centigrade and held there for a period of about 2 to 10 days or more and allowed to ferment with the naturally occurring organisms present 4 without further heating to then produce a high solids effluent 5 . The high solids effluent 5 can be used directly as a fertilizer 7 or the solids can be separated such as by pressing 6 to use as a solid fertilizer 7 . Biogas 8 is produced as is a liquid leachate 9 which can be returned for further digestion or discord.
FIG. 2 is the system of the present invention slurry the actual system used in one embodiment. In this view a solid phase digester, tank 21 is filled with biomass 22 . As biomass 22 moves down in tank 21 it becomes further and further digested 22 a , 22 b , and 22 c . While depicted as layers it would likely be a gradient of digested biomass. The primary anaerobic 23 digester delivers effluent 24 to the tank 21 and biomass 22 . The effluent is at least about 50 degrees C. when it enters tank 21 via emitter 25 . The digestion is about 5-10 days and during the digestion biogas 26 is produced. At the end a semi-solid mass 27 (about 20-40% solid or more) is produced which can be utilized as fertilizer. Any liquid left, if any, is removed as a leachate 28 which can be disposed of or reused in digestion.
In FIG. 3 the solid phase digester is shown in another process. In this embodiment water 31 and animal manure 32 are added to a hydrolytic degritter 33 and degritted. The effluent is added to an anaerobic digester 34 . Biogas 35 is removed and a low-solids slurry 36 delivered to the solid phase digester 37 of the present invention. Once again further biogas 35 is pictured as is a semi-solid fertilization 36 and a leachate 39 . The fertilizer 36 could then be shipped 38 as desired.
In FIG. 4 a continuous sequential process method is shown. In this embodiment, water 41 and animal manure 42 are again added to a hydrolytic degritter 43 and the effluent is added to anaerobic digester 44 . Biogas 45 is removed and the low solids slurry 46 is delivered to five separate solid phase digesters 47 by filling one each day and draining each after five days. Any number two or greater could be utilized and five as shown by way of example. Semisolid fertilizer 46 is removed as is leachate 49 which could be shipped out 48 .
Those skilled in the art to which the present invention pertains may make modifications resulting in other embodiments employing principles of the present invention without departing from its spirit or characteristics, particularly upon considering the foregoing teachings. Accordingly, the described embodiments are to be considered in all respects only as illustrative, and not restrictive, and the scope of the present invention is, therefore, indicated by the appended claims rather than by the foregoing description or drawings. Consequently, while the present invention has been described with reference to particular embodiments, modifications of structure, sequence, materials and the like apparent to those skilled in the art still fall within the scope of the invention as claimed by the applicant. | The present invention relates to a method for taking liquid anaerobic digestion effluent and increasing the solids content by using the effluent and biomass to further digest both. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates to generation of join query results in the management and execution of relational database queries.
BACKGROUND OF THE INVENTION
[0002] Relational Database Management System (RDBMS) software using a Structured Query Language (SQL) interface is well known in the art. The SQL interface has evolved into a standard language for RDBMS software and has been adopted as such by both the American Nationals Standard Organization (ANSI) and the International Standards Organization (ISO).
[0003] In RDBMS software, all data is externally structured into relations, each relation dealing with one or more attributes and comprising one or more tuples of data, each tuple associating attribute values with each other. A relation can be visualized as a table, having rows and columns (indeed, the relations in a particular database are often referred to as the “tables” of the database). When a relation is visualized as a table, the columns of the table represent attributes of the relation, and the rows of the table represent individual tuples or records that are stored using those attributes. To aid in visualizing relations in this manner, in the following, the relations in an RDBMS system will frequently be referred to as that system's “tables”.
[0004] An RDBMS system may be used to store and manipulate a wide variety of data. For example, consider a RDBMS system for storing and manipulating sales information for a chain of store. In such a system, a “Sales” table storing sales information might have a first column “Date” for the date of a sale, a second column “SKU” for the inventory control number for the item sold, and a third column “Store” for the name of the store where the sale was made. Each row in the table would identify these attributes, and others, for each sale made in a store in the chain.
[0005] Often, columns in different tables are related. Thus, in the above example, the SKU identified in the “Sales” table might be used to find detailed information about the product sold in a second, “SKU” table. (In such a relationship, the SKU is known as a “foreign key” in the Sales table, because it is a lookup key for information in the SKU table.) The SKU table provides details for the product identified by the SKU, e.g., a text name for the product, the name of the vendor of the product and the vendor's address. Similarly, the store identified in the Store table may be identified by an ID number, and a “Stores” table may be used to provide detailed information about the store, such as the name, address, and geographic region of the store.
[0006] The example described so far has come to be known as a “star schema” database, common to business intelligence applications. FIG. 1A illustrates in general the layout of the foreign key links between tables in a star schema database. A central table 10 (in the example, the Sales table), known as a “fact table” conveys basic facts of interest to the architect of the database, in this case, the Sales made. Details regarding those facts are provided by other tables, known as “dimension tables”, linked to the fact table through foreign keys. In this example, the SKU table 12 and Stores table 14 are linked by foreign keys. FIG. 1B illustrates representative content of the Sales, SKUs and Stores tables 10 , 12 and 14 discussed in the above examples.
[0007] As will be appreciated, in may business intelligence applications, the fact table can become extremely large. For example, a fact table in which each row (tuple) represents a sale of a single item at a single store of a large national chain, will quickly grow to billions of rows and terabytes of data. Because of the structure of the database, queries will frequently involve the fact table in a join with other of the tables. For example, a query seeking the total sales figures for a product matching a text search string (including wildcards) in the New England region, would involve a join of the SKU table, Sales table and Stores tables. The join of the SKU table would be necessitated to find those SKU's that match the identified text string; the join of the Stores table would be necessitated to find the stores in the New England region.
[0008] The challenge inherent in such queries is that the conventional online transaction processing (OLTP) implementation of the join operations, would treat the Sales table as the inner table of one or both of the joins; that is, for example, the join of the SKU table and Sales table would be performed by reviewing each row (tuple) in the SKU table, and for each matching SKU, reviewing the entire Sales table for matching sales. Because the outer loop of this process involves review of the SKU table, whereas the inner loop involves review(s) of the Sales table, the SKU table is known as the outer table and the Sales table is known as the inner table. It can be seen that this table join process with the Sales table used as the inner table, will involve repeated review of the Sales table, once for each matching SKU in the SKU table. Where the Sales table expands to the terabyte size mentioned above, this conventional OLTP methodology becomes extremely inefficient.
[0009] To confront this inefficiency, it has been proposed to utilize a “starjoin” methodology in business intelligence applications. For example, U.S. Pat. No. 6,105,020, assigned to the assignee of the present application, and incorporated herein by reference, describes a methodology for attempting to identify a fact table and dimension or “snowflake” tables, for the purpose of applying a unique “star join” method to those tables instead of conventional OLTP methods in which the fact table would likely be used as the inner table. In summary, “star join” methods involve developing, from the dimension tables, an intermediate result of all tuples matching the selection criterion operative on the dimension table, and then comparing all of these tuples to tuples in the fact table at the same time, so that only one pass need be made through the fact table. Thus, membership in the intermediate result is used as a selection predicate for the tuples in the fact table during a single pass through the fact table. Since this selection predicate is based upon the advance processing of a selection criterion from the dimension table, it may be referred to as a “look-ahead predicate”.
[0010] Unfortunately, known methods cannot reliably identify many situations where a “star join” method should be substituted for a conventional inner/outer join, for the reason that business intelligence database schema often do not follow a conventional star pattern. Rather, in some instances the schema for a business intelligence database has a more complex, “snowflake” pattern such as is shown in FIG. 2A .
[0011] Snowflake pattern databases frequently arise when normalization practices are used on the dimension tables of a database. For example, as seen in FIG. 2B , the dimension table 12 for SKUs has been normalized into two tables 12 a and 12 b , by separating vendor identification information and SKU information; the SKU table 12 a includes the name of a product under a SKU, and an identifier for the product vendor, which is a foreign key to a Vendors table 12 b which identifies the name and address of the vendor. Similarly, the dimension table 14 for Stores has been normalized into three tables 14 a , 14 b and 14 c , by separating store regional information and store information; the Store table 14 a includes the name of a store and identifiers for the store region and store type, which are foreign keys to a Regions table 14 b that identifies a region and a Types table 14 c that identifies types of stores.
[0012] The key difficulty with databases having a “snowflake” or other complex schema is that techniques used to determine when to use a star join and when to use a conventional inner/outer join, are specialized and are applicable only to schema that fit a specific typical or expected schema.
[0013] Accordingly, there is a need for a method for identifying when a query may be more efficiently implemented with nonconventional join techniques in more diverse circumstances than has previously been the case.
SUMMARY OF THE INVENTION
[0014] In accordance with principles of the present invention, these needs are met by a process for systematically evaluating join predicates in a query to determine the selectivity in a first relation in the join, as a consequence of the join, and/or any selection predicates operative upon the second relation in the join.
[0015] In specific embodiments in accord with principles of the present invention, a relational database system analyzes each potential join in a query, to determine whether a relation involved in the join is subject to a selection criterion, and evaluate whether the join per se, or the join after application of the selection criterion, effects a join reduction. In the described embodiment, the amount of join reduction is determined by identifying whether the number of rows in the join result produced will be smaller than the number of rows from second relation, although join reduction can be identified with other criteria.
[0016] Upon identifying a potential join reduction involving a first and a second relation, and any selection criterion on the second relation, the potential benefit of that join reduction is assessed. Specifically, the relational database system evaluates the computational expense of generating a look-ahead predicate comprising the tuples of the second relation that match any selection criterion, and this expense is compared to the computational savings that result from the join reduction. In the event the formation of the look-ahead predicate is beneficial, processing of the query forms and utilizes the look-ahead in the join of the first and second relations.
[0017] In the described specific embodiment, the most beneficial look-ahead predicate among all potential joins of relations in the query is identified through iterative analysis of all possible joins. Thereafter, membership in a look-ahead predicate is added as a selection criterion on the first relation, and further iterative analysis is performed of all possible joins of the remaining relations and the look-ahead predicate. This process thus finds additional joins in the query that benefit from the formation of the look-ahead predicate.
[0018] These and other features and advantages, which characterize the invention, are set forth in the claims annexed hereto and forming a further part hereof. However, for a better understanding of the invention, and of the advantages and objectives attained through its use, reference should be made to the Drawing, and to the accompanying descriptive matter, in which there is described exemplary embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWING
[0019] FIG. 1A is an abstract schema diagram for a star schema database having a fact table and dimension tables, and FIG. 1B is a schema diagram showing Sales, SKUs and Stores tables in such a database;
[0020] FIG. 2A is an abstract schema diagram for a snowflake schema database having a fact table and dimension tables, and FIG. 2B is a schema diagram showing Sales, SKUs, Vendors, Stores, Regions and Managers tables in such a database;
[0021] FIG. 3 is a block diagram of an apparatus according to an embodiment of the present invention; and
[0022] FIG. 4 is a flow diagram of a process for evaluating a query to identify beneficial look-ahead predicates in an iterative fashion.
DETAILED DESCRIPTION
[0023] The methods of the present invention employ computer-implemented routines to query information from a database. Referring now to FIG. 3 , a block diagram of a computer system which can implement an embodiment of the present invention is shown. The computer system shown in FIG. 3 has a particular configuration; however, those skilled in the art will appreciate that the method and apparatus of the present invention apply equally to any computer system, regardless of whether the computer system is a complicated multi-user computing apparatus or a single user device such as a personal computer or workstation. Thus, computer system 100 can comprise other types of computers such as IBM compatible personal computers running OS/2 or Microsoft's Windows. Computer system 100 suitably comprises a processor 110 , main memory 120 , a memory controller 130 , an auxiliary storage interface 140 , and a terminal interface 150 , all of which are interconnected via a system bus 160 . Note that various modifications, additions, or deletions may be made to computer system 100 illustrated in FIG. 3 within the scope of the present invention such as the addition of cache memory or other peripheral devices. FIG. 3 is presented to simply illustrate some of the salient features of an exemplary computer system 100 .
[0024] Processor 110 performs computation and control functions of computer system 100 , and comprises a suitable central processing unit (CPU). Processor 110 may comprise a single integrated circuit, such as a microprocessor, or may comprise any suitable number of integrated circuit devices and/or circuit boards working in cooperation to accomplish the functions of a processor. Processor 110 suitably executes a computer program within main memory 120 .
[0025] Auxiliary storage interface 140 allows computer system 100 to store and retrieve information such as relational database table or relation 174 from auxiliary storage devices, such as magnetic disk (e.g., hard disks or floppy diskettes) or optical storage devices (e.g., CD-ROM). As shown in FIG. 3 , one suitable storage device is a direct access storage device (DASD) 170 . DASD 170 may alternatively be a floppy disk drive which may read programs and data such as relational database table 174 from a floppy disk. In this application, the term “disk” will be used to collectively refer to all types of storage devices, including disk drives, optical drives, tape drives, etc. It is important to note that while the present invention has been (and will continue to be) described in the context of a fully functional computer system, those skilled in the art will appreciate that the mechanisms of the present invention are capable of being distributed as a program product in a variety of forms, and that the present invention applies equally regardless of the particular type of signal bearing media to actually carry out the distribution. Examples of signal bearing media include: recordable type media such as floppy disks (e.g., a floppy disk) and CD ROMS, and transmission type media such as digital and analog communication links, including wireless communication links.
[0026] Memory controller 130 , through use of a processor is responsible for moving requested information from main memory 120 and/or through auxiliary storage interface 140 to processor 110 . While for the purposes of explanation, memory controller 130 is shown as a separate entity, those skilled in the art understand that, in practice, portions of the function provided by memory controller 130 may actually reside in the circuitry associated with processor 110 , main memory 120 , and/or auxiliary storage interface 140 .
[0027] Terminal interface 150 allows system administrators and computer programmers to communicate with computer system 100 , normally through programmable workstations. Although the system 100 depicted in FIG. 3 contains only a single main processor 110 and a single system bus 160 , it should be understood that the present invention applies equally to computer systems having multiple buses. Similarly, although the system bus 160 of the embodiment is a typical hardwired, multidrop bus, any connection means that supports-directional communication in a computer-related environment could be used.
[0028] In the illustrated embodiment, memory 120 suitably includes an operating system 122 , a relational database system 123 , and user storage pools 125 . Relational database system 123 includes structured query language (SQL) 124 , which is an interactive query and report writing interface. Those skilled in the art will realize that SQL 124 could reside independent of relational database system 123 , in a separate memory location.
[0029] User storage pools 125 include indexes 126 such as that illustrated in FIG. 3 , as well as storage for temporary data such as a user query 129 . User query 129 is a request for information from relational database table 174 stored in DASD 170 . The methods of the present invention do not require that the entire relational database table be loaded into memory 120 to obtain the information requested in user query 129 . Instead, indexes are loaded into memory 120 and provide relational database system 123 an efficient way to obtain the information requested by user query 129 .
[0030] It should be understood that for purposes of this application, memory 120 is used in its broadest sense, and can include Dynamic Random Access Memory (DRAM), Static RAM (SRAM), flash memory, cache memory, etc. Additionally, memory 120 can comprise a portion of a disk drive used as a swap file. While not explicitly shown in FIG. 3 , memory 120 may be a single type of memory component or may be composed of many different types of memory components. For example, memory 120 and CPU 110 may be distributed across several different computers that collectively comprise system 100 . It should also be understood that programs in memory 120 can include any and all forms of computer programs, including source code, intermediate code, machine code, and any other representation of a computer program.
[0031] Users of relational database system 123 provide requests for information in a useful form by creating user query 129 . User query 129 is a way to ask relational database system 123 to provide only the set of information from relational database table 174 that meets certain criteria. Structured Query Language (SQL) 124 is the standard command language used to query relational databases. SQL commands are entered by a user to create user query 129 , which then typically undergoes the following front-end processing by relational database system 123 . User query 129 is parsed for syntax errors. The relational database table from where the user wants his information is identified. The field name(s) associated with the information are verified to exist in the relational database table. And, the SQL commands in user query 129 are reviewed by optimization software in relational database system 123 to determine the most efficient manner in which to process the user's request.
[0032] The front-end optimization processing of user query 129 by relational database system 123 determines whether a particular index 127 exists that can facilitate scanning for requested data more efficiently than another database index or than the relational database housed in DASD 170 . In order for an index to be useful to the methods of the present invention, the index must be built over the database fields specified by the criteria in user query 129 . That is, there must be an index for those particular fields in that particular database.
[0033] Referring now to FIG. 4 , a process for evaluating a query for beneficial join operations can be described. In a first step 200 , all tables referenced in the query are identified. Then, in an iterative process, the potential join of each table with each other table is evaluated for potentially beneficial use of a look-ahead predicate.
[0034] Specifically, for each table in the query as a candidate first joined table (step 202 ), and for each other table in the query as a candidate second joined table (step 204 ), the potential join of the tables is evaluated, to determine whether the join is reductive on the first table. In many cases, the tables will have no joinable columns or no join criterion in the query, and will therefore form a Cartesian product join, which is clearly not reductive. For this reason, in step 206 the join is evaluated to determine whether it will be a Cartesian product join.
[0035] In the event the candidate first and second tables have joinable columns, and thus will not form a Cartesian product join, processing continues through step 206 to step 208 in which it is determined whether there is a selection criterion in the query that is operative on the candidate second table. If so, then the effect of this selection criterion on the join is evaluated in step 210 . Specifically, indexes available for the database are used to estimate the size of the result set produced by the selection criterion from the query. The use of indexes to form such estimates is well known and frequently utilized in relational database processing, and so will not be explored at length here. After forming such an estimate, in step 212 , an estimate is made of the selectivity of the join of the thus-reduced second table to the first table. For example, indexes may be used in determining, as one example, a count of the unique values that are likely to remain in the joined column of the second table after application of the selection criterion on the second table, and a count of the unique values in the joined column of the first table, which can be used together to estimate the likely number of matching tuples in the first table after the application of the selection criterion in the second table.
[0036] In the event the candidate second table does not have a selection criterion, in step 209 , the selectivity of the join of the two tables, per se, is evaluated for selectivity. It will be appreciated that databases frequently are constructed without referential integrity between tables. For example, a table may be formed that has only special cases applicable to a handful of values of a foreign key in another table. In such an instance, a join of the tables with a join predicate on the foreign key, will be reductive regardless of the existence of any selection criterion on either table. Accordingly, even in the absence of a selection criterion, the join per se is assessed for selectivity.
[0037] In step 214 , it is determined whether the join with the candidate second table (including the use of any selection criterion on the candidate second table), based on the computed estimates, will be beneficially reductive. Specifically, the computational cost of forming a look-ahead predicate for a join of the first and second tables, is compared to the computational benefit of avoiding the inefficiencies of a conventional inner-outer join operation. The details of this evaluation may turn on a few or a large number of factors, such as the relative size of the relations in the database, the number of unique values remaining in the look-ahead predicate, and others.
[0038] If, in step 214 , the formation of a look-ahead predicate for the current candidate join is deemed beneficial, in step 216 a measure of the resulting benefit is compared to the same measures formed for any other candidate join deemed beneficial during the current iteration of the main loop that begins at step 202 . If the current candidate is the most beneficial join, in step 218 the candidate first and second tables and the measures generated from them are stored as the currently most beneficial candidate join for look-ahead predicate generation.
[0039] After step 218 , or immediately after steps 216 , 214 or 206 in the event a candidate join is not deemed beneficial or the most beneficial, processing continues to step 222 , where it is determined whether there is another candidate second table to evaluate. If so, then processing returns to step 206 to determine whether the new candidate second joined table has a potentially reductive join with the candidate first joined table.
[0040] After every candidate second joined table has been evaluated in the loop of steps from 204 through 222, in step 224 it is determined whether there is another candidate first table to evaluate. If so, then processing returns to step 204 to begin the process of evaluating candidate joins of the new candidate first table with each other table in the loop of steps from 204 to 222.
[0041] Once all candidate first tables have been evaluated with all candidate second tables, processing continues from step 224 to step 226 , in which it is determined whether any beneficial candidate joins were identified in the current pass through the main loop of steps from 202 through 224. If so, then in step 228 , the query processing is reformed to utilize a look-ahead predicate, which is formed from the tuples of the second table of the most beneficial join, that match any selection criterion of the second table. Thereafter, commencing in step 230 , the loop of steps beginning at step 202 is restarted, to re-evaluate possible joins in the event that the look-ahead predicate has made other joins more beneficial.
[0042] Through this iterative process, it is likely that multiple, sequential look-ahead predicates may be identified, resulting in a beneficial sequencing of look-ahead predicates through joins that dramatically reduces processing expense of a query.
[0043] For the purposes of example, consider a query in an SQL-like language, operative upon the “snowflake” schema database of FIG. 2B :
SELECT * FROM Sales, Stores, Regions WHERE Sales.StoreID = Stores.StoreID and Stores.RegionID = Regions.RegionID and Store.TypeID = ″1″ and Regions.RegionlID = ″New England″
[0044] Summarizing this query, it seeks a table of all sales at retail stores (Store type 1 ) in New England.
[0045] Applying the process described above, the tables Sales, Stores and Regions are initially considered. The potential join between Sales and Regions is a cartesian product join, and is eliminated. The potential join between Sales and Stores is evaluated, but the selection criterion Stores.TypeID=“1” is found to be of limited reductive effect, for the reason that most sales are made at retail stores, and so this join is rejected. The potential join between Stores as a first table and Regions as a second table, is found to be beneficial, for the reason that few stores are in New England. As a consequence, query processing is reformed to utilize a look-ahead predicate generated from the results of selecting those tuples in the “New England” region in the Regions table (which may, in the stated example, be a single tuple). This look-ahead predicate, which for referential ease will be called Regions', is then substituted for the Regions table in the next pass through the analysis. Written in SQL, the query would now be
WITH Regions' as (SELECT * FROM Regions WHERE Regions.Name = ″New England″) SELECT * FROM Sales, Stores, Regions' WHERE Sales.StoreID = Stores.StoreID and Stores.RegionID = Regions'.RegionID and Stores.TypeID = ″1″ and Stores.RegionID IN LIST (Regions'.RegionID)
(The syntax of IN LIST in this SQL-like language, refers to the star-join use of a look-ahead predicate, which is a hybrid between the SQL IN list and an IN subquery.)
[0046] In the second pass through the process, the join combinations of Sales, Stores and Regions' are evaluated. Regions' and Sales is a cartesian product join, and so is not beneficially reductive. The combination of Regions' as a first table with Stores as a second table subject to the Stores.TypeID=“1” criterion, is not beneficially reductive, because Regions' already has been substantially reduced in size. However, the join combination of Sales as a first table and Stores as a second table, which was previously not beneficially reductive, is now beneficially reductive, due to the new look-ahead predicate Stores.RegionID IN LIST (Regions'.RegionID), which is substantially selective of the tuples of Stores (there are only a few stores in New England).
[0047] Hence, at the conclusion of the second pass, query processing is again reformed to utilize a second look-ahead predicate, generated from the first look-ahead predicate and the Stores table, the second look-ahead predicate selecting only those Stores in the “New England” region. This look-ahead predicate, which for referential ease will be called Stores', is then substituted for the Regions table in the next pass through the analysis. Written in SQL-like language, the query would now be
WITH Regions' as (SELECT * FROM Regions WHERE Regions.Name = “New England”), Stores' as (SELECT * FROM Stores WHERE Stores.TypeID = “1” and Stores.RegionID IN LIST (Regions'.RegionID)) SELECT * FROM Sales, Stores', Regions' WHERE Sales.StoreID IN LIST (Stores'.StoreID) and Sales.StoreID = Stores'.StoreID Stores'.RegionID = Regions'.RegionID
[0048] As can be seen, the iterative process described, successfully identified a proper ordering for join and selection operation for greatest efficiency in responding to the original query: first a look-ahead predicate is formed listing all regionID's (only one) that is for the New England region. Then a second look-ahead predicate is formed for all retail stores having that region ID. Finally, all sales identifying the StoreID of a store in the second look-ahead predicate, are reported.
[0049] The invention in its broader aspects is not limited to the specific details, representative apparatus and method, and illustrative example shown and described. For example, while the invention has been explained in connection with its application to a “snowflake” or star schema database, the invention is readily applicable to evaluation of any query involving joins of tables using selection criteria. Accordingly, departures may be made from such details without departing from the spirit or scope of applicant's general inventive concept. | A relational database system analyzes each potential join in a query, to determine whether a relation involved in the join is subject to a selection criterion, and evaluate whether that selection criterion or the join per se effects a join reduction. The computational expense of generating a look-ahead predicate comprising the tuples of the second relation matching any applicable selection criterion, is compared to the computational savings that result from the join reduction. The most beneficial look-ahead predicate among all potential joins of relations in the query is identified through iterative analysis of all possible joins. Thereafter, membership in the look-ahead predicate is added as a selection criterion on the first relation, and further iterative analysis is performed of all possible joins of the remaining relations and the look-ahead predicate, to iteratively identify additional joins in the query that benefit from the formation of the look-ahead predicate, and potentially form further look-ahead predicates. | 6 |
TECHNICAL FIELD
An apparatus for locking and unlocking a boom and its supporting structure to the vehicle upon which they are carried to prevent motion of the boom about a horizontal and a vertical axis.
Most commercially available earthworking implements employ a boom that is pivoted on a boom support or swing tower which in turn is pivoted to a vehicle or base with a tool or bucket assembly pivoted on the free end of the boom. The boom and bucket assemblies are moved by fluid rams.
There are times when it is desirable to positively lock the boom and boom support without relying upon the fluid in the boom and boom support fluid rams (ex. hydraulic power plant maintenance, transportation with hydraulic fluid drained, etc.) In other instances it is desirable to hold the boom in the upright position to permit maximum utilization of fluid power for lifting and swinging payloads carried by the earthworking tool or bucket assembly.
It is also desirable to lock the boom to prevent it from swinging about a vertical axis. This is particularly true when the vehicle is travelling on public roads. When sharp turns at slow speed or normal turns at high speed are made abrupt swinging of the boom may result from the momentum of the boom and boom supported tool. This could jeopardize the stability of the vehicle and perhaps even overturn it. In addition, it is desirable to have the backhoe positively restrained since even slight movements of such a heavy mass could result in injury to personnel and damage to adjacent equipment.
BACKGROUND OF THE INVENTION
One locking device is described in U.S. Pat. No. 3,376,984 by Long and assigned to the assignee of the present invention. The disclosure of Long relates to what is referred to as an "over-center" boom, that is a boom which can be swung to a transport or storage position that is generally vertical and slightly toward the vehicle side of the boom support. In the Long patent, the boom is held in the transport position by the fluid rams that are used to pivot the boom about a horizontal axis on the boom support. The boom may be swung about a vertical axis by one or more hydraulic rams joining the boom support to the base. Similarly, the boom support may be restrained from swinging freely about its vertical axis during transportation or storage by forming a hydraulic lock in the fluid rams joining the boom support to the base.
Positive interlocks between the boom and the boom support are also disclosed in U.S. Pat. No. 3,811,582 by Shumaker and U.S. Pat. No. 3,921,835 by Baker both assigned to the assignee of the present invention. These latter disclosures do not provide for locking the boom support and thus do not completely lock the boom against rotation in two directions.
SUMMARY OF THE INVENTION
According to the present invention, a boom is positively locked to its support in a storage or transport position by utilizing a minimum number of parts and using where possible existing components that are already in use. A releasable lock means is utilized to lock the boom both horizontally and vertically. This device automatically locks the boom against rotating in a vertical plane when the boom is moved to the storage or transport position. After the boom support has been brought to the proper position for locking against further rotation in a horizontal plane, a second locking device is actuated by the equipment operator. These interlocks can be readily released in sequence or at the same time from the vehicle operator's control console by means of a single two position control lever.
More specifically, the releasable lock means consists of a first member that is carried by the boom and movable relative to it, a second member that is fixed to the vehicle, a third member that is fixed to the boom support and a fourth member that is attached to the vehicle and moveable relative to it.
The first member consists of a ring-like structure that is pivotally supported about a horizontal pivot axis on the boom and is biased by an elastomeric member to a first position. The advantage of utilizing an elastomeric member is that the member also holds the ring in a substantially fixed position during normal manipulation of the boom. The second member is the free end of a pin that is normally utilized for mounting the boom support to the base of the vehicle for pivotal movement about a vertical axis. Thus, the pin may be considered fixed relative to the boom support. The first and second members are located so that the first member engages and slides into the second member as the boom is pivoted about its horizontal axis towards the storage or transport position. This locks the first and second members together. A release means separates the first and second members by overcoming the biasing means.
When the boom is moved out of the vertical storage position, the biasing means returns the first member to the first position thereby automatically placing in a configuration for subsequent locking to the second member.
The third member is a pin fixed to the boom support structure and is offset from the pivot pin joining the boom support to the vehicle. The fourth member is a ring-like structure that is pivotally supported about a horizontal pivot axis on the vehicle base. When the third and fourth members are brought into alignment by manipulating the boom support, the equipment operation lowers the fourth member thereby locking the boom support to the vehicle base. To unlock the third and fourth members the equipment operator actuates the release means which raises the fourth member free from the third member. The same control that locks the two members together also is used to release the two members.
The release means for the third and fourth members also actuates the release means between the first and the second members. This is accomplished by a cam and follower to transmit motion from the control lever for the fourth member to the releasing device for the second member. In particular, the second member must be freed from the first member before the third and fourth members can be freed. The converse is also true; the first and second members are locked before the third and fourth members. Thus, the boom is first locked against rotation in a vertical plane and then locked against rotation in the horizontal plane.
To recapitulate, the boom is first locked to the boom support and then the boom support is locked to the vehicle. Using one control lever the vehicle operator first unlatches the boom support and then the boom thereby freeing the boom for movement.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary side view of a vehicle having an earthworking implement mounted thereon and having the present invention incorporated therein;
FIG. 2 is an enlarged fragmentary plan view showing the details in releasable lock means of the present invention as viewed along line 2--2 of FIG. 1;
FIG. 3 is an enlarged fragmentary elevation view of the releasable lock means as viewed along line 3--3 of FIG. 2; and
FIG. 4 is a further fragmentary elevation view of the releasable lock means, as viewed along line 4--4 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
While this invention is susceptible to embodiment in many different forms, there is shown in the drawings and will herein be described in detail an embodiment 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 embodiment illustrated.
FIG. 1 of the drawing shows a vehicle generally designated by reference numeral 10, having an earthworking tool or implement 12 supported thereon. The implement 12 consists of a backhoe which includes a frame 14 having outriggers 16 supported thereon with the frame being attached to the end of the vehicle, adjacent an operator's station 18. The operator's station 18 may be part of the vehicle or may be a separate area on the frame 14.
A swing tower or boom support 20 is pivoted about a vertical axis defined by two vertical pivot pins 22, which will be described in more detail later, while a boom 24 is supported at its lower end by horizontal pivot pins 26 on the boom support or swing tower 20. The boom 24 is pivoted about a horizontal pivot axis (defined by the horizontal pivot pins 26) by a pair of boom fluid rams 28 (only one being shown) located on opposite sides of the boom 24 with the cylinder 30 of the ram secured to the boom support 20 and the piston rod 32 secured to the boom 24.
A dipper stick assembly 34 is supported on the other end of said boom; it includes a member 36 pivoted intermediate its ends on the free end of the boom 24 by pivot pin 38. Movement of the member 36 is controlled by a dipper stick fluid ram 40 having its cylinder 42 pivotally supported on the boom adjacent to the boom support 20 with its piston rod 46 pivotally supported on one end of the member 36 by pin 48. A bucket 50 is pivoted on the opposite or outer end of dipper stick by an additional fluid ram 52. Finally, other fluid rams 54 are used to pivot the boom support about the vertical axis.
It is generally true in vehicles of this type that the boom 24 is connected to the boom support structure 20 and pivots about it in a vertical plane. The boom support structure 20 is in turn attached to the vehicle frame 14 so that the boom support structure pivots in a horizontal plane. The pivot pin 22 joining the boom support structure to the vehicle frame 14 may be attached to either the boom support structure 20 or the vehicle frame 14. Consequently, two locks are necessary to completely restrain the motion of the boom.
For purposes of identification, the two locks will be referred to as the "vertical lock" and the "horizontal lock." The vertical lock prevents vertical motion or motion of the boom in a vertical plane. Similarly, the horizontal lock prevents motion of the boom and its support in a horizontal plane. Collectively the locks are referred to as "the releasable lock means."
The so-called vertical lock closely resembles and follows the teachings of the Baker patent previously identified and is herein incorporated by reference.
During normal operation of the earthworking implement, the boom is maintained rearwardly (FIG. 1) or to the left of the vertical axis previously defined. The boom, dipper stick and bucket are manipulated by applying pressurized fluid to the fluid rams 28, 40, 52 and 54. When it is desired to move the implement to its transport or storage position, the boom fluid rams 28 are manipulated in such a manner that the boom is moved to the vehicle side of the vertical axis. This manner of moving a boom to its transport position is explained in greater detail in the Long patent which is incorporated herein by reference.
According to the present invention, the boom and support carry a releasable lock means to lock the boom to the boom support and lock the boom support to the vehicle when the boom is moved to the transport or storage position. Referring to FIG. 2, the vertical lock portion of the releasable lock means includes a first member or vertical lock ring structure 56 that has an opening 58 for receiving a pin or second member 22. The first member 56 is supported for movement by a pair of ears 60 that form part of the boom 24 and a horizontal pin 62 received through a bushing 64 that is fixedly secured by snap rings 68 and forms part of the first member, the ring-like structure or locking plate 56.
Referring to FIG. 3, the first member 56 is normally biased to a first position by biasing means 70 interposed between the boom 24 and the first member 56 which accommodates movement of the first member from the first position. Preferably the biasing means is in the form of an elastomeric or rubber member 72 that has one end connected to a bracket 74 carried by the boom and the opposite end connected to a bracket 76 on the first member 56. The bias means is shown attached to the boom and first member by metal fasteners 78.
The horizontal lock portion of the releasable lock means is shown in FIGS. 2 and 4. It includes a lock pin or third element 82 attached to an extension 80 of the boom support 20 and a horizontal lock ring structure or fourth element 84 attached to the vehicle or base 14. The lock pin 82 is offset from the pivot pin 22 of the boom support 20. The horizontal lock ring 84 is pivoted about a horizontal axis 86 defined by two brackets 88 and 90 attached to the vehicle.
Both the horizontal and vertical locks are released by a release means 91. One portion of the release means releases the horizontal lock and is referred to as the "horizontal release means," while another portion releases the vertical lock and is referred to as the "vertical release means." The release means 91 consists of three spaced brackets 88, 90, and 92 attached to the vehicle frame 14 and two concentric shafts; an outer shaft 94 and an inner shaft 96. Horizontal lock ring 84 is attached to the outer shaft 94 by a lock screw 98, and an operating lever 100 is attached to the lock ring 84, and extends to the operator's station 18. The horizontal lock ring 84 is restrained against counterclockwise rotation by a stop 102. Thus, manipulation of the operating lever 100, as shown in FIG. 4, rotates the outer shaft 94 and raises the horizontal lock ring 84.
Referring to FIG. 3, as the operating lever 100 rotates outer shaft 94, motion is induced to the vertical release means to release the vertical lock. The vertical lock unlocking means includes a trip lever 104 which is an offset portion of the inner shaft 96. This lever has a stop 106 to limit counterclockwise rotation of the trip lever. Fixedly attached to the inner shaft 96 is a follower 108 and fixedly attached to the outer shaft 94 is a cam 110 (shown integrally attached to one end of the outer shaft in FIG. 2).
Successive positions of the operating lever 100 are identified by Roman Numerals I, II and III. With the operating lever in the first position (I) the horizontal lock ring is indexed upon the lock pin 82, thereby locking the boom support to the vehicle frame 14. As the outer shaft is moved to the next position (II) by operating lever 100 the horizontal lock ring is lifted free of the lock pin 82, thereby allowing the boom support structure to rotate in a horizontal plane.
In moving to this position, the cam 110 on the outer shaft 94 comes into contact with the follower 108 on the inner shaft. Rotation of the operating lever 100 to a third position (III) further raises the horizontal lock ring 84 and at the same time lifts trip lever 104 by virtue of cam 110 engaging follower 108. This overcomes the biasing means and lifts the vertical lock ring 56 free from its first or locked position to an unlocked position (shown by dotted lines in FIG. 3).
Once the boom is unlocked in both the vertical and horizontal planes, the operator may return the operating lever 100 from the third position (III) to the second position (II). If left in second position (II), the boom is ready to be automatically locked in the vertical plane; while the horizontal lock ring remains clear of the horizontal lock pin 82. Once the boom is locked vertically, the control lever may then be placed to the first position (I) when the horizontal lock pin 82 on the boom support is in proper alignment with the horizontal lock ring 84. When the operating lever is in this position (I), the boom is locked in both the horizontal and vertical directions.
The operation of the releasable lock means will now be reviewed. To lock the boom, the boom 24 is pivoted to a storage position (FIG. 1). When the pin 22 defining the vertical pivot axis of the boom is in alignment with the vertical lock ring or first member 56, the lower surface of the vertical locking ring is just slightly above the free end of the vertical pivot pin 22. As opening 58 becomes in general vertical alignment with pin 22, the opening surrounds the pin to provide a lock between the boom and the boom support. This will hold the boom in the transport position with respect to the boom support 20. After alignment of the horizontal lock pin 82 to the horizontal lock ring 84 the horizontal locking ring may be lowered by actuation of operating lever 100. Thus the boom is locked in both the horizontal and vertical directions.
To release the boom from the support for pivotal movement thereto, it is only necessary for the equipment operator to rotate operating lever 100 to raise both locking rings free from the lock pins.
As can be appreciated from the above description the releasable lock means between the boom and support be incorporated into any existing machine with a minimum amount of modification and with ordinary parts. While the particular interlock means and its operation has been shown and described in connection with the overcenter type boom, the same arrangement can be incorporated into a boom structure wherein the boom never travels across the top of the boom support. | A combination of two pins and two lock rings are used to restrain the motion of a vehicle based boom having the ability to rotate in both the horizontal and vertical directions. Each lock ring is a plate like structure having a hole to receive the corresponding pin. One plate is attached to the boom; the corresponding pin is attached to the boom support. The second plate is attached to the vehicle body; the corresponding pin is attached to the boom support. A single control lever is provided so that the boom operator may actuate the lock rings and unlock each one in sequence. | 4 |
This is a continuation of application Ser. No. 548,500, filed Feb. 10, 1975, now abandoned.
BACKGROUND OF THE INVENTION
This invention is an improvement of that disclosed in U.S. application Ser. No. 408,778 filed Oct. 23, 1973, now abandoned. The present invention concerns the automatic control of the position of the working tool of an earth working machine and, according to the preferred embodiment, the position of the blade of the motor grader. More specifically, the present invention concerns the control of the transverse slope of the working tool or blade of an earth working machine. The preferred embodiment of the invention relates to the slope control of the blade of a motor grader although it is recognized that other types of machines may be controlled by the present invention.
In view of today's highway requirements, particularly high speed travel over modern highways, the demand for greater accuracy in preparing roadbeds for surfacing is substantial. At the same time, the grading operation must be accomplished quickly and efficiently in order to cope with the long distances over which our today's modern highways are to span. The present invention results in quick and efficient operation of a grading machine as well as a highly accurate grading operation by providing refinements in the automatic slope control system of the machine.
SUMMARY OF THE INVENTION
One such refinement results in a more accurately simulated slope of the motor grader blade. If the blade and blade circle arrangement of a grader are always maintained in a plane which is parallel to the line of flight of the machine, the rotation of the blade about an axis perpendicular to this plane will not affect the slope angle of the blade. But if this plane is not maintained parallel to the line of flight of the machine, the slope angle of the motor grader blade changes upon rotation of the blade support circle as is discussed in U.S. Pat. Nos. 3,229,391 and 2,961,783. It is necessary, therefore, to introduce a correction factor dependent upon the rotation of the blade circle into the control system in order to effectively control the blade at the desired slope angle.
This control is accomplished in the instant invention by providing for the slope sensor, which may take the form of a pendulum, a support platform assembly for correcting the attitude of the slope sensor dependent upon the angle of the blade circle plane with respect to the line of flight of the machine and the rotation of the blade about an axis perpendicular to this plane.
A characteristic of some machines is that the blade of a grader can be swung either to the right or left of the machine so that the blade assumes a vertical position alongside the machine. In the apparatus shown in the above mentioned patent application Ser. No. 408,778, such movement of the blade would result in damage to or destruction of the slope sensing structure. A further refinement of the instant invention is, therefore, an arrangement of the slope control system which will allow such movement of the blade without resulting in damage to or destruction of the slope sensing apparatus.
Other advantages of the present invention will be apparent from a review of the following specification, wherein a preferred form of the invention is described, by reference to the accompanying drawings.
SHORT DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of the motor grader with the control system components mounted thereon.
FIG. 2 is a side view of the slope control apparatus with in the housing 21 shown in FIG. 1.
FIGS. 3-5 show various sub-assemblies of the slope control apparatus 21.
DETAILED DESCRIPTION
In FIG. 1 there is shown a motor grader 10 having rear wheels 11 and front wheels 12. The front wheels 12 rotate about an axle 13 which is transversely pivotable around its connection to the front of the machine. The blade 14 of the machine is supported from a blade circle 15 the elevation of which is controlled by hydraulic rams 16 and 17 which also control the slope of the machine blade. The circle 15 is supported at the front of the machine by a drawbar assembly 18.
The drawbar assembly 18 comprises an A-frame having a cross-bar member 19 attached to the blade circle 15 by gears or other suitable means to allow for the rotation of the blade circle 15 with respect to cross-piece 19 and drawbar assembly 18. The drawbar assembly 18 is pivotally secured at 20 to the front of the machine frame and allows for both slope and grade adjustments of the blade. Hydraulic rams 16 and 17 are connected to respective ends of the cross-member 19. Hydraulic ram 16 has been broken away to show in detail the A-frame and circle assemblies. A control box 21 is securedly affixed, by suitable means not shown, to the drawbar assembly 18.
A side view of the contents of control box 21 is shown in FIG. 2. A slope sensor 22 is supported from a platform 23 the rear of which is suspended from the top of the housing 21 by a ball and socket arrangement 24 which is shown in more detail in FIG. 3. A member 25 supports the platform 23 and is arranged for rotational as well as vertical movement. The support member 25 is in the form of a tapered cylinder as shown in FIGS. 2 and 4.
The support member 25 is biased against the platform 23 by a spring 26 which surrounds a shaft 27 and the shaft 27 is supported for rotation by a bearing 28 and a bearing 29. The shaft 27, which is connected to a gear 30, extends through bearing 29, through appropriate holes in the platform 23 and support member 25 to the bearing 28. The platform 23 is biased against the support member 25 by an additional spring 31.
FIG. 4, which shows an enlarged frontal view of only a portion of the apparatus of FIG. 2 and in particular the manner in which the platform 23 is supported to be maintained parallel to the line of flight of the machine, shows in more detail how the support member 25 is supported on the shaft 27. The member 25 has a cylindrical opening to allow the shaft 27 to pass therethrough resulting in the support member 25 being slidably supported by the shaft 27 in cooperation with the spring 26. The shaft 27 has a slot 32 therein and the support member 25 has a slot 33 therein. A key 34 fits into both of the slots 32 and 33 to prevent any rotational movement of the support member 25 with respect to the shaft 27. The key 34 is help captive, by suitable means not shown, to the shaft 27.
In FIG. 2, radial arm 44 is attached to the front of the platform 23 by a joint 35 and joint 35 is shown in more detail in FIG. 4. A bracket 66, affixed to platform 23, has a pin 36 supporting a ball 37 in socket 38. The socket 38 is connected by an arm 39 to a member 40 which is fixedly secured to a shaft 65. As shown in FIG. 2, radial arm 44 is fixedly connected at its other end to shaft 41. As shown in FIG. 1, shaft 41 has a cam follower 42 thereon which follows a cam surface 43 fixed to the earth working machine. The radial arm 44 is rotatably supported on the shaft 65 and held in place by retaining clips 45 and 46.
In order to provide floating proportional positional control as described in U.S. Pat. No. 3,908,765, an arm 47 is frictionally driven by the shaft 41 and has mounted on the end thereof a magnet 48 with pole pieces 49 and 50. Limits 51 and 52 are provided in accordance with the teachings of the above mentioned application to limit the sweep of the arm 47. The magnet and pole piece assembly 48-50 is designed to cooperate with the Hall effect sensor 53 which provides a proportional electrical output signal dependent upon the position across its surface of the magnetic assembly supported at the end of arm 47.
FIG. 5 shows how the arm 47 is frictionally driven by the rotation of shaft 41. The friction drive arrangement comprises a collar 54 which is fixedly secured to the shaft 41 and a cork disc 55 which is secured by suitable means between the collar 54 and the arm 47. The cork disc 55 and arm 47 fit over a flared sleeve 56 which is secured to the shaft 41. A wave spring 57 fits between the arm 47 and a collar 58 which is held in place by the flared end of sleeve 56. Because the cork disc is flexible, the rotation of shaft 41 will cause the rotation of the arm 47 until the arm 47 butts against a limit 51 or 52. At that time, the cork disc will flex and, although the shaft 41 may continue to rotate, the arm 47 will remain stationary against the limit.
The gear 30 shown in FIG. 1 has a chain 59 wrapped therearound and cooperates with a gear 60 rotatably supported on the cross-piece 19 of the drawbar frame 18. The gear 60 is rotated by a connection therefrom through member 19 to a member 61 fixedly secured upon the blade circle. Thus, as the blade circle is rotated, the gear 60 rotates which, through the chain 59, rotates the gear 30.
IN OPERATION
Assuming that the blade circle 15 and drawbar frame 18 are in a plane parallel to the line of flight of the machine, rotation of the blade circle 15 and blade 14 will not affect the slope angle of the blade 14. Furthermore, as the gear 30, in FIG. 2, rotates, support member 25 will also rotate. However, since the platform 23 is also parallel to the line of flight of the machine, the slope of the platform 23 will not be altered by rotation of the blade circle; and thus, the output signal from the slope sensor 22 will represent the true slope of the machine.
Assuming that the hydraulic rams 16 and 17 move the blade circle 15 and drawbar frame 18 to a position below this plane, the movement is sensed by the cam follower 42 and causes shaft 41 to rotate the radial arm 44 of FIG. 2 in a counterclock wise direction pushing down on the front of platform 23. This movement maintains the platform 23 parallel to the line of flight of the machine. However, the shaft 27 and support member 25 retain the same orientation with respect to the housing 21 that they had when the blade circle was parallel to the line of flight of its machine. Now if the blade circle assembly 15 is rotated, the gear 30 will rotate the support member 25 which will change the slope of the platform 23, and thus the sensor 22, by an amount dependent upon the amount of rotation of the blade circle 15.
If the hydraulic rams 16 and 17 operate the blade circle 15 to a position above this plane, the cam 42 and shaft 41 will sense this movement to rotate the radial arm 44 of FIG. 2 in a clock wise direction which will raise the front of the platform 23. The platform 23 is again maintained parallel to the line of fight of the machine and shaft 27 and member 25 remain in their fixed attitude with respect to housing 21. Therefore, any rotation of the gear 30 and member 25 will result in a change in the slope of the platform 23 and sensor 22 by an amount dependent upon the amount of rotation of the blade circle 15. Thus, the sensor 22 will sense the true slope of the blade.
Since the shaft 41 rotates by an amount dependent upon the movement of the drawbar frame 18 with respect to the machine 10, the movement of the arm 47 is also dependent upon movement of the drawbar frame 18 with respect to the machine 10 which control is disclosed in U.S. Pat. No. 3,908,765 above mentioned. Thus the output from the Hall effect sensor 53 can be used in the feedback circuit of a grade control system. | In a slope control apparatus for the working tool of a motor grader or other earth working machine, the slope sensor used for controlling the slope of the tool is mounted on a revolving platform the attitude of which is corrected by a factor related to the rotational angle of the tool about a vertical axis and also related to the angle of the tool with respect to the line of flight axis of the machine. The apparatus is mounted in a fashion to allow the tool to be swung to a vertical position without damage to said apparatus. | 4 |
BACKGROUND OF THE INVENTION
This invention relates generally to a merchandise display device for supporting merchandise thereon, and more particularly concerns a cantilevered rod or arm display whereon merchandise is hung, for example, clothing from a hanger. Many items of merchandise, especially light-weight items, are intended for display by hanging from specially designed display arms of extended length that have a free end and an end fixedly attached to a support surface, for example, a wall. The arm for hanging merchandise thereon generally extends horizontally at a right angle with the supporting wall. However, because of constraints in setting up display devices on a selling floor, display arms of fixed construction are frequently too short or too long for the intended space or perhaps the arm extends at an angle from the support structure which takes poor advantage of the available space. Therefore, many different arm assemblies may be required to satisfy ongoing needs. Selection and interchanging of display arms are time consuming and inconvenient.
What is needed is a display arm that can be easily adjusted for varying lengths and orientation angles relative to a support structure without need for removal of the arm or interchanging of parts.
SUMMARY OF THE INVENTION
Accordingly, it is an object of this invention to provide an improved display arm that is readily adjustable in arm length and orientation with respect to a support structure.
A further object of this invention is to provide an improved display arm that has few parts and is easy to assemble at the display location.
Yet another object of the invention is to provide an improved display arm that is easily detached from the support structure.
Another object of this invention is to provide an improved display arm that is attractive in appearance and has few components.
Generally speaking, the display arm assembly in accordance with the invention for supporting merchandise includes a horizontal arm assembly comprising a pair of elongated nesting segments that can be selectably and reversibly locked at any number of longitudinal positions relative to each other. One end of the arm assembly is free whereas the other end connects to an indexing pin assembly that in turn connects to a support structure. A support bracket is directly connected to the support structure, for example, a wall, and the arm assembly mounts to the support bracket by a vertical indexing pin that is rotatably supported in openings in the support bracket and is keyed to the support arm. A key on the indexing pin engages any one of a plurality of slots on the support bracket to selectively set the angular position of the arm relative to the support structure.
Other objects, features and advantages of the invention will be apparent from the specification. This invention accordingly comprises the features of construction, combination of elements and arrangement of parts that will be exemplified in the constructions hereinafter set forth, and the scope of the invention will be indicated in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the invention, reference is made to the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a side elevational view of the adjustable display arm assembly in accordance with the invention, with the outer arm in a pivoted position;
FIG. 2 is a top perspective view of the outer arm;
FIG. 3 is a top view of the outer arm;
FIG. 4 is a top perspective view of the inner arm;
FIG. 5 is a top view of the inner arm;
FIG. 6 is a partial exploded view in perspective of the attachment of the inner arm to a support bracket;
FIG. 7 is a bottom view of the indexing pin of FIG. 6;
FIG. 8 is a partial exploded view in perspective of an end of the arm assembly; and
FIG. 9a-c are alternative arm assembly cross sections in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The adjustable display arm assembly 10 in accordance with the invention includes an outer movable arm 12, an inner arm 14, a support bracket 16 and an indexing pin assembly 18.
The outer arm 12 is a U-shaped channel 20 of extended length that has an inclined surface 22 at one end 24. The surface 22 meets with the end edges of the branches 26 of the U-shape and extends toward the opposite end 28 of the U-shaped channel 20. A cylindrical pin 30 extends transversely between the branches 26 of the U-shape, the pin 30 being positioned adjacent to the lower edges 32 and rear edges 34 of the channel 20. A slot 36, which is transverse to the length of the channel 20 is formed through the curved crest of the U-shaped channel 20.
The inner arm 14 is also a U-shaped channel 38 of extended length and dimensioned such that the channel 38 can be nested within the channel 20 of the outer arm 12. A plurality of substantially semicircular notches 40 are formed in the lower edges 42, the notches 40 being at regularly spaced longitudinal intervals along the inner arm 14. The notches 40 are dimensioned to receive therein the pin 30 of the outer arm 12.
At one end of the inner arm 14 is a vertically oriented socket or bearing 44 that includes a substantially circular bore 46 having a rectangular key 48 extending from the bore surface into the cylindrical opening as best illustrated in FIG. 5.
The socket or bearing 44 at the end of the inner arm 14 connects to the support bracket 16, which includes an upper flange 50 and a lower flange 52 connected together by a cross bar 54. The spacing between the upper flange 50 and lower flange 52 allows for the socket or bearing 44 to be received therebetween with a sliding fit. Holes 56, 58 in the upper flange 50 and lower flange 52, respectively, align with the bore 46 of the inner arm 14 when the inner arm is slipped between the flanges 50, 52.
A plurality of rectangular slots 60, formed concentrically around the hole 56 in the upper flange 50 of the support bracket 16, are used in angular alignment of the inner arm 14 relative to a support structure 19 when the complete assembly 10 is mounted to the support structure 19.
A locking or indexing pin 62 comprises a circular head 64 connected to a cylindrical body 66 that includes a rectilinear keyway 68 running the length of the body 66. The keyway 68 is dimensioned to receive therein the key 48 of the inner arm 14.
A key 70 extends from the bottom surface of the pin head 64 and is dimensioned to be received in the slots 60 on the upper flange 50 of the support bracket 16 when the body 66 of the pin 62 passes through the holes 56, 58 of the support bracket 16. The body 66 of the pin 64 is hollow, at least for a portion of its length, having a circular opening 72 in the bottom surface 74 wherein a closure pin 76 is received. The pin 76 includes a head 78 and body 80.
Upper and lower rear wings 82, 84 join to the crossbar 54 of the support bracket 16 and provide a C-shaped attachment member for connecting to the support structure 19 by any suitable means. With such a mounting arrangement, as illustrated (54, 82, 84), the support bracket 16 can be connected to a correspondingly-shaped T element 85 fixedly attached to the support structure 19. Any suitable means of attachment between the support bracket 16 and the support structure 19 may be used, including, for example, adhesives, screws, clamps, etc.
The adjustable display arm assembly 10 in accordance with the invention is assembled as follow. The support bracket 16 is rigidly connected to the desired support structure 19 in any suitable manner. Then, the socket or bearing 44 on the inner arm 14 is slipped between the upper and lower flanges 50, 52 of the support bracket 16. The pin 62 is then inserted through the flange opening 56, through the aligned circular bore 46 of the inner arm 14, so that the key 48 is received in the keyway 68 of the locking pin 62. This engagement of the key 48 in the keyway 68 fixes the angular position of the inner arm 14 relative to the longitudinal axis of the locking pin 62.
Before the locking pin 62 is fully seated in the downward direction, indicated by the arrow 86 (FIG. 6) the key 70 on the under side of the pin head 64 is aligned with any desired one of the slots 60 on the upper flange 50 of the support bracket 16. After this desired alignment is achieved, the locking pin 62 is pressed further downward in the direction of the arrow 86 such that the key 70 seats in the aligned slot 60. Thus, the angular position of the arm 14 relative to the bracket 16 and structure 19 is fixed. Attachment of the inner arm 14 to the support bracket 16 is completed by insertion of the closure pin 76 into the cylindrical opening 72 in the bottom surface 74 of the locking pin 62. The closure pin 76 can be permanently fastened in place, for example, by means of an adhesive, or there may be a reversible press or snap fit. Once the closure pin 76 is engaged with the locking pin 62, the inner arm 14 is fixed in position relative to the support structure 19.
Then, the outer arm 12 is slipped onto the inner arm 14. This can only be accomplished when the free end 28 of the outer arm 12 is pivoted in the direction of the arrow 96 and elevated above the inner arm 14 (FIG. 1). Then, the outer arm 12 is translated in the direction indicated by the arrow 88. In this pivoted and elevated position, the spacing 90 between the pin 30 and the internal crest 92 of the U-shape of the outer arm 12, is greater than the height 94 of the inner arm 14. Thus, the outer arm 12 can be translated to any position along the length of the inner arm 14 before the outer arm is pivoted downwardly, in the direction opposite to the arrow 96, until the arms 12, 14 are nesting, in parallel (not shown) with the pin 30 seated in the selected opposed pair of semi-circular notches 40. No tools are required to adjust the length of the display arm.
In this parallel nested position, longitudinal translation of the arms 12, 14, relative to each other is not possible, except by again pivoting the arm 12 relative to the arm 14 in the direction 96 as shown in FIG. 1. The internal height 97 of the outer arm 12 between the pin 30 and the internal crest 92 being less than the height 94 of the inner arm 14 prevents disengagement of the pin 30 from the slots 40 when the arms 12, 14 are parallel.
For the sake of interesting, attractive and variable appearance and to remove a possible hazard, the open end 28 of the outer arm 12 is closed off with a closure plate 98 having a cylindrical body 100 connected at right angles to a nameplate 102. An arcuate boss partially encircles the body 104 and is positioned along the length of the body 100 such that when the body 100 is pressed in the direction of the arrow 106 into the U-shaped opening of the outer arm 12, the arcuate boss 104 engages in the slot 36 of the upper arm 12. The closure plate 98 is held in position on the outer arm 12 by a press fit and is readily interchangeable. The nameplate 102 may include a trademark, letters or design as indicated in FIG. 8, and is easily customized to suit a particular manufacturer or merchandiser.
In alternative embodiments of an adjustable display arm assembly in accordance with the invention, more than one key 70 may be provided on the underside of the head 64 of the locking pin 62, and additional slots 60 may be provided in the upper flange 50 to accommodate such additional keys. Also, it should be understood, that there may be protrusions corresponding to the key 70 extending upward from the upper surface of the upper flange 50 on the support bracket 16 that engage in recesses in the underside of the head 64 of the locking pin 62. Further, there may be more than one key 48 protruding from the surface of the bore 46 and a corresponding number of keyways 68 would be provided in the body 66 of the locking pin 62. Also, the position of the key 48 and keyway 68 could be reversed with a key protruding from the body 66 of the pin 62 to be received in a keyway located as a recess in the bore 46. In another alternative embodiment in accordance with the invention, the closure pin 76 may be screwed into the cylindrical opening 72 of the pin 62 in a self-tapping fashion, or the inner surface of the cylindrical opening 72 can be threaded to receive a threaded pin 76. The sloping surface 22 may be replaced with, for example, a right angled notch.
Also, the U-shape can be achieved with right-angled channels 12',14' (FIG. 9b), and, in the sense of this invention, the intersecting branches 13", 14" (inverted V) of FIG. 9c are considered as U-shaped. Basically, any nesting cross sectional shapes can be adapted, using a pin 30, 30', 30" etc., to provide longitudinal relative translation between the inner and outer arms only when the outer arm is upwardly pivoted as in FIG. 1.
The adjustable display arm assembly 10 may be fabricated of any suitable rigid materials depending upon the load that is to be carried on the cantilevered arms. Thus, the entire assembly may be of wood, metal or rigid plastic, or combinations thereof.
It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in the above constructions without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention hereindescribed and all statements of the scope of the invention that might be said to fall therebetween. | A display for supporting merchandise includes a horizontal arm assembly comprising a pair of elongated nesting segments that can be selectively and reversibly locked at a number of longitudinally positions relative to each other. One end of the arm assembly is free. The other end connects to an indexing pin assembly that in turn connects to a support structure. A support bracket directly connects to the support structure, for example, a wall, and the arm assembly mounts to the support bracket by a vertical indexing pin that is rotatably supported in support bracket openings and keyed to the support arm. A key on the indexing pin engages any one of a plurality of slots on the support bracket to selectively set the angular position of the arm assembly relative to the support structure. Arm length is adjustable without using tools. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates to an imaging-based bar code reader and, more particularly, to a bar code reader that facilitates capturing images.
BACKGROUND OF THE INVENTION
[0002] Various electro-optical systems have been developed for reading optical indicia, such as bar codes. A bar code is a coded pattern of graphical indicia comprised of a series of bars and spaces having differing light reflecting characteristics. The pattern of the bars and spaces encode information. In certain bar codes, there is a single row of bars and spaces, typically of varying widths. Such bar codes are referred to as one dimensional (1D) bar codes. Other bar codes include multiple rows of bars and spaces, each row typically having the same width. Such bar codes are referred to as two dimensional (2D) bar codes.
[0003] Imaging systems include charge coupled device (CCD) arrays, complementary metal oxide semiconductor (CMOS) arrays, or other imaging pixel arrays having a plurality of photosensitive elements or pixels. An illumination system comprising light emitting diodes (LEDs) or other light source directs illumination toward a target object, e.g., a target bar code. Light reflected from the target bar code is focused through a lens of the imaging system onto the pixel array. Thus, an image of a field of view of the focusing lens is focused on the pixel array. Periodically, the pixels of the array are sequentially read out generating an analog signal representative of a captured image frame. The analog signal is amplified by a gain factor and the amplified analog signal is digitized by an analog-to-digital converter. Decoding circuitry of the imaging system processes the digitized signals and decodes the imaged bar code.
[0004] Efficient decoding of text has been more difficult than decoding of bar code symbols. Unlike flatbed scanners, which usually have perfect focus, perfect illumination, hand held bar code scanners are prone to blurry images, distortion, uneven illumination etc. at least compared to the images from a stationary flatbed scanner. Current existing methods of formatting text involves either scanning a representing barcode for each character, or providing a regular expression of the format of the characters to be read by the bar code reader. The first method is error prone and the second requires a well trained user to provide an appropriate regular expression as a template.
[0005] OCR A, OCR B and MICR are standardized, monospaced fonts designed for “Optical Character Recognition” on electronic devices. OCR A was developed to meet the standards set by the American National Standards Institute in 1966 for the processing of documents by banks, credit card companies and similar businesses. This font was intended to be “read” by scanning devices, and not necessarily by humans.
[0006] OCR B was designed in 1968 to meet the standards of the European Computer Manufacturer's Association. It was intended for use on products that were to be scanned by electronic devices as well as read by humans. OCR B was made a world standard in 1973 , and is more legible to human eyes than most other OCR fonts.
[0007] MICR is a character recognition technology adopted mainly by the banking industry to facilitate the processing of cheques. The major MICR fonts used around the world are E-13B and CMC-7. Almost all US and UK cheques now include MICR characters at the bottom of the paper in the E-13B font. Some countries, including France, use the CMC-7 font developed by Bull. Other fonts have been developed and are known in the optical character recognition art.
SUMMARY OF THE INVENTION
[0008] An imaging-based bar code reader that includes an imaging and decoding system. The system automates the generation of a pattern of the format of an optical character recognition string whose content is unknown and is to be read by the hand held scanner. One advantage to such a system is to decrease errors and to promote efficiency. An exemplary method does not require user training and is quite user friendly during operation.
[0009] The exemplary system automates the generation of a pattern of the format to be read by scanning one or more test or template samples of the same format that will be encountered in reading unknown strings. The template is easy to read so that once the string is decoded, the format of the decoded data is recorded in the memory of the system to allow strings of the same format to be correctly read.
[0010] These and other objects, advantages, and features of the exemplary embodiment of the invention are described in detail in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of a bar code scanner supported on a stationary stand;
[0012] FIG. 2 is a schematic sectional view of a portion of the imaging-based bar code reader showing the scanner head;
[0013] FIG. 3 is a block circuit diagram of the imaging-based bar code reader of FIG. 1 ; and
[0014] FIG. 4 is an illustration of a format for characterizing a character string of a target input.
DETAILED DESCRIPTION
[0015] An imaging-based scanner that is capable of reading bar codes is shown schematically at 10 in the Figures. The scanner 10 is capable of imaging and decoding bar codes, such as a 2D bar code shown at 14 in FIG. 3 . Additionally, the reader 10 is also capable of capturing images such as an image or a document 12 in FIG. 3 that contains signatures, graphics or the like. The bar code reader 10 includes a housing 11 supporting an imaging system 20 and a decoding system 40 ( FIG. 3 ). The housing 11 supports a transparent window 17 through which reflected illumination from the target bar code 14 is received by the imaging system 20 .
[0016] When enabled, the imaging system 20 captures an image frame 42 of a field of view FV of the imaging system. If imaging a target bar code 14 , the imaging process captures an image 14 ′ of the target bar code. The decoding system 40 analyzes a captured image frame 42 and attempts to decode decodable portions of the imaged bar code 14 ′. The decoded portions 14 a ′ of the imaged bar code 14 ′ are stored in a buffer memory 44 a . Alternately, a series of image frames 43 are captured and using a sequence stitching method. A decoded portion 14 a ′ is stored in the buffer memory 44 a and the decoding system 40 attempts to combine or stitch the decoded portions 14 a ′ stored in buffer memory to achieve a full decode of the target bar code 14 .
[0017] The imaging system 20 includes an imaging camera 22 ( FIG. 2 ) and associated imaging circuitry 24 . The imaging camera 22 includes a housing supporting focusing optics including a focusing lens 26 and a 2D photosensor or pixel array 28 . The imaging camera 22 is enabled during an imaging session to capture a sequence of images of the field of view FV of the focusing lens 26 .
[0018] In one mode of operation, the bar code reader 10 is a hands-free reader including a generally upright housing 11 having a flat base portion that can be placed on a counter or tabletop. The scanner 10 of FIG. 1 is supported by a support stand 100 . When so mounted, the exposure operation mode of the camera can be altered as described more completely below to enhance the image quality of the resulting image produced by the scanner 10 .
[0019] As is best seen in FIG. 2 , the housing 11 defines the interior area 11 a . Disposed within the interior area 11 a circuitry 13 including the imaging and decoding systems 20 , 40 and an illumination assembly 60 which, when enabled, directs illumination through the transparent window 17 and onto a target. The bar code reader circuitry 13 is electrically coupled to a power supply 16 , which may be in the form of an on-board battery or a connected off-board power supply. If powered by an on-board battery, the reader 10 may be a stand-alone, portable unit. If powered by an off-board power supply, the reader 10 may have some or all of the reader's functionality provided by a connected host device.
[0020] Circuitry associated with the imaging and decoding systems 20 , 40 , including the imaging circuitry 24 , may be embodied in hardware, software, electrical circuitry or any combination thereof and may be disposed within, partially within, or external to the camera assembly housing 25 . In the illustrated embodiment, the functions of the reader are controlled and co-ordinated by a microprocessor controller 101 . The controller 101 also manages outputs from the decoding system 40 such as an output 56 to a display 58 and communications output port 57 and visual and audible signals from an LED 59 b and speaker 59 a . The imaging camera housing 25 is supported with an upper or scanning head portion 11 c of the housing and receives reflected illumination from the target bar code 14 through the transparent window 17 supported by the scanning head 11 c . The focusing lens 26 is supported by a lens holder 26 a . The camera housing 25 defines a front opening 25 a that supports and seals against the lens holder 26 a so that the only illumination incident upon the sensor array 28 is illumination passing through the focusing lens 26 .
[0021] Depending on the specifics of the camera assembly 22 , the lens holder 26 a may slide in and out within the camera housing front opening 25 a to allow dual focusing under the control of the imaging circuitry 24 or the lens holder 26 a may be fixed with respect to the camera housing 25 in a fixed focus camera assembly. The lens holder 26 a is typically made of metal. A back end of the housing 25 may be comprised of a printed circuit board 24 b , which forms part of the imaging circuitry 24 and may extend beyond the housing 25 to support the illumination system 60 .
[0022] The imaging system 20 includes the sensor array 28 which may comprise a charged coupled device (CCD), a complementary metal oxide semiconductor (CMOS), or other imaging pixel array, operating under the control of the imaging circuitry 24 . In one exemplary embodiment, the pixel array 28 comprises a two dimensional (2D) mega pixel array with a typical size of the pixel array being on the order of 1280×1024 pixels. The pixel array 28 is secured to the printed circuit board 24 b , in parallel direction for stability.
[0023] As is best seen in FIG. 2 , the focusing lens 26 focuses light reflected from the target bar code 14 through an aperture 26 b onto the pixel/photosensor array 28 . Thus, the focusing lens 26 focuses an image of the target bar code 14 (assuming it is within the field of view FV) onto the array of pixels comprising the pixel array 28 . The focusing lens 26 field of view FV includes both a horizontal and a vertical field of view, the vertical field of view being shown schematically as FV in FIG. 1 .
[0024] During an imaging session, one or more images in the field of view FV of the reader 10 may be obtained by the imaging system 20 . An imaging session may be instituted by an operator, for example, pressing a trigger to institute an imaging session. Alternately, the imaging system 20 may institute an imaging session when a lower or bottom edge of the item 15 moves through an upper portion of the field of view FV. Yet another alternative is to have the imaging system 30 always operational such that image after image is captured and analyzed for the presence of data within an imaged target. In any event, the process of capturing an image 42 of the field of view FV during an imaging session is known in the scanner art. Electrical signals are generated by reading out of some or all of the pixels of the pixel array 28 after an exposure period. After the exposure time has elapsed, some or all of the pixels of pixel array 28 are successively read out, thereby generating an analog signal 46 . In some sensors, particularly CMOS sensors, all pixels of the pixel array 28 are not exposed at the same time, thus, reading out of some pixels may coincide in time with an exposure period for some other pixels.
[0025] The analog image signal 46 from the pixel array represents a sequence of photosensor voltage values, the magnitude of each value representing an intensity of the reflected light received by a photosensor/pixel during an exposure period. The analog signal 46 is amplified by a gain factor, generating an amplified analog signal 48 . The imaging circuitry 24 further includes an analog-to-digital (A/D) converter 50 . The amplified analog signal 48 is digitized by the A/D converter 50 generating a digitized signal 52 . The digitized signal 52 comprises a sequence of digital gray scale values 53 typically ranging from 0-255 (for an eight bit processor, i.e., 2 8 =256), where a 0 gray scale value would represent an absence of any reflected light received by a pixel (characterized as low pixel brightness) and a 255 gray scale value would represent a very intense level of reflected light received by a pixel during an integration period (characterized as high pixel brightness).
Imaging and Decoding Process
[0026] The exemplary image based scanner 10 has a character recognition capability. If, as depicted in FIG. 3 the image captured by the scanner includes characters, the scanner has the ability to interpret, store and transmit the data embodied by those characters using the exemplary process.
[0027] In order to more effectively capture character data, the exemplary system reads the data from easy to read sample or template targets and generates a format for the easy to read data so that unknown data can then be accurately read without resort to user input.
[0028] Consider the drivers license identified with reference character 15 in FIG. 3 . The imaging system 10 captures an image of the entire front or face of the license. In set up mode, easy to read character data such as the city, state and zip data is gathered by reading out the pixel array 28 after an exposure time to generate the analog signal 46 and the analog signal is digitized and digital gray scale values 53 are generated and stored in memory 44 . This process may be repeated multiple times during a setup up imaging session by storing a sequence of captured images in the memory 44 . Easily recognized characters may be obtained in a reliable non error prone manner. This may be due to use of a particular font (OCR A or OCR B) on this data, or it may be due to a reliable image capture process such as assuring that the reader is mounted to its stand 100 . An additional safeguard for reliability can be use of only easy to recognize characters within a character set. O's can be confused with zeros and Z's can be confused with the letter two, but the letters C, P, E, etc. are fairly unique and are not likely to be misinterpreted by the decoding circuity. Stated another way, only characters that are known in advance and that are not easily confused with other characters within a character set are used for setting up the character format.
[0029] The decoding system 40 then interprets the data to simplify or automate the generation of the pattern of the format of an OCR string to be read. To accomplish this task, scan several OCR strings that are printed very well and can be read easily. These OCR strings should be able to represent a string/strings to be read. Once these several strings are decoded correctly, the system will analyze the common attributes of their format to generate and store the format for reading other new strings with the same format.
[0030] For example, the format of a city address could have different length for city names, 2 alphabetic characters for state abbreviation, 5 digits or 9 digits for zip code. After scanning several representatives and interpreting from the system, a format for a regular expression ( FIG. 4 ) could be generated as the format of OCR strings that are going to be read. Certain targets can have multiple strings per target and for those known targets multiple regular expressions are created so that in matching an unknown string the controller would try to match the regular expressions and if a match is found the string is saved. If no match is found, then the controller will reject the string and issue an audible or visible warning from the speaker or Led output.
[0031] This is illustrated by FIG. 4 . In that figure, the symbology designates what is acceptable for certain locations within a character string. Beginning at the head or beginning of the string the first symbol is identified as the designator[A-Za-z ]<Any>. This indicates that the first part of the string can be any number of characters, both upper or lower case that can be separated by any number of spaces. One appropriate character string would be ‘Atown’. This string has one capital letter followed by four lower case letters and no spaces. A similar acceptable string would be ‘New York’ which has two upper case letters with six lower case letters and one space. Note, appropriate symbology is available for alphanumerics, that is numbers or letters as well as specific symbols such as hyphens, commas etc.
[0032] For the decoding circuitry to recognize this example, more than one example would be used in the setup process since the use of spaces might not occur in a single example and accordingly would not be taken into account in the shorthand notation for the possible matching string.
[0033] Use of regular expressions is well documented in the literature as is filtering of string inputs to derive a regular expression that describes all examples in the input test string are known in the art. Examples of treatment of character strings and generation of regular expressions representing those strings are found in an article entitled “How to Use Regular Expression in Microsoft Visual Basic 6.0)” (http://support microsoft.com/kb/818802) and “How to use regular expression in PHPH” (http://www.ibm.com/developerworks/edu/os-dw-os-phpexpr-i.html). These articles are incorporated herein by reference.
[0034] While the present invention has been described with a degree of particularity, it is the intent that the invention includes all modifications and alterations from the disclosed design falling within the spirit or scope of the appended claims. | An imaging-based bar code reader that includes an imaging and decoding system. Focusing optics and a sensor array define a field of view. A data processor has a memory for storing a pattern definition of previously imaged OCR characters and comparing a format of said previously stored characters to a present image to determine a character content of the present image. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to butter makers; and, more particularly, a butter maker adapted to be set on top of a counter and activated to make butter and buttermilk.
[0003] 2. Related Art
[0004] In my U.S. Pat. Nos. 6,511,219 and 6,257,755, I disclose a compact butter maker that can be used in a kitchen or the like. Butter is a common food fat product that has been used throughout the world for centuries as an ingredient of other foods or as a condiment. Today, butter is commonly made on an industrial scale with apparatus suitable for handling tens, hundreds, or more gallons of cream or milk. In a day before commercial creameries, butter was commonly made in the home using mechanical churns that, typically, were manually operated. As commercial creameries became prevalent, home butter making became less popular and advances in equipment for home butter making slowed. As a result, modem improvements in kitchen appliances have not been incorporated into home butter makers. Therefore, my patents fill a need for a butter maker that can be conveniently used in a contemporary home kitchen.
[0005] Thus, my butter maker in my patents used in the contemporary home kitchen. The butter maker therein is compact and fits on a counter or other surface in a home kitchen. The butter maker includes a cream container, a drive housing, a drive, and a dasher. The drive housing houses a drive, which is coupled to the dasher and adapted and configured to drive the dasher in reciprocal motion. The drive housing and the cream container are adapted and configured to reversibly mate and to position the dasher in the cream container for reciprocal motion within the container. The dasher and the container have complementary shapes with the dasher dimension to fit within the container and to define a space that can be occupied by cream within the container and around the dasher. Reciprocal motion of the dasher within the container converts the cream to butter.
[0006] I have determined that there is a need for a more substantial butter maker which is the type of appliance suitable for use in a kitchen.
SUMMARY OF THE INVENTION
[0007] It is an object of this invention to provide a butter maker adapted to be set on top of a counter and activated to make butter and buttermilk.
BRIEF DESCRIPTION OF THE DRAWING
[0008] FIG. 1 is a front elevation view of a butter maker in accordance with the invention;
[0009] FIG. 2 is a right side view of the butter maker of FIG. 1 , the left side view being a mirror image;
[0010] FIG. 3 is a sectional elevation view of the container assembly of the maker of FIGS. 1 and 2 removed from the housing;
[0011] FIG. 4 is a view taken along lines 4 - 4 of FIG. 3 ;
[0012] FIG. 5 is a side view of the beaters along of the assembly of FIG. 3 ;
[0013] FIG. 6 is a side sectional view of the drive assembly alone of the butter maker of FIGS. 1 and 2 removed from the housing thereof;
[0014] FIG. 7 is a view taken along lines 7 - 7 of FIG. 6 ;
[0015] FIG. 8 is a top plan view of the butter maker of FIGS. 1 to 7 ;
[0016] FIG. 9 is a schematic view of a circuit a circuit diagram that may be used in the device of the invention;
[0017] FIG. 10 is a top plan view of one of the parts of the butter maker of FIG. 1 removed therefrom for convenience of illustration;
[0018] FIG. 10A is a side view of the part shown in FIG. 10 ; and
[0019] FIG. 11 is a front elevation view of the butter maker of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] Referring now to FIG. 1 of the drawings, a butter maker 10 is shown comprising a main housing 11 extending upwardly from a base 12 . A plurality, such as four, of resilient feet 13 , one at each corner, may be provided on the undersurface of base 12 . Butter maker 10 includes a cream container 14 , which may be generally cylindrical and transparent and of glass or plastic or the like, normally disposed on the upper surface 15 of base 12 and open at the top (as will be discussed). The side walls 16 , 17 (see also FIG. 2 ) of main housing 11 may be cut-out at a forward portion thereof, such as at cut-out area 18 (in each side wall 16 , 17 ) to facilitate insertion and removal of container assembly 14 and allow access to jog switch 207 .
[0021] Butter maker 10 includes a stepped container lid 19 which may be of a resilient material so that the container 14 press fits into an annular groove 20 ( FIG. 3 ) in the lower wall 21 of upper stepped portion 22 of lid 19 . As seen, the integral lower stepped portion 23 of lid 19 extends down into the open top of container 14 . A resilient o-ring 24 may be provided in groove 20 to provide a liquid seal.
[0022] Referring again to FIG. 1 , the upper portion of housing 11 may have a start button 25 at top and a movable panel 26 below button 25 having an elongated handle 27 (see also FIG. 2 ) for lifting panel 26 as will be discussed. FIG. 2 shows in dotted lines the movement of panel 26 from the lower to the upper position. Suitable indicia, such as a direction indicating arrow 28 , may be provided on panel 26 along with other suitable operating indicia 29 .
[0023] A beater assembly 30 is provided internally of butter maker 10 extending downwardly through lid 19 .
[0024] Thus, as seen in FIG. 3 , beater assembly 30 includes a pair of spaced paddles 31 , 32 . As seen in FIG. 4 , each paddle, such as paddle 31 , paddle 32 being identical, is generally circular, having a central aperture 34 , with a plurality of round spaced holes 33 extending about aperture 32 . Each paddle also has a centrally located hub portion 35 adapted to mate with a like hub portion 36 ( FIG. 5 ) on a mating paddle 32 and sealed or otherwise secured together in a fluid tight manner.
[0025] As seen in FIG. 2 , a suitable plug 37 is provided for plugging the butter maker 10 into a suitable electrical outlet (not shown).
[0026] Referring again to FIG. 3 , the paddle 31 , 32 are secured together by a shaft 38 extending down through the aligned holes 34 to a barrel nut 39 . A resilient washer 40 may be provided through which shaft 38 extends. The shaft 38 may be threaded to thread into aligned holes 34 , or holes 34 may be smooth bored with only the terminal end of the shaft 38 being threaded to thread to nut 39 .
[0027] Shaft 38 , at its upper end, extends through a bearing 41 mounted in a throughhole 42 extending through lid 19 .
[0028] As seen, a centrally located integral hub portion 43 extends downwardly from stepped portion 23 of lid 19 . A conventional shaft seal 44 may be provided at the area where shaft 38 enters bearing 41 .
[0029] The upper end 45 of shaft 38 terminates in a beater drive assembly 46 as will be discussed. A closure member 47 is centrally mounted on lid 19 through which shaft 45 extends and is secured to lid 19 by a plurality of screws 48 . The entire assembly shown in FIG. 3 is removable for ease of cleaning after the butter and buttermilk is removed.
[0030] The beater drive assembly 46 is coupled to a motor assembly 49 comprising a motor mount 50 coupled via screws 51 or the like to a mounting plate 52 . Motor assembly 49 has a motor shaft 53 extending through an opening 54 in mounting plate 50 into driving engagement with a flywheel 55 . A drive shaft 56 extends from flywheel 55 to a bearing 57 A ( FIG. 7 ) coupled to a second bearing 57 ′B and drive pin 58 via connecting link 59 .
[0031] A fan 60 ( FIG. 6 ) may be mounted in housing 11 for cooling motor assembly 49 .
[0032] The beater drive assembly 46 is seen more particularly in FIG. 7 and mounts into a T-shaped opening 204 in drive block 61 with shaft end 45 fixed thereto. Drive assembly 46 further includes a pair of spaced posts 62 , 63 extending through openings in block 61 . Bearing sleeves 64 , 65 are associated with posts 62 , 63 , respectively.
[0033] It can be seen in FIG. 7 that actuation of motor assembly 49 rotates shaft 53 and flywheel 55 . Drive shaft 56 on rotating flywheel 55 through connecting link 59 transfers its rotating movement, guided by posts 62 and 63 and bearing sleeves 64 and 65 , into a vertical reciprocal movement of drive pin 58 . Drive pin 58 , being part of drive block 61 , carries the beater drive assembly 46 when inserted.
[0034] As seen in FIG. 8 , a suitable timer 67 may be provided on the upper wall 68 of housing 11 with suitable actuating means and switches, such as power “on” light 69 , power switch 70 and an automatic or time control slide switch 71 .
[0035] In operation, the user pours 1 pint of heavy whipping cream into container 14 . Preferably, the cream should be at room temperature. The lid assembly, which includes the lid 19 and paddle assembly 30 , is now inserted into the cream in container 14 . The lid assembly fits automatically in place.
[0036] Switch 71 is set to either automatic or time and the start button 25 is pressed. If automatic, the butter will churn until done. If time controlled, the timer 67 may be set for any time between 0 and 30 minutes.
[0037] Inserting the container assembly 14 into the maker 10 automatically seals the container. Closing the door 26 , and pressing the start button 25 , starts the churning process. The churn process either stops automatically when butter is separated or runs for a predetermined length of time.
[0038] The user now removes the container and lifts the lid 19 . The churned butter and buttermilk are placed in suitable containers.
[0039] Although the basic process for churning butter is disclosed, certain refinements can be made by the user. For example, ultra-heavy pasteurized whipping cream may be used. Various types of cream from different manufacturers may be used.
[0040] If the whipping cream is too cold, it does not separate or takes a long time. If the cream is too warm, it melts the butter and does not separate properly; the butter may get too creamy and mushy containing most of the buttermilk.
[0041] Preferably, the best cream temperature is about 55 to 65 degrees Fahrenheit. It should be removed from the refrigerator about 3-4 hours before processing.
[0042] Time setting: Depending on conditions and type of whipped cream the time for churning varies from 2-5 minutes. One should start with time setting of 5 minutes. If the butter separates in less time, the machine should be stopped by opening the access door. If more time is needed after the machine is stopped, the start switch should be pressed again. When the butter maker 10 is started in the “Auto” mode, the butter maker 10 runs until the churning process is completed (butter is done) and the motor is deenergized and stops. In the “Auto” mode, the churning process is controlled by the “Auto” control unit as seen in the wiring diagram of FIG. 9 .
[0043] When the butter is done, the buttermilk separates and the butter solidifies. The motor may labor heavily and may stop under load. The access door should be opened and the container removed.
[0044] The cover should be removed along with accumulated butter from the container.
[0045] The butter may be collected into a shallow dish and, working with a spoon, compressed and drained to draw out all excess buttermilk.
[0046] The butter may be placed into a suitable container and keep cold in the refrigerator.
[0047] Briefly, the short operation is as follows:
Pour whipping cream in container. Replace cover assembly. Set timer to desired time in minutes. Open access door and insert container. Close access door. Press start button. Churning will stop, when cycle completed. Open access door, remove container. Butter churn Power requirements: 120 VAC 50/60 Hz 250 watts specification. Dimensions: 10″ high × 7″ wide × 11″ deep Weight: 16 lb.
[0048] Container 14 may be of any suitable materials and dimensions, such as a 1½ pint mixing container of strong, clear acrylic material.
[0049] All container 14 components should be dishwasher safe. The butter maker assembly, (motor, etc.) stays clean during the churning process and is not submersible.
[0050] Any suitable motor dimensions and specifications may be used. For example, a 250 watt, 120 VAC 50/60 Hz motor may be used. The overall dimensions of maker 10 may be about 10″ high, 7″ wide, 11″ deep and about 16 pounds in weight.
[0051] FIG. 11 illustrates how the beater assembly 30 and container 14 is removed from butter maker 10 . Access door 26 has indicia 28 , as seen in FIG. 1 , and the beater drive assembly 46 enters a T-shaped opening 204 in mounting block 61 (see also FIG. 7 ). Door or panel 26 may slide up and down between spaced side flanges 205 , 206 . A jog switch 207 is mounted on the front wall 208 of butter maker 10 . Mixing container 14 and beater assembly 30 can not be removed or inserted unless the access door 26 is fully open and the mounting block 61 is properly aligned and visible in the access door opening. If one does not see the mounting block 61 in the door opening, as shown, a light touch of the “jog” switch 207 on the front wall 208 will move it to the desired position.
[0052] Thus, the door opening is rather small so that people will not insert fingers in it. Unless the container 14 is properly aligned, the container 14 can no be removed or inserted, the door 20 itself is in the way.
[0053] Opening the door 26 disconnects the electric power and thus the motor except for the jog switch 207 , becomes inoperative.
[0054] The door safety disconnect switch 72 is shown in FIG. 1 . A finger 73 extending from door panel 26 activates the switch 72 when door 26 is closed.
[0055] Just behind the container 14 is the container switch 74 . This is a normally open wherein inserting the container 14 pushes the plunger 75 and activates the switch 74 . The maker 10 can not be run without container 14 inserted.
[0056] Any suitable electronic means may be used to carry out the invention. For example, a schematic illustration of a circuit that may be used is shown in FIG. 9 wherein like numerals refer to like parts of FIGS. 1-8 .
[0057] Receptacle container 14 may be 4½″ in height, 4″ in diameter with a ⅛″ wall thickness. Paddles 31 , 32 may be about 3.375″ in diameter so a spacing of about 0.375″ is provided between the outer periphery of the paddles and the inner wall of container 14 .
[0058] In order to seal the container 14 and hold it firmly in place, a tension spring 200 ( FIG. 6 —see also FIG. 10 ) may be provided mounted to mounting plate 52 and having a pair of spaced forward hooked or curved portions 201 , 202 (see FIGS. 10 and 10 A) extending from flat portion 203 . Thus, the lip of container 14 abuts there against and is held firmly in position. It applies pressure, seals the container 14 in position and holds it in place until removed. Spring 200 may be of any suitable material, such as phosphor bronze. Mounting holes 210 are provided for secured spring 200 to plate 52 .
[0059] In conclusion, the maker 10 includes a container 14 with a separate cover assembly. The container 14 may be conventional kitchen type-type Pyrex Glass container that is dish washer safe. The cover assembly includes container lid 22 , beater paddle assembly 30 and driver rod 45 are assembled into one unit. This unit can not be home disassembled and is dish washer safe. Container lid 22 has an O-ring style seal 24 on its underside matching the upper rim of the class container 14 .
[0060] Both the glass container 14 and the cover assembly are individual parts and have no interlocking features and, unless inserted into maker 10 , are always free to separate.
[0061] Sliding container 14 into the maker activates the tension spring parts 201 , 202 located on each side underneath the maker 10 and seals the container 14 and holds it in place. In order to remove container 14 , one opens the door 26 and slides the container 14 out.
[0062] Although a particular embodiment of the invention is disclosed, variations thereof may occur to an artisan and the scope of the invention should only be limited by the scope of the appended claims. | A butter maker having a housing for mounting on a countertop in a kitchen or the like. The butter maker includes a cream holding container in which cream is placed and also includes drive assembly having a shaft both rotatable along its vertical axis and reciprocal therealong. The shaft includes a dasher having a pair of spaced paddles with a plurality of spaced throughholes extending into the container conforming generally to the inner configuration of the interior of the container but spaced from the inner wall thereof. | 1 |
This is a division of application Ser. No. 844,366, filed Oct. 21, 1977.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 4,029,549 discloses and claims a steroid conversion process for making 9α-hydroxy-3-ketobisnorchol-4-en-22-oic acid (9α-OH BN acid). The process can be conducted using a mutant of a variety of steroid degrading microorganisms. The mutation process to prepare the mutants is disclosed in the patent Specifically exemplified is the use of Mycobacterium fortuitum NRRL B-8119.
U.S. Pat. No. 4,035,236 discloses and claims a process for preparing 9α-hydroxyandrostenedione (9α-OH AD). This compound is also produced by the process as disclosed in U.S. Pat. No. 4,029,549.
The presence of additional compounds in the fermentation beers disclosed in the above patents was previously recognized, but the identity of the compounds was not known prior to the date of the subject invention. These additional compounds were subsequently shown by advanced identification techniques to be useful steroid intermediates as diclosed herein. Of these compounds, 9α-OH testosterone is a known compound, whereas the others are novel.
BRIEF SUMMARY OF THE INVENTION
9α-OH testosterone, 9α-OH BN alcohol and 9α-OH BN acid methyl ester are produced in a fermentation process using the microorganism Mycobacterium fortuitum NRRL B-8119. This organism is disclosed and characterized in U.S. Pat. No. 4,029,549. In addition to the characteristics given in said patent, this microorganism is further characterized by its ability to accumulate the compounds disclosed herein under fermentation conditions, also as disclosed herein. Other mutants of Mycobacterium, as well as mutants from the genera of microorganisms diclosed in U.S. Pat. No. 4,029,549, can be used in the subject invention. Examples of suitable steroid substrates are sitosterol, cholesterol, stigmasterol, campesterol, and like steroids with 17-alkyl side chains of from 8 to 10 carbon atoms, inclusive. These steroid substrates can be in either the pure or crude form.
DETAILED DESCRIPTION OF THE INVENTION
The microorganisms which can be used to produce the compounds of the subject invention are the same as disclosed in U.S. Pat. No. 4,029,549. The microorganism specifically exemplified is Mycobacterium fortuitum, NRRL B-8119. A subculture of this microorganism is freely available from the depository at the Northern Regional Research Laboratory, U.S. Department of Agriculture, Peoria, Illinois, U.S.A., by request made thereto. It should be understood that the availability of the culture does not constitute a license to practice the subject invention in derogation of patent rights granted with the subject instrument by governmental action.
The transformation process of the subject invention is also as disclosed in U.S. Pat. No. 4,029,549.
Also, the procedure for the preparation of Mycobacterium fortuitum NRRL B-8119 is as disclosed in U.S. Pat. No. 4,029,549. This process can also be used to prepare mutants of other genera of microorganisms as disclosed in U.S. Pat. No. 4,029,549 and herein.
The isolation of the products of the subject invention from the fermentation broth is accomplished by first removing the major products of the sterol conversions, i.e., 9α-OH AD and 9α-OH BN acid. These major products are recovered from the fermentation beer by first extracting the fermentation beer with a water-immiscible organic solvent for steroids. Suitable solvents are methylene chloride (preferred), chloroform, carbon tetrachloride, ethylene chloride, trichloroethylene, ether, amyl acetate, benzene and the like.
Alternatively, the fermentation liquor and cells can be first separated by conventional methods, e.g., filtration or centrifugation, and then separately extracted with suitable solvents. The cells can be extracted with either water-miscible or water-immiscible solvents. The fermentation liquor, freed of cells, can be extracted with water-immiscible solvents.
The extract from the fermentation beer is dried. The resulting solids are taken up in chloroform and sufficient methanol is added to precipitate residual sterols which are then filtered off. The filtrate is dried and the residue dissolved in hot acetone. Upon cooling and subsequent addition of cyclohexane most of the 9α-OH AD is precipitated and recovered by filtration. The filtrate is then dried and the residue dissolved in chloroform and extracted with a saturated sodium bicarbonate solution to remove 9α-OH BN acid. The individual components remaining in the chloroform after the bicarbonate extraction are separated by chromatography on a silica gel column, eluting with chloroform-methanol (98:2).
The first compound to elute is the methyl ester of 9α-OH BN acid. The second compound to elute is residual 9α-OH AD which remains soluble in the acetone-cyclohexane solution described above. The third compound is 9α-OH BN alcohol. The next compound to elute from the column is 9α-OH testosterone.
The compounds of the subject invention are valuable as intermediates in the manufacture of steroids. For example, 9α-OH BN acid methyl ester can be converted to 9(11)-dehydro BN acid by treatment with N-bromoacetamide and sulfur dioxide in pyridine, as disclosed in British Pat. No. 869,815, followed by hydrolysis to generate the 22-carboxyl. 9(11)-Dehydro BN acid can be converted to 9(11)-dehydroprogesterone by, for example, the method described in Ber. 88: 883 (1955), and subsequently to 11β-hydroxyprogesterone as described in JACS 88: 3016 (1966). Treatment of 11β-hydroxyprogesterone with chromic acid yields 11-ketoprogesterone which is a known intermediate in the synthesis of cortisol acetate, a major and highly active cortical steroid [see, for example, Fieser and Fieser, Steroids, page 676, Reinhold (1959)].
9α-OH BN alcohol can be readily converted to 9α-OH BN acid by chromic acid oxidation, then to 9α-OH BN acid methyl ester by treatment with diazomethane and subsequently to 11-ketoprogesterone as described above.
9α-Hydroxy-11-unsubstituted steroids of the androstane series can also easily be dehydrated to the valuable 9(11)-dehydro steroids in accordance with methods known in the art, e.g., with thionyl chloride in the presence of pyridine. The 9(11)-dehydro compounds thus obtained are known intermediates in the production of highly active compounds. For example, the 9(11)-dehydro steroids can be converted to the corresponding 9α-halo-11βhydroxy compounds in accordance with procedures known in the art, e.g., U.S. Pat. No. 2,852,511 for the preparation of 9α-halo-hydrocortisone. Also, 9α-hydroxy compounds of the androstane series are useful as antiandrogenic, antiestrogenic and antifertility agents.
The following examples are illustrative of the process and products of the subject invention but are not to be construed as limiting. All percentages are by weight and all solvent mixture proportions are by volume unless otherwise noted.
EXAMPLE 1 Preparation of Mutant M. fortuitum NRRL B-8119 From M. fortuitum ATCC 6842.
(a) Nitrosoguanidine Mutagenesis
Cells of M. fortuitum ATCC 6842 are grown at 28° C. in the following sterile seed medium:
______________________________________Nutrient Broth (Difco) 8 g/literYeast Extract 1 g/literSodium Propionate 0.5 g/literDistilled Water, q.s. 1 liter______________________________________
The pH is adjusted to 7.0 with 1N NaOH prior to sterilization at 121° C. for 20 minutes.
The cells are grown to a density of about 5×10 8 per ml, pelleted by centrifugation, and then washed with an equal volume of sterile 0.1 M sodium citrate, pH 5.6. Washed cells are resuspended in the same volume of citrate buffer, a sample removed for titering (cell count), and nitrosoguanidine added to a final concentration of 50 μg/ml. The cell suspension is incubated at 37° C. in a water bath for 30 minutes, after which a sample is again removed for titering and the remainder centrifuged down and washed with an equal volume of sterile 0.1 M potassium phosphate, pH 7.0. Finally, the cells are resuspended in a sterile minimal salts medium, minus a carbon source, consisting of the following:
______________________________________NH.sub.4 NO.sub.3 1.0 g/literK.sub.2 HPO.sub.4 0.25 g/literMgSO.sub.4 . 7H.sub.2 O 0.25 g/literNaCl 0.005 g/literFeSO.sub.4 . 7H.sub.2 O 0.001 g/literDistilled Water, q.s. 1 liter______________________________________
The pH is adjusted to 7.0 with 1N HCl prior to sterilization at 121° C. for 20 minutes. The cells are then plated out to select for mutants.
(b) Selection And Isolation Of Mutant M. fortuitum NRRL B-8119
Mutagenized cells, as described above, are diluted and spread onto plates containing a medium consisting of the following (modified from Fraser and Jerrel. 1963. J. Biol. Chem. 205: 291-295):
______________________________________Glycerol 10.0 g/literK.sub.2 HPO.sub.4 0.5 g/literNH.sub.4 Cl 1.5 g/literMgSO.sub.4 . 7H.sub.2 O 0.5 g/literFeCl.sub.3 . 6H.sub.2 O 0.05 g/literDistilled Water, q.s. 1 liter______________________________________
Agar (15 g/liter) is added, and the medium is autoclaved at 121° C. for 30 minutes and then poured into sterile Petri plates.
Growth on this medium eliminates most nutritional auxotrophes produced by the mutagensis procedure, e.g. cultures that require vitamins, growth factors, etc. in order to grow on chemically defined medium are eliminated. After incubation at 28° C. for about 7 days, the resulting colonies are replicated to test plates suitable for selecting mutants and then back onto control plates containing the glycerol-based medium. The test plates are prepared as described by Peterson, G. E., H. L. Lewis and J. R. David. 1962. "Preparation of uniform dispersions of cholesterol and other water-insoluble carbon sources in agar media." J. Lipid Research 3: 275-276. The minimal salts medium in these plates is as described above in section (a) of Example 1. Agar (15 g/liter), and an appropriate carbon source (1.0 g/liter), such as sitosterol or androstenedione (AD), are added and the resulting suspension autoclaved for 30 minutes at 121° C. The sterile, hot mixture is then poured into a sterile blender vessel, blended for several minutes, and then poured into sterile Petri plates. Foaming tends to be a problem in this procedure but can be reduced by blending when the mixture is hot and by flaming the surface of the molten agar plates. In this manner uniform dispersions of water-insoluble carbon sources are obtained which facilitates the preparation of very homogenous but opaque agar plates.
Colonies which grew on the control plates, but not on test plates containing AD as the sole carbon source, are purified by streaking onto nutrient agar plates. After growth at 28° C., individual clones are picked from the nutrient agar plates with sterile toothpicks and retested by inoculating gridded plates containing AD as the carbon source. Purified isolates which exhibit a phenotype different from the parental culture are then evaluated in shake flasks.
(c) Shake Flask Evaluation
Shake flasks (500 ml) contain 100 ml of biotransformation medium consisting of the following ingredients:
______________________________________Glycerol 10.0 g/literK.sub.2 HPO.sub.4 0.5 g/literNH.sub.4 Cl 1.5 g/literMgSO.sub.4 . 7H.sub.2 O 0.5 g/literFeCl.sub.3 . 6H.sub.2 O 0.05 g/literDistilled Water, q.s. 1 liter______________________________________
Soyflour (1 g/liter) is blended into the medium and then sitosterol (10 g/liter) is also blended into the medium. After the flasks are autoclaved for 30 minutes at 121° C., they are cooled to 28° C. and then inoculated with 10 ml of seed growth prepared as follows:
The purified isolates from part (b) are grown on agar slants at 28° C. A loop of cells taken from a slant is used to inoculate a 500-ml flask containing 100 ml of sterile seed medium consisting of the following ingredients:
______________________________________Nutrient Broth (Difco) 8 g/literYeast Extract 1 g/literGlycerol 5 g/literDistilled Water, q.s. 1 liter______________________________________
The pH is adjusted to 7.0 with 1N NaOH prior to autoclaving the flasks at 121° C. for 20 minutes. The seed flasks are incubated at 28° C. for 72 hours.
As disclosed above, 10 ml of seed growth is then used to inoculate each 500-ml flask containing 100 ml of sterile transformation medium. The flasks are then incubated at 28° C. to 30° C. on a rotary shaker and sampled at various intervals. Ten ml samples are removed and extracted by shaking with 3 volumes of methylene chloride. Portions of the extracts are analyzed by thin layer chromatography (tlc) using silica gel and the solvent system described above, i.e., 2:3 (by volume) ethyl acetate-cyclohexane, and by gas-liquid chromatography. Evidence of the presence of 9α-OH AD confirms the selective degradation of sitosterol by the novel mutant produced from the parent M. fortuitum ATCC 6842.
EXAMPLE 2
To a medium consisting of 1.0 part of glycerol, 0.15 part of ammonium chloride, 0.05 part of magnesium sulfate heptahydrate, 0.05 part of dipotassium hydrogen phosphate, 0.005 part of ferric chloride hexahydrate, and 100 parts of distilled water is added to 0.1 part of soyflour and 1.0 part of sitosterols, N.F. The resultant mixture is sterilized by heating 30 minutes at 121° C., whereupon it is cooled to 30° C. and then inoculated with 10 parts of a seed culture of the mutant Mycobacterium fortuitum NRRL B-8119, prepared as described in Example 1(c). The inoculated mixture is incubated at 30° C. for 336 hours with agitation to promote submerged growth. Following incubation, the mixture is extracted with methylene chloride. The extract is filtered through diatomaceous earth and the filtrate is vacuum distilled to dryness. The residue is taken up in 10% chloroform in methanol and then concentrated with nitrogen on a steam bath until crystals appear. The solution is then cooled to room temperature and filtered to remove the precipitated sitosterols. From the supernatant, on evaporation of solvent, good yields of 9α-OH testosterone, 9α-OH BN alcohol and 9α-OH BN acid methyl ester, as well as 9α-OH AD and 9α-OH BN acid are obtained.
EXAMPLE 3
By substituting cholesterol for sitosterol in Example 2 there are obtained the compounds produced in Example 2.
EXAMPLE 4
By substituting stigmasterol for sitosterol in Example 2 there are obtained the compounds produced in Example 2.
EXAMPLE 5
By substituting campesterol for sitosterol in Example 2 there are obtained the compounds produced in Example 2.
EXAMPLE 6
By adding a combination of any of the steroids in Examples 2-5, in addition to sitosterol, or in place of sitosterol, in Example 2 there are obtained the compounds produced in Example 2.
EXAMPLE 7
The products produced in Example 2 can be isolated as separate entities in the essentially pure form by the following procedure. The supernatant of Example 2, containing the products produced in the fermentation, is dried and the residue dissolved in hot acetone. Upon cooling and subsequent addition of cyclohexane most of the major product, 9α-OH AD, is precipitated and recovered by filtration. The filtrate is then dried and the residue dissolved in chloroform and extracted with a saturated sodium bicarbonate solution to remove 9α-OH BN acid. The individual components remaining in the chloroform after the bicarbonate extraction are separated by chromatography on a silica gel column, eluting with chloroform-methanol (98:2 v/v). Fractions containing the same component as determined by tlc are combined and further purified by liquid chromatography or preparative tlc followed by recrystallization, to give more 9α-OH AD plus the compounds of the subject invention.
The mass spectrum of the first eluted compound in its essentially pure form has a molecular ion at 374, and also exhibits intense ions at m/e 124, 136 and 137 confirming its close relationship to 9α-OH AD. The ir spectrum exhibits bands at 3540 and 3400 cm -1 (hydroxyl) and also at 1735 cm -1 and 1655 cm -1 suggesting the presence of two carbonyl groups. Comparison of the 1 H-nmr spectrum with that of 9α-OH BN acid shows that they are virtually identical except for an additional 3 proton peak at δ3.63 where a methyl ester would be expected. This compound is therefore identified as the methyl ester of 9α-OH BN acid, and confirmation of this is obtained from the 13 C-nmr spectrum which shows signals for 23 carbon atoms including four methyl groups (δ11.1, 17.0, 19.8 and 5.13), two carbonyls (δ176.9 and 199.0), two olefinic carbons (δ126.7 and 168.6) and a quaternary carbon atom bearing oxygen (δ76.2).
The second eluted compound in its essentially pure form is residual 9α-OH AD which remains soluble in the acetone-cyclohexane solution described above.
The third component in its essentially pure form has a molecular weight of 346, the mass spectrum of which again exhibits the characteristic ions at m/e 124, 136 and 137. The presence of a hydroxyl group and an unsaturated carbonyl are deduced from infrared peaks at 3400 cm -1 and 1650 cm -1 and it is evident from the doublet centered at δ1.05 in the 1 H-nmr spectrum that a side chain similar to that of 9α-OH BN acid and 9α-OH BN acid methyl ester is present at C-17. The 1 H-nmr spectrum in dimethyl sulfoxide-d 0 also indicates the presence of both a primary (δ4.18, t, J=5) and a tertiary (δ3.95) alcohol. Signals due to 22 carbon atoms are seen in the 13 C-nmr spectrum, including three methyl groups (δ11.1, 16.7 and 19.9), two olefinic carbons (δ126.6 and 169.4), one carbonyl (δ199.2) and two carbon atoms bearing hydroxyls (δ67.7, triplet and 76.3, singlet). On the basis of the above spectral evidence the structure 9α-hydroxy-3-oxo-23,24-bisnorchol-4-en-22-ol (9α-OH BN alcohol) is assigned to this compound.
The mass spectrum of the next major eluted compound in its essentially pure form from this column shows a molecular ion at 304, and the usual intense ions at 124, 136 and 137. Given the evident close relationship to 9α-OH AD, and the fact that the 13 C-nmr spectrum showed 19 carbon atoms, only one of which was part of a carbonyl group (δ199.3), this compound is identified as 9α-OH testosterone, and the structural assignment is confirmed by comparison with an authentic sample.
EXAMPLE 8
By substituting a microorganism from the genera Arthrobacter, Bacillus, Brevibacterium, Corynebacterium, Microbacterium, Nocardia, Protaminobacter, Serratia, and Streptomyces, in Example 1 for Mycobacterium fortuitum ATCC 6842 there are obtained mutant microorganisms which are characterized by their ability to selectively degrade steroids having 17-alkyl side chains of from 8 to 10 carbon atoms, inclusive, and accumulate the products disclosed herein in the fermentation beer.
EXAMPLE 9
By substituting the mutants obtained in Example 8 for M. fortuitum NRRL B-8119 in Examples 2-7, there are obtained the products as disclosed herein.
EXAMPLE 10
By substituting a microorganism selected from the group consisting of Mycobacterium phlei, M. smegmatis, M. rhodochrous, M. mucosum, and M. butyricum for M. fortuitum ATCC 6842 in Example 1 there are obtained mutant microorganisms which are characterized by their ability to selectively degrade steroids having 17-alkyl side chains of from 8 to 10 carbon atoms, inclusive, and accumulate the products disclosed herein in the fermentation beer.
EXAMPLE 11
By substituting the mutants obtained in Example 10 for M. fortuitum NRRL B-8119 in Examples 2-7, there are obtained the products as disclosed herein.
The structural formulae for the novel compounds of the invention can be shown as follows: ##STR1## | Valuable steroid intermediates, 9α-hydroxyandrost-4-ene-17β-ol-3-one (9α-OH testosterone), 9α-hydroxy-3-ketobisnorchol-4-en-22-ol (9α-OH BN alcohol) and 9α-hydroxy-3-ketobisnorchol-4-en-22-oic methyl ester (9α-OH BN acid methyl ester), prepared by microbiological conversion of steroids having 17-alkyl side chains of 8 to 10 carbons. | 2 |
CLAIM OF PRIORITY
[0001] This application claims the benefit of Korean Patent Application No. 2005-60380 filed on Jul. 5, 2005, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a multi-chip package with at least two semiconductor chips packaged therein, and more particularly, to a semiconductor multi-chip package which is designed to minimize noise generated through a bonding wire connecting a substrate with a chip to ensure stable operation of the chip, and to reduce the size of a substrate and number of components mounted thereon, thereby achieving miniaturization.
[0004] 2. Description of the Related Art
[0005] Electronic devices are becoming more miniaturized and multi-functional to meet the needs arising from recent developments in the semiconductor industry and the users. Multi-chip packaging technology, which is developed to meet such needs, packages a single type or different types of semiconductor chips in a single unit package.
[0006] This is more advantageous in terms of package size, weight or mounting area compared with packaging each semiconductor chip in one package. Thus, the multi-chip packaging technology is extensively applied to mobile phones and the like that require miniaturization and light weight in order to reduce mounting area and weight thereof.
[0007] In general, to package a plurality of semiconductor elements such as chips or dies in a single package, the semiconductor elements are either arranged in a stacked structure or aligned in parallel. In the case of the former, the stacked structure complicates the manufacturing process in a limited thickness. In the case of the latter, at least two semiconductor chips are disposed on the same plane, which renders it difficult to achieve miniaturization of the package.
[0008] In general, semiconductor chips are stacked in a package that needs to be miniaturized and light-weighted. Such an exemple of a conventional multi-chip package is described hereunder.
[0009] FIG. 1 is a sectional view illustrating the conventional multi-chip package. The multi-chip package 1 shown in FIG. 1 includes a first semiconductor chip 10 mounted on a substrate 2 , a second semiconductor chip 20 disposed above the first semiconductor chip 10 in a predetermined interval and a spacer 30 having a predetermined height. The spacer 30 is disposed between the second semiconductor chip 20 and the substrate 2 to maintain a predetermined interval between the first and second semiconductor chips 10 and 20 .
[0010] Each of the semiconductor chips 10 and 20 is adhered by a surface opposite of the active surface that has an integrated circuit formed thereon. The active surfaces of the semiconductor chips 10 and 20 face the same direction.
[0011] The first semiconductor chip 10 is electrically connected to the substrate 2 with chip pads thereof wire-bonded to bonding pads 43 of the substrate 2 by bonding wires 44 . The second semiconductor chip 20 is electrically connected to the substrate 2 with chip pads thereof wire-bonded to bonding pads 41 of the substrate 2 by bonding wires 42 .
[0012] In addition, plastic encapsulating material such as epoxy molding compound completes the package body in the upper part of the substrate 2 where at least one electric component is mounted by sealing the first and second semiconductor chips 10 and 20 and mounted components 15 to protect them from the external environment. Solder balls (not shown) may be provided on the lower surface of the substrate 2 as external terminals for electric connection to the outside.
[0013] In the meantime, a supplementary spacer 35 is disposed between the first and second semiconductor chips 10 and 20 . The substrate 2 is a ceramic substrate manufactured in Low Temperature Co-fired Ceramic (LTCC) process to have passive elements such as a resistor, a capacitor and a coil embedded therein.
[0014] However, in such a configuration of the conventional multi-chip package 1 , the second bonding wire 42 connecting the second semiconductor chip 20 and the substrate 2 is longer than the first bonding wire 44 electrically connecting the first semiconductor chip 10 and the substrate 2 . This entails higher incidence of noise during transmission of signals and greater bonding inductance, and thus the operation is unstable.
[0015] In addition, as the second bonding wire 42 has an end connected to the second semiconductor chip 20 and the other end directly bonded to the substrate 2 , a horizontal length L between the bonding locations of the second bonding wire 42 is longer, thus limiting reduction of the size of the substrate 2 for miniaturization.
SUMMARY OF THE INVENTION
[0016] The present invention has been made to solve the foregoing problems of the prior art and therefore an object of certain embodiments of the present invention is to provide a semiconductor multi-chip package which can minimize noise generated through a bonding wire connecting a substrate with a chip and reduce the size of the substrate and number of components mounted thereon, thereby achieving miniaturization.
[0017] According to an aspect of the invention for realizing the object, there is provided a semiconductor multi-chip package including: a substrate; a first semiconductor chip mounted on an upper surface of the substrate; at least one second semiconductor chip disposed directly above the first semiconductor chip; and a spacer disposed between the substrate and the second semiconductor chip to maintain a predetermined interval between the first and second semiconductor chips and electrically connect the second semiconductor chip to the substrate.
[0018] Preferably, the first semiconductor chip is wire-bonded onto the substrate.
[0019] Preferably, the first semiconductor chip is flip-chip bonded onto the substrate.
[0020] Preferably, the second semiconductor chip is wire-bonded onto the spacer.
[0021] Preferably, the spacer comprises a Low Temperature Co-fired Ceramic (LTCC) substrate having at least one passive element therein.
[0022] Preferably, the spacer has a portion of an upper surface adhered to a lower surface of the second semiconductor chip with an adhesive, and has an undersurface adhered to the substrate via solder balls therebetween.
[0023] Preferably, the semiconductor multi-chip package according to the present invention further includes an encapsulant that covers the first and second semiconductor chips on the substrate.
[0024] Preferably, the semiconductor multi-chip package according to the present invention further includes a supplementary spacer between the first semiconductor chip and the second semiconductor chip, and preferably, the supplementary spacer is made of insulation material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
[0026] FIG. 1 is a sectional view illustrating a semiconductor multi-chip package according to prior art;
[0027] FIG. 2 is a sectional view illustrating a semiconductor multi-chip package according to the present invention; and
[0028] FIG. 3 is a plan view illustrating the semiconductor multi-chip package according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] Preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings.
[0030] FIG. 2 is a sectional view illustrating a semiconductor multi-chip package according to the present invention, and FIG. 3 is a plan view illustrating the semiconductor multi-chip package according to the present invention.
[0031] As shown in FIGS. 2 and 3 , according to a preferred embodiment of the present invention, the semiconductor multi-chip package 100 achieves miniaturization of a final product by reducing the number of components and the size of a substrate. The semiconductor multi-chip package 100 includes a substrate 101 , first and second semiconductor chips 110 and 120 and a spacer 130 .
[0032] That is, the substrate 101 , which is a ceramic substrate with at least one ceramic layer stacked, has various circuits pattern-printed thereon, a plurality of bonding pads 103 for wire-bonding, and a plurality of components 105 mounted in accordance with the circuits on an upper surface thereof.
[0033] In addition, the substrate 101 has lower terminals 107 on an undersurface thereof and the lower terminals 107 have solder balls (not shown) for electrical connection with a main substrate. Thereby, the substrate 101 can be mounted on the main substrate with the solder balls (not shown) therebetween.
[0034] Herein, the substrate 101 is a Low Temperature Co-fired Ceramic (LTCC) substrate. The LTCC substrate is obtained by first, forming passive elements R, L and C (filter, balun and coupler) for configuring the circuits on a plurality of green sheets made of glass-ceramics, via screen printing and photo patterning using highly conductive Ag, Cu, etc. With these green sheets stacked on one another, ceramic and metal conductors are fired simultaneously at a temperature of 1000° C. or lower to obtain the LTCC substrate.
[0035] Thereby, the passive elements such as a capacitor, a resistor and an inductor are embedded in the substrate 101 in the form of patterns.
[0036] The first semiconductor chip 110 is a chip component which is mounted on an upper surface of the substrate 101 to be electrically connected to the circuits pattern-printed on an upper surface of the substrate 101 . As shown in FIGS. 2 and 3 , adhered to the substrate 101 by an adhesive 109 , the first semiconductor chip 110 can be wire-bonded onto the substrate 101 by a plurality of first wires 141 .
[0037] Each of the first bonding wires 141 is a conductive member having one end bonded to a chip pad 112 formed on an upper surface of the first semiconductor chip 110 and the other end bonded to the bonding pad 103 formed on the substrate 101 .
[0038] However, the first semiconductor chip 110 is not limited to the above, and alternatively can be flip-chip bonded to an upper surface of the substrate 101 , with ball pads (not shown) and a plurality of solder balls (not shown) formed on a lower surface thereof.
[0039] In addition, the second semiconductor chip 120 is composed of at least one chip component disposed directly above the first semiconductor chip 110 in a predetermined interval. The second semiconductor chip 120 is not directly connected to the substrate 101 but stacked in parallel and above the substrate 101 with a spacer 130 having conductive lines formed therein disposed therebetween.
[0040] The first and second semiconductor chips 110 and 120 may be ones selected from a group consisting of a memory chip such as SRAM and DRAM, a digital integrated circuit chip, an RF integrated circuit chip and a base band chip.
[0041] In addition, the spacer 130 has upper and lower ends thereof connected respectively to an upper surface of the substrate 101 and a lower surface of the second semiconductor chip 120 , and having a thickness greater than the height of the first semiconductor chip 110 mounted on the substrate 101 , in order to maintain a vertical interval between the first and second semiconductor chips 110 and 120 .
[0042] Herein, the spacer 130 is composed of at least two LTCC substrates with at least one passive elements R, L and C (filter, balun and coupler) embedded therein, and disposed along the outer peripheral portions of the second semiconductor chip 120 to electrically connect the second semiconductor chip 120 with the substrate 101 .
[0043] Thus, the passive elements such as a decoupling capacitor or Electrostatic Discharge (ESD) device that may be required depending on the operation of the second semiconductor chip 120 can be embedded in the spacer 130 without being mounted on the substrate 101 , thereby reducing the number of components mounted on the substrate 101 .
[0044] The second semiconductor chip 120 is bonded to the spacer 140 by second bonding wires 142 . Each of the second bonding wires 142 has an end bonded to a chip pad 122 formed on an upper surface of the second semiconductor chip 120 and the other end bonded to a bonding pad 133 formed on an upper surface of the spacer 130 . The bonding pads 133 are electrically connected to the passive elements R, L and C (filter, balun and coupler) through vias or patterns.
[0045] Here, the spacer 130 is fixedly adhered to a lower surface of the second semiconductor chip 120 with an insulating adhesive 139 .
[0046] The spacer 130 has a plurality of solder pads on a lower surface thereof to be electrically connected to the pattern circuits formed on the substrate 101 via solder balls 136 .
[0047] Thereby, the second semiconductor chip 120 is electrically connected to the substrate 101 by the second bonding wires 142 and the solder balls 136 .
[0048] Further, a horizontal length L 1 measured between the chip pad 122 and the bonding pad 133 connected, respectively, to each end of the second bonding wire 142 is shorter than a horizontal length L (see FIG. 1 ) measured between the chip pad and the bonding pad 41 of the substrate 2 connected, respectively, to each end of the second bonding wire 42 in the conventional package. Thus, the second bonding wire 142 can be formed in a shorter length, and also the substrate 101 where the first and second semiconductor chips 110 and 120 are mounted can be designed smaller.
[0049] As the second bonding wires 142 are formed in a shorter length, noise of signals transmitted therethrough can be reduced, thereby minimizing occurrence of parasitic component due to bonding inductance.
[0050] In the meantime, an encapsulant 150 made of plastic encapsulating material such as epoxy molding compound is formed on the substrate 101 to protect the mounted components 105 , the first and second semiconductor chips 110 and 120 and the first and second bonding wires 141 and 142 from being damaged or corroded by the outside environment, thereby completing the package.
[0051] In addition, a supplementary spacer 135 made of insulation material such as silicone can be additionally disposed between the first semiconductor chip 110 mounted on the substrate 101 and the second semiconductor chip 120 adhered to the spacer 130 , thereby stably maintaining an interval between the first and second semiconductor chips 110 and 120 .
[0052] Herein, it is preferable that the supplementary spacer 135 is formed in a shape substantially the same as those of the first and second semiconductor chips 110 and 120 , and formed smaller than an upper surface area of the first semiconductor chip 110 .
[0053] According to a preferred embodiment of the invention as set forth above, the passive elements involved in the operation of the second semiconductor chip can be embedded in the LTCC spacer disposed between the first and second semiconductor chips instead of being mounted on the substrate. This allows reducing the number of components mounted on the substrate and the size of the substrate, thereby miniaturizing the final product.
[0054] Further, the second bonding wires can be formed in a length smaller than that in the prior art, thus reducing noise of a signal transmitted therethrough and occurrence of parasitic component due to bonding inductance. Thereby, the stable operation of the package is ensured to enhance reliability of the package and attain stable electric characteristics.
[0055] While the present invention has been shown and described in connection with the preferred embodiments, it will be apparent to those skilled in the art that modifications and variations can be made without departing from the spirit and scope of the invention as defined by the appended claims. | The invention provides a semiconductor multi-chip package including a substrate, a first semiconductor chip mounted on the substrate and a second semiconductor chip disposed directly above the first semiconductor chip. The package further includes a spacer disposed between the substrate and the second semiconductor chip to maintain a vertical interval between the first and second semiconductor chips and electrically connect the second semiconductor chip to the substrate. The invention minimizes noise generated through a bonding wire connecting the substrate with the chip to ensure stable operation of the chip, and reduces the size of the substrate and the number of mounted components, thereby achieving miniaturization of the package. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. application Ser. No. 14/264,794, entitled, “COILED TUBING DOWNHOLE TOOL,” filed Apr. 29, 2014, which is hereby incorporated by reference in its entirety.
FIELD OF THE DISCLOSURE
[0002] The embodiments described herein relate to a method and apparatus for a downhole device connected to coiled tubing to obtain diagnostic information of a wellbore. The downhole device may be connected to the interior of the coiled tubing. Alternatively, the downhole device may be connected to an exterior carrier portion of the coiled tubing.
BACKGROUND
Description of the Related Art
[0003] Natural resources such as gas and oil may be recovered from subterranean formations using well-known techniques. For example, a horizontal wellbore may be drilled within the subterranean formation. After formation of the horizontal wellbore, a string of pipe, e.g., casing, may be run or cemented into the well bore. Hydrocarbons may then be produced from the horizontal wellbore.
[0004] In an attempt to increase the production of hydrocarbons from the wellbore, the casing may be perforated and fracturing fluid may be pumped into the wellbore to fracture the subterranean formation. The fracturing fluid is pumped into the well bore at a rate and a pressure sufficient to form fractures that extend into the subterranean formation, providing additional pathways through which fluids being produced can flow into the well bores. The fracturing fluid typically includes particulate matter known as a proppant, e.g., graded sand, bauxite, or resin coated sand, that may be suspended in the fracturing fluid. The proppant becomes deposited into the fractures and thus holds the fractures open after the pressure exerted on the fracturing fluid has been released.
[0005] A production zone within a wellbore may have been previously fractured, but the prior fracturing may not have adequately fractured the formation leading to inadequate production from the production zone. Even if the formation was adequately fractured, the production zone may no longer be producing at adequate levels. Over an extended period of time, the production from a previously fractured horizontal wellbore may decrease below a minimum threshold level. One technique in attempting to increase the hydrocarbon production from the wellbore may be the re-fracturing of some of the previously fractured locations of the horizontal wellbore. However, it may not be beneficial to re-fracture every previously fractured location. It may be beneficial to use a diagnostic tool to analyze the production zones in a horizontal wellbore to determine which zones should be re-fractured.
[0006] FIG. 8 shows a prior art diagnostic tool 22 conveyed into a wellbore 10 on coiled tubing 40 via a wellhead 16 . The coiled tubing 40 moves the diagnostic tool 22 down the wellbore 10 along the casing 18 until the diagnostic tool 22 is positioned at a desired location. The diagnostic tool 22 is connected to the surface via a cable 14 , which transmits diagnostic information obtained from the device 22 . The cable 14 and diagnostic tool 22 are connected to the end of the coiled tubing 40 via a cable head 20 and connector 21 . Prior to running the diagnostic tool 22 into the wellbore 10 , coiled tubing 40 may be run into the wellbore 10 to conduct a clean-out procedure. The coiled tubing 40 is then tripped out of the wellhead 16 and the diagnostic tool 22 and cable 14 may be connected to the coiled tubing 40 for a second trip into the wellbore 10 with the coiled tubing 40 . The positioning of the cable 14 outside of the coiled tubing 40 as well as the diagnostic tool 22 being connected to end of the coiled tubing 40 may present an increased chance the coiled tubing 40 becomes stuck within the wellbore 10 . It may also be beneficial to permit a cleanout procedure and conveyance of a diagnostic tool 22 into a wellbore in a single trip of coiled tubing 40 .
SUMMARY
[0007] The present disclosure is directed to a downhole device connected to coiled tubing that substantially overcomes some of the problems and disadvantages discussed above.
[0008] One embodiment is a method of determining information about the production from a zone of a wellbore comprising running a downhole device into a wellbore. The device comprises an electronic device positioned inside of a housing within an interior of coiled tubing. The method includes positioning the downhole device adjacent a first zone of the wellbore, determining diagnostic information of the first zone of the wellbore, and storing the determined diagnostic information of the first zone in a memory device.
[0009] The method may include connecting the housing to the interior of coiled tubing. The method may include pumping fluid down the interior of the coiled tubing past the downhole device while determining diagnostic information of the first zone. The method may include positioning the downhole device adjacent a second zone of the wellbore, determining diagnostic information of the second zone of the wellbore, and storing the determined diagnostic information of the second zone in the memory device. The electronic device may be a logging tool. The method may include pulling the downhole device out of the wellbore and analyzing the diagnostic information of the first zone stored in the memory device.
[0010] One embodiment is a method of determining information about the production from a zone of a wellbore comprising running a downhole device into a wellbore. The downhole device comprises an electronic device positioned inside of a housing connected to a recess in an exterior of coiled tubing. The method includes positioning the downhole device adjacent a first zone of the wellbore, determining diagnostic information concerning the first zone of the wellbore, and storing the determined diagnostic information of the first zone in a memory device.
[0011] The electronic device may be a logging tool. The method may further comprise positioning the downhole device adjacent a second zone of the wellbore, determining diagnostic information of the second zone of the wellbore, and storing the determined diagnostic information of the second zone in the memory device. The method may include pulling the downhole device out of the wellbore and analyzing the diagnostic information of the first zone stored in the memory device.
[0012] One embodiment is a system to monitor a zone of a wellbore. The system comprises a string of coiled tubing and a housing having a first end and a second end. The housing is closed at the first end and is closed at the second end and at least one of the ends being selectively closed to permit access into the housing. The system includes an electronic device positioned within the housing. The electronic device is configured to obtain diagnostic information of a wellbore. The housing is connected to a portion of an interior of the string of coiled tubing with a flow path between the housing and the interior of the string of coiled tubing.
[0013] The electronic device may be a logging tool. The system may include a memory storage device connected to the electronic device. The housing may be welded to the interior of the string of coiled tubing. The housing may be positioned between an end of the string of coiled tubing and a location ten feet from the end of the string of coiled tubing, the location being along the string of coiled tubing.
[0014] One embodiment is a system to monitor a zone of a wellbore. The system comprises a string of coiled tubing and a housing having a first end and a second end. The housing is closed at the first end and is closed at the second end and at least one of the ends being selectively closed to permit access into the housing. The system includes an electronic device positioned within the housing. The electronic device is configured to obtain diagnostic information of a wellbore. The housing is connected to a recess in a portion of an exterior of the string of coiled tubing with a flow path in an interior of the string of coiled tubing past the recess.
[0015] The electronic device may be a logging tool. The system may include a memory storage device connected to the electronic device. The housing may be welded to the exterior of the string of coiled tubing. The housing may be positioned between an end of the string of coiled tubing and a location ten feet from the end of the string of coiled tubing, the location being along the string of coiled tubing.
[0016] One embodiment is a system to monitor a wellbore. The system comprises a string of coiled tubing and a housing having a first end, a second end, at least one inner wall forming a cavity, and a flow path from the first end to the second end. The cavity is selectively sealed from the flow path. The housing is connected to an end of the string of coiled tubing. The system includes an electronic device positioned within the selectively sealed cavity of the housing. The electronic device is configured to obtain diagnostic information of a wellbore. The system includes a memory storage device connected to the electronic device. The memory storage device is positioned within the selectively sealed cavity of the housing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 shows an embodiment of a downhole device positioned within a housing inside of coiled tubing;
[0018] FIG. 2 shows an end cross-section view of an embodiment of a downhole device positioned within a housing inside of coiled tubing;
[0019] FIG. 3 shows an end cross-section view of an embodiment of a downhole device positioned within a housing inside of coiled tubing within casing;
[0020] FIG. 4 shows an embodiment of a downhole device positioned adjacent a first zone of a wellbore;
[0021] FIG. 5 shows an embodiment of a downhole device positioned adjacent a second zone of a wellbore;
[0022] FIG. 6 shows an embodiment of a downhole device positioned within a housing connected to the outside of coiled tubing;
[0023] FIG. 7 shows an embodiment of a downhole device that may be connected to the end of coiled tubing; and
[0024] FIG. 8 shows a prior art downhole device connected to coiled tubing.
[0025] While the disclosure is susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. However, it should be understood that the disclosure is not intended to be limited to the particular forms disclosed. Rather, the intention is to cover all modifications, equivalents and alternatives falling within the scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION
[0026] FIG. 1 shows an embodiment of a downhole device 100 that may be connected to the interior of coiled tubing 40 . The downhole device 100 may include a housing 50 that is connected to the inside of the coiled tubing 40 . The housing 50 may be connected to the inside of the coiled tubing 40 by various mechanisms such as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure. For example, the housing 50 could be welded to the interior of the coiled tubing 40 . An electronic device 60 configured to monitor various aspects of a production zone (e.g. 30 a or 30 b shown in FIG. 4 and FIG. 5 ) of a wellbore 10 is positioned within the housing 50 . The coiled tubing 40 is used to run the device 100 down a wellbore 10 within casing or tubing 18 and position the electronic device 60 of the downhole device 100 at a desired location within the wellbore 10 . The ends of the housing 50 are closed so that fluid flows around the housing through a flow area 45 (shown in FIG. 2 ) between the housing 50 and the coiled tubing 40 as shown by arrows 41 in FIG. 1 . The positioning of the downhole device 100 inside of the coiled tubing 40 may permit the attachment of a bottom hole assembly to the bottom of the coiled tubing 40 that is adapted for other purposes. A conventional logging tool connected to the bottom of the coiled tubing 40 may prevent the connection of an additional bottom hole assembly to the coiled tubing 40 .
[0027] The downhole device 100 is preferably connected to the interior of the coiled tubing 40 near the downhole end of the coiled tubing. For example, the downhole device 100 may be positioned flush with the end of the coil or between the end of the coiled and ten (10) feet from the end of the coiled tubing 40 . FIG. 1 shows a distance, D, from the end of the coiled tubing 40 within which the downhole device 100 is preferably positioned within. The distance, D, may be various lengths. For example, D may be two (2) feet, which is approximately shown in FIG. 1 . However, this distance is for illustrative purposes only and may be varied as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure. Preferably, the distance D may be approximately ten (10) feet. Coiled tubing 40 is often inserted into a wellbore 10 to perform a cleaning operation prior to other wellbore operations. The insertion of the downhole device 100 inside of the coiled tubing 40 permits the transmittal of an electronic device 60 , which may be a diagnostic tool, into the wellbore 10 during the cleaning trip into the wellbore 10 . The housing 100 connected inside of the coiled tubing 40 may provide added protection as the electronic device 60 , which may be fragile, is tripped in and out of the wellbore 10 . The addition of the housing 50 to the end of the coiled tubing string 40 may provide higher rigidity at the end of the coiled tubing string 40 , which may aid in the insertion of the coiled tubing string 40 into a wellbore 10 , in particular if the wellbore 10 is a horizontal wellbore.
[0028] FIG. 2 shows an end cross-section view of the downhole device 100 connected to an interior portion of the coiled tubing 40 creating a flow path 45 between the housing 50 of the device 100 and the rest of the interior of the coiled tubing 40 that is not connected to the housing 50 . The outer diameter of the housing 50 may be configured to permit an adequate flow path past the housing 50 . The housing 50 encloses an electronic device 60 that may be used to analyze the condition of the wellbore 10 and its surroundings. For example, the electronic device 60 may be a logging tool also referred to as a diagnostic tool. The diagnostic information gathered from the electronic device 60 may be stored on a memory device 70 also positioned within the housing 50 . The diagnostic information stored on the memory device 70 may then be analyzed after the device 100 is removed from the wellbore 10 . FIG. 3 shows an end cross-section view of a downhole device 100 connected to coiled tubing 40 positioned within casing, or tubing, 18 of a wellbore. The device creates a flow area 45 between the housing 50 of the device 100 and the coiled tubing 40 . Likewise, the coiled tubing 40 creates a flow area 25 between the exterior of the coiled tubing 40 and the casing 18 . The flow area 45 between the housing 50 and the coiled tubing 40 may permit the pumping of fluid down the coiled tubing 40 during the capturing of diagnostic information from the electronic device 60 . The housing 50 may also act as a fluid displacer, which may enhance the response on neutralizing wellbore fluids.
[0029] FIG. 4 shows the downhole device 100 connected to coiled tubing 40 being positioned adjacent a first zone 30 a of a wellbore 10 . The electronic device 60 of the downhole device may be used to determine whether the first zone 30 a should be re-fractured during a re-fracturing procedure. For example, the downhole device 100 may be run into the wellbore 10 to determine which locations of the wellbore should be re-fractured by the process disclosed in related and commonly owned U.S. patent application Ser. No. 14/091,677 filed on Nov. 27, 2013 entitled System and Method for Re-fracturing Multizone Horizontal Wellbore, which is incorporated by reference herein in its entirety.
[0030] The electronic device 60 of the downhole device may be adapted to obtain various information about a desired location of a wellbore 10 . The diagnostic device 60 of the downhole device 100 may provide information concerning the temperature, pressure, fluid flow, and formation. The electronic device 60 may use various mechanisms to obtain diagnostic information as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure. For instance, the device 60 may generate pulsed neutrons that penetrate the housing 50 and reflect off the wellbore fluid as well as the wellbore 10 and surrounding formation measuring its activity. All of the diagnostic information gathered by the electronic device 60 may be stored in the memory device 70 for later analysis.
[0031] The coiled tubing 40 may be used to position the downhole device 100 adjacent a first zone 30 a of a wellbore 10 so that the electronic device 60 may obtain diagnostic information concerning the first zone 30 a . This diagnostic information is stored in the memory device 70 and may be used later to determine whether it would be beneficial to re-fracture the first zone 30 a during a re-fracturing process. After storing the diagnostic information for the first zone 30 a , the coiled tubing 40 may be used to position the downhole device 100 adjacent a second zone 30 b of the wellbore 10 as shown in FIG. 5 . The electronic device 60 may then obtain diagnostic information concerning the second zone 30 b , which may be stored in the memory device 70 . This process may be repeated until all desired locations within the wellbore 10 have been analyzed by the electronic device 60 .
[0032] FIG. 6 shows an end cross-section view of an embodiment of a downhole device 100 connected to the exterior of coiled tubing 140 . The coiled tubing 140 includes a carrier portion 141 , which is a concave portion that creates a recess for the placement of downhole device 100 . The housing 50 of the downhole device 100 may be connected to the recess in the coiled tubing 140 by various means. For example, the housing 50 may be welded to the carrier portion 141 of the coiled tubing 140 . The carrier portion 141 may be connected to coiled tubing 140 at connection points 142 . For example, the carrier portion 141 may be welded to the coiled tubing at connection points 142 . The carrier portion 141 may be formed from crimping the coiled tubing 140 to form bends at connection points 142 forming a recess for the positioning of the downhole device 100 . The coiled tubing 140 includes a flow path 145 between the interior of the coiled tubing 140 and the carrier portion 141 . The downhole device 100 includes an electronic device 60 used to diagnose conditions of the wellbore 10 and memory device 70 protected by housing 50 . The coiled tubing 140 may be used to positioned the downhole device 100 at desired locations within the wellbore 10 to obtain diagnostic information as detailed herein. As shown in FIG. 6 , the addition of the downhole device 100 to the coiled tubing 140 may result in substantially the same outer diameter of the coiled tubing 140 if it did not contain the carrier portion 141 .
[0033] FIG. 7 shows an exploded view of an embodiment of a downhole device 200 that may be connected to the end of a coiled tubing string 240 by a connector 270 . The downhole device 200 includes an electronic device 60 that is configured as a wellbore diagnostic tool and a memory device 70 positioned within a cavity 205 within the downhole device 200 . As disclosed herein, the electronic device 60 may be positioned at various locations within the wellbore to obtain information concerning the wellbore 10 that may be stored in the memory device 70 for later analysis. The downhole device 200 may be formed by machining a housing 201 that includes an flow path 245 that is in communication with the interior of the coiled tubing 240 and a cavity that is formed by inner wall 202 and end caps 210 and 215 . End caps 210 and 215 seal the cavity 205 from fluids flowing through the flow path 245 of the downhole device. One or both of the end caps 210 and 215 may be selectively disconnected form the cavity 205 to permit access to the cavity 205 as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure. The end caps 210 and 215 may be connected to the cavity 205 by various mechanisms as would be appreciated by one of ordinary skill in the art having the benefit of this disclosure. Various mechanisms may be used to selectively seal the chamber 205 from the flow path 245 within the device 200 . For example, one end may be permanently closed with the other including a removable plugging element.
[0034] Although this invention has been described in terms of certain preferred embodiments, other embodiments that are apparent to those of ordinary skill in the art, including embodiments that do not provide all of the features and advantages set forth herein, are also within the scope of this invention. Accordingly, the scope of the present invention is defined only by reference to the appended claims and equivalents thereof. | A method and system for determining information about a wellbore with coiled tubing. A downhole device may be positioned within coiled tubing and run down the wellbore to determine diagnostic information about a location with the wellbore. The downhole device may store diagnostic information in a storage device that may be analyzed when the device is returned to the surface. A downhole device may be connected to the end of a string of coiled tubing that includes a diagnostic device and memory sealed in a chamber. A flow path past the chamber is in communication with the coiled tubing string permitting the flow of fluid past the chamber. A downhole device including a diagnostic device may be connected to a recess in an exterior of a coiled tubing string. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a vise apparatus and more particularly, to a swivel vise which is characterized by a vise assembly having fixed and movable jaw members attached to one end of a ball mount shaft and a ball joint assembly connecting the ball mount shaft to a ring tensioner secured to a mount block, in order to facilitate positioning the vise assembly into a selected position with respect to the mount block, for finishing a gun stock mounted between the fixed and movable vise jaws. In a most preferred embodiment of the invention, the ball joint assembly is characterized by a split ball rotatably joined to the ball mount shaft by means of a cooperating split ring, one end of which split ring is secured to the fixed element of the ring tensioner and the opposite end fastened to the movable element of the ring tensioner. Accordingly, compression of the split ring against the split ball by manipulation of the ring tensioner locates the vise assembly and the gun stock in any desired position with respect to the mount block or workbench to which the mount block is secured, in order to present all surfaces of the gun stock to the craftsman at a selected angle.
One of the problems realized in the finishing of various asymmetrical objects such as wooden gun stocks and the like, is that of positioning the object in a vise at an attitude and location which easily facilitates shaping, smoothing and finishing all surfaces of the object. For example, in the case of wooden gun stocks, a conventional vise is capable of securing the gun stock in an immobile position in either a vertical or a horizontal plane without further adjustment. This limitation in orientation of the gun stock in the vise jaws makes it difficult to accurately shape, smooth and finish the gun stock, since all surfaces of the gun stock cannot be viewed at the proper angle by the craftsman. Furthermore, mounting of the gun stock in a conventional vise does not facilitate access to all areas of the gun stock in any given stage of the operation, for proper finishing.
2. Description of the Prior Art
The search revealed a number of prior art patents concerned with vise apparatus used for various purposes. These patents are listed below and a copy of each is enclosed. U.S. Pat. No. 1,192,267, dated July 25, 1916, to U. G. Bond, details an "Armed Vise". The armed vise is characterized by a base, a staff upstanding from the base, a ball and socket mechanism operatively uniting the staff with the base and means for holding the constituent parts of the ball and socket mechanism against relative movement. An arm is pivoted to the staff, along with means for preventing relative swinging movement between the staff and the arm, an extension and a work-holding grip located at the outer end of the extension, with a second ball and socket mechanism connecting the inner end of the extension to the outer end of the arm. The device further includes means for preventing relative movement between the constituent parts of the second ball and socket mechanism. U.S. Pat. No. 1,379,382, dated May 24, 1921, to F. E. Bergstedt, details a "Vise". The vise detailed in this patent includes a stationary jaw, a sliding bar having slotted plunger seats therein, a trip-rod extending longitudinally of the bar and through the seats, means for operating the rod to be raised and lowered through the seats, an adjusting screw provided in one end of the bar and a jaw carried by the adjusting screw and adapted to be adjusted relative to the stationary jaw. A "Work Holding Clamp" is disclosed in U.S. Pat. No. 1,446,811, dated Feb. 27, 1923, to J. H. Rowland. The work holding clamp detailed in this patent includes a supporting rod having a ball head at one end, a supporting standard with a ball socket at one end thereof and a ball at the remaining end, means for clamping the socket upon the ball head of the rod and a pair of gripping jaws fitted for universal adjustment on the ball of the standard. A bracket is fitted on the supporting rod and is provided with a socket, along with a second pair of gripping jaws and an intermediate member by which the second jaw is held for universal adjustment on the bracket socket. U.S. Pat. No. 2,488,296, dated Nov. 15, 1949, to H. E. Kraus, discloses a "Work Support". The work support is designed for supporting work of various shape and size for rotation in a balanced condition about an axis. The device includes a rotatable shaft, means for supporting the shaft with its axis in various angular relationship with respect to the horizontal, an arm, a work-supported supporting table rotatably mounted on one end of the arm to rotate on an axis substantially perpendicular to the arm and a universal joint connection between the other end of the arm and one end of the shaft, for positioning the arm at various angular relationship with respect to the shaft. Further included is means for securing the arm in the desired angular relationship to the shaft to support the work, such that the center of gravity of the arm and the work carried thereby will lie substantially in the axis of rotation of the shaft. U.S. Pat. No. 4,140,307, dated Feb. 20, 1979, entitled "Vises" and issued to Jordi Dalmau, et al. The vise detailed in this patent also includes a pair of conventional vise jaws or a jig for holding the workpiece. The jaws or jig are mounted for rotational movement about a first axis when released from a locked position and also for tilting movement through 90 degrees to the first axis. This movement is achieved by mounting the jaws or jig on the ball element of a ball and socket arrangement, wherein the socket is slotted to enable the tilting movement. The socket arrangement is mounted for rotation, when released from a locked position, in a plane normal to the plane of rotation of the jaws or a jig. Accordingly, by a combination of rotational movement of the jaws or jig and the socket arrangement, as well as tilting movement of the jaws or jig, the workpiece may be disposed in a selected angular orientation and locked in that position. Locking is achieved by conventional clamping means. U.S. Pat. No. 4,171,800, dated Oct. 23, 1979, to Earl R. Weaver, details a "Bench Mounted Support for Jewelry Articles and the Like". The device of this patent includes a work holder assembly which is characterized by a clamp assembly for clamp-retention of the jewelry article, a bench mount assembly and a gimbal-type connector coupling the clamp to the bench mount. The gimbal-connector includes a ring assembly rotatably and hingedly connected to the bench mount and rotatably connected to the clamp. A filing block, interchangeable with the clamp assembly, is adapted for connection with the bench mount.
It is an object of this invention to provide a swivel vise having a vise assembly and a cooperating ball joint assembly for mounting an object in the vise assembly and locating the vise assembly and the object in substantially any selected angular position by operation of the ball joint assembly.
Another object of the invention is to provide a ball joint assembly for supporting a clamp member such as a swivel vise, which is capable of supporting a workpiece, which ball joint assembly enables adjustment of the clamp member to any desired angular position.
Yet another object of the invention is to provide a new and improved swivel vise for mounting on a workbench or other work area, which swivel vise is characterized by a vise assembly mounted on one end of a shaft and a ball joint assembly also attached to the shaft, which ball joint assembly is operable to selectively orient the vise assembly in substantially any desired angular orientation with respect to the workbench for finishing a work stock clamped in the vise assembly.
A still further object of the invention is to provide a swivel vise which includes a vise assembly for securing a work stock, which vise assembly is mounted on one end of a shaft. The shaft is clamped between a pair of hemispherically-shaped ball segments joined by a split ring carried by a ring tensioner, such that the vise assembly and work stock can be positioned in substantially any desired angular orientation with respect to a craftsman by manipulation of the shaft and ball segments in the split ring, responsive to operation of the ring tensioner.
SUMMARY OF THE INVENTION
These and other objects of the invention are provided in a new and improved swivel vise which includes a shaft having a clamp member such as a vise assembly located on one end, which vise assembly is capable of mounting a work stock between the jaws thereof, and a ball joint assembly spaced from the vise assembly and characterized by a pair of hemispherically-shaped ball segments carried by a ring for clamping the ball segments to the shaft in spaced relationship with respect to the vice assembly. The swivel vise further includes a ring tensioner attached to the split ring for selectively clamping the ball segments on the shaft and locating the vise assembly in a selected angular orientation with respect to a craftsman.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be better understood by reference to the accompanying drawing, wherein:
FIG. 1 is a perspective view of a preferred embodiment of the swivel vise of this invention;
FIG. 2 is a top elevation of the swivel vise illustrated in FIG. 1;
FIG. 3 is an exploded view of the split ball component of a ball joint assembly utilized in the swivel vise illustrated in FIGS. 1 and 2;
FIG. 4 is a front elevation, partially in section, of the split ball and split ring elements of the ball joint assembly illustrated in FIGS. 1 and 2; and
FIG. 5 is an end view of the ball joint assembly illustrated in FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring initially to FIGS. 1 and 2 of the drawing, the swivel vise of this invention is generally illustrated by reference numeral 1. The swivel vise 1 is characterized by a round ball mount shaft 2, having a vise end 3 and a free end 4. A vise assembly 6 is mounted on the vise end 3 of the ball mount shaft 2 and is further characterized by a fixed jaw 7, which is attached to the vise end 3 by means of a weld 32 and is provided with a fixed jaw bracket 8, to which a fixed jaw plate 9 is attached. The fixed jaw plate 9 further receives a fixed jaw plate pad 10 for engaging a work stock such as the stock of a shotgun or a rifle (not illustrated). In a most preferred embodiment of the invention, the fixed jaw plate 9 and thus, the fixed jaw plate pad 10, are removably secured to the fixed jaw bracket 8 by means of an insert (not illustrated) which recesses in a cooperating slot (not illustrated) provided in the fixed jaw bracket 8. A fixed jaw allen screw 11 is threadibly seated in the fixed jaw bracket 8 and engages the insert carried by the fixed jaw plate 9, to removably seat the fixed jaw plate 9 and the fixed jaw plate pad 10 in the fixed jaw bracket 8, as illustrated in FIGS. 1 and 2. A telescoping shaft 12 is inserted in the vise end 3 of the ball mount shaft 2 and supports a movable jaw 13, as illustrated. In a preferred embodiment of the invention, the movable jaw bracket 14 component of the movable jaw 13 is attached to the telescoping shaft 12 by means of a weld 32 and receives a movable jaw plate 15, which in turn, carries a movable jaw plate pad 16 that mates with the fixed jaw plate pad 10 when the telescoping shaft 12 is fully telescoped inside the vise end 3 of the ball mount shaft 2, as illustrated in FIGS. 1 and 2. As in the case of the fixed jaw bracket 8, the movable jaw bracket 14 is fitted with a movable jaw allen screw 17, which engages a corresponding insert (not illustrated) that is provided in registration with a cooperating slot (not illustrated) located in the face of the movable jaw bracket 14, in order to mount the movable jaw plate 14 and the movable jaw plate pad 16 to the movable jaw bracket 14. Accordingly, it will be appreciated that both the fixed jaw plate pad 10 and the movable jaw plate pad 16 can be periodically removed, when damaged, by loosening the fixed jaw allen screw 11 and the movable jaw allen screw 17 and removing the fixed jaw plate 9 and the movable jaw plate 15, respectively. The fixed jaw plate pad 10 and the movable jaw plate pad 16 can then be removed from the fixed jaw plate 9 and the movable jaw plate 15, respectively, and periodically replaced, as desired. Alternatively, it will be appreciated by those skilled in the art that the fixed jaw allen screw 11 and movable jaw allen screw 17 may be replaced by roll pins (not illustrated), which extend through the fixed jaw bracket 8 and the movable jaw bracket 14, as well as the respective inserts, to pivotally mount the fixed jaw plate 9 and the movable jaw plate 15 in the fixed jaw bracket 8 and the movable jaw bracket 14, respectively. This mounting of the fixed jaw plate 9 and the movable jaw plate 15 facilitates a more consistent grip by the fixed jaw plate pad 10 and the movable jaw plate pad 16 on a work stock. The handle base 22 of a handle 19 is provided with a threaded rod (not illustrated) which extends through the telescoping shaft 12 into threadible engagement with the interior of the vise end 3 of the ball mount shaft 2. Accordingly, grasping of the handle grip 20, which is attached to one end of the handle shaft 21, and rotation of the handle 19 in the counterclockwise direction as viewed from the front, will cause the telescoping shaft 12 and thus, the movable jaw 13, to retract from the fixed jaw 7, to facilitate insertion of a work stock between the fixed jaw plate pad 10 and removable jaw plate pad 16, respectively. Conversely, rotation of the handle 19 in the clockwise direction as viewed from the front, causes the movable jaw 13 to approach the fixed jaw 7 and tighten the fixed jaw plate pad 10 and the movable jaw plate pad 16 on a work stock located therebetween.
A ball joint assembly 24 is used to attach the mid-section of the ball mount shaft 2 to a ring tensioner 46, as further illustrated in FIGS. 1 and 2. Referring now to FIGS. 1-5 of the drawing and specifically to FIGS. 1, and 5, a pair of ball hemispheres 26 of a split ball 25 are mounted on the ball mount shaft 2 by operation of a split ring 33. As illustrated in FIG. 3, each of the ball hemispheres 26 is characterized by spaced, truncated end portions 27, a ball radius 28 connecting the end portions 27 and a curved shaft seat 29 positioned in oppositely-disposed relationship, respectively, for seating on the ball mount shaft 2. The split edges 30 of the respective ball hemispheres 26 are dislocated to define a ball slot 31 for insertion of the free end 4 of the ball mount shaft 2 through the respective shaft seats 29, as illustrated in FIG. 3. As further illustrated in FIGS. 4 and 5 of the drawing, the split ring 33 is further characterized by a ring body 34, provided with a body split 36 at one point on the circumference thereof and an internal body radius 35, which matches the curvature of the ball radius 28, for maintaining the split ring 33 on the ball hemispheres 26 of the split ball 25. As illustrated in FIGS. 1 and 5, the movable body segment 34a of the ring body 34 is fixedly secured to the pedestal ring 44 of the ring tensioner 46. Furthermore, the fixed body segment 34b of the ring body 34 is welded or otherwise fixedly attached to the pedestal 43 of the ring tensioner 46. The pedestal 43 of the ring tensioner 46 is secured to the collar seat plate 42 of a collar seat 41, which collar seat 41 is in turn, fixedly mounted to a collar seat base 40, mounted on a mount block 38. The fixed pedestal 43 receives the "floating" pedestal ring 44 at a pedestal match line 45, as illustrated in FIG. 1. A bushing 50 is provided on the top surface of the pedestal ring 44 and receives a tensioner collar 49, fitted with a projecting tensioner handle 48 and a tensioner grip 47, as further illustrated in FIG. 1. In a first preferred embodiment, the tensioner collar 49 is further provided with a threaded member (not illustrated) which extends through the bushing 50 and the pedestal ring 44 and threadibly seats in the pedestal 43. In a second preferred embodiment of the invention, the tensioner collar 49 includes a tensioner shank 52, which projects through aligned openings (not illustrated) in the pedestal 43, collar seat plate 42, collar seat base 40 and mount block 38, respectively. A mount block washer 51 is fitted adjacent the bottom surface of the mount block 38 and a shank nut 54 is threaded on the shank threads 53 of the tensioner shank 52. Accordingly, in both embodiments, rotation of the tensioner handle 48 in the counterclockwise direction as viewed from the top, loosens the tensioner collar 49 and the pedestal ring 44, to facilitate opening of the body split 36 as the pedestal match line 45 is opened. This maneuver also facilitates movement of the ball mount shaft 2 and the split ball 25 into substantially any angular orientation with respect to the ring tensioner 46, and the mount block 38. The maneuver further facilitates both linear and rotational movement of the ball mount shaft 2 inside the split ball 25 to locate the vise assembly 6 at a selected distance from the ball joint assembly 24 in a 360 degree circle about the axis of the ball mount shaft 2. Conversely, tightening of the ring tensioner 46 by manipulation of the tensioner grip 47 and the tensioner handle 48 in the clockwise direction as the ring tensioner is viewed from the top, tightens the tensioner collar 49 on the bushing 50 and the pedestal ring 44 and closes the pedestal match line 45 and the split edge match line 37 between the ball hemispheres 26, to maintain the ball mount shaft 2 in a selected linear and rotated position inside the split ball 25 and the split ball 25 in a selected rotated position inside the split ring 33. Consequently, the vise assembly 6 can be located in any angular position with respect to the mount block 38 and to the craftsman, by initially loosening the ring tensioner 46, manipulating the vise assembly 6 and the ball mount shaft 2 into a desired configuration and subsequently tightening the ring tensioner 46.
Referring again to FIGS. 1 and 2 of the drawing, it will be appreciated that the mount block 38 may be secured to a conventional workbench or other work area by C-clamps or otherwise, as desired. However, in a most preferred embodiment of the invention, a mount block opening 39 is provided in the mount block 38 for bolting the mount block 38 to a workbench or other work facility, in order to immobilize the mount block 38 and facilitate manipulation of the vise assembly 6 into a desired configuration for finishing a work stock clamped between the fixed jaw 7 and the movable jaw 13 of the vise assembly 6, as heretofore described.
It is understood by those skilled in the art that the ball joint assembly 24 element of the swivel vise 1 of this invention facilitates manipulation of a clamp member and work stock into substantially any angular orientation and position with respect to a craftsman by adjustment of the ring tensioner 46 and orienting the vice assembly 6 in that selected position. Alternatively, the ball joint assembly 24 can also be used to selectively orient a working means in other mechanisms such as jigs, robotic devices and the like, in non-exclusive particular, according to the knowledge of those skilled in the art. Furthermore, the swivel vise 1 is portable, in that the mount block 38 can be removed from attachment to a workbench or other fixed surface and carried to another location for reattachment using C-clamps or an appropriate bolt for fitting through the mount block opening 39, as heretofore described. Alternatively, it will be appreciated that the swivel vise 1 can be permanently mounted by means of the collar seat base 40 directly to a workbench or other work facility without using the mount block 38, as desired.
While the preferred embodiments of the invention have been described above, it will be recognized and understood that various modifications may be made therein and the appended claims are intended to cover all such modifications which may fall within the spirit and scope of the invention. | A swivel vise which is used primarily for finishing gun stocks and is characterized by a conventional vise assembly mounted on one end of a ball mount shaft for engaging a gun stock and a ball joint assembly also engaging the ball mount shaft intermediate the ends thereof and spaced from the vise assembly, to facilitate manipulation of the ball mount shaft and the vise assembly into a selected position. In a preferred embodiment of the invention, positioning of the vise assembly in a selected attitude is facilitated by operation of a ring tensioning device which receives the ball joint assembly and is mounted on a mount block that can be attached to a work bench. The ball joint assembly includes a split ball carried by a split ring, the ends of which split ring are attached to fixed and movable elements, respectively, of the ring tensioning device, in order to manipulate the vise assembly into the selected position with respect to the mount block for finishing the gun stock. | 1 |
FIELD OF THE INVENTION
The present invention relates to depositing tin as well as copper or rhodium alloys thereof on various substrates; more particularly the invention pertains to depositing of bright, metallic tin from stable baths wherein the tin is in the form of divalent tin sulfate or fluoroborate, i.e. stannous sulfate or fluoroborate.
BACKGROUND OF THE INVENTION
There is a substantial body of prior art patents concerned with tin or tin alloy electroplating baths and processes for utilizing the same. Some of the more relevant patents for the present purposes include U.S. Pat. Nos. 3,730,853 (Sedlacek et al.); 3,749,649 (Valayil); 3,769,182 (Beckwith et al.); 3,785,939 (Hsu); 3,850,765 (Karustis, Jr. et al.); 3,875,029 (Rosenberg et al.); 3,905,878 (Dohi et al.); 3,926,749 (Passal); 3,954,573 (Dahlgren et al.); 3,956,123 (Rosenberg et al.); 3,977,949 (Rosenberg); 4,000,047 (Ostrow et al.); 4,135,991 (Canaris et al.); 4,118,289 (Hsu); and British Pat. Nos. 1,351,875 and 1,408,148.
Despite the existence of this extensive literature and the various formulations which have been suggested for commercial applications, there is still a need for electroplating baths which will effectively deposit bright metallic tin on various substrates. Another important characteristic is bath stability, especially premature tin compound precipitation in the bath. The variety of bath formulations proposed heretofore reveal, moreover, that all of the ingredients employed in the bath formulation must be taken into consideration not only with respect to the type of deposit obtained but also with respect to questions of bath stability, by-product formation, etc.
OBJECTS OF THE INVENTION
One object of the present invention is to provide a tin electroplating bath which ensures the deposition of bright metallic tin on various substrates.
Another object of the present invention is to provide a divalent tin electroplating bath of improved stability.
A further object of the present invention is to provide an improved electroplating bath for the deposition of alloys of tin with copper and rhodium.
These and other objects will become readily apparent from the following description and illustrative embodiments of the present invention.
SUMMARY OF THE INVENTION
In accordance with the present invention it has now been found that by utilizing certain aromatic sulfonic acid additives in conjunction with certain other additives an improved tin electroplating bath, formulated with bath soluble divalent tin compounds, can be achieved. The resulting bath will not only lead to the deposition of bright metallic tin but will be further characterized by outstanding stability.
The other bath ingredients will comprise an inorganic acid, an aromatic amine brightener, and a nonionic surface active agent. Preferably, the bath will also contain an aliphatic aldehyde brightener.
In accordance with another aspect of the present invention copper or rhodium metals may be effectively co-deposited with the tin from the electroplating baths.
DETAILED DESCRIPTION OF THE INVENTION
The electroplating baths of this invention are formulated with divalent tin in the form of a bath soluble compound. Typical of such compounds are stannous sulfate, stannous fluoroborate and stannous chloride. Free inorganic acid is also present in amounts sufficient to provide conductivity, maintain bath pH below 2.0 and maintain the solubility of metal salts. It will be understood that the particular acid used will correspond to the anion of divalent tin compound, e.g. sulfuric acid, fluoroboric acid, hydrochloric acid or the like.
The brightener system will comprise one or more aromatic amines and, most preferably will comprise a combination of one or more aromatic amines and aliphatic aldehydes. The aromatic or aryl amines useful for the present purposes include o-toluidine; p-toluidine; m-toluidine; aniline; and o-chloroaniline. For most purposes the use of o-chloroaniline is especially preferred.
Suitable aliphatic aldehydes are those containing from 1 to 4 carbon atoms and include, for example, formaldehyde, acetaldehyde, propionaldehyde, butyraaldehyde, crotonaldehyde, etc. In this invention the preferred aldehyde is formaldehyde or formalin, a 37% solution of formaldehyde.
Nonionic surfactants are employed in the bath to provide grain refinement of the electrodeposit. These can be commercially available materials such as nonyl phenoxy polyethlene oxide ethanol (Igelpal C0630 and Triton Q515); ethoxylated alkylolamide (Amidex L5 and C3); alkyl phenyl polyglycoletherethylene oxide (Newtronyx 675) and the like.
The nonionic surface active agents which have been found to be particularly effective for the present purposes are the polyoxyalkylene ethers, where the alkylene group contains from 2 to 20 carbon atoms. Polyoxyethylene ethers having from 10 to 20 moles of ethylene oxide per mole of lipophilic groups are preferred, and include such surfactants as polyoxyethylene lauryl ether (sold under the tradename Brij 25-SP).
As previously described, the essential feature of the present invention is to utilize an aromatic sulfonic acid compound in conjunction with the bath ingredients set forth above. These sulfonic acid compounds maintain stability of the plating bath and provide supplemental brightening and grain refinement to the electrodeposit. Preferred aromatic sulfonic acids for these purposes are:
o-cresol sulfonic acid
m-cresol sulfonic acid
phenol sulfonic acid
Other phenol sulfonic acid derivatives of phenol and cresol which could be employed are, for example:
2,6-dimethyl phenol sulfonic acid
2-chloro, 6-methyl phenol sulfonic acid
2,4-dimethyl phenol sulfonic acid
2,4,6-trimethyl phenol sulfonic acid
m-cresol sulfonic acid
p-cresol sulfonic acid
Sulfonic acid derivatives of alpha- and beta-naphthols are also possible candidates for the aromatic sulphonic acid ingredient. Additionally, the bath soluble salts of the above acids, such as the alkali metal salts, may be used instead of or in addition to the acid.
In formulating the plating baths of the present invention, the divalent tin compound will be used in an amount at least sufficient to deposit tin on the substrate to be plated, up to its maximum solubility in the bath. The inorganic acid will be present in an amount sufficient to maintain the pH of the plating bath not in excess of about 2.0. The aromatic amine or the combination of the aromatic amine and the aliphatic aldehyde are present in amounts at least sufficient to impart brightness to the tin electrodeposit, while the nonionic surfactant is present in the bath in a grain refining amount. The aromatic sulfonic acid derivative is present in an amount sufficient to maintain the stability of the plating bath and enhance the brightness of the electrodeposit.
More specifically, the ingredients of the aqueous electroplating baths of this invention will be present in amounts within the following ranges:
______________________________________ Amounts (grams/liter)Ingredients Typical Preferred______________________________________(1) Tin (II), as stannous sulfate, fluoroborate or chloride 5-50 15-30(2) Sulfuric, fluoroboric or hydrochloric acid 100-250 160-190(3) Aromatic Amine 0.3-15 0.5-1.5(4) Aliphatic Aldehyde 0.5-11 0.9-5.4(5) Nonionic surfactant 0.1-20 0.5-2.5(6) Aromatic sulfonic acid derivative 0.5-3.0 3-9______________________________________
The pH of the bath will not be in excess of about 2.0 and will usually be less than about 1, with ranges from about 0 to 0.5 being typical and ranges from about 0 to 0.3 being preferred. Electroplating temperatures and current densities used will be those at which there are no adverse effects on either the plating bath or the electrodeposit produced. Typically, the temperatures will be from about 10 degrees to 40 degrees C., with temperatures of about 15 degrees to 25 degrees C. being preferred. Typical current densities will be about 10 to 400 Amps/square foot (ASF) and preferably about 25 to 200 ASF.
The substrates which may be satisfactorily plated utilizing the electroplating baths of this invention include most metallic substrates, except zinc, such as copper, copper alloys, iron, steel, nickel, nickel alloys and the like. Additionally, non-metallic substrates that have been treated to provide sufficient conductivity may also be plated with the bath and process of the present invention.
Another aspect of this invention involves the discovery that copper and rhodium metals can be deposited with tin on the substrates when utilizing the electroplating baths described above without additional additives or complexing agents. In contrast, metals such as nickel, iron and indium did not codeposit under the same conditions.
Typically, the copper or rhodium is added to the bath as bath soluble compounds, preferably having the same anions as the divalent tin compounds. The amounts of such compounds added with be sufficient to provide up to about 5% by weight of copper or rhodium, alloyed with tin, in the electrodeposit. Typical amounts of copper and rhodium in the electroplating baths to provide such quantities of the metal in the electrodeposit are about 0.2 to 4 grams/liter and 0.2 to 2 grams/liter, respectively.
The invention will be more fully understood by reference to the following specific embodiments:
EXAMPLE I
An electroplating bath was prepared from the ingredients set forth below:
______________________________________Ingredients Amount g/l______________________________________Tin (II), as stannous sulfate 22.5Sulfuric Acid 175o-chloroaniline 1.0, cc/lFormalin 10, cc/lPolyoxyethylene lauryl ether 1.0o-Cresol sulfonic acid 5.0Water Remainder______________________________________
This resulting stable bath was operated at 20 degrees C., 30 ASF, with rapid agitation to plate a copper panel. The tin deposit thus formed had a very bright appearance.
EXAMPLE II
It has been found that there is a side reaction between formaldehyde and the sulfonic acid which causes a precipitate to form and settle out of the bath solution. However, it was further found that if the ortho position, and to a lesser extent the meta position, of the phenol sulfonic acid are blocked by methyl groups, as in o-cresol sulfonic acid, this undesirable side reaction, and hence the precipitation, slows down. The other ingredients of Example I may also be further optimized (e.g., work load, agitation, etc.) to minimize, if not eliminate this precipitate. Utilizing the other ingredients of Example I, a number of the aromatic sulfonic acids were tested to determine bath stability. The results were as follows:
______________________________________Additive Amount (ml/l) Stability (hrs)______________________________________o-Cresol sulfonic acid (65%) 8 24m-Cresol sulfonic acid (33%) 6 16Phenol sulfonic acid (65%) 10 12______________________________________
EXAMPLE III
An electroplating bath was prepared from the following ingredients:
______________________________________Ingredients Amount (g/l)______________________________________Tin II, as stannous sulfate 30Sulfuric acid 175Copper, as copper sulfate 0.4Formalin 10, cc/lo-Chloroaniline 0.4 cc/lPolyoxyethylene lauryl ether 0.4o-Cresol sulfonic acid 0.8______________________________________
The resulting bath was operated at 60 asf produced a tin/copper alloy deposit containing 1.0% copper, the deposit was semi-bright.
EXAMPLE IV
In the formulation of Example III the copper was replaced with rhodium at a concentration of 0.5 g/l from rhodium sulfate. The bath was operated at 60 asf and produced a very bright tin/rhodium alloy deposit containing 0.07% rhodium.
When nickel, iron or indium metal were employed in the divalent tin baths of this invention, they failed to codeposit with the metallic tin.
EXAMPLE V
To demonstrate the stability enhancing effects achieved by the use of an aromatic sulfonic acid in the tin electroplating baths of this invention the following baths were prepared.
______________________________________ g/l______________________________________BATH AStannous sulfate 60Sulfuric acid 180o-Cresol sulfonic acid 5.6Water RemainderBATH BStannous sulfate 60Sulfuric acid 180Water Remainder______________________________________
An electric air compressor with spargers was employed to pump air at a flow rate of approximately 15 cubic feet per minute through the bath in a 1 liter beaker.
______________________________________Time Stannic Tin Conc. (g/l)Period BATH A BATH B______________________________________Start 0.3 0.55 days 2.2 9.110 days 3.5 13.6______________________________________
In commercial operations air is normally present as a result of agitation, and becomes a serious problem because high rates of agitation will entrap substantial amounts of air which, in the absence of the aromatic sulfonic acid, will cause formation of stannic tin in the bath which is a measure of bath degradation.
It will be further understood that the foregoing examples are illustrative only, and that variations and modifications may be made without departing from the scope of this invention. | Improved electroplating bath for depositing bright, metallic tin wherein divalent tin, in the form of stannous sulfate or fluoroborate, is present in conjunction with sulfuric or fluoroboric acid, brighteners including an aromatic amine and an aliphatic aldehyde, a polyalkylene ether surfactant, and an aromatic sulfonic acid to ensure bath stability as well as the requisite brightness. The divalent tin-containing electroplating bath may also be provided with copper or rhodium salts to achieve codeposition of tin with at least one of these alloying metals. The method of utilizing such divalent tin electroplating baths to plate substrates with bright metallic tin is also described and claimed. | 2 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims priority as a continuation-in-part of prior filed U.S. Non-provisional application Ser. No. 13/968,179 filed Aug. 15, 2013 which in turn claims priority on prior filed U.S. Provisional application No. 61/691,229, filed Aug. 20, 2012 and incorporates both of these applications herein by reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of firearms and more particularly relates to an extendable grip tang for use with a firearms, with particular use with a concealable spring-actuated revolver.
BACKGROUND OF THE INVENTION
[0003] Personal defense is a matter of choice for individuals. Some choose to not have any, others prefer training in martial arts, some choose a weapon. Often times, that weapon is a firearm such as a small handgun, so the use of a firearm for personal defense is well known. Users of firearms tend to conceal them in their clothing or other objects. Law enforcement and military personnel often conceal them on their persons as a “back-up” weapon, in case their primary weapon fails or situations become dire. As such, the ideal back-up weapon is ideally small and easily concealable. Their positioning is not to hinder the movement of the carrier. They tend to carry a few rounds of ammunition and maybe have some container or magazine to carry spare rounds. They tend not to be very accurate at a distance.
[0004] The present invention is a an extendable grip tang with many different embodiments, all being suitable for reducing the stowage profile of a firearm, such as one of the many types suitable for a back-up weapon. The tang may or may not be spring-loaded and may be actuated by use of a pressure plate or by the cocking of the hammer or may be keyed such that removal from a holster deploys the tang or any other means known in the art or later discovered may be used to deploy the tang.
SUMMARY OF THE INVENTION
[0005] In view of the foregoing disadvantages inherent in the known types of firearms, this invention provides an extendable grip tang for many types of firearms, including the concealable spring-loaded revolver of the parent application. As such, the present invention's general purpose is to provide a new and improved tang which allows the firearm to be more compact and concealable, is easily constructed, and safe when in a concealable configuration.
[0006] To accomplish these objectives, the tang comprises a tang body concealable in an orifice within the grip of the firearm. Embodiments of the extendable tang may be either spring operated or pressure operated by the natural positioning of the user's hand. Embodiments for both revolvers and magazine fed handguns are shown, though the invention may be practiced on any type of firearm, or other device, with a suitable grip.
[0007] The more important features of the invention have thus been outlined in order that the more detailed description that follows may be better understood and in order that the present contribution to the art may better be appreciated. Additional features of the invention will be described hereinafter and will form the subject matter of the claims that follow.
[0008] Many objects of this invention will appear from the following description and appended claims, reference being made to the accompanying drawings forming a part of this specification wherein like reference characters designate corresponding parts in the several views.
[0009] Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting. As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a side elevation of one embodiment of a revolver according to the present invention.
[0011] FIG. 2 is a sectional view of the revolver of FIG. 1 in a stowed orientation.
[0012] FIG. 3 is a sectional view of the revolver of FIG. 1 , in the process of cocking.
[0013] FIG. 4 is a sectional view of the revolver of FIG. 1 , fully cocked.
[0014] FIG. 5 is a sectional view of the revolver of FIG. 1 , firing.
[0015] FIG. 6 is a rear elevation of the cylinder of the revolver of FIG. 1 .
[0016] FIG. 7 is a front elevation of the cylinder of the revolver of FIG. 1 .
[0017] FIG. 8 is a sectional view of a second embodiment of a revolver with which the present invention may be utilized.
[0018] FIG. 9 is a sectional view of the revolver of FIG. 8 , with a deployed grip extension tang.
[0019] FIG. 10 is a sectional view of the an alternate revolver embodiment, with a stowed extension tang.
[0020] FIG. 11 is a side elevation of a handgun utilizing one embodiment of the present invention with the extension tang stowed.
[0021] FIG. 12 is the handgun of FIG. 11 , with one grip panel removed.
[0022] FIG. 13 is the handgun of FIG. 11 , with the extension tang deployed.
[0023] FIG. 14 is the handgun of FIG. 13 , with one grip panel removed.
[0024] FIG. 15 is a perspective view of the mechanism utilized in the handgun of FIG. 11 , in a stowed orientation.
[0025] FIG. 16 is a perspective view of the mechanism utilized in the handgun of FIG. 11 , in a deployed orientation.
[0026] FIG. 17 is a perspective view of the linkage components of the mechanism used in the handgun of FIG. 11 , in a stowed orientation.
[0027] FIG. 18 is a perspective view of the linkage components of the mechanism used in the handgun of FIG. 11 , in a deployed orientation.
[0028] FIG. 19 is a perspective view of the plunger rod of the mechanism used in the handgun of FIG. 11 .
[0029] FIG. 20 is a perspective view of the blade of the mechanism used in the handgun of FIG. 11 .
[0030] FIG. 21 is a partial section of a magazine fed handgun, utilizing a modified embodiment of the mechanism of the handgun of FIG. 11 .
[0031] FIG. 22 is a perspective view of one embodiment of an extension grip tang for use with a magazine fed handgun.
[0032] FIG. 23 is an exploded view of a handgun utilizing a second embodiment of the invention.
[0033] FIG. 24 is a side elevation of the handgun of FIG. 23 , with one grip panel removed the grip extension tang in a stowed orientation.
[0034] FIG. 25 is a side elevation of the handgun of FIG. 23 , with one grip panel removed, the grip extension tang in a deployed orientation.
[0035] FIG. 26 is an exploded view of a handgun utilizing a third embodiment of the invention.
[0036] FIG. 27 is a side elevation of the handgun of FIG. 26 , with one grip panel removed the grip extension tang in a stowed orientation.
[0037] FIG. 28 is a side elevation of the handgun of FIG. 26 , with one grip panel removed, the grip extension tang in a deployed orientation.
[0038] FIG. 29 is an exploded view of a handgun utilizing a fourth embodiment of the invention.
[0039] FIG. 30 is a side elevation of the handgun of FIG. 29 , with one grip panel removed the grip extension tang in a stowed orientation.
[0040] FIG. 31 is a side elevation of the handgun of FIG. 29 , with one grip panel removed, the grip extension tang in a deployed orientation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0041] With reference now to the drawings, the preferred embodiment and alternate embodiments of the grip extension tang are herein described. It should be noted that the articles “a”, “an”, and “the”, as used in this specification, include plural referents unless the content clearly dictates otherwise. It should also be realized that while the figures depict handguns, the invention may be practiced on any firearm or other object with a suitable grip, such as an AR-15 rifle with a “pistol grip” attachment. The use of handguns in the drawings and use of terminology in this Specification related to handguns should not be deemed limiting the invention to practice with handguns alone.
[0042] A basic revolver with which the invention may be used is illustrated in FIGS. 1-7 . With reference to FIG. 1 , a revolver 100 has the main components expected of a revolver, that is to say it has a barrel 110 , cylinder 120 , hammer 130 , trigger 140 and grip 150 all mounted upon a frame or receiver. Its internal workings, however, shown in FIGS. 2-5 , however, reveal a different sort of weapon. First, the cylinder 120 is powered by a torsion-type cylinder spring 112 mounted beneath the barrel 110 . A pivoting locking bar 114 maintains the cylinder 120 against the spring pressure. The forward end of the locking bar 114 is a locking bar key 116 designed to interface with specifically positioned lock grooves 126 , 128 on a forward end of the cylinder 120 . The end of the locking bar opposite the key features a locking bar plate 134 which interfaces with a hammer pawl 132 pivotably mounted upon the hammer 130 .
[0043] When stowed, FIG. 2 , the cylinder rests in a unique position off-chamber from the bore of the barrel 110 (and consequently the hammer 130 ). It is held in this position by the locking bar key 116 residing in a specially positioned safety lock groove 128 (shown in FIG. 3 ). In subsequent use, the action of cocking the hammer 130 drives the hammer pawl 132 against the locking bar plate 134 , pushing it upwards. The locking bar 114 pivots about its pivot point 118 and forces the locking bar key 116 downward, releasing the cylinder 120 . Immediate over-rotation of the cylinder is prevented by a chamfer 142 in the locking bar 114 . The chamfer 142 stops rotation of the cylinder 120 by blocking one of its corners. Other structures may of course be utilized, including having other structure on the cylinder interface with the chamfer 142 or other movable blocking structure; however, this embodiment is preferred. In the fully cocked position ( FIG. 4 ), the hammer pawl 132 has passed beyond the locking bar plate 134 , releasing it and thereby forcing the locking bar key 116 to move upwards into the next successive position lock groove 126 . In this position, the revolver is ready to fire with a chamber 122 in line with the barrel 110 and hammer 130 . An interface with the trigger 140 holds the hammer 130 in cocked position. The illustrated mechanism is a simple spur-and-groove lock where a sear-spur 138 on the trigger 140 interfaces with a groove 136 on the hammer 130 . Other structures of sears may of course be used. Upon firing ( FIG. 5 ), the sear lock is broken and the hammer 130 begins to return. The pawl 132 rotates against the locking bar plate 134 and into a crevice in the hammer 130 until the pawl 132 is moved away from the locking bar plate 134 and returns to its position underneath the locking bar plate 134 .
[0044] The cylinder 120 provides a slim profile to aid in concealment. As can be seen in FIGS. 6 and 7 , the cylinder is uniquely shaped. There are limited lines of symmetry with the design of the cylinder and the outside surface of the cylinder proximate each chamber is not consistent relative to the axis of rotation of the cylinder.
[0045] Another revolver 200 is shown in FIGS. 8-10 , where a specialized grip is used to provide a still smaller stowed profile. A grip extension tang 242 is provided in the bottom of grip 240 that may be deployed into an extended position and thus provide a larger gripping surface ( FIG. 9 ). The tang 242 may be spring-loaded and actuated by use of a pressure plate or may be actuated by the cocking of the hammer or may be keyed to removal from a holster or any other means known in the art or later discovered. The tang 242 may also not be spring-loaded and may pivot or slide into position due to direct pressure on some part of the grip.
[0046] One tang embodiment is shown in FIGS. 11-20 . This particular embodiment is spring-biased. Tang 310 resides hingedly within the grip 300 of a handgun, firearm, or other device and is actuated by a plunger 320 connected to a push button 330 . Plunger 320 is a bent rod pivotably attached to the tang 310 and passing through blade 340 on the back of push button 330 . The bend in the rod of the plunger allows for free movement of the tang 310 and plunger 320 relative to each other between the stowed and extended positions. Two notches reside in an upper portion of the plunger 320 , forming a narrower portion 327 (“notched portion”) of the plunger. A spring 325 resides about plunger 320 between blade 340 and tang 310 while at least one spring 335 biases the push button outward from the grip 300 . Blade 340 features a T-shaped aperture 345 ( FIG. 20 ), through which plunger 320 passes. In the stowed position, the notched portion 327 ( FIGS. 18 , 19 ) resides in the narrower portion of the T-shaped aperture 345 and spring 325 is compressed ( FIG. 15 ).
[0047] When actuated, the push button 330 biases the blade 340 such that the notched portion resides in the broader portion of the T-shaped aperture 345 , allowing the plunger 320 to slide through the aperture 345 and allows spring 325 to release, forcing the plunger 320 downwards and deploying the tang 310 ( FIG. 16 ). Springs 335 remain compressed as the plunger 320 forces the push button 330 to remain depressed. When the tang 310 is pressed back into the grip 300 , the notched portion 327 of the plunger is again positioned in the aperture 345 . This then allows the push button 330 to return to its original position and bias the blade 340 forward so that the notched portion 327 again resides in the narrower portion of the T-shaped aperture 345 , locking the system in place.
[0048] Any tang embodiment may be adapted for magazine fed firearms, as this one is shown in FIGS. 21 and 22 , simply by providing a hollow tang 350 which fits about the magazine or any solid obstruction in the design of the firearm.
[0049] A second embodiment involves a specially shaped tang 420 with a tang extension 430 that is deployed due to direct pressure on the tang extension 430 . This embodiment is shown in FIGS. 23-25 . Tang 420 and tang extension 430 are hollow and surround firearm receiver 400 . The tang extension 430 extends, when tang 420 stowed, past the back strap of the firearm grip 410 . Grip panels 405 for firearm grip 410 each feature an arcuate channel 415 through which the tang extension 430 of the tang travels. The tang extension 430 acts as a push button that is passively depressed when the weapon is brought to bear in the user's hand. When grasping the firearm, the user's hand depresses the tang extension 430 into receiver 400 (with a provided notch), thereby forcing the tang 420 downwards. The tang 420 may be spring-biased so that holstering the firearm, or in any way unhanding it, will automatically retract the tang 420 to a stowed position.
[0050] As shown in FIGS. 26-28 , a third embodiment is also passively deployed, but utilizes a lever 520 so that pressure from the user grasping the firearm is indirectly applied from the user's hands to the extendible tang 530 . Lever 520 protrudes from the front of grip 510 and is pivotally mounted within the grip 510 , between the grip panels 507 and receiver frame 505 . The location of this protruding end of the lever 520 is such that a user will automatically actuate the lever 520 when gripping the firearm 500 . Grip panels 507 may provide the fulcrum for the lever and possibly channels for the tang 530 . The other end of the lever is connected to the tang 530 , close to its pivot point 535 on the receiver frame 505 of the firearm 500 , or, alternately, on the grip panels 507 . Because of its location on the tang 530 , small movements of the lever 520 create arcuately significant movement of the tang 530 , such that the tang 530 is fully exposed when the lever 520 is actuated by the user. The lever 520 and/or tang 530 may be spring biased to have the tang 530 remain in a stowed orientation when the lever is not actuated, thus allowing for automatic stowage when the firearm 500 is released. For optimum operation, this embodiment features an oblong slot 525 in the lever 520 where the lever 520 and tang 530 meet. This provides a certain amount of play between the components which aids in the linkage of said components. This play may also be achieved by placing the slot 525 on the tang 530 and a pivot point on the lever 520 .
[0051] A fourth embodiment of the invention is shown in FIGS. 29-31 in which the tang 630 is held in a sliding relationship between grip panels 620 and frame 610 . A notch is provided in frame 610 to accommodate the tang 630 and this notch may be cut out of existing frames or the frame may be manufactured with this invention in mind. The tang may or may not be spring biased and may be utilized with any of the latching and/or deployment mechanisms described in the previous three embodiments with little alteration. It is to be readily understood that the angular motion of the tang described in the previous embodiment may also be translated into a linear motion without departing from the scope of this invention. As such, the depicted fourth embodiment, in actuality, represents a variation on the previous three and may utilize any of the features previously described.
[0052] The embodiments indicated within this specification may be utilized on any existing firearm with minimal alteration of the firearm. In some cases, the receiver frame may need to be cut in order to accommodate the mechanisms described herein. Grip panels are easily designed to incorporate the mechanisms described. Tangs and other components may be mounted either upon the firearm frame or grip panels. Firearms may also be developed and designed with the mechanisms described herein specifically in mind such that grip panels and receiver frames may be manufactured intending for the use of the present invention therewith. It is easily considered that the spring pressure may be used to either deploy or stow the tang and embodiments described herein may be altered within the scope of this invention such that the tang is automatically deployed when unholstered and stowed when holstered.
[0053] Although the present invention has been described with reference to preferred embodiments, numerous modifications and variations can be made and still the result will come within the scope of the invention. No limitation with respect to the specific embodiments disclosed herein is intended or should be inferred. | Extendable tangs are used to increase the surface area of grips so as to better enable users with larger hands to adequately control smaller items. Tangs are stowed within the body of a grip and deployed through one of a number of mechanisms, including spring-loaded and non-spring loaded mechanisms. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to processing systems, and more specifically to multi-core processing systems.
[0003] 2. Background Art
[0004] In the past, increasing performance in processing-intensive electronic devices, such as base transceiver stations and other types of communications devices, could be achieved merely by increasing the processor clock speed of the devices. However, the introduction of applications requiring very fast processing performance to meet application latency requirements, such as Voice over Internet Protocol (VoIP), video conferencing, multimedia streaming, and other real-time applications have rendered this simple approach as no longer practical. As a result, the use of multi-core systems has become a popular approach for increasing performance in processing-intensive electronic devices, such as base station transceivers. To realize the potential increase in performance that multiple processing cores can provide, however, each processing core needs to be programmed so that the processing workload is appropriately divided over all of the processing cores.
[0005] However, programming multiple processing cores can be significantly more complicated than programming a single core, placing a heavy burden on programmers. To avoid this burden, many software development paradigms are still focused on sequentially organized single-core applications. As a result, development tools are often not well suited to programming for multi-core systems. In order to efficiently utilize multiple cores, programmers have thus been traditionally required to understand the low-level hardware implementation details for the multi-core system to be programmed, manually specifying intra-core communication, task delegation, and other hardware details. Programmers may find it difficult to adhere to application development budgets and schedules with this extra burden, leading to software applications that may be poorly optimized for use on multi-core hardware systems.
[0006] Accordingly, there is a need in the art for a multi-core system that can effectively address the aforementioned difficulty of programming, facilitating development and optimizing of software for multi-core systems.
SUMMARY OF THE INVENTION
[0007] There is provided a multi-core system with automated task list generation, parallelism templates, and memory management, substantially as shown in and/or described in connection with at least one of the figures, as set forth more completely in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The features and advantages of the present invention will become more readily apparent to those ordinarily skilled in the art after reviewing the following detailed description and accompanying drawings, wherein:
[0009] FIG. 1 shows a diagram of an exemplary multi-core system, according to one embodiment of the present invention;
[0010] FIG. 2 shows a diagram showing the generation of a task list, according to one embodiment of the present invention; and
[0011] FIG. 3 is a flowchart presenting a method of generating a task list comprising a plurality of transaction control blocks for execution on a multi-core system, according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0012] Although the invention is described with respect to specific embodiments, the principles of the invention, as defined by the claims appended herein, can obviously be applied beyond the specifically described embodiments of the invention described herein. Moreover, in the description of the present invention, certain details have been left out in order to not obscure the inventive aspects of the invention. The details left out are within the knowledge of a person of ordinary skill in the art. The drawings in the present application and their accompanying detailed description are directed to merely example embodiments of the invention. To maintain brevity, other embodiments of the invention which use the principles of the present invention are not specifically described in the present application and are not specifically illustrated by the present drawings. It should be borne in mind that, unless noted otherwise, like or corresponding elements among the figures may be indicated by like or corresponding reference numerals.
[0013] FIG. 1 shows a diagram of an exemplary multi-core system, according to one embodiment of the present invention. Multi-core system 100 of FIG. 1 includes upper sub-system 110 containing application 115 , which includes a sequential function list 116 . Application 115 may be executing on an upper processor (not shown), which may also execute an operating system and operating system programs. Application 115 may be written to process input data 111 , which may be updated in real-time. Input data 111 may be received from, for example, an Ethernet network interface. Upon processing of input data 111 , output data 112 may be generated and sent through another interface, such as a radio broadcast interface. Thus, an example application 115 may receive input data 111 as a digitized voice stream for encoding to output data 112 as a compressed and encrypted data stream for transmission via a wireless radio broadcast.
[0014] As shown in FIG. 1 , upper sub-system 110 is in communication with processor 121 of lower sub-system 120 through application program interface (API) 125 a and data analysis and partitioning (DAP) 125 b , which provide well-defined communication protocols for exchanging data between the upper and lower sub-systems. Using API 125 a , application 115 can pass sequential function list 116 for execution on lower sub-system 120 . The contents of sequential function list 116 may be constructed depending on the tasks necessary to execute on input data 111 , which may change in real-time. After such data-driven construction, sequential function list 116 may be passed to template matcher 130 for matching against template database 131 , or passed to task parallelism analyzer 140 for full parallelism analysis from scratch. Template database 131 may contain a collection of pre-optimized task list templates, allowing template matcher 130 to create an optimal task list 150 much faster than using task parallelism analyzer 140 . Since template database 131 only contains template task lists, a matched template may be passed to reference resolver 135 to finalize data pointers in the matched template. Reference resolver 135 may also add additional tasks or remove tasks as necessary. If template matcher 130 is unable to find a suitable template, then it may fail-safe back to task parallelism analyzer 140 for full analysis from scratch. In either case, the result is an optimized task list 150 containing a list of transaction control blocks, which may then optionally be converted into a template and stored within template database 131 for future reference. Task list 150 may then be passed to scheduler 160 , which can then distribute the transaction control blocks of task list 150 to slave processing cores 170 for execution. As shown in FIG. 1 , slave processing cores 170 include slave processing cores 171 a - 171 d , each having a respective core local memory 172 a - 172 d and access to a shared memory 175 via Direct Memory Access (DMA) controller 174 .
[0015] While only four slave processing cores are shown in FIG. 1 , alternative embodiments may use any number of slave processing cores. Additionally, each slave processing core may be of the same architectural type, such as an individual core of a multi-core embedded processor, or of different architectural types. For example, slave processing core 171 a could comprise a specialized custom digital signal processor (DSP), slave processing core 171 b could comprise a general DSP, and slave processing cores 171 c - 171 d could comprise individual cores of a dual-core embedded processor. Furthermore, as the diagram shown in FIG. 1 is presented as a high level overview, implementation details have been simplified or omitted for reasons of clarity.
[0016] Moving to FIG. 2 , FIG. 2 shows a diagram showing the generation of a task list, according to one embodiment of the present invention. Diagram 200 of FIG. 2 includes input data 211 containing the inputs as shown, with Input 1 including {i1, i2, i3} and Input 2 including {i4, i5, i6}. Input data 211 may be updated in real-time, varying in size and number of inputs to reflect changing user workloads and load patterns. Function 1 , Function 2 , and Function 3 in sequential function list 216 are thus programmed to process input data 211 .
[0017] While sequential function list 216 may be constructed and executed sequentially on a single slave processing core, this represents a non-optimal use of multi-core processing resources, especially if no other execution threads are active. Additionally, a single slave processing core may not have enough processing cycles available to meet required real-time data processing deadlines. For example, if audio processing is not expedited in a timely fashion, buffer underruns may occur, causing audio stuttering and artifacts that negatively impact the end user experience.
[0018] Thus, sequential function list 216 may be constructed, traced and analyzed in advance for optimal multi-core execution on lower sub-system 120 . Certain function tasks may be given higher processing priorities than others. For example, audio processing may be given high priority due to human sensitivity to audio defects, but video processing may be given less priority since minor visual defects may be better tolerated. Similarly, some applications such as real-time conferencing may require low latency and thus be assigned high priority, while other applications may tolerate large delays without significant ill effects and thus be assigned lower priority. Once sequential function list 216 is thus optimized, corresponding parallel execution templates can be created for template database 231 . In this manner, template matcher 230 can recognize defined configurations of sequential function list 216 and provide an appropriate template from template database 231 that allows optimal multi-core execution appropriate for the application at hand, avoiding the need for a full parallelism analysis that may be difficult to timely complete while concurrently processing a real-time workload.
[0019] Returning to the example input data 211 shown in FIG. 2 , template matcher 230 may determine that Function 3 is not necessary for execution since Input 3 is empty or unavailable at the present time. Thus, only Function 1 and Function 2 may be selected. Since Function 1 and Function 2 are operating on independent data, there are no data dependencies requiring in-order execution and thus Function 1 and Function 2 can be executed in parallel and/or out-of-order. Thus, a preliminary ordered function list may include Function 1 then Function 2 or Function 2 then Function 1 . To match against a template in template database 231 , template matcher 230 may use certain high-level task parameters, such as the size or number of inputs or type of task. For example, template matcher 230 may see that Input 1 and Input 2 each reference three data streams or {i1, i2, i3} and {i4, i5, i6} respectively, which may be defined to be audio streams of a known bit-rate. This information may be embedded as high-level data descriptors within the Header section of template 232 , which can then be searched and matched by template matcher 230 . As shown in template 232 , a task list containing two transaction control blocks (TCBs) is included in template 232 , but with empty data references to be filled by reference resolver 235 . Reference resolver 235 may make the necessary modifications to TCB 1 and TCB 2 such that data pointers are correctly set to Input 1 , Input 2 , Output 1 , and Output 2 . Additionally, as previously discussed, reference resolver 235 may add, remove, and adjust TCBs as necessary if the retrieved template does not exactly align with the operations specified by sequential function list 216 and input data 211 .
[0020] While Function 1 and Function 2 operate on independent data in FIG. 2 , alternative embodiments may include sequential function lists where the output of one function is used as the input of another function, or other shared data dependencies. In this case, depending on the size of data being processed, it may be advantageous to consolidate transaction control blocks into one large block for execution sequentially on a single core so that data may remain in one of core local memory 172 a - 172 d . This memory management reduces the number of memory transfers required between memory 175 and core local memory 172 a - 172 d via DMA controller 174 , leading to faster processing. Thus, reference resolver 235 may consolidate one or more groups of transaction control blocks based on data dependencies and whether the data workloads can fit within a given core local memory size. Scheduler 160 is therefore prevented from splitting the consolidated workload across different cores, reducing unnecessary transfers between memory 175 and core local memory 172 a - 172 d.
[0021] After finalization by reference resolver 235 , the end result is an optimized task list 250 , with transaction control blocks 251 a - 251 b as shown. Since the optimization shown in FIG. 2 is by selecting a closest matching pre-optimized template and performing adjustments as necessary, the resulting optimization may not be most efficient possible. However, since template lookup and adjustment incurs only a small real-time processing penalty compared to full parallelism analysis, a high level of processing efficiency may be achieved for optimization. This is of particular benefit for real-time applications having limited resources to allocate for parallelism analysis.
[0022] As previously discussed, since sequential function list 216 is constructed to execute on lower sub-system 120 as part of the preparatory parallelism analysis, a lower sub-system 120 native Thread_Function 1 corresponding to Function 1 and a lower sub-system 120 native Thread_Function 2 corresponding to Function 2 may be accessible for reference by TCB 251 a - 251 b to execute on slave processing cores 170 .
[0023] FIG. 3 is a flowchart presenting a method of generating a task list comprising a plurality of transaction control blocks for execution on a multi-core system, according to one embodiment of the present invention. Certain details and features have been left out of flowchart 300 of FIG. 3 that are apparent to a person of ordinary skill in the art. For example, a step may consist of one or more sub-steps or may involve specialized equipment, as known in the art. While steps 310 through 350 shown in flowchart 300 are sufficient to describe one embodiment of the present invention, other embodiments of the invention may utilize steps different from those shown in flowchart 300 .
[0024] Referring to step 310 of flowchart 300 in FIG. 3 and multi-core system 100 of FIG. 1 , step 310 of flowchart 300 comprises processor 121 receiving input data 111 . As previously discussed, processor 121 may use API 125 a to allow application 115 executing on upper sub-system 110 to pass input data 111 for processing. Since input data 111 may be updated in real-time for real-time applications, processor 121 may receive a continuously updated stream of input data 111 . After processing of some amount of input data 111 is finished, processor 121 may then provide the results back to application 115 via DAP 125 b to fill output data 112 .
[0025] Referring to step 320 of flowchart 300 in FIG. 3 and multi-core system 100 of FIG. 1 , step 320 of flowchart 300 comprises processor 121 accessing sequential function list 116 constructed for execution on slave processing cores 170 . As previously discussed, sequential function list 116 may be constructed, traced, and analyzed in advance for optimal execution on slave processing cores 170 , with corresponding optimized execution templates stored in template database 131 . Moreover, the contents of sequential function list 116 may vary depending on tasks appropriate for input data 111 received from step 310 .
[0026] Referring to step 330 of flowchart 300 in FIG. 3 , multi-core system 100 of FIG. 1 , and diagram 200 of FIG. 2 , step 330 of flowchart 300 comprises processor 121 selecting Function 1 and Function 2 from sequential function list 216 using Input 1 and Input 2 from input data 211 as function parameters. In other words, step 330 performs a data driven analysis as dictated by input data 211 to select required functions from sequential function list 216 .
[0027] Referring to step 340 of flowchart 300 in FIG. 3 , multi-core system 100 of FIG. 1 , and diagram 200 of FIG. 2 , step 340 of flowchart 300 comprises processor 121 translating Function 1 and Function 2 selected from step 330 into task list 250 comprising transaction control blocks 251 a - 251 b for execution on multi-core system 100 . As shown in FIG. 2 , template matcher 230 may perform a lookup against template database 231 to find the closest matching template 232 . As previously discussed, the template lookup may match against header descriptors such as input size, quantity, task type, and other criteria. Reference resolver 235 may then finalize template 232 by inserting data pointers and adding or removing TCBs as necessary. Additionally, tasks operating on common data may be consolidated into a larger task for execution on a single core and core local memory to reduce memory transfers and optimize for closest memory locality. Alternatively, as shown in FIG. 1 , if no suitable template is found or if API 125 a is explicitly called to perform full analysis, then task parallelism analyzer 140 may perform a full analysis to generate task list 250 , corresponding to task list 150 in FIG. 1 .
[0028] Referring to step 350 of flowchart 300 in FIG. 3 and multi-core system 100 of FIG. 1 , step 350 of flowchart 300 comprises processor 121 forwarding task list 150 to scheduler 160 for execution on slave processing cores 170 of multi-core system 100 . As task list 150 has already been pre-processed for optimal execution on slave processing cores 170 , scheduler 160 may simply proceed as normal using parallel processing methods well known in the art. After processing of task list 150 is completed, the results may then exposed back to application 115 via DAP 125 b , as indicated in FIG. 1 . In this manner, highly optimized execution of applications on multi-core systems can be achieved while avoiding the processing penalty of full real-time analysis. Moreover, the programmer of application 115 is freed from the burden of having to explicitly generate task list 150 to achieve high levels of parallelism on slave processing cores 170 .
[0029] From the above description of the embodiments of the present invention, it is manifest that various techniques can be used for implementing the concepts of the present invention without departing from its scope. Moreover, while the present invention ha's been described with specific reference to certain embodiments, a person of ordinary skill in the art would recognize that changes can be made in form and detail without departing from the spirit and the scope of the invention. It should also be understood that the invention is not limited to the particular embodiments described herein, but is capable of many rearrangements, modifications, and substitutions without departing from the scope of the invention. | There is provided a multi-core system that provides automated task list generation, parallelism templates, and memory management. By constructing, profiling, and analyzing a sequential list of functions to be executed in a parallel fashion, corresponding parallel execution templates may be stored for future lookup in a database. A processor may then select a subset of functions from the sequential list of functions based on input data, select a template from the template database based on particular matching criteria such as high-level task parameters, finalize the template by resolving pointers and adding or removing transaction control blocks, and forward the resulting optimized task list to a scheduler for distribution to multiple slave processing cores. The processor may also analyze data dependencies between tasks to consolidate tasks working on the same data to a single core, thereby implementing memory management and efficient memory locality. | 6 |
BRIEF DESCRIPTION OF THE INVENTION
The present invention relates to an apparatus for stacking a printed paper with pleats. More particularly, the invention relates to an improved apparatus for stacking a continuous printed paper delivered from an information processing system, such as a line-printer or the like, and supplied into a stacking apparatus.
Such paper to be supplied into the stacking apparatus has been given a plurality of equally spaced folded lines by means of a creasing machine or the like. During the time the stacking operation of the paper is being carried out, the swelling tendency along the edges of said folded paper upwardly from its normal lever, where said paper is to be folded along its folded line and stacked on an accumulation means of the stacking apparatus, are controlled by selecting the tilt of the accumulation plates of the paper accumulation means properly, so that the uppermost surface of the stacked paper is constantly maintained in a flat condition.
BRIEF DESCRIPTION OF THE PRIOR ART
Along with a recent use of a high-speed line-printer, the requirement for the automatic stacking apparatus of the printed paper has greatly increased. There have been several apparatuses designed to meet such a requirement. Two typical types of the above apparatus are described as follows.
One type of apparatus depends on the oscillation of a delivering mechanical element in such a manner that said element oscillates synchronistically with the distance of the folded lines on the paper, so that both of the folding and the stacking operations are being carried out simultaneously.
The other type of apparatus does not utilize the above-mentioned synchronizing movement but depends on the inherent tendency of the paper to be folded.
From the point of view of folding, we may say that the former apparatus provides a type of more positive and steadier operation, but owing to the complicated mechanism and operation, the manufacturing cost of said apparatus becomes quite high. Contrary to the above, the latter apparatus utilizes several kinds of air flows and mechanical oscillating motions, for instantaneously recovering the creasing of said paper. When comparing both said operations, the latter has a negative type of operation, but owing to the simplicity of its mechanism, the manufacturing cost of the latter is cheaper.
In a case of any of the above-mentioned conventional apparatuses, common and inevitable necessities are as follows: firstly, it is necessary to maintain a constant distance between the terminal end of the paper guide means and the uppermost surface of the stacked paper on the accumulation means, secondly, it is also necessary to prevent the edges of the folded paper from being swelled upwardly from its level, so as to maintain the uppermost surface of the stacked paper in a flat condition. Thus the uniform and regular stacking of the paper is realized on the paper accumulation means.
OBJECTS OF THE INVENTION
Accordingly, it is an object of the present invention to provide an improved apparatus for stacking a paper, which is easy for maintaining a constant distance between a terminal end of a paper guide means and the uppermost surface of the stacked paper on a paper accumulation means.
It is an another object of the present invention to provide an improved apparatus for folding and stacking a paper, in which apparatus the swelling of the edges of the folded and stacked paper is completely eliminated by varying the tilt of the accumulation plates provided on the paper accumulation means, so that the uppermost surface of the stacked paper is always maintained in a flat condition.
To attain the above-mentioned former object, some of the conventional apparatuses are using a preferably adjusted coil spring or a control device for a drive motor. To attain latter object, the other conventional apparatuses use several kinds of pressing devices for pressing the swelled edges of the paper downwardly.
Among the above-mentioned apparatuses of the prior art, the latter has an excellent effect in pressing down on the edges of the folded paper; however, many accessories, such as exclusive motors, pulleys and belts, are needed. Furthermore, sometimes there are other disadvantages and drawbacks, e.g., the folded edges are scratched and/or the printed surfaces of the paper are soiled from the movement of the pressing devices. When the processed paper is thin, such drawbacks are enhanced. Sometimes, when the pressing device, e.g., the conveyor belt, is being used, there may be a danger wherein the operator's finger may be injured by such a conveyor belt. A further drawback resides in this type of an apparatus in that, when the conveyor belt is to be operated by an operator, it is necessary to remove or to open the conveyor belt for performing the operation, because of the complicated construction of the apparatus. When the stacking operation is being carried out by the apparatus of the prior art, there is a further drawback on the observation of the stacked condition, because it is difficult to observe the stacking paper from the outside of the apparatus. Because the above-mentioned problems are caused by the existence of the conveyor belt or the like, it is preferable that the apparatus does not utilize them.
Thus, the most principal object of the present invention is to provide an improved apparatus for folding and stacking a printed paper, wherein the swelling tendency at both edges of the folded paper being stacked on the paper accumulation means is securely controlled without utilizing the above-mentioned pressing device, so as to maintain the uppermost surface of the stacked paper in a flat condition.
This object is achieved by means of an apparatus for folding and stacking a printed paper, in which said paper is folded after passing through a terminal end of a paper guide means and then stacked onto a paper accumulation means, said paper accumulation means is caused to descend according to the height of the stacked paper on the accumulation means so as to maintain an approximately constant distance between the terminal end of the paper guide means and the uppermost surface of the stacked paper on the paper accumulation means, which apparatus according to the present invention is characterized in that said paper accumulation means is provided with two accumulation plates, which support both edge portions of the stacked paper thereon and which are pivotably inclined, whereby the angle of said accumulation plates is being controlled in such a way that the wider the distance between the terminal end of the paper guide means and the paper accumulation means, the greater the downward inclination of the accumulation plates.
BRIEF EXPLANATION OF THE DRAWINGS
A preferred embodiment of the invention will now be described in detail with reference to the accompanying drawings, wherein the same reference numerals are used to designate similar parts throughout the several views, in which:
FIG. 1 through FIG. 5 show several schematic cross-sectional views of the paper stacking apparatuses of the prior arts; wherein
FIG. 1 is a cross-sectional view illustrating a basic concept of the conventional apparatus;
FIG. 2 is a cross-sectional view of the conveyor belts utilized for the conventional apparatus, which are downwardly inclined in a diverging direction;
FIG. 3 is a cross-sectional view of the conveyor belts utilized for the conventional apparatus, which belts are disposed vertically and in parallel;
FIG. 4 is a cross-sectional view of two wing wheels utilized for the conventional apparatus;
FIG. 5 is a cross-sectional view of two blowers utilized for the conventional apparatus;
FIG. 6 is a schematic cross-sectional view showing the main constructive parts of the apparatus according to the present invention, in which the placing of the fresh paper to be laid onto a paper accumulation means has commenced;
FIG. 7 is a schematic cross-sectional view showing the main parts of the apparatus in FIG. 6, in which the paper is folded and stacked onto the paper accumulation means;
FIG. 8 is a cross-sectional detailed view of the apparatus according to the present invention, in which the paper accumulation means is located at the starting-up position; and
FIG. 9 is a cross-sectional detailed view of the apparatus according to the present invention, in which the paper accumulation means is located at the finishing position.
DETAILED DESCRIPTION OF THE INVENTION
For the sake of understanding the present invention better, before entering into the illustration of the present invention in detail, the conventional stacking apparatus for printed paper is hereinafter illustrated with reference to the attached drawings FIGS. 1 through FIG. 5.
Referring to the attached drawings, FIG. 1 shows a basic concept of the paper stacking apparatus of the prior art. The most typical paper stacking apparatus comprises a pair of feed rollers 9 utilized to effect the folding operation of the paper 1 and a paper accumulation table 10, which is adapted for descents according to the increasing height of the stacked paper 1 thereon. The problem encountered in the above-mentioned conventional apparatus is that, when the stacking operation of the paper 1 is being carried out, both edges 2 of the stacked paper 1 show a swelled arrangement. This means that both sides of the stacked paper 1 rise up higher when compared to the midportion thereof. Therefore, if the paper 1 is continuously stacked onto said surface and if the height of the paper at that surface becomes too great, then there is a good chance for the stacked paper to become disarranged, or out of its regular stacked order and, moreover, cannot attain the uniform stacking of the folded paper. To avoid this problem, several kinds of paper stacking apparatuses have been designed.
In FIG. 2 showing the second example of the prior art, two conveyor belts (3a, 3b) are arranged at both sides of the stacked paper in such a manner that the belts are inclined diverging downwardly, so that said belts act upon the both sides of edges 2 on the uppermost surface of the stacked paper. The conveyor belts have a plurality of projections projected outwardly therefrom (such conveyor belts hereinafter referred to as the create conveyor belts), and are so arranged that they are constantly in contact with said edges 2 such that the swelled edges can be pressed down by the create conveyor belts.
In FIG. 3 showing the third example of the prior art, two create conveyor belts (4a, 4b) are arranged vertically and in parallel to each other. When the create conveyor belts are running, the projections of the belts come into contact with each of the edges progressively, so that the each of the edges 2 is pressed downwardly by the friction occuring between the projections of the belts and the edges 2 of the paper 1.
In FIG. 4 showing the fourth example of the prior art, both edges 2 on the uppermost surface of the stacked paper 1 are pressed downwardly by means of the wing wheels (5a, 5b), which are disposed above both sides of the said edges.
In FIG. 5 showing the fifth example of the prior art, two blowers (6a, 6b) for blowing air toward both said edges are utilized. Since the directions of the air flows are inclined diverging downwardly, they blow both edges on the uppermost surface of the stacked paper 1 downwardly. Owing to such air flows, the pressing down action against both edges of said paper may be accomplished.
All of foregoing apparatuses are adapted for facilitating the folding and stacking operation; however the pressing down effect on the stack paper is not too satisfactory.
Contrary to the above, the apparatus according to the present invention includes a controlling mechanism (not shown), which comprises a coil spring or a control device for a drive motor, so as to carry out the stacking of paper on the paper accumulation means by displacing the paper accumulation means along the vertical direction thereof. In this way, the distance between the terminal end of the paper guide means and the uppermost surface of the stacked paper on the paper accumulation means is maintained constant.
Furthermore, the apparatus according to the present invention is designed in such a way that, in accordance with the descent of the paper accumulation means, the inclination of both accumulation plates, on which both sides of the stacked paper are held, is increased to the horizontal. As a result, there is no swelling tendency of the edges on the uppermost surface of the stacked paper and said surface will always be maintained in a flat condition.
A preferred embodiment of the invention will now be described in detail with reference to the accompanying drawings.
FIGS. 6 and 7 show the main parts of an embodiment according to the present invention. FIG. 6 is a view of the paper folding and stacking apparatus at its starting position, and FIG. 7 is a view of the same when some stacking has already been accomplished. With regard to FIGS. 6 and 7, many elements of the apparatus are not shown in order to reveal important details.
As shown in FIGS. 6 and 7, the printed paper 1 delivered from a line-printer (not shown) is supplied to an accumulation means 20 after passing through a pair of feed rollers 22a, 22b so as to achieve a stacking of a folded paper 1 in such a manner that the paper 1 is folded along the folded or creased lines which were premade in a creasing machine (not shown).
Referring to FIG. 6, in order to cause the leading edge 3 of the supplied paper 1 to abut against a stop member 26, a center base plate 25 is inclined downwardly toward said stop member 26, so that the neighboring edge of said center base plate 25 adjacent to said stop member 26 is lower than the other edge as shown by the phantom line 125 in FIG. 6. In turn, when the leading edge 3 of the paper abuts against the stop member 26, the center base plate 25 swings back to its horizontal position as shown by the solid line 25, in response to a signal from a detector (not shown). Since the feed rollers 22a, 22b are rotated continuously, the folding and stacking operation of the paper 1 on the accumulation means 20 is carried out smoothly.
The accumulation means 20 includes the above-mentioned center base plate 25 and two accumulation plates (28a, 28b) provided under the center base plate 25. The outer portions of said plates (28a, 28b) are projected upwardly in an obtuse angle while the inside terminal ends of said plates are pivotally supported on the pins (27a, 27b) which are disposed under the center base plate 25. Each of the pins (27a, 27b) is adapted for sliding along two rails (31a, 31b) which rails are disposed vertically and in parallel to each other (FIG. 8). As the pins (27a, 27b) descend along the vertical rails 31a, 31b in accordance with an increase in the height of the stacked paper 1 on the accumulation means 20, the accumulation plates (28a, 28b) are swung downwardly around the pins (27a, 27b) as shown in FIG. 7. According to the increased stacking of the paper on the accumulation table 20, the swelling tendency of the edges of the stacked paper becomes greater. However, owing to the position of the angle in the accumulation plates (12a, 12b), said possible swelled height of the paper is compensated by the inclination of the plates. Therefore, the upper surface of the paper to be stacked is always maintained in a flat condition, so that the succeeding paper coming from the line-printer is continuously stacked in a uniform condition on the accumulation means 20.
The operation of the paper stacking apparatus of the present invention is hereinafter explained in more detail.
FIG. 8 is a constructive illustration of the apparatus embodying the novel concept of the present invention. In the drawing, the numeral 21 is a paper guide means, in which a printed paper (for example, printed by a line-printer or the like) passes. At the terminal end of said paper guide means 21 is provided a pair of feed rollers (22a, 22b), which are formed in the shape of an oval or an ellipse. The outer surface of the rollers (22a, 22b) are always in contact with each other and are rotated by means of a drive mechanism (not shown). On the other hand, on the sides to the above right and left of the pair of rollers (22a, 22b) are disposed two blowers (23a, 23b), which blow air flow downwardly against the outer peripheries of the uppermost surface of the stacked paper so as to assist the folding operation. By means of the vibrating motion of the rollers (22a, 22b), caused by the rolling contact between the elliptical rollers, the folding operation is performed effectively.
Then the paper is delivered continuously onto an accumulation apparatus 40 after passing through an opening 34 provided in a separate plate 24, which is disposed beneath said rollers (22a, 22b). A paper accumulation means 40 comprises a center base plate 25 movably mounted on a support table 30 and two U-shaped accumulation plates or combs (28a, 28b). Each of said accumulation plates (28a, 28b) consists of one long side, which is depressed downwardly, a curved portion, and another short side. The end of said one long side is pivotably mounted to a hinge pin (27a, 27b), which is rotatably fixed to the support table 30. Also on an extreme end of the other short side, a guide roller (29a, 29b) is pivotably mounted. Said guide rollers (29a, 29b) are so arranged that they can slide downwardly along two guide rails (32a, 32b), which are disposed vertically and can converge downwardly. All of the foregoing parts of the accumulation plates (28a, 28b) and of the guide rails (32a, 32b) are symmetrically arranged. Said guide rails have steps (132a, 132b) at their upper portions and have other steps (232a, 232b) at their lower portions as shown in FIGS. 8 and 9, respectively.
As the stacking operation is starting up, the accumulation plates take position at the upper portion of guide rails (32a, 32b), as shown by phantom lines (128a, 128b), owing to the fact that said rollers (29a, 29b) are held on said upper steps of the guide rails (32a, 32b), as shown by phantom lines (129a, 129b); the positions of the accumulation plates (28a, 28b) are inclined while diverging downwardly as shown by phantom lines (128a, 128b). At the same time, in accordance with the above-mentioned positions of the accumulation plates, a center base plate 25 is downwardly inclined toward a stop member 26, disposed beneath the separate plate 24. Said position of the center base plate 25 is shown by the phantom line 125. In this way, the leading edge of the supplied paper 1 is abutted against the stop member 26, i.e., the center base plate functions as an introducer for said paper.
In turn, when the leading edge of the paper 1 abuts against the stop member 26, the accumulation plates move to the position as shown by block lines (28a, 28b), and the center base 25 plate swings back to its horizontal position as shown by the solid line 25.
The above-mentioned movement of the accumulation plates (28a, 28b ) and the center base plate 25 are achieved by the downward movement of the support table 30. Further, the movement of the support table is carried out, e.g., by means of a pair of vertically traversing endless belts (31a, 31b) being disposed between two pairs of rollers rotatably provided in the apparatus. The traverse motion of the above-mentioned belts (31a, 31b) may be achieved by a drive motor (not shown) with a control means which consists of a well-known controlling device.
When the accumulation plates take the position as shown by the solid lines (28a, 28b), the guide rollers are positioned at the shoulder portion of the guide rails (32a, 32b) as shown by the solid lines (29a, 29b). The height of the uppermost surface of the stacked paper is detected by means of a photoelectric switch 33 provided on the apparatus. If the level of the stacked paper is greater than the standard level, the support table 30, which carries the accumulation means 40, commences to descend by means of the drive motor along the belts (31a, 31b), in response to a signal from said photoelectric switch 33. As the same time the guide rollers (29a, 29b) will descend along the guide rails (32a, 32b). Since the guide rails (32a, 32b) are converging toward each other at their lowest ends, as the accumulation plates (28a, 28b) descend, the angle of inclination to the horizontal ground level increases; thus, said inclination of the accumulation plates becomes maximum at the lowest ends of the guide rails shown by phantom lines (228a, 228b) in FIG. 9. This produces the effect of the flat condition on the uppermost surface of the stacked paper, thus making it possible to take out the uniformly stacked paper through a take out plate 34, which is provided on the lower portion of the apparatus.
Although the descending of the paper accumulation means is employed in the illustrated embodiment by the driving of the motor which is actuated by means of a photoelectric switch, and the inclination of the accumulation plates depends on the guide rails, it will be apparent that any equivalent control means may be employed for this purpose. Also the intensity and the direction of the air flow produced by the blowers (23a, 23b) are chosen so that the most effective introducing of the leading edge of the paper and folding of the same may be achieved upon the stacked paper. | In an apparatus for stacking a continuous printed paper delivered from an information processing system, such as a line-printer or the like, for paper stacking apparatus comprises a paper guide means for conveying a printed paper and a paper accumulation means which includes a center base plate and two accumulation plates disposed at both sides thereof, on which said printed paper is orderly stacked in its folded fashion along its pleats. In accordance with the increasing height of the stacked paper, the paper accumulation means descends and also tilting of said accumulation plates varies, which together help to maintain the uppermost surface of the stacked paper in a flat condition. Thus, the desirable stacking of paper is achieved on the accumulation means. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
This is a continuation of PCT application No. PCT/EP2009/066809, entitled “Reactor Inlet”, filed Dec. 10, 2009, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a reactor for anaerobically purifying waste water, especially waste water from the paper industry, comprising a reactor vessel, several inlets arranged in the bottom region of the reactor vessel to feed waste water to be purified into the reactor, at least one outlet for discharging purified water, and at least one sediment drain, whereby one or more inlets are fed by one supply pipe and several supply pipes are fed by one collecting supply pipe.
The invention moreover relates to a method for anaerobically purifying waste water, especially waste water from the paper industry, comprising a reactor vessel, several inlets arranged in the bottom region of the reactor vessel to feed waste water to be purified into the reactor, at least one outlet for discharging purified water, and at least one sediment drain, whereby one or more inlets are fed by one supply pipe and several supply pipes are fed by one collecting supply pipe.
2. Description of the Related Art
A multitude of mechanical, chemical and biological methods and corresponding reactors are known for purification of waste water. In biological waste water purification, the waste water to be purified is brought into contact with aerobic or anaerobic micro-organisms which, in the case of aerobic micro-organisms decompose organic contaminants contained in the waste water predominantly to carbon dioxide, biomass and water, and in the case of anaerobic micro-organisms mainly to carbon dioxide and methane and only in small part to biomass.
In recent times the biological waste water purification methods are hereby carried out increasingly with anaerobic micro-organisms, since with the anaerobic waste water purification oxygen does not have to be fed with high energy expenditure into the bioreactor; energy-rich biogas is produced during purification which can subsequently be utilized for generating of energy; and substantially lower volumes of excess sludge are produced.
Depending on the type and form of the utilized biomass, the reactors for anaerobic waste water purification are categorized into contact sludge reactors, UASA-reactors, EGSB-reactors, fixed bed reactors and fluidized bed reactors.
Whereas the micro-organisms in fixed bed reactors adhere to stationary carrier materials and the micro-organisms in fluidized bed reactors adhere to freely moving, small carrier material, the micro-organisms in UASB and EGSB reactors are utilized in the form of so-called pellets. In contrast to UASB (upflow anaerobic sludge bed) reactors, EGSB (expanded granular sludge bed) reactors are higher and at same volume have a substantially smaller base area.
In the case of UASB and EGSB reactors, waste water which is to be purified, or a mixture of waste water which is to be purified and already purified waste water from the outlet of the anaerobic reactor is fed continuously to the reactor through an inlet which is arranged in the lower region of the reactor and is directed through a micro-organism pellet-containing sludge bed which is located above the inlet.
During decomposition of the organic compounds from the waste water, the micro-organisms form in particular methane and carbon dioxide containing gas (which is also referred to as biogas) which partially adheres to the micro-organism pellets in the form of small bubbles and which partially rises to the top in the reactor in the form of free gas bubbles. Because of the added gas bubbles the specific weight of the pellets decreases, which is the reason that the pellets rise to the top in the reactor. In order to separate the formed biogas and the rising pellets from the water, separators are arranged in the center and/or upper part of the reactor, mostly in the embodiment of gas hoods under the top of which biogas accumulates, forming gas cushions. Purified water, relieved of gas and micro-organism pellets rises to the top in the reactor and is drawn off at the upper end of the reactor through overflows. Methods and associated reactors are described for example from EP 0170 332 A and EP 1 071 636 B.
For the previously described methods uniform distribution of the waste water added to the reactor through the inlet across the reactor cross section is particularly important in order to achieve good blending of the sludge pellets which are present in the reactor, of the water which is present in the reactor and of the added waste water. In order to meet these requirements, a multitude of reactors, equipped with appropriate inlet distributors have already been suggested.
These have a multitude of inlets in the region of the reactor chamber through which the waste water which is to be purified is to be distributed.
Especially with waste water having high lime content, such as waste water from the paper industry, precipitation and sediment deposits occur frequently. These settle on the bottom of the reactor vessel and thereby increase the flow resistance at the discharge openings of the inlets. The result is that a greater volume flows from other inlets of the inlet distributor.
This may result in that more than 75% of the inlets are inactive without this being recognizable from the outside. Because of the non-uniform supply of waste water associated with this, the efficiency of the waste water treatment can be substantially lowered.
What is needed in the art is to ensure an as uniform as possible infeed of waste water to be purified at the bottom of the reactor vessel. In the following the term “pellets” is to be understood to be in particular granulated bio-sludge.
SUMMARY OF THE INVENTION
The present invention provides that at least the majority of the supply pipes of a collecting supply pipe supplies a maximum of 10 inlets with waste water which is to be purified and whereby at least the majority of said supply pipes each respectively is equipped with a control valve.
By minimizing the inlets allocated to the supply pipes the distribution of waste water that is to be purified can be better controlled across the cross section of the reactor vessel and can thereby also be made more uniform.
This is also still possible even when individual inlets are partially or totally covered by sediment deposits.
Moreover—because of the low number or inlets in a supply pipe—when only one or few inlets are obstructed, there is a strong increase of flow in the other unobstructed inlets of this supply pipe, thereby counteracting the obstruction.
With the higher number of supply pipes a more uniform distribution across the bottom of the reactor vessel of the supply of waste water which is to be purified can be ensured, even when inlets are obstructed.
In the event of an obstruction or respectively uneven flow this can be recognized in that these inlets become cold.
Depending on the construction and size of the reactors, as well as the type of waste water it can be advantageous—even when considering the higher expenditure for the increased number of supply pipes and control valves—if the majority of the supply pipes of a collecting supply pipe supply a maximum of 6, preferably a maximum of 3 or even only one inlet with waste water to be purified.
To comprehensively influence the supply of waste water to be purified, all supply pipes should be equipped with a control valve.
Moreover it is advantageous if at least a majority of the inlets, preferably all inlets protrude beyond the bottom of the reactor vessel. This can prevent that sediments settling on the bottom of the reactor vessel even cover the inlets, or at least prevent that they cover them too quickly.
Only a definitive distance to the bottom of the reactor is hereby crucial, so that the inlets can be brought through the bottom or through the side into the reactor vessel.
It is moreover advantageous when at least the majority of the supply pipes, preferably all supply pipes are routed out of the reactor vessel. Since generally also the inlet distributor is located outside the reactor vessel this can on the one hand easily be realized, and on the other hand allows accessibility to measuring and control devices in as far as they are installed or arranged in the section of the supply pipe which is located outside the reactor vessel.
In addition to the control valves at least a majority of supply pipes, preferably all supply pipes should be equipped with a flow meter which would facilitate relatively easy determination if any or how many inlets of the relevant supply pipe are obstructed. The supply distribution across the cross section of the reactor can then be more effectively controlled.
To be able to loosen and remove the sediment more easily from the reactor bottom it is advantageous if at least one inlet, preferably all inlets of at least one supply pipe is directed to a sediment drain.
Moreover, in the interest of a uniform distribution of the added volume of waste water, all inlets should also preferably be distributed uniformly across the bottom of the reactor vessel.
In regard to the constructive embodiment of the reactor vessel it was shown to be advantageous if the reactor vessel has at least one downward tapering funnel and if the sediment drain is located at the lower end of the funnel. The reactor, as well as the funnel can have a round or angular cross section.
The funnel-shaped reactor bottom, especially in the form of a downward tapering single cone or double cone ensures that solids having a high specific weight descending from the upper section of the reactor can be discharged from there.
Accumulation of sediments in the area of the inlets which would lead to formation of dead spaces and to a reduction of the effective reactor cross section could hereby be avoided.
Here, the reactor bottom may also be formed by several funnels with sediment drainage.
Moreover, at least one central supply pipe for the addition of liquid should feed into the bottom end of the funnel, whereby the furnished liquid can consist of waste water to be purified, purified waste water or a mixture thereof. The pellets can be reactivated and/or the sediment detachment and discharge can be assisted through this liquid.
In order to adapt the inlets to the prevailing conditions in the reactor and in order to avoid blockages, as well as to assist the sediment detachment or discharge it is also advantageous if at least some, preferably all inlets are changeable in regard to their location and/or orientation.
In regard to the inventive method it is important that several supply pipes are each equipped with a control valve and that at least individual control valves are from time to time opened to a different level. The flow volume in the supply pipes is thereby adjusted to the requirements and if needed, lowered to zero.
In the interest of comprehensive controllability the waste water volume flow should therefore be controlled in all supply pipes via control valves.
In order to be able to better homogenize the distribution of the waste water to be fed into the reactor vessel, the flow rate on some, preferably on all supply pipes should be measured and the control valves controlled depending upon the flow rate in the supply pipes.
Moreover it is advantageous for the process control if the extent of the sediment deposit on the bottom of the reactor vessel and/or the removed sediment volume is measured.
In this manner not only the extent of the sediment deposit, but also distribution thereof may be determined.
This also permits a targeted sediment removal.
If, for example, sediments in a certain section of the reactor bottom are to be loosened or removed, then only those inlets are supplied through the control valves—intensified or exclusively—with liquid, especially waste water to be purified which are arranged in that section of the bottom which is to be flushed clean and/or which are directed onto a sediment drain in that section.
Independent of the sediment removal in a certain section it can also be advantageous for general support of the sediment discharge if only those inlets are intensified or exclusively supplied with liquid, especially waste water to be purified through the control valves which are directed onto one or several sediment drains.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a schematic longitudinal section through a reactor; and
FIGS. 2 and 3 are various supply distribution systems on bottom 8 of the reactor.
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate embodiments of the invention, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
The bioreactor illustrated in FIG. 1 comprises a reactor vessel 1 which is cylindrical in its center and upper region and which tapers conically downward in its lower region. The supply distribution system to feed the waste water to be purified is located in the lower region, in other words in the funnel of the reactor.
Two separators 11 , 12 which each are equipped with several gas hoods 13 are located in the center and upper reactor vessel 1 . In practical operation each of the separators 11 , 12 consists of several layers of gas hoods 13 ; for reasons of simplification however, only one layer of gas hoods 13 per separator 11 , 12 is depicted in current FIG. 1 .
Drains 4 are located above upper separator 12 , each in the embodiment of an overflow through which the purified water is drawn from the reactor.
A gas separation device 14 is arranged on the reactor which is connected via pipes 15 with the two separators 11 , 12 . In addition, a drain pipe 16 leads from the bottom of gas separation device 14 into the lower region of reactor vessel 1 .
Moreover, a sediment drain 3 , as well as a central supply pipe 10 are located in the lower region of reactor vessel 1 , more precisely in the lower region of the funnel, whereby solids or respectively a suspension consisting of solids and liquid can be drawn from reactor vessel 1 via sediment drain 3 , and liquid for flushing of lower reactor vessel region 1 can be furnished through central supply pipe 10 .
The inlet distribution system is formed by a multitude of inlets 2 which are arranged uniformly on bottom 8 of reactor vessel 1 —in this example on the inside wall of the funnel.
The water to be purified is fed into reactor vessel 1 via these inlets 2 . Here, only a few, specifically no more than five inlets 2 are supplied with the waste water by a common supply pipe 5 . Each supply pipe 5 is connected through one control valve 7 each with a collecting supply pipe 6 which is allocated to several supply pipes 5 .
In this way an obstruction of an inlet 2 affects the other few inlets 2 of supply pipe 5 more significantly, so that the remaining open inlets 2 experience a stronger flow rate, thus accordingly counteracting a sediment deposit on respective inlet 2 .
Moreover, blocked inlets 2 are freed through the pressure increase in supply pipe 5 , whereby the pressure can also be raised simply through closing other supply pipes.
Moreover, due to the high number of supply pipes 5 which can be controlled through control valves 7 , the distribution of the added waste water on bottom 8 of reactor vessel 1 can be controlled much more precisely.
Inlets 2 allocated to a supply pipe 5 can be arranged adjacent to each other and/or on top of each other in reactor vessel 1 .
During operation of the reactor, waste water to be purified is fed into reactor vessel 1 through inlets 2 , whereby homogeneous mixing occurs between the added waste water and the medium in the reactor which consists partially of purified waste water, micro-organism pellets (indicated in FIG. 1 by small dots) and small gas bubbles.
The furnished waste water flows from inlets 2 slowly upward in reactor vessel 1 until it reaches the fermentation zone containing the micro-organism containing sludge pellets. The micro-organisms contained in the pellets decompose the organic contaminates contained in the waste water, predominantly to methane and carbon dioxide gas. Due to the produced gas, gas bubbles occur, the larger of which detach themselves from the pellets and bubble through the medium, whereas the smaller gas bubbles remain adhered to the sludge pellets. The pellets on which small gas bubbles adhere and which, therefore, have a lower specific weight than the other pellets and the water, rise in reactor vessel 1 until they reach the lower separator 11 .
The free gas bubbles collect in gas hoods 13 and form a gas cushion below the top of gas hoods 13 .
The gas accumulated in gas hoods 13 , as well as a small amount of carried along pellets and water are discharged for example from gas hoods 13 through an opening which is not illustrated and which is located on the face side of gas hoods 13 , and is fed into gas separation device 14 through pipe 15 .
The water, the rising micro-organism pellets and the gas bubbles which were not already separated in lower separator 11 , rise further in reactor vessel 1 to the upper separator 12 . Due to the decrease of the hydrostatic pressure between lower separator 11 and upper separator 12 , the remaining small gas bubbles detach form the micro-organism pellets which got into upper separator 12 , so that the specific weight of the pellets increases again and the pellets sink downward.
The remaining gas bubbles are captured in gas hoods 13 of upper separator 12 and are again transferred into a gas collecting pipe on the face sides of individual gas hoods 13 , from where the gas is fed into the gas separation device 14 via pipe 15 .
The now purified water rises from upper separator 12 further upwards, until it is drawn by the overflows from reactor vessel 1 and is discharged through an outlet pipe.
In gas separation device 14 the gas separates from the remaining water and the micro-organism pellets, whereby the suspension consisting of pellets and the waste water recirculates through the drain pipe 16 into reactor vessel 1 . The outlet opening of drain pipe 16 feeds into the lower section of reactor vessel 1 where the re-circulated suspension of pellets and waste water is mixed with the waste water fed to reactor 1 through inlets 2 , after which the cycle begins again.
Depending on the origin of the waste water furnished to reactor 1 through inlets 2 , the waste water has greater or lesser solids content. Waste water from the paper industry for example contains significant concentrations of solid filler materials and lime. After the solids-containing waste water has left inlets 2 it rises upward into the cylindrical reactor vessel section. The portion of solids contained in the waste water which exceeds a minimum of specific density, descends already after leaving inlets 2 into the downward tapering funnel where it accumulates.
Moreover, a portion of the calcium dissolved in the waste water precipitates on the sludge pellets after the waste water has risen in the sludge bed zone. Thus, a portion of the sludge pellets exceeds a critical specific density and therefore descends from the sludge bed and also accumulates in the funnel.
Inlets 2 are arranged and aligned to sediment drain 3 so that the pellets which descend downward from the top do not settle on inlets 2 , but glide off the outside surface of inlets 2 and also accumulate in the tip of the funnel.
The sediment accumulating in the tip of reactor vessel 1 can be removed from the reactor continuously, or in batches as required, through sediment drain 3 .
Moreover, liquid can also be fed through central supply pipe 10 continuously or in batches, as required, into lower section 2 of the reactor vessel. The liquid fed into the reactor through this central supply pipe 10 can be waste water to be purified, re-circulated waste water from the reactor, fresh water or a mixture thereof.
In contrast, the reactor depicted in FIG. 2 has a square cross section. As can be seen in the top view of bottom 8 of the reactor, several supply pipes 5 feed into reactor vessel 1 , laterally from the reactor wall.
Each supply pipe 5 has a maximum of five inlets 2 , which here are directed into the upper section of reactor vessel 1 . This is to assist mixing of the waste water furnished through inlets 2 , with the medium in reactor vessel 1 .
In order to impede covering of inlets 2 with sediment, the inlets are arranged several centimeters above bottom 8 of the reactor.
Located outside reactor vessel 1 is also flow meter 9 which, in this example, is allocated to each supply pipe 5 , as well as a control valve to influence the flow rate in supply line 5 .
In place of a stationary flow meter 9 , mobile units can also be utilized.
In any event, locating the control and meter devices 7 , 9 outside of reactor vessel 1 makes them less susceptible to failure than inside the reactor in the sometimes aggressive atmosphere. Assembly and maintenance are hereby also simplified.
Through flow meters 9 it can easily be determined if individual or several inlets 2 of a supply pipe 5 are compromised.
In the case of a blockage for example a momentary pressure increase in the respective supply pipe 5 can free blocked inlets 2 . Here, the pressure increase can also occur through closing other supply pipes 5 .
On the assumption that all inlets 2 of this supply pipe 5 are compromised, the pressure in supply pipe 5 can also be increased in general.
Reactor vessel 1 depicted in FIG. 3 as a longitudinal sectional view through the lower section has a square bottom 8 .
Here, supply pipes 5 protrude above bottom 8 , from below through reactor vessel 1 . In the current example each supply pipe 5 is shown with only one inlet 2 which is arranged at such height above bottom 8 that protrudes in all events above a possible sediment deposit—which in this example is slanted—on bottom 8 .
If required, supply pipes 5 may also be designed so that they are adjustable from outside the reactor. In this way the height and orientation of inlets 2 of corresponding supply pipe 5 can be changed or adapted relatively easily.
To impede sediment deposit on bottom 8 in the region of supply pipes 5 , bottom 8 is generally slanted, whereby the slant is realized so that the sediment slides in the direction of a sediment drain 3 on bottom 8 of the reactor.
Moreover, all inlets 2 are directed toward this sediment drain 3 . This causes the waste water fed into reactor vessel 1 through the inlets to already loosen and transport sediments in the direction of this sediment drain 3 . For flushing bottom 8 , individual or all inlets 2 can inject waste water at a higher than normal pressure into reactor vessel 1 .
While this invention has been described with respect to at least one embodiment, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims. | The invention relates to a reactor for anaerobically purifying waster water, especially waste water from the paper industry, comprising a reactor vessel, several inlets arranged in the bottom region of the reactor vessel to feed waste water to be purified into the reactor, at least one outlet for discharging purified water, and at least one sediment drain. One or more inlets are fed by a supply pipe, and several supply pipes are fed by a collecting supply pipe. In order to ensure that waste water to be purified is fed as regularly as possible at the bottom of the reactor vessel, at least the majority of the supply pipes of a collecting supply pipe supply waste water to be purified to a maximum of 10 inlets, and at least the majority of said supply pipes each have a control valve. | 2 |
RELATED APPLICATION
This application is a continuation of our prior application Ser. No. 09/085,382, filed May 26, 1998 now abandoned, originally entitled Quick-Connect Coupling and amended to be entitled Coupling.
FIELD OF THE INVENTION
The present invention pertains to a fluid coupling and more particularly to a fluid coupling having coupling members that are quickly connectable and disconnectable and also to a coded fluid coupling that is quickly connectable and latchable but only if the coupling members match and to a method for their use.
BACKGROUND
In various industries, it is necessary to use many chemicals in the manufacturing process. In the semiconductor industry, for example, some fifteen to twenty liquid chemicals are typically stored in adjacent fifty-gallon supply drums from which they are dispensed during the manufacture of the semiconductors. In the usual installation, sets of separate umbilical delivery lines for various chemicals are suspended above the drums with a particular set dedicated to a particular chemical. Each set of delivery lines is connected to its associated supply drum by a coupling that has one coupling member on the delivery lines and a second coupling member on the drum.
As each supply drum is emptied during the manufacturing process, a full drum is brought in to replace the empty one. Accordingly, the coupling members must be repeatedly connected and disconnected. Because of the incompatibility of the chemicals, it is critical that each set of delivery lines be connected only to its intended drum to avoid unsafe mixing and undesired contamination. Moreover, to maintain productivity, such connections and disconnections must be made quickly and routinely by production personnel.
To insure correct connection of delivery lines to their intended supply drums, the known chemical extraction apparatus uses fluid couplings that incorporate matching coding elements on the coupling members. Examples of such fluid couplings and their coding devices are shown and described in the U.S. Pat. No. 4,699,298 to Grant et al. and U.S. Pat. No. 5,108,015 to Rauworth et al. A significant disadvantage of these known couplings, however, is that they cannot be as quickly connected and disconnected as is desired. Although referred to as quick-connect couplings, they use threaded parts to secure the connection. Repeated threading and unthreading of couplings over a production run consumes a significant amount of valuable time and also can produce additional delays if the threads become fouled and otherwise fail to mesh properly.
Fluid couplings that can be connected and disconnected without threading are of course available and are truly quick-connect and -disconnect couplings. Examples of known quick-connect couplings are disclosed in U.S. Pat. No. 4,436,125 to Blenkush and U.S. Pat. No. 5,052,725 to Meyer et al. Such known couplings of this type, however, are not suitable for the chemical extraction industry or other industries where matched connections are mandatory since they make no provision for coding, that is, insurance against making mismatches. Moreover, the latching mechanisms used in such known quick-connect couplings do not lend themselves to balanced and dependable two-handed operation by personnel in production processes such as described above.
The copending reissue application of Kazarian, Application Ser. No. 091693,627, filed Oct. 20, 2000 which is a reissue of U.S. Pat. No. 6,007,107 granted Dec. 28, 1999 which is based on Kazarian Application Ser. No. 08/683,516, filed Jul. 12, 1996, entitled Fluid Coupling For Matching Delivery and Supply Lines Irrespective Of The Relative Rotational Positions Of The Coupling Members, and having a common assignee with the present application, is one solution to the problems set forth above. The invention of the present application provides an alternative solution.
SUMMARY
A fluid coupling including coded and non-coded embodiments and a method for their use are provided. The coded embodiment allows interconnection of only matching fluent material delivery and supply lines while preventing the inadvertent connection of mismatched lines in a system where there are matched and mismatched delivery and supply lines. Both embodiments of the coupling include axially movable first and second coupling members and a radially operating latch. The coupling members are releasably slideably, axially interfitted with their fluid passageways in communication, and the latch moves radially of the passageways to secure the couplings when they are intermitted. In the coded embodiment, key coding elements on the coded coupling members are movable into matched interengagement when the supply and delivery lines are matched but are precluded from moving into matched interengagement when the lines are mismatched. If a match exists, the coding elements interfit by limited rotation of one of the key coding elements but without rotation of the coupling members and without any threading action of the parts. A mechanism latches the couplings together when the key coding elements match and allows the coupling members to interfit but does not latch when the key coding elements do not match and thus do not allow an interfit. In both embodiments, the coupling members are uncoupled solely by axial separation of the parts, again with out threading, and in the case of the first embodiment, without even any rotation of the parts. In both cases, therefore, neither the coupling members, the coding elements, nor the latch involves threaded connections, whether for connection or disconnection or for latching or unlatching.
An object of this invention is to provide an improved fluid coupling.
Another object is to provide a coded quick-connect and disconnect coupling for use in a chemical extraction system involving supply drums of chemicals and separate delivery lines suspended above the drums.
A further object is to improve the productivity and safety of dispensing a plurality of incompatible chemicals through different delivery lines from different supply drums in a manufacturing process.
A still further object is to provide a simplified coupling that enables dependable quick connection and quick disconnection of the coupling members.
Additionally, an object is to reduce the manufacturing costs of a quick-connect coupling.
Another object is to provide an interactive key coding system and latching mechanism in a quick-connect coupling wherein the coupling members cannot be coupled and latched unless they match.
Yet another object is to provide a simplified quick-connect coupling that does not involve threading or unthreading of the parts.
An additional object is to provide a coupling for supply and delivery lines that allows establishing a coupling without twisting of the lines or relative rotation of the coupling members or threading of the parts and without regard to the relative rotational positions of the coupling members prior to or during interfitting thereof.
A still further object is to provide a key-coded, quick-connect coupling that does not require swiveling of its coupling members for connection but permits the parts being coupled to swivel relative to each other without affecting the rapidity of interconnecting matched coupling members and without affecting the operation of coupling.
Another object is to minimize the time required dependably to connect and disconnect matched coupling members of a coded coupling or to determine that the coupling members are mismatched and will not couple.
An additional object is to provide a key coding system for a coupling that can handle many different combinations of matches and mismatches.
Yet another object is to provide a balanced coding system for a coded quick-connect coupling that lends itself to two-handed operation by a user.
A still further object is to provide an indicator that allows an operator to confirm whether the coupling members are matched and interfitted or whether they are mismatched and not interfitted.
Another object is to isolate the coding and latching elements of a quick-connect coupling from the fluids carried by the coupling and to provide such elements with protection from the fluids.
An additional object is provide a quick-connect fluid coupling in which latching members are captured in the coupling by the assembly thereof.
A further object is to provide a method for using the couplings disclosed herein.
These and other objects, features and advantages of the present invention will become apparent upon reference to the following description, accompanying drawings, and appended claims.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation of a supply drum (partially broken away) and umbilical delivery lines of a chemical extraction system and showing a side elevation of coded quick-connect fluid coupling in accordance with the present invention mounted on the drum and interconnecting the drum and the delivery lines.
FIG. 2 is an enlarged, longitudinal section of the preferred embodiment of the coded coupling shown in FIG. 1, such coupling including an extractor head providing one of the coupling members, a coded extractor drum insert providing the other coupling member, and a coded latching sleeve, the coupling members being shown in interfitted relationship but unlatched.
FIG. 3 is a view similar to FIG. 2 but with the coupling members interfitted, matched and latched.
FIGS. 4 a and 4 b are views similar to FIGS. 2 and 3 but respectively showing the extractor head and sleeve separated and uncoupled from the extractor insert.
FIG. 5 is a somewhat enlarged, longitudinal section of the extractor drum insert shown in FIG. 4 b.
FIG. 6 is a bottom plan view of the extractor drum insert taken from a position indicated by line 6 — 6 in FIG. 5 .
FIG. 7 is a somewhat reduced, longitudinal section of the extractor head shown in FIG. 4 a but separated from the sleeve and without the delivery lines and poppet valve.
FIG. 8 is a top plan view of the extractor head taken from a position indicated by line 8 — 8 in FIG. 7 .
FIG. 9 is a somewhat reduced, longitudinal section of the coded latching sleeve shown in FIG. 4 a but separated from the extractor head.
FIG. 10 is a bottom plan view of the coded latching sleeve taken from a position indicated by line 10 — 10 in FIG. 9 .
FIG. 11 is a side elevation of a coil spring employed in the present invention although enlarged from FIGS. 2 through 4 a.
FIG. 12 is a longitudinal section of either end portion of the coil spring shown in FIG. 11 .
FIG. 13 is a longitudinal section of a second no-coded embodiment of the quick-connect coupling of the present invention shown with the coupling members interfitted and latched.
FIG. 14 is a somewhat enlarged longitudinal section of only the extractor head of the coupling shown in FIG. 13 .
FIG. 15 is a top plan view of the extractor head shown in FIG. 14 .
FIG. 16 is a somewhat enlarged longitudinal section of only the sleeve of the coupling shown in FIG. 13 .
FIG. 17 is a bottom plan view of the sleeve shown in FIG. 16 .
DETAILED DESCRIPTION
A preferred embodiment of the coded fluid coupling of the present invention is generally indicated by the numeral 25 in FIGS. 1 through 4. The coupling is both a “quick-connect” and a “quick-disconnect” coupling. As is well known, such expressions as “quick-connect,” “quick-disconnect,” and “quick-release” couplings are commonly used to mean a coupling that has both quick-connecting and quick-disconnecting capabilities. Accordingly, the expression “quick connect” coupling is used herein to mean a coupling that is both quick to connect and quick to disconnect without repeating the word “disconnect” every time.
The subject coupling 25 (FIGS. 1 and 2) is particularly suited for use in conducting chemicals in the semiconductor industry where a variety of highly corrosive and incompatible chemicals are used. Such chemicals include ammonium hydroxide; hydrogen peroxide; and hydrofluoric, phosphoric, nitric, hydrochloride and sulfuric acids. These chemicals are typically stored in a fifty-five gallon drum, as 27 , as more fully illustrated in U.S. Pat. No. 5,108,015. The system employed in the semiconductor industry for supplying these chemicals may involve from fifteen to twenty of the drums with each drum containing a particular chemical.
The chemical extraction system or apparatus generally indicated in FIG. 1 includes a chemical supply or down tube or line 30 immersed in the chemical of one of the drums and extending up to the bung hole generally indicated at 32 . The extraction system also includes a chemical delivery line or hose 34 and an air or nitrogen feed line or hose 36 , each of which is connected to the coded quick-connect coupling 25 . An air indicator or sensor line or hose 38 is also connected to the coupling for a purpose to be described. The chemical delivery hose 34 extends from the drum to the work area of the semiconductor plant where the chemical in that drum is to be used. The hoses 36 and 38 respectively extend to sources of nitrogen and air under pressure, not shown.
As is well known, the hoses 34 and 36 associated with each chemical are suspended in an umbilical fashion above the drums 27 and are connected to their respective drums by a fluid coupling which in the present case is the coupling 25 . The hose 38 is similarly suspended and connected. The subject coupling allows for the quick and dependable disconnection and reconnection of these umbilical hoses to the down tube 30 when a depleted drum 27 is removed and a full drum replaces it, while ensuring that the chemical hoses for a particular chemical is connected to the corresponding drum containing that chemical.
The coded quick-connect coupling 25 (FIGS. 1 through 4) of the present invention in general includes an extractor head 50 connected to the delivery, feed and indicator hoses 34 , 36 , and 38 ; an extractor drum insert 52 connected to the drum 27 and its down tube 30 ; a latch generally indicated at 54 for securing the extractor head and the extractor drum insert together when they are matched and interfitted; a poppet valve 56 that opens and closes upon connection and disconnection, respectively, of the extractor head and the extractor drum insert; and a key coding system 58 that ensures connection of the extractor head and delivery hose 34 for a certain chemical to the extractor drum insert and supply drum 27 containing that chemical.
The subject coded fluid coupling 25 is best described in detail by reference to FIGS. 2 through 4. The coupling is shown partially assembled in FIG. 2 with the extractor head 50 and the extractor drum insert 52 matched, interfitted and unlatched, that is, unlocked. FIG. 3 shows the coupling fully assembled, matched, interfitted and securely latched or locked. FIGS. 4 a, b show the extractor head separated from the extractor insert but in condition to be thrust down on an extractor insert and coupled thereto if a match exists.
In describing the orientation of the extractor head 50 and drum insert 52 (FIGS. 2 through 4 ), a vertical orientation of the coupling 25 is assumed since this is its normal orientation in use. It will be understood, however, that the coupling is not limited to use in a vertical orientation, although such reference is convenient for descriptive purposes. Furthermore, the coupling is made almost exclusively of a corrosion-resistant, durable, and hard fluoropolymer plastic, such as “Teflon” PFA, that is perfluoroalkoxy, sold by the Dupont Corporation among others, or polyethylene. The only parts of the coupling that are not of this plastic material are the cores of coil springs, as explained below. Most of the parts of the coupling may be either molded or machined, although one of the major advantages of the subject coupling is that it may be readily molded rather than machined since the latter is more expensive.
The extractor drum insert 52 (FIGS. 5, 6 ) includes a lower, cylindrical, adapter fitting 66 having external threads 68 and providing a main or central fluid passageway 70 having a longitudinal central axis 72 . The drum insert also includes an upper male coupling member 74 , coaxial with the passageway and having a smooth external cylindrical surface 76 . A spider 78 is provided at the top of the male coupling member and, as is well known, provides a solid central portion surrounded by a plurality of openings allowing fluid material to flow therethrough and around the central portion. The adapter fitting also has a plurality of longitudinal air passages 80 , six in the disclosed embodiment, that are parallel to the central passageway and in substantially equally spaced relation around the central passageway. The main passageway connects to the down tube 30 (FIGS. 1, 2 ) for extracting the chemical from the drum 27 , and the air passages open into the drum above the level of the chemical therein. A gasket 82 seals between the drum and the insert.
The extractor drum insert 52 (FIGS. 5, 6 ) also has an annular key-coding flange 86 projecting radially outwardly from the adapter fitting 66 and terminating in an annular skirt 88 . The skirt has external threads 90 so that the insert is adapted for fitting into a bung hole, as 32 , of a different dimension from the adapter fitting 66 . The coding flange 86 has a plurality of coding holes 92 that are part of the key-coding system 58 of the present invention which will be subsequently described in more detail. At this point, however, it is to be noted (FIG. 6) that the coding holes include balancing holes 92 a and 92 b located in diametrically opposite positions on the coding flange and indexing holes 92 c , 92 d , and 92 e located in angularly spaced relation to each other and to the balancing holes 92 a and 92 b , all of the holes being adjacent to the rim of the coding flange. In the subsequent description when the coding holes are generally referred to, the reference number 92 is used, but when a specific coding hole is referred to, the reference number 92 followed by a letter is used.
The latch 54 (FIG. 2) includes an inner latching ring 110 (FIGS. 5 and 6) projecting upwardly from and integral with the coding flange 86 in radially outwardly spaced, concentric relation to the male coupling member 74 and in radially inwardly spaced relation to the coding holes 92 . The inner latching ring has an annular, radially outwardly opening, latching groove 112 that is V-shaped in cross section thereby to provide outwardly, upwardly and downwardly extending, divergent or beveled groove surfaces.
The extractor head 50 (FIGS. 7, 8 ) includes a radial upper end wall 120 that has a large central recessed area 121 , an upper annular canopy 122 extending downwardly from the upper end wall, a cylindrical upper external surface 124 extending downwardly from the upper end wall and radially inwardly spaced from the canopy, and a cylindrical lower external surface 126 of a reduced diameter from the upper surface and extending downwardly therefrom to provide an upper radial shoulder 128 . The extractor head also includes an outer latching ring 130 that is a lower annular extension of the lower external surface but forms part of the latch 54 .
The latch 54 (FIGS. 2 through 4 a, b and 7 ) of the present coupling 25 also includes a plurality of latching holes or bores 140 , eight in this disclosed first embodiment, that extend radially through the outer latching ring 130 of the extractor head 50 . These latching holes are equally angularly spaced about the outer latching ring so that with the eight holes in the disclosed embodiment, the holes are spaced approximately forty-five degrees apart. In addition, these holes have insides chamfers 141 that taper inwardly. That is, each hole has an inside diameter slightly less than its principal or outside diameter. The outer latching ring terminates in a lower radial end face 142 , and an annular radially outwardly opening retainer groove 144 is located in the outside face of the outer latching ring between the latching holes and the lower end face.
The extractor head 50 (FIGS. 7, 8 ) also has a lower female coupling member 150 providing a central, downwardly opening axial socket 152 defining a central longitudinal axis 154 of the extractor head. The female coupling member is equidistantly, radially, inwardly spaced from the outer latching ring 130 so as to define a downwardly opening latching annulus 154 therebetween. The female coupling member has an inner, annular sealing groove 158 facing into the socket and an outer annular sealing groove 160 facing into the latching annulus. An inner O-ring 162 (FIG. 3) is positioned in the inner groove, and an outer O-ring 164 is located in the outer groove. In this regard, it is to be noted that both of these O-rings are located in the extractor head and that no O-rings are located in the extractor drum insert, thereby facilitating molding of the insert.
The extractor head 50 (FIGS. 7, 8 ) also has a main or central fluid passageway 170 extending coaxially upwardly from and in fluid communication with a valve seat 172 that opens downwardly into the female coupling member 150 and connects to the delivery hose 34 . The main passageway opens upwardly in the center of the upper end wall 120 and has an upper threaded section 174 , a lower smooth section 176 , and a radial shoulder 178 between the upper and lower sections.
Still further, the extractor head 50 (FIGS. 7, 8 ) provides a threaded air return bore 184 offset from the main passageway 170 for connection to the feed hose 36 . Dual, longitudinally extending air passages 186 extend longitudinally through the extractor head in parallel relation to the main passageway and in offset relation to the air return bore. These air passages have upper ends connected to the air return bore and lower ends opening downwardly from the head through the female coupling member 150 . Also, the head has a threaded air indicator or sensor bore 194 on the opposite side of the main passageway from the air return bore. A single air passage 196 extends from the indicator bore longitudinally downwardly and thence radially of the head to an air vent 198 that opens through the lower external surface 126 of the head above the latching holes 140 .
The latch 54 of the subject coupling 25 (FIGS. 2 through 4) includes a plurality of spherical, uniformly sized, latching balls 200 each having a diameter greater than the minimum, but less than the maximum, diameter of the latching holes 140 . The balls are individually located in the latching holes for movement radially of the extractor head 50 between latching positions wherein portions of their spherical surfaces project into the latching annulus 154 (FIGS. 3 and 4) and retracted positions (FIG. 2) wherein the balls are entirely withdrawn into the latching holes so that none of the peripheries of the balls projects into the latching annulus. As previously mentioned, the latching holes are tapered so as to limit radial inward movement of the balls into the latching annulus. That is, only spherical segments of the balls are allowed to project into the annulus, whereas the balls are free to move outwardly in the latching holes so as to drop out of the extractor head, except that they are retained therein in a manner described below.
A coded latching sleeve 210 (FIGS. 2 through 4, 9 , 10 ) is axially and rotatably, slideably mounted on the extractor head 50 . The sleeve includes an upper cylindrical section 212 slideably fitted around the upper cylindrical surface 124 of the head and radially outwardly spaced from the lower cylindrical surface 126 of the head. The sleeve also has a lower cylindrical section 218 slideably received on the lower external surface. A lower radial shoulder 220 between the upper and lower sections is in downwardly spaced, opposed relation to the upper radial shoulder 128 , and these shoulders together with the upper cylindrical section 212 and the lower external surface 126 define an annular pocket 214 . The sleeve also has an external, knurled actuating ring 216 (see also FIG. 1) projecting radially outwardly from the upper and lower sections 212 and 218 approximately midway between the upper and lower ends of the sleeve. The sleeve is thus axially slideable on the head into and out of unlatched and latched positions and is rotatable on the head into and out of matched and unmatched positions, as will be more fully described below.
The lower cylindrical section 218 of the latching sleeve 210 (FIGS. 2 through 4, 9 , 10 ) has an inside, lower, cylindrical bearing surface 224 that slideably engages the lower cylindrical surface 126 of the extractor head 50 in their assembled condition. An annular venting passage 228 in the sleeve opens inwardly of this bearing surface and is registrable with the air vent 198 in the unlatched position of the sleeve. The sleeve also has a radially extending air vent 230 that communicates with the venting passage and opens outwardly from the sleeve just under the actuating ring 216 . Still further, the sleeve has a cylindrical recessed surface 232 of slightly greater diameter than the bearing surface and extending endwardly therefrom. The bearing and recessed surfaces are joined by a radial annular shoulder 234 . The sleeve also has a lower outer skirt 236 that projects downwardly from the lower end of the sleeve in radially outwardly spaced relation to the recessed surface.
The key coding system 58 of the subject coupling includes a coding ring 250 (FIGS. 2 through 4, 9 , and 10 ) that is integral with and projects downwardly from the lower cylindrical section 218 of the coded latching sleeve 210 . The recessed surface 232 is the inside surface of the ring and is in circumscribing, closely radially spaced relation to the lower external surface 126 of the extractor head 50 when the head and the sleeve are assembled. A plurality of coding pegs 258 project downwardly from the coding ring, with each peg being of a shape and size as to fit into a coding hole 92 . Circular pegs and holes are disclosed and preferred but other shapes may be used. The coding pegs include diametrically opposed coding pegs 258 a and 258 b and angularly spaced coding pegs, as 258 c , in equally, angularly spaced relation around the coding ring corresponding to the location of the coding holes and depending on whether a match is made between a particular extractor head 50 and a particular extractor drum insert 52 . The nomenclature and reference characters for the pegs correspond to that discussed in the description of the coding holes.
As referred to above, multiple coding combinations are provided by the key-coding system 58 of the subject invention (FIGS. 6 and 10 ). These combinations are achieved by varying the number, size, shape, and location, i.e., angular spacing, of the coding pegs 258 and the coding holes 92 . The disclosed preferred embodiment effects the desired combinations by varying the number and angular spacing of the holes and pegs. Although not used in the preferred embodiment, additional combinations can be achieved by varying the size and/or shape of the pegs and holes. In the preferred embodiment, the coding system uses circular pegs and circular holes of the same diameter, i.e., so that the pegs are capable of fitting in the holes when they are aligned and there is a complete match. The preferred coding system further involves using diametrically opposite balancing pegs 258 a and 258 b and corresponding diametrically opposite balancing holes 92 a and 92 b plus from one to sixteen more indexing pegs 258 c through 258 r and indexing holes 92 c through 92 r , with adjacent pegs and adjacent holes being separated by twenty degrees. In this preferred system, sixteen different chemicals are accommodated by the described coding. For simplicity, only one indexing peg 258 c and one indexing hole 92 c are shown, but it will be understood that, depending on the particular code, there may be pegs and holes at each twenty-degree interval. A few other pegs and holes are indicated by dashed lines and reference characters pointing to cross-hatches where the pegs and holes are located.
For example, (FIGS. 6 and 9) key code 1 involves the two balancing pegs 258 a,b and holes 92 a,b and just one indexing peg 258 c and indexing hole 92 c spaced twenty degrees counterclockwise from the peg 258 a and the hole 92 a ; key code 2 involves the two balancing pegs 258 a,b and holes 92 a,b and two indexing pegs 258 c,d and indexing holes 92 c,d spaced twenty degrees and forty degrees counterclockwise from the peg 258 a and the hole 92 a ; key code 3 involves the two balancing pegs and holes and three indexing pegs 258 c,d,e and holes 92 c,d,e spaced twenty, forty, and sixty degrees counterclockwise from the peg 258 a and the hole 92 a ; and so forth up to key code 16 using all eighteen pegs and holes. Although the key-coding examples as described above provide sixteen different combinations, it will be understood that many other combinations can be provided by varying the number, size, shape, and location of the coding pegs and the coding holes, as previously explained.
After the extractor head 50 and latching sleeve 210 are assembled, and the sleeve is pulled up on the head (FIGS. 2 and 3 ), a retaining ring 260 is fitted in the retainer groove 144 of the extractor head and projects radially outwardly from the retainer groove in opposed relation to the recessed surface 232 of the latching sleeve and provides an outside diameter that exceeds the inside diameter of the bearing surface 224 . The retaining ring has an endless metal core, preferably made of spring steel, and an external plastic coating, preferably made of Teflon or polyethylene, similar to the construction shown in FIGS. 11 and 12. Thus, the ring is extremely durable and tough, but it does have a measure of diametric elasticity. In other words, in its normally relaxed condition, the internal diameter of this retainer ring is approximately equal to the diameter of the retainer groove. For assembly of the retainer ring on the extractor head, the diametric elasticity of the ring allows it to expand just enough to increase its diameter to a size greater than the outside diameter of the lower cylindrical surface 126 , that is, the outer latching ring 130 . The retainer ring is thus expanded to slip over the lower end of the extractor head and then allowed to contract into the groove where it fits with its peripheral portion extending slightly outwardly from the lower cylindrical surface of the head, as seen in FIGS. 2 through 4 a.
A coiled actuator spring 270 (FIGS. 2-4, 11 , 12 ) circumscribes the lower cylindrical surface 126 of the extractor head 150 and is positioned in the annular pocket 214 between the upper and lower radial shoulders 128 and 220 so as yieldingly to urge the latching sleeve 210 downwardly on the head 50 toward its latching position. The spring is compressible, however, to allow the sleeve to be moved upwardly on the head in a manner to be described more fully when discussing the operation of the subject coupling 25 . This spring also includes an internal metal core 272 (FIGS. 11, 12 ) preferably of spring steel and an external plastic cover 274 surrounding the metal core and having opposite open ends 276 . Plastic balls 278 are frictionally fitted in fluid-tight relation to the cover in the open ends thereof so as to isolate the metal core and preclude the entry of fluids into the cover into contact with the core. The cover and the balls are preferably made of Teflon or polyethylene.
The poppet valve 56 (FIGS. 2 through 4) includes a frusto-conical valve head 302 and upper and lower valve stems 304 and 306 extending respectively upwardly and downwardly from the valve head coaxially of the main passageway 170 . The valve also includes a tubular extension 308 connected to the upper valve stem and axially slideably fitted in the lower smooth section 176 of the main passageway. This tubular extension has a lower end wall with openings 310 providing communication therethrough. A valve spring 311 is positioned in the tubular extension and bears against a spring retainer 312 secured within the main passageway above the tubular extension for resiliently urging the valve head 302 into the valve seat 172 . The spring 311 is constructed like the actuator spring with an internal metal core and a plastic cover.
OPERATION AND METHOD OF USE
Before describing the operation and method of use of the subject coupling 25 , brief reference is made to the chemical extraction apparatus or system (FIG. 1) in which this coupling is especially suited for use. Thus, the down tube 30 is connected to the main passageway 70 of the extractor drum insert 52 , and the insert is threaded into the bung hole 32 of a fifty-five gallon drum 27 containing a chemical to be extracted. As such, the male coupling member 74 and the latching ring 110 extend upwardly from the drum, it being assumed at this point in the operation of the coupling that the extractor head 50 is not connected to the extractor drum insert (FIGS. 4 a and 4 b ). As part of the chemical extraction system, the extractor head is, however, connected to the chemical delivery and feed hoses 34 and 36 with the delivery hose 34 connected to the main passageway 170 and the feed hose connected to the air return bore 184 . Also, as part of the subject invention, the air indicator hose 38 is connected to the air indicator bore 194 . Also, at this time, the poppet valve 56 is closed with the valve head 302 in sealing engagement in the valve seat 172 , being urged there by the valve spring 310 .
Also, at this initial stage, with extractor head 50 and drum insert 52 separated, the actuating spring 270 urges the coded latching sleeve 210 into its fully extended position on the extractor head 50 , as shown in FIG. 4 a . Several relationships between the sleeve and the head are to be noted in this position of the sleeve. First, the upper section 212 of the sleeve is spaced below the upper end wall 120 of the extractor head so as to permit subsequent upward travel of the sleeve on the head. Secondly, the venting passage 228 in the sleeve is not in registration with the inner air vent 198 . Next, the lower radial shoulder 220 of the sleeve is forced against the retaining ring 260 by the actuating spring 270 . In other words, the retaining ring prevents the sleeve from being pushed off the head by the actuating spring. It is thus understood why the retaining ring must have the durability and strength as described above since it must withstand the pressure of the spring 270 and preclude release of the sleeve; furthermore, repeated abutment of the shoulder 220 with the ring subjects the ring to considerable wear and tear. Also at this initial stage, the lower bearing surface 224 of the sleeve precludes outward movement of the latching balls 200 and thus captures them in the latching holes 140 . It will be recalled that the balls cannot fall from the holes inwardly of the sleeve because the inner diameters of the holes do not permit the balls to move therethrough. In addition, at this stage, the coding ring 250 and the coding pegs 258 project downwardly below the lower end face 142 of the extractor head.
It is now assumed that the extractor head 50 (FIGS. 1 and 2 through 4 a, b ) is to be connected to the extractor drum insert 52 . More broadly, in the context of the chemical extraction system, it is assumed that a delivery hose 54 for a particular chemical is to be connected to a drum 27 containing that chemical. It is further first assumed that the extractor head and the extractor drum insert to be connected are matching, thereby indicating that the particular chemical intended to be delivered in the hose 34 is in fact the chemical in the drum 27 . The key coding system 58 of the present invention thus will provide matching coding holes 92 and coding pegs 258 . If the key code illustrated in FIGS. 6 and 10 is being used (designated herein as Code 1 ), there are three coding holes and three coding pegs in matching locations respectively on the key coding flange 86 and the coding ring 250 . In other words, the code being used includes diametrically opposed balancing holes 92 a and 92 b , diametrically opposed balancing pegs 258 a and 258 b , one indexing hole 92 c spaced twenty degrees counterclockwise from the balancing hole 92 a , as viewed looking up at the coding flange (FIG. 6 ), and one indexing peg 258 c spaced twenty-degrees counterclockwise from the balancing peg 258 a , also as viewed looking upwardly at the coding ring (FIG. 10 ).
The extractor head 50 and coded latching sleeve 210 , as may be visualized in FIG. 1 and FIGS. 4 a , and 4 b are manually grasped in the two hands of an operator and brought down over the extractor drum insert 52 . Preferably, the thumbs of the operator's hands bear downwardly on the upper end wall 120 of the extractor head and the other fingers are placed under the actuating ring 216 of the sleeve. When the male and female coupling members 74 and 150 are in adjacent axial alignment, the sleeve and the head are squeezed together to lift the sleeve relative to the head, from the FIG. 4 a, b position to the FIG. 2 position. While so moved and held, the air port 230 and the air vent 198 are brought into registration so that air escapes from the air port and can be heard or even felt by an operator's hands on the ring 216 . Also at this time, the recessed surface 252 of the sleeve is opposite to the latching holes 140 , thereby freeing the latching balls 200 so they can move outwardly in their respective holes.
While squeezing the extractor head 50 and latching sleeve 210 together (FIG. 2 ), the extractor head (FIG. 2) is pushed down onto the extractor drum insert 52 so that the female coupling member 150 fits over the male coupling member 74 and the latching annulus 154 fits over and receives the latching ring 110 . With the sleeve pulled upwardly in this fully retracted position, the latching balls 200 are allowed to move outwardly and allow the latching annulus to move down over the latching ring into fully interfitted relationship. Whether or not the coding pegs 258 are exactly aligned with the coding holes 92 when the head is brought down onto the insert in this manner, the latching ring fully seats within the latching annulus.
While still squeezing the latching sleeve 210 and extractor 50 (FIG. 2 ), the operator allows the sleeve to move axially toward the extractor insert 52 whereby the coding pegs 258 engage the coding flange 86 , a position not shown, but easily visualized from FIG. 2 . At this time, it is possible, but not probable, that the coding pegs will be exactly aligned with the coding holes 92 and slip right into them. More likely, the operator will need to rotate the sleeve relative to the extractor head 50 and the extractor drum insert 52 , causing the coding pegs to slide circumferentially on the coding flange. Since the insert is secured to the drum 27 , the sleeve rotates easily relative to the insert. Since the extractor head is connected to the hoses 34 , 36 , and 38 , it is maintained relatively stationary so that the sleeve can rotate relative to the extractor head. Such rotation occurs until the coding pegs 258 are exactly aligned with their corresponding coding holes 92 , assuming of course that the pegs and holes are matching as was earlier assumed in this example. At this time, the sleeve is forced downwardly by the actuator spring 270 , and the pegs are thrust into the holes (FIG. 3 ). Also, the bearing surface 224 moves downwardly over the latching holes 140 , pushing the latching balls 200 inwardly and their inner peripheries into the latching groove 112 . Moreover, as long as the expansive force of the actuating spring 270 remains on the sleeve, the bearing surface maintains the balls in the groove, whereupon the extractor head 50 and the drum insert 52 are maintained latched in coupled relationship, until manually released.
Also, when the latching ring 110 (FIGS. 2 and 3) fully seats in the latching annulus 154 , lower valve stem 306 engages the spider 78 and lifts the valve head 302 off the valve seat 172 . Opening the valve 56 establishes fluid communication from the down tube 30 (FIG. 1 ), through the male and female coupling members 74 and 150 , through the valve seat, into the main passageway 170 of the extractor head 50 , and eventually into the delivery hose 34 . At the same time, nitrogen or air is supplied from the feed hose 36 into the air return bore 184 , through the dual air passages 186 and into the manifold 320 that is formed between the extractor head and the extractor drum insert 52 in circumscribing relation to the male coupling member. From the manifold, air travels through the air passages 80 into the drum to replace the chemical withdrawn through the delivery hose and to prevent the formation of a vacuum. The O-rings 162 and 164 seal between the coupling members and prevent the escape of chemical or air.
Of prime significance, coupling of the extractor head 50 and the drum insert 52 is achieved without twisting or swiveling the head or the hoses 34 , 36 , 38 connected to it, although swiveling is accommodated if the natural position of the hoses forces an untwisting action. Only the latching sleeve 210 need rotate, but here, no time-consuming threading or unthreading is required. It is also significant that when the sleeve is released by the operator allowing interfitting of the coding pegs 258 and the coding holes 92 (FIG. 3 ), the air port 230 moves out of registration with the air vent 198 thereby to cut off the outflowing stream of air and indicating to the operator that, in fact, a matched interfitted relationship has been established between the extractor head 50 and the extractor drum insert 52 . Until the pegs drop into the holes, however, the port and vent remain aligned and air continues to escape, telling the operator that a match has not occurred.
If there is a mismatch between the extractor head 50 and the extractor drum insert 52 , and thus between the delivery hose 34 and drum 27 , the coding pegs 258 will not match the coding holes 92 . Therefore, rotation of the coded latching sleeve 210 will not result in an alignment of pegs and holes, and interconnection will be impossible. It is significant that the sleeve need be turned a maximum of only about three-hundred sixty degrees, and usually less, to test for a match, thus taking only a few seconds, whereupon if there is no match, the head and sleeve can be immediately lifted off the drum insert to close the poppet valve 56 .
When it is desired to uncouple the extractor head 50 from the extractor drum insert 52 (FIGS. 2-4 a , 4 b ), the operator grasps the extractor head and the actuator ring 216 of the latching sleeve 210 with both hands, in the same manner as above described to connect the coupling 25 , thereby to squeeze the ring and the canopy 122 together against the urging of the actuator spring 270 . This squeezing action causes the recessed surface 252 (FIG. 2) to move into opposition with the latching balls 200 (FIG. 3) so that the balls are freed to move outwardly into their retracted positions. While continuing to squeeze the head and sleeve, the operator then lifts the head and sleeve thereby causing the upper bevel on the latching groove 112 to force the balls into their retracted positions. Such upward movement also lifts the lower valve stem 306 off the spider 78 allowing the valve spring 310 to close the poppet valve 56 and shut off the flow of chemical through the central passageways 70 and 170 . Any chemical that drips from the extractor head will fall through the spider or into the manifold 320 and drain into the drum 27 (FIG. 1 ). After the extractor head is free of the extractor insert (FIGS. 4 a , 4 b ), the operator releases his grasp on the head and sleeve thereby allowing the actuator spring to move the sleeve relative to the head into the fully extended position of the sleeve with the shoulder 220 bearing against the retainer ring 260 (FIG. 4 ). It is again emphasized that no threading and not even any rotation of parts is required to uncouple the coupling 25 .
From the foregoing it will be understood that an improved fluid coupling 25 is disclosed having particular application in a chemical extraction system involving drums 27 of chemicals and delivery lines 34 suspended above the drums (FIG. 1 ). The subject coupling offers many advantages including improvement in the productivity and safety of dispensing a plurality of incompatible chemicals through different delivery lines from different drums in a manufacturing process; the dependable, yet quick connection and disconnection of only matched coupling members; and reduced manufacturing costs because of the ability to mold rather than machine the parts, although machining is possible.
A significant feature of the coupling 25 is that the parts are connected and disconnected without any threading or unthreading of the parts and without twisting of the lines or relative rotation of the coupling members and without regard to the relative rotational positions of the coupling members prior to or during interfitting thereof. In this regard, although the coupling does not require swiveling of its coupling members for connection or disconnection, such swiveling of the parts may occur and is accommodated during connection or disconnection without affecting the operation of the coupling.
The subject coupling 25 minimizes the time required dependably to connect and disconnect matched coupling members of a coded coupling or to determine that the coupling members are mismatched and will not couple; enables many different matching combinations; is balanced for dependable two-handed operation by a user; and allows an operator to confirm whether the coupling members are matched and interfitted or whether they are mismatched and not intermitted.
SECOND EMBODIMENT
A second embodiment of the subject coupling is shown in FIGS. 13 through 17 and is identified by the numeral 425 . In general, the coupling 425 differs from the coupling 25 in that the coupling 425 is not coded and thus is used where coding is unnecessary. The coupling 425 is similar to the coupling 25 , however, in the way in which the coupling 425 latches. The coupling 425 is preferably molded entirely of Teflon or polyethylene and, as shown assembled in FIG. 13 ), includes an extractor head 430 , an extractor drum insert 52 identical to that used with the first embodiment, and a latch generally indicated at 432 , including a latching sleeve 434 . Like the coupling 25 , the coupling 425 may be used in any orientation, but vertical is the most common and is thus a vertical orientation is used for descriptive convenience.
The extractor head 430 (shown separately in FIGS. 14 and 15) includes an upper adapter fitting 440 providing an outer, externally threaded cylindrical section 442 and an inner spider 444 defining an upper socket 446 therebetween, and a lower female coupling member 448 providing a lower socket 450 . The adapter fitting thus accommodates connection to a standard dispensing head, not shown, which in turn is connected to an umbilical dispensing hose. Suitable inner and outer O-rings 452 , 454 , and 456 (FIG. 13) seal between the dispensing head and the adapter fitting. The adapter fitting has a main fluid passageway 458 and an air return passage 459 .
The adapter fitting 440 (FIGS. 14 and 15) has an external cylindrical smooth surface 460 below external threads 462 . An annular wall 464 extends radially outwardly from the surface 460 , and an annular outer latching ring 466 , which is part of the latch 432 , extends axially downwardly from the wall, terminating in a radial end face 468 . For a purpose to be described, a stop lug 470 extends upwardly from the annular wall 464 adjacent to the rim of the wall.
The outer latching ring 466 (FIGS. 14 and 15) is radially outwardly spaced from the female coupling member 448 thereby to define an annular downwardly opening latching annulus 474 therebetween. The ring has a plurality of latching holes 476 drilled therein in equally angularly spaced relation to each other circumferentially of the skirt. These holes are like the latching holes 140 of the first embodiment, but in this second embodiment, only four holes are provided spaced ninety degrees apart. As with the first embodiment, however, the invention is not limited to any particular number of holes, although eight are preferred in the first embodiment and four are preferred in this second embodiment.
Like the latching holes 140 , the latching holes 476 FIGS. 14 and 15) having inner frusto-conical chamfers that taper radially inwardly of the outer latching ring 466 whereby the 432 also includes spherical latching balls 480 (FIG. 13) of uniform diameter like the balls individually placed in the latching holes, with each ball having a diameter greater than the inner or minimum diameter of the latching holes but less than the principal or outer diameter, i.e., maximum diameter, of the holes. Each ball is thus movable between a latching position (FIG. 13) wherein a segment of its periphery projects into the latching annulus 474 and a retracted position (not shown, but similar to FIGS. 2 and 4 a ) wherein the peripheral segment is withdrawn into its hole. The female coupling member 448 (FIG. 14) has annular inside and outside sealing grooves 486 and 488 respectively facing into the socket 450 and the latching annulus 474 . The inside groove receives an inside O-ring 490 and the outside groove receives an outside O-ring 492 .
The latching sleeve 434 (shown assembled in FIG. 13 but separately in FIGS. 16 and 17) which is part of the latch 432 , has an upper annular radial shoulder 512 that provides a top outside surface 514 , an inside underneath surface 516 , and a cylindrical neck 518 . An annular resiliently flexible lip 519 extends radially inwardly from the neck. A cylindrical skirt 520 depends from the shoulder and has an eternal knurled surface 522 , an annular internal surface 524 , and a radial end wall 526 . The internal surface (FIGS. 16 and 17) of the skirt has a plurality of arcuate latch recesses 530 , equal in number and spacing to the latching holes 476 . Each latch recess preferably subtends an arc of about forty degrees, although this angle is not critical as will be subsequently understood. Each of these recesses extends axially of the skirt from an upper shoulder 532 to the end wall 526 .
The latch recesses 530 (FIGS. 16 and 17) are thus separated by a plurality of arcuate bearing surfaces 534 that are portions of the internal annular surface 524 of the skirt 520 . As a result and as best seen in FIG. 17, the inside radius of the skirt at each latch recess 530 is greater than the inside radius of the skirt at the bearing surfaces. Each recess has a radial depth that varies from zero at its ends to a maximum at its center, such maximum depth being less than the diameter of each latching ball 480 but greater than the effective depth of the latching grove 112 in the outer latching ring 110 , that is, the distance that the projecting segment of each ball 480 extends out of each hole 476 into the latching groove 112 .
The underneath surface 516 (FIGS. 16 and 17) of the upper shoulder 512 of the latching sleeve 434 has a downwardly opening arcuate limit slot 540 therein. In the disclosed second embodiment, this slot subtends and arc of about sixty degrees circumferentially of the shoulder between its ends 542 . As will be seen in FIG. 17, this slot extends from about the midpoint of one latch recess about to the adjacent end of the adjacent latch recess.
In order to assemble the latching sleeve 434 and the extractor head 430 (FIG. 13 ), the latching balls 480 are placed in their latching holes 476 , and the skirt 520 is fitted down over the extractor head with the stop lug 470 aligned with the limit slot 540 . In so doing, the outer cylindrical section 442 fits through the neck 518 , the lip 519 resiliently yielding to allow the section 442 to pass through; actually, the lip yields and slips from one thread to the next as it snaps down below the externally threaded section 442 into the position shown in FIG. 13 . It is to be noted that whereas FIG. 13 shows the assembled sleeve and head coupled to the extractor insert, what is being described at this point is only the assembly of the sleeve and head; it is
In this assembled condition of the latching sleeve 434 and the extractor head 430 (FIG. 13) several relationships are to be noted: the stop lug 470 is received in the limit slot 540 , the latching holes 476 and their latching balls 480 are either opposite the latch recesses 530 or the bearing surfaces 534 , depending on the relative angular positions of the sleeve and head; the end wall 526 of the sleeve is in the same plane as the end face 468 of the inner latching ring 110 ; and the lip 519 is in adjacent axially downwardly spaced relation to the outer section 442 of the adapter fitting 440 . assumed that the coupled state of the members 448 and 74 has not yet occurred.
In order to retain this assembled condition (FIG. 13) of the sleeve 434 and the head 430 , a flat, resiliently diametrically expandable, radially split, lock washer 550 is spread apart, fitted over the outer section 442 , rested on the radial wall 464 , and allowed to contract around the cylindrical surface 460 between the outer section 442 and the lip 519 and the shoulder 512 . By rotating the sleeve relative to the head through an angle of about sixty degrees, i.e., the length the limit slot 540 , or about ⅙ th of a turn, the sleeve is moved between latching and unlatching positions. In its latching position, the bearing surfaces 534 are opposite to the latching holes 476 , engage the latching balls 480 , and force them inwardly of their holes into their latching positions, as shown in FIG. 13 . In its unlatching position, the latch recesses are opposite to the latching holes and allow the balls to move outwardly into the recesses and thus into their unlatching positions, a position not shown in the drawings but similar to FIG. 2 and believed to be understood.
When it is desired to connect the extractor head 430 to the drum insert 52 (FIG. 13 ), the latching sleeve 434 is first turned on the head into its unlatched position. It is, of course, understood that the extractor head is connected to a dispensing head and hoses not shown. The assembled head and latching sleeve are then brought down over the insert (visualized in FIG. 13 ), and the inner latching ring 110 is fitted in the latching annulus 474 with the lower socket 450 of the female coupling member placed down over the male coupling member 74 . The inside diameter of the inside O-ring 490 is slightly less than the outside diameter of the male coupling member so that the parts must be pressed tightly together to snap and seat the male coupling member into the female coupling member and the inner latching ring into the latching annulus. When thus assembled, an annular manifold 560 is defined between the extractor head and the drum insert circumscribing male coupling member so as to provide communication from the air return bore 459 to the air passages 80 . Communication is also established between the passageways 70 and 458 . It is to be noted that the extractor head and drum insert can be interfitted irrespective of their relative rotational positions so that no rotation of the head is required to couple it to the insert, although swiveling of the head is accommodated if forces on the head require it.
After the extractor head 430 and the drum insert 52 are thusly interfitted, the latching sleeve 434 is rotated clockwise (from the top) about sixty degrees or one-sixth of a turn into its latching position (FIG. 13 ). Such rotation causes the bearing surfaces 534 to push the latching balls 480 into the latching groove 112 thereby to latch the coupling members 74 and 448 together. Rotation of the sleeve on the head is limited by the stop lug 470 engaging one of the ends 542 of the limit slot 540 so as to insure alignment and to indicate t and to indicate to the operator that latching has been achieved.
To uncouple the extractor head 430 from the drum insert 52 , the latching sleeve 434 is rotated counterclockwise (from the top) about sixty degrees or one-sixth of a turn into its unlatched position (not shown). Again, engagement of the stop lug 470 with the opposite end 542 of the limit slot indicates to the operator that the unlatched position is reached. As such, the recesses 530 are opposite to the holes 476 and balls 480 , thereby allowing the balls to move into the recesses and withdraw into their holes. The head can then be lifted off from the insert.
It will be understood from the foregoing that a very simple, yet highly effective, fluid coupling 425 has been provided. The coupling enables the extractor head 430 to be coupled and latched, and unlatched and uncoupled, without requiring any rotation of the extractor head relative to the drum insert. Yet the coupling allows swiveling of the head relative to the insert and the sleeve if necessary. Moreover, this coupling and uncoupling and latching and unlatching is achieved without any threaded or unthreading of the parts. The coupling can be entirely and effectively molded out of chemically-resistant plastic as described thus minimizing manufacturing costs. In addition, the head and sleeve are compatible with the same drum insert that is used with the multiple delivery lines involved with the first embodiment.
Although preferred embodiments of the present invention have been shown and described, various modifications, substitutions and equivalents may be used therein without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration and not limitation. | A fluid coupling including coded and non-coded embodiments and a method for their use. The coded embodiment allows connection of such lines while preventing the inadvertent connection of mismatched lines in a system where there are matched and mismatched delivery and supply lines. Both embodiments of the coupling include axially movable first and second coupling members and a radially operating latch. The coupling members are releasably slideably, axially interfitted with their fluid passageways in communication, and the latch moves radially of the passageways to secure the couplings when they are interfitted. In the coded embodiment, key coding elements on the coded coupling members are movable into matched interengagement when the supply and delivery lines are matched but are precluded from moving into matched interengagement when the lines are mismatched. If a match exists, the coding elements interfit by limited rotation of one of the key coding elements but without rotation of the coupling members and without any threading action of the parts. A mechanism latches the couplings together when the key coding elements match and allow the coupling members to interfit but does not latch when the key coding elements do not match and thus do not allow an interfit. In both embodiments, the coupling members are uncoupled solely by axial separation of the parts, again with out threading, and in the case of the first embodiment, without even any rotation of the parts. In both cases, therefore, neither the coupling members, the coding elements, nor the latch involves threaded connections, whether for connection or disconnection or for latching or unlatching. | 8 |
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This patent application claims the benefit of German Patent Application No. 10 2015 122 348.1 filed Dec. 21, 2015. The disclosure of the above patent application is hereby incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The invention relates to a heating and air conditioning system for a motor vehicle. This system comprises a housing having one or more air outlets, at least one heating heat exchanger and/or one heater, which is/are disposed inside the housing and over which a warm air path extends so that air flowing through the warm air path is heated as it passes across the heating heat exchanger and/or the heater. The heating and air conditioning system further comprises a warm air duct having a warm air intake opening and a warm air duct discharge opening, which is disposed downstream of the heating heat exchanger and/or the heater for the purpose of channeling a partial air flow of warm air from the warm air path to one of the air outlets, and a mode control damper, which is rotatable about a rotational axis and is connected downstream of the warm air duct in terms of flow, and by means of which the at least one air outlet can be selectively opened completely or partially, and in a closed state can be partially or completely closed.
BACKGROUND OF THE INVENTION
[0003] Warm air ducts typically supply warm air to one or more outlets of an air conditioning system. The air from the warm air duct usually is not controlled based on the mode-dependent volume of air being delivered to the outlets that are supplied with air. In other words, the volume of warm air channeled through the warm air duct does not change when the mode is changed. This leads to the problem that, in a mode in which the volume of diverted air is small, the corresponding outlet becomes much too warm.
[0004] Warm air ducts supply warm air, for example, to the defrost outlet of the heating and air conditioning system for the purpose of de-icing the windshield. The volume of warm air channeled through the warm air duct is determined by the cross-section of the warm air duct, and must be adjusted to a level that will ensure that, even in the most unfavorable case, sufficient warm air is conveyed to an outlet, typically to the defrost outlet. This generally applies to the defrost mode, in which a large volume of air is required for defrosting, but a similar volume of air is also required in the direction of the floor, and a small volume may also be required in the direction of the dashboard. If the defrost outlet has only a small opening cross-section, then depending on the mode, for example in footwell mode, the defrost outlet will become too warm because the amount of air coming from the warm air duct is not reduced in accordance with the generally diminished volume of air going to the defrost outlet.
[0005] Numerous different arrangements of warm air ducts in air conditioning systems are known from the prior art. DE 101 27 339 A1 describes a heating, ventilating and/or air conditioning system in particular for a motor vehicle, which has a distribution case in which at least two air flow paths up to a mixing zone can be defined and which is equipped with at least two outlets, at least one of which can be supplied with air from the mixing zone. The apparatus comprises a device connected downstream of the mixing zone in terms of flow, which reduces, more specifically substantially excludes any interaction of the air exiting the mixing zone with air that is moving in a different direction, by the formation, for example, of duct-like passages that permit an uncoupled crossing of air flows. In the heating, ventilating and/or air conditioning apparatus a device may also be provided, for example, that enables air to be diverted from one of the definable flow paths in order to supply air that is moving in a direction that is different from the direction of the air exiting the mixing zone. This device can provide a selective and/or adjustable diversion. Thus it is possible, for example, to divert warm air that is intended for channeling toward the windshield out of a flow path, and to feed the remaining portion of warm air to the mixing zone.
[0006] DE 1 96 49 512 A1 describes a heating or air conditioning system for a vehicle, said system comprising a housing which has an inlet opening through which fresh air and/or recirculated air can be fed as intake air, a warm air duct in which a heating element is disposed, a cold air duct with a mixing chamber in which the warm air flow channeled through the warm air duct and the cold air flow channeled through the cold air duct are mixed, a plurality of outlet openings through which the mixed air flow is channeled to the corresponding outlet nozzles, air control elements for controlling the volume of air passing through the warm air duct, the cold air duct and the outlet openings, and an additional duct for conducting a partial air flow to an outlet opening. This additional duct is designed to be closeable by means of an air control element (defroster damper) assigned to the outlet opening (defroster outlet opening). The additional duct may be embodied as a duct extension that extends from an outlet region of the warm air duct directly into the region of a defroster damper.
[0007] DE 10 2007 013 432 A1 describes a warm air duct for an air conditioning apparatus of a motor vehicle which may have various air outlets, wherein the warm air duct comprises at least one warm air intake opening through which warm air can be received, and at least one warm air duct discharge opening through which warm air can be delivered to the air outlets of the air conditioning apparatus. In this case, at least one divider is disposed above the at least one warm air duct discharge opening in such a way that the warm air duct discharge opening is divided at least into a first discharge opening region and a second discharge opening region. In addition, warm air is received in the region of a heat exchanger through at least one warm air intake opening of the warm air duct, this warm air then exiting the warm air duct through the individual discharge opening regions, whereby the warm air exiting the warm air duct through the warm air duct discharge opening is divided into at least two warm air partial flows, each of which supplies warm air to respectively assigned air outlets of the air conditioning apparatus.
[0008] However, the volume of warm air passing through the warm air duct does not change when the mode is changed. This leads to the problem that, in operating modes that require a low volume of diverted air, the corresponding outlets can become much too warm. The current solution to this problem involves conducting air outside of the warm air duct to the outlets in such a way as to enable a suitable mixture of cold and warm air to be achieved, based on the mode. (The closest prior art).
[0009] The object of the invention is to improve the temperature behavior of an outlet which is supplied with air from a separate warm air duct.
SUMMARY OF THE INVENTION
[0010] The object of the invention is achieved by means of a heating and air conditioning system as disclosed herein.
A heating and air conditioning system for a motor vehicle, according to the invention, comprises a housing having one or more air outlets, at least one heating heat exchanger and/or one heater, which is/are disposed inside the housing and across which a warm air path extends, so that air flowing through the warm air path is heated as it passes the heating heat exchanger and/or the heater, a warm air duct having a warm air intake opening and a warm air duct discharge opening, which is disposed downstream of the heating heat exchanger and/or the heater for the purpose of channeling a partial air flow of warm air from the warm air path to one of the air outlets, and a mode control damper, which is rotatable about a rotational axis and is connected downstream of the warm air duct in terms of flow, and by means of which the at least one air outlet may be selectively opened completely or partially, and in a closed state may be partially or completely closed.
[0016] The mode control damper and the warm air duct are arranged such that the mode control damper is designed to also function simultaneously as the control damper for the volume of air exiting through the warm air duct discharge opening. According to the invention, the mode control damper has two lateral segments, spaced from one another on its side that faces the warm air duct discharge opening, in other words the inner side, which segments are configured, positioned and aligned in such a way that they block the flow of air outward and inward parallel to the axis of rotation in the region of the warm air duct discharge opening, over the entire adjustment range of the mode control damper. The lateral segments thus block both a flow of warm air parallel to the axis of rotation and out of the warm air duct and a flow of cold air parallel to the axis of rotation and into the region of the warm air duct discharge opening. If cold air were to flow parallel to the axis of rotation and into the region of the warm air duct discharge opening, the discharge of warm air from the warm air duct discharge opening, which flows substantially perpendicular to the axis of rotation, could be impeded and in the worst case even blocked.
[0017] According to the design of the present invention, the mode control damper of an air outlet and the warm air duct discharge opening are thus designed and disposed in such a way that the mode control damper is able to control the volume of air exiting the warm air duct to the corresponding outlet. The advantage of the invention is that it therefore enables the temperature of an outlet to which air from the warm air duct can be supplied to be controlled dependent on the mode. The invention involves an optimization of a warm air duct combined with a mode control damper whereby the temperature layering function of a heating and air conditioning system can be improved. The features of the invention can be implemented easily and without substantial added cost.
[0018] There are two different preferred embodiments for the solution according to the invention. In both embodiments, segments on the mode door, preferably formed as circular segments, prevent warm air from flowing out parallel to the axis of rotation. As mentioned above, this applies to the entire adjustment range of the mode control damper. The outlet of the warm air duct is configured accordingly.
[0019] According to one advantageous embodiment, the warm air duct discharge opening extends in a direction from the rotational axis of the mode control damper up to an opposing sealing edge against which the mode control damper rests in the closed state. The warm air duct discharge opening of the warm air duct thus preferably extends between the rotational axis of the mode control damper and a housing wall of the housing. The segments of the mode control damper are preferably positioned and aligned in such a way that, as the mode control damper rotates, they pass outside of the warm air duct alongside walls of the warm air duct which are disposed opposite one another and are oriented perpendicular to the axis of rotation.
[0020] According to the second preferred embodiment, the warm air duct discharge opening extends alongside walls of the warm air duct, which are disposed opposite one another and are oriented perpendicular to the axis of rotation, from a first housing side up to a second, opposite housing side of the housing. In this case, the lateral segments are attached and positioned on the mode control damper in such a way that, as the mode control damper rotates about the rotational axis, the segments move in cutouts in the side walls of the warm air duct at the warm air duct discharge opening, each of the cutouts being formed as complementary to the lateral segments. This can be achieved, for example, by designing the lateral segments in the form of circular segments and the complementary cutouts in the side walls of the warm air duct at the warm air duct discharge opening as half-moon shaped, and by the circular segments then moving in the cutouts as the mode control damper rotates.
[0021] The mode control damper and/or the warm air duct may have one or more openings, and/or a small distance may be provided between the warm air duct discharge opening and the mode control damper in the closed state, either of which will result in the warm air duct discharge opening not being completely closed even when the mode control damper is in the closed state. Even when the mode control damper is closed, the design according to the invention will operate with constant ventilation due to the openings or the distance between the warm air duct discharge opening and the mode control damper. It is therefore unnecessary for the warm air duct to be completely closed.
[0022] According to one embodiment of the invention, at least one baffle plate is formed at the warm air duct for conducting a portion of the air flow from the warm air duct so as to bypass the mode control damper.
[0023] According to a further embodiment of the invention, the intermediate space between the two lateral segments at a warm air duct is provided with a filler. Alternatively, the space between the two adjacent lateral segments may be filled by a depression on the opposite side of the mode control damper.
[0024] The warm air duct is preferably provided for supplying warm air to the defrost outlet. In other words, in this case the mode control damper is the defroster damper.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Additional details, features and advantages of embodiments of the invention will be apparent from the following description of embodiment examples, with reference to the attached set of drawings. The drawings show:
[0026] FIG. 1 : a heating and air conditioning system with a warm air duct, according to the prior art,
[0027] FIG. 2 : a portion of a heating and air conditioning system according to the invention, having a warm air duct and a mode control damper,
[0028] FIG. 3 : a portion of a heating and air conditioning system according to one embodiment example of the invention, in which the warm air duct cannot be completely closed by the mode control damper,
[0029] FIG. 4 : a portion of a heating and air conditioning system according to the invention having a warm air duct, a mode control damper, and baffle plates,
[0030] FIG. 5 : a portion of a heating and air conditioning system according to the invention having a mode control damper in which the hollow space is filled (this may also be accomplished by a depression on the other side of the mode control damper),
[0031] FIG. 6 : a diagram illustrating the temperature curve as a function of the position of the temperature damper, obtained in the defrost/foot mode in an assembly of the prior art,
[0032] FIG. 7 : a diagram illustrating the temperature curve as a function of the position of the temperature damper, obtained in the foot mode in an assembly of the prior art,
[0033] FIG. 8 : a diagram illustrating the temperature curve as a function of the position of the temperature damper, obtained in the defrost/foot mode in an assembly according to the invention, and
[0034] FIG. 9 : a diagram illustrating the temperature curve as a function of the position of the temperature damper, obtained in the foot mode in an assembly according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0035] FIG. 1 shows a heating and air conditioning system 1 according to the prior art. This system comprises a housing 2 having one air inlet and three air outlets 3 , 4 , 5 . In FIG. 1 , a defrost outlet 3 , a dashboard outlet 4 and a foot well outlet 5 are illustrated schematically. The incoming air is conducted across an evaporator 6 , which cools the air. Connected downstream of evaporator 6 in terms of flow is a heating heat exchanger 7 , across which a portion of the air that was previously cooled by evaporator 6 flows. Another portion of the cooled air is conducted past heating heat exchanger 7 , rather than across it. In other words, a warm air path extends across heating heat exchanger 7 toward air outlets 3 , 4 , 5 and a cold air path extends directly toward air outlets 3 , 4 , 5 , bypassing the heating heat exchanger.
[0036] Inside housing 2 , a separate warm air duct 8 having a warm air duct intake opening 9 and a warm air duct discharge opening 10 is positioned, this separate duct being disposed downstream of heating heat exchanger 7 and conducting a partial flow of air from the warm air path toward defrost outlet 3 .
[0037] FIG. 1 illustrates the foot mode as the operating mode. In this mode, defrost outlet 3 is nearly closed by a rotatable defroster damper 11 as the mode control damper 11 . In this case, warm air duct 8 typically supplies the same volume of warm air as is required in another mode in which a large quantity of warm air from warm air duct 8 is required, for example in the defrost/foot mode. In the foot mode, in which no warm air is required at the windshield, the temperature at defrost outlet 3 would then be too high. To control the temperature, means 12 for controlling the air flow such as baffle plates 13 on housing 2 and temperature dampers 14 and mode control dampers 11 are provided in order to conduct cold air toward the appropriate outlet that has become too warm, in this case toward defrost outlet 3 . This is highly complex, since these measures also impact the other modes.
[0038] The heating and air conditioning system according to the invention, specifically the assembly comprising the mode control damper and the warm air duct that supplies warm air in the direction of one of the outlets, has a number of exemplary embodiments. In these embodiments, the volume of warm air coming from warm air duct discharge opening 10 can be controlled based on mode control damper 11 .
[0039] FIG. 2 shows a first exemplary embodiment of the region 1 a of housing 2 of a heating and air conditioning system that comprises warm air duct 8 and a mode control damper 15 designed according to the invention. Mode control damper 15 is designed to be rotatable about a rotational axis 16 , with the door leaf of the mode control damper according to FIG. 2 having two sections 15 a , 15 b on the two sides of rotational axis 16 . In the embodiment shown, warm air duct discharge opening 10 extends in a direction from rotational axis 16 of mode control damper 15 up to the opposite sealing edge 17 of the warm air duct in the region of housing wall 2 a of housing 2 , against which edge the mode control damper 15 rests in the closed state. In addition, two circular segment-shaped lateral segments 18 are attached to mode control damper 15 , these lateral segments 18 being positioned on mode control damper 15 in such a way that, as mode control damper 15 rotates, the segments pass outside of the warm air duct along two side walls 8 a , 8 b of the warm air duct 8 which are disposed opposite one another and are oriented perpendicular to rotational axis 16 . The circular segment-shaped lateral segments 18 each extend radially from the region of rotational axis 16 up to an outer edge of mode control damper 15 . Even when mode control damper 15 is open, the two lateral segments 18 of mode control damper 15 prevent a flow of air parallel to rotational axis 16 at the warm air duct discharge opening 10 in the region of the two opposing side walls 8 a , 8 b of warm air duct 8 . The assembly shown in FIG. 2 enables the cross-section that determines the volume of warm air exiting warm air duct 8 to be controlled. The width of warm air duct 8 is adjusted based on the warm air flow volume required.
[0040] FIG. 3 shows a schematic illustration of a second exemplary embodiment of the region of housing 2 of a heating and air conditioning system 1 according to the invention, which comprises warm air duct 8 and mode control damper 15 having circular segment-shaped lateral segments 18 . The difference of this assembly, which is otherwise identical to that of the embodiment shown in FIG. 2 , is that the door leaf of mode control damper 15 has a rectangular opening 19 , which prevents warm air duct discharge opening 10 from being completely closed even when the mode control damper is in the closed state in which mode control damper 15 rests against the sealing surface of warm air duct 8 .
[0041] Additional embodiment examples of a combination according to the invention of a mode control damper, the defroster damper, and a warm air duct are illustrated in FIGS. 4 and 5 , each of which shows a region 1 a of a heating and air conditioning system. In these variants, warm air duct discharge opening 10 extends in the housing (not shown) from one housing wall up to an opposite housing wall.
[0042] FIGS. 4 and 5 each show an assembly having a warm air duct 8 and an associated mode control damper 15 with two lateral segments 18 . In contrast to the embodiments shown in FIGS. 2 and 3 , the circular segment-shaped lateral segments 18 are attached and positioned on mode control damper 15 in such a way that, as mode control damper 15 rotates, the segments do not pass by warm air duct 8 , and instead move in the area above half-moon shaped cutouts 20 , formed as complementary to the respective circular arc regions of the lateral segments, in side walls 8 a , 8 b of warm air duct 8 at warm air duct discharge opening 10 . The opposing housing walls (not shown) are oriented parallel to rotational axis 16 of mode control damper 15 .
[0043] In each of the two embodiments shown in FIGS. 4 and 5 , a baffle plate 21 is formed on warm air duct 8 , which conducts a portion of the air flow from warm air duct 8 so as to bypass mode control damper 15 . In addition, in the embodiment shown in FIG. 5 , the intermediate space between the two lateral segments 18 at warm air duct 8 is provided with a filler 22 . As an alternative to the filler, the intermediate space between the two adjacent lateral segments 18 may also be filled by a depression on the opposite side of the door leaf of the mode control damper.
[0044] In all of the above-described embodiments, the volume of air exiting warm air duct 8 can be controlled by adjusting the defroster damper as mode control damper 15 , and thus dependent on the operating mode setting.
[0045] As is also apparent from the examples described in FIGS. 4 and 5 , it is not critical to the invention for mode control damper 15 to completely close warm air duct 8 . Thus an opening or a small distance between warm air duct discharge opening 10 and mode control damper 15 may also be provided in the closed state. In particular, small intermediate spaces 23 may be formed in each case between warm air duct discharge opening 10 and mode control damper 15 in the closed state. In FIGS. 4 and 5 , such an intermediate space 23 is designed, for example, in the form of an opening 23 on sealing edge 17 of warm air duct discharge opening 10 , against which mode control damper 15 rests.
[0046] The advantage of the present invention is particularly evident in a comparison of the defrost/foot mode with the foot/mode. The analysis was performed using computational fluid dynamics (CFD).
[0047] The temperature curves shown in FIG. 6 and FIG. 7 , which were obtained as a function of the position of the temperature damper, are for an assembly of the prior art comprising a mode control damper and a warm air duct.
[0048] FIG. 6 shows the temperature curve as a function of the position of the temperature damper, obtained in the defrost/foot mode. FIG. 7 shows the temperature curve as a function of the position of the temperature damper, obtained in the foot mode.
[0049] The temperature curves shown in FIG. 8 and FIG. 9 , which were obtained as a function of the position of the temperature damper, are for an assembly according to the invention comprising a mode control damper and a warm air duct.
[0050] FIG. 8 shows the temperature curve as a function of the position of the temperature damper, obtained in the defrost/foot mode. FIG. 9 shows the temperature curve as a function of the position of the temperature damper, obtained in the foot mode.
[0051] A comparison of the curves in FIG. 7 and FIG. 9 reveals a significant improvement in terms of the temperature increase in the foot mode for the assembly according to the invention. In other words, FIG. 9 shows that, in the assembly according to the invention, as the temperature damper is opened in the foot mode, the temperature at the defrost outlet no longer increases as abruptly as in a prior art assembly, as shown in FIG. 7 . It is thereby possible to control the temperature of the defrost outlet dependent on the mode.
LIST OF REFERENCE SIGNS
[0000]
1 heating and air conditioning system
1 a region of a heating and air conditioning system
2 housing
2 a housing wall
3 defrost outlet, air outlet
4 dashboard outlet, air outlet
5 footwell outlet, air outlet
6 evaporator
7 heating heat exchanger
8 warm air duct
8 a side wall of warm air duct 8
8 b side wall of warm air duct 8
9 warm air duct intake opening
10 warm air duct discharge opening
11 mode control damper, rotatable defroster damper (prior art)
12 means for controlling air flow
13 baffle plates
14 temperature dampers
15 mode control damper (at warm air duct discharge opening)
15 a section of door leaf of mode control damper
15 b section of door leaf of mode control damper
16 rotational axis
17 sealing edge (against which mode control damper rests in the closed state)
18 lateral segments
19 opening (in mode control damper 15 )
20 cutouts in the side walls of the warm air duct at the warm air duct discharge opening
21 baffle plates
22 filler between lateral segments 18
23 opening in warm air duct 8 , intermediate space | A heating and air conditioning system for a motor vehicle including a housing having an air outlet, a heating heat exchanger disposed inside the housing with a warm air path to heat air flowing therethrough, a warm air duct having a warm air intake opening and a warm air duct discharge opening disposed downstream of the heating heat exchanger channeling a partial flow of warm air from the warm air path to the air outlet, and a mode control damper rotatable about a rotational axis and connected downstream of the warm air duct in terms of flow, wherein the air outlet may be selectively opened completely or partially, and in a closed state may be partially or completely closed. The mode control damper functions simultaneously as the control damper for controlling the volume of air exiting the warm air duct discharge opening. | 1 |
FIELD OF THE INVENTION
The present invention relates to coverings for rolls used in the papermaking process in general and to compliant roll coverings for gloss calenders in particular.
BACKGROUND OF THE INVENTION
Calenders are employed in the papermaking industry to improve or modify the surface finish of a paper web. Calenders can also be used to modify the thickness of the paper web or to even out the thickness along or across the web.
A major function of paper calenders is to improve the surface finish of paper which can improve both its appearance and printability. A calender functions by employing pressure to smooth the surface of a paper web as it passes the rolls. One or more of the rolls may be heated.
Supercalenders are comprised of multiple rolls stacked one above the other forming a plurality of nips through which the paper web is passed. Supercalendering is often accomplished on the papermaking machine just prior to forming the paper web into a reel on a winder. Supercalenders are also used in off-machine applications, in combination with reminders, to improve the surface finish of paper on reels. Supercalenders are used to increases the amount of calendering by increasing the length of time the paper web spends transiting a nip by increasing the number of nips. Supercalenders have also employed rolls with compliant covers which form nips of increased length, thus increasing the amount of surface improvement which can be accomplished in passing through each of the nips formed by a supercalender.
Supercalenders have some drawbacks in that the multiplicity of stacked calender rolls adds to the complexity and cost of a calender. Supercalenders also require more time to change calender rolls. Roll change out is often required when the paper grade being processed is changed. Supercalenders can present additional problems upon machine startup or when a paper break occurs because of the multiplicity of nips which are required to be threaded.
For many grades of paper, it has been found that the supercalender can be replaced by a calender of the gloss type. A gloss calender, or a soft calender, typically employs two rolls forming a single nip, or two pairs of rolls forming two nips. The soft calender has one roll with a compliant cover opposed to a hard surfaced heated roll. When the soft nip calender is run at high nip loads of up to 3,000 pounds per linear inch (PLI), one or more soft nip calenders can perform the supercalender function with certain grades of paper. Where the soft nip calender can be used, increased economies are achieved by the greater simplicity of the soft nip calender over that of the supercalender.
Compliant roll covers have typically been manufactured of leather, rubber or specialized synthetic materials such as polyurethane.
There is a significant detriment to using a roll with a compliant surface in a gloss calender. Modern gloss calenders operate with the hard noncompliant roll at a temperature as high as 400° to 500° F., and compliant rolls have limited capability for withstand high temperatures. Hysteresis effects in the compliant roll surface produce heating which aggravates the problem of roll heating. The high temperature and high pressures used in the gloss calender can also create a potential for failure of the roll cover causing it to separate from the metallic shell to which the compliant roll surface is attached. The continual increase in the speed at which paper is formed, from less than 3,000 feet per minute to over 6,000 feet per minute, with the future holding the likelihood that speeds of over 9,000 feet per minute will be reached relatively soon, adds urgency to the need to develop roll covers with reduced hysteresis losses.
One approach to overcoming the limitations of compliant rolls as used in gloss calenders is disclosed in U.S. Pat. No. 5,546,856 to Neider et al. which discloses a compliant belt which is passed through a calender opposite a heated roll. The belt reduces some of the problems produced by hysteresis in a compliant roll in a gloss calender, however at the cost of adding additional complexity and cost to the gloss calender.
The effectiveness of the calender requires the highest temperature possible in the heated roll without overheating the compliant surface. By reducing the hysteresis-generated heat, the amount of heat the compliant roll can accept from the heated roll is increased.
What is needed a roll cover which reduces shear stresses between a roll cover and a steel roll and which reduces internal heat generation due to hysteresis.
SUMMARY OF THE INVENTION
The soft nip or gloss calender of this invention has a compliant roll constructed of circumferentially positioned layers of compliant material which become progressively less compliant as the layers approach an underlying steel roll.
It is a feature of the present invention to provide a gloss calender with a compliant roll which has reduced hysteresis heating.
It is a further feature of the present invention to provide a gloss calender with a compliant roll which resists de-bonding of the compliant roll cover from the metal base roll.
It is another feature of the present invention to provide a gloss calender with a compliant roll which can be used at higher speeds or with a higher temperature heated roll.
Further objects, features and advantages of the invention will be apparent from the following detailed description when taken in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
The figure is a schematic cross-sectional view of the gloss calender of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to the figure, a soft nip calender 20 is shown. The calender 20 has a heated metal roll 22 in nipping engagement with a compliant roll 24. A paper web 26 passes through the nip 28 formed between the heated roll 22 and the compliant roll 24. The compliant roll 24 has an inner metal shell 30 and an outer compliant covering 32 which is constructed of four layers: an inner layer 34, a second layer 36, a third layer 38, and an outer layer 40.
To increase the performance of the soft nip calender 20, the temperature of the heated roll 22 can be increased. The temperature will be a minimum of 200° Fahrenheit. By circulating heated oil through the metal roll 22, the temperature can be raised to about 350° F. Through the use of induction heaters the temperature of the roll 22 can be increased to 500° to 600° F. Temperatures higher than this typically result in scorching of the paper and excessive heating of the compliant roll 24.
Performance of the soft nip calender is further improved by increasing the width of the nip 28 to increase the dwell time of the web 26 in the nip 28. Increasing the nip width is accomplished by making the compliant cover 32 softer. However if this is done with a single layer of soft material, two problems with soft calender rolls are aggravated. The first is that the cover is more likely to separate from the inner metal shell 30 because of the greater shear stress at the interface between the cover and the metal shell. The second problem is that the greater deflection in the thickness of the cover results in greater hysteresis heating.
The soft cover compliant roll 24 overcomes this problem by using multiple layers 34, 36, 38, 40 which are progressively softer as distance from the metal shall 30 increases. The first layer 34 has a very high hardness 0-4 Pusey and Jones. The second layer 36 is slightly softer with a hardness of 5 to 10 Pusey and Jones. The third layer 38 has a softer layer with a hardness of 10-15 Pusey and Jones and the final layer 40 has a hardness of 15 to 30 Pusey and Jones.
By using a series of layers with increasing softness the shear at the interface between each layer is reduced so that separation of the roll cover 32 from the metal shell 30 is reduced. Because the last layer 40 is relatively thin, it can be softer, thus allowing for a greater nip width and so greater calendering effect.
Ideally the hardness or durometer of the roll cover would vary continuously from the shell 30 to the surface of the roll cover 32. However practical considerations suggest that separate layers be used to develop the roll properties. Materials suitable for achieving the properties required for the roll cover 32 include polyurethane, which can be formulated in a wide range of hardnesses. Another approach is to employ rubber with varying additives and varying levels of vulcanization.
It should be understood that the thickness of the compliant cover may vary depending on the paper being processed, and that a typical thickness for the cover would be between about one inch and two inches. The upper most there will have a thickness of between 0.5 and 0.8 inches to allowed for refinishing the roll surface. The first layer and the intermediate layers will typically have a thickness of about 0.3 inches.
It should be understood that the soft nip calender 20 of this invention will typically have a load of about 2,000 lbs per linear inch in the cross machine direction. Nevertheless, soft nip calenders including gloss calenders can have nip loads between 1,000 and 3,000 lbs per linear inch or higher.
It should be understood that the Pusey & Jones system for measuring as described in ASTM designation: D531-85 can be correlated with the A-scale durometer or shore A system with a Pusey and Jones of 30 corresponding to 80 Shore A, a Pusey and Jones of 25 corresponding to 87 Shore A, a Pusey and Jones of 20 corresponding to 90 Shore A, a Pusey and Jones of 15 corresponding to 94 Shore A and a Pusey and Jones of 8 corresponding to 98 Shore A.
It should be understood that a metal inner roll is herein defined to include a metal roll over wrapped with fiberglass or other very hard composite material which serves to improve bonding between the compliant layers and the metal roll.
It should be understood that the preferred compliant roll cover material will be polyurethane.
It is understood that the invention is not limited to the particular construction and arrangement of parts herein illustrated and described, but embraces such modified forms thereof as come within the scope of the following claims. | A soft nip calender employing a compliant roll constructed of circumferentially superpositioned layers of compliant material which are progressively less compliant as the layers approach an underlying steel roll. | 3 |
BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The present invention relates to a vertical wafer boat, for example, relates to a vertical wafer boat which holds a silicon wafer in a vertical low pressure CVD apparatus used in a manufacturing process of a semiconductor device.
Description of the Related Art
[0002] In the case of depositing film on a surface of a silicon wafer to be processed, a CVD apparatus which performs film deposition by chemical vapor deposition is used. FIG. 3 shows a conventional vertical low-pressure CVD apparatus 30 . The CVD apparatus 30 includes a furnace body 31 , a process tube 32 which is accommodated in the furnace body 31 and in which a plurality of silicon wafers W are accommodated, and a heater (not illustrated) arranged between the furnace body 31 and the process tube 32 . The process tube 32 is formed using high-purity quartz or silicon carbide (SiC) such that an interior temperature is maintained at a high temperature state when the inside of the process tube is heated. Further, the process tube 32 is connected to a vacuum pump (not shown) and the pressure inside the process tube 32 can be reduced to a predetermined pressure (for example, 1.3 kPa) or less.
[0003] A boat receiver 34 is provided in a center portion of a base 33 covered by the process tube 32 , and a vertical rack-shaped wafer boat 1 is disposed on the boat receiver 34 . In the wafer boat 1 , a plurality of silicon wafers W are held with a predetermined interval in a vertical direction. A gas introduction pipe 35 configured to introduce a reactive gas into the furnace is disposed in a circumference of the wafer boat 1 , and a thermocouple protection pipe 36 with a built-in thermocouple to measure the temperature inside the furnace is provided.
[0004] In such a vertical low-pressure CVD apparatus 30 , the plurality of silicon wafers W are held in the wafer boat 1 , and accommodated in the furnace body 31 .
[0005] Subsequently, the interior of the furnace is depressurized to a predetermined pressure (for example, 1.3 kPa or less), and is heated to a temperature of, for example, 600 to 900° C., and the reactive gas (a raw material gas) such as SiH 4 together with a carrier gas (such as H2) is introduced into the furnace through the gas introduction pipe 35 such that a polycrystalline silicon film, a silicon nitride film (Si 3 N 4 ), or the like is formed on a surface of the silicon wafer W.
[0006] The conventional wafer boat 1 is disclosed in, for example, JP 2008-277781 A. As illustrated in FIG. 4 , the wafer boat 1 disclosed in JP 2008-277781 A includes a pair of a top plate 3 and a bottom plate 4 having an outer diameter larger than that of the silicon wafer W to be loaded, and a plurality of (three in FIG. 4 ) struts 2 which connects the top plate 3 and the bottom plate 4 . Incidentally, the top plate 3 and the bottom plate 4 are formed in a disk shape, which is similar to the silicon wafer W.
[0007] Further, a plurality of support grooves 2 a configured to support the silicon wafer W is provided in the strut 2 as illustrated, partially enlarged, in FIG. 5 . As a result, a plurality of shelf plate portions 2 b protruding from a side surface of the strut are provided to form multiple stages, and an upper surface of the shelf plate portions is a wafer support portion 2 b 1 . A peripheral edge portion of the silicon wafer W is supported by the wafer support portion 2 b 1 .
[0008] However, when the silicon wafer W is supported by the wafer support portion 2 b 1 which is the upper surface of the shelf plate portion 2 b, the wafer support portion 2 b 1 and a lower surface of the wafer peripheral edge portion are brought into surface-contact with each other. Thus, there is a case where a large number of particles are generated by sliding contact at the time of loading and unloading the wafer and adhere to a back surface of the silicon wafer W.
[0009] Further, there is a problem that the particles generated on the back surface of the silicon wafer W at an upper side fall and adhere even to the surface of the silicon wafer W.
[0010] Further, when the silicon wafer W is heated during heat treatment, some warp occurs at the wafer peripheral edge portion as illustrated in FIG. 5 , an interval (clearance CL) from the upper shelf plate portion 2 b decreases so that a wafer edge contacts a lower surface of the shelf plate portion 2 b in some cases.
[0011] In order to solve the above-described problem, Patent Literature JP H9-82648 A discloses a vertical boat in which the wafer support portion 2 b 1 of the shelf plate portion 2 b formed in the strut 2 is formed as an inclined surface inclined with respect to the horizontal plane as illustrated in FIG. 6 .
[0012] When the wafer support portion 2 b 1 is inclined in this manner, the silicon wafer W supported in a substantially horizontal state is supported by line contact. Thus, the generation of particles is suppressed.
[0013] Further, when the entire shelf plate portion 2 b is inclined as illustrated in FIG. 6 , the interval (clearance CL) between the wafer end and the upper shelf plate portion 2 b is secured to be large even if some warp occurs at the end of the silicon wafer W during the heat treatment. Thus, the contact between the wafer end and the lower surface of the shelf plate portion 2 b can be prevented.
[0014] In recent years, however, an increase of a diameter of the silicon wafer W causes it difficult to hold the silicon wafer W in the substantially horizontal state.
[0015] That is, a center portion of the silicon wafer W deflects downward by its own weight, and the wafer peripheral edge portion rises upward irrespective of the heat treatment. When the wafer peripheral edge portion rises upward in this manner, the inclined wafer support portion 2 b 1 and the wafer peripheral edge portion become partially parallel to each other, thereby causing the surface contact to occur instead of the line contact.
[0016] Thus, there is a problem that particles are generated due to the sliding contact, stress across the entire silicon wafer W increases, and slip is liable to occur.
SUMMARY OF THE INVENTION
[0017] The present invention has been made under the circumstances as described above, and an object the invention is to provide a vertical wafer boat which supports a silicon wafer to be processed by a shelf plate portion provided in multiple stages, the vertical wafer boat being capable of reducing a risk of contact between a warped outer peripheral portion of a wafer and the shelf plate portion and suppressing deflection of the silicon wafer even when the silicon wafer has a large diameter. The vertical wafer boat according to the present invention includes a plurality of struts having a shelf plate portion as to mount silicon wafers; and a top plate and a bottom plate which fix upper and lower ends of the strut. The shelf plate portion is inclined downward toward the center of the wafer boat, and a wafer support portion, which protrudes upward and abuts on an edge portion of the silicon wafer, is formed at a distal end of the shelf plate portion.
[0018] Incidentally, an inclination angle of the shelf plate portion is desirably in a range of 1° or more and 2° or less.
[0019] Further, an upper surface of the wafer support portion is desirably formed in a horizontal plane.
[0020] Further, it is desirable that a length of the shelf plate portion in a radial direction be in a range of 40 mm or more and 80 mm or less, and a length of the wafer support portion in the radial direction be in a range of 5 mm or more and 10 mm or less.
[0021] Since the shelf plate portion is inclined downward toward the center of the boat, according to such a configuration, it is possible to secure a sufficient interval (clearance CL) from the upper shelf plate portion and to prevent contact between the peripheral edge portion of the wafer and a lower surface of the shelf plate portion even when a peripheral edge portion of the wafer is warped upward when the silicon wafer is held for heat treatment.
[0022] Further, since the wafer support portion that abuts on the silicon wafer is provided at the distal end of the shelf plate portion, a support position of the silicon wafer is located at a radially inner side of the peripheral edge of the wafer so that it is possible to suppress the amount of deflection to be small even if the center of the silicon wafer having the large diameter is deflected downward by its own weight.
[0023] Further, since the wafer support portion is formed in a horizontal plane and the lower surface of the inclined silicon wafer abuts on the wafer support portion by the deflection, line contact is made in the abutment portion, and the stress to the silicon wafer is suppressed to be small, whereby it is possible to prevent occurrence of slip.
BRIEF DESCRIPTION OF THE DRAWING
[0024] FIG. 1 is a partially enlarged cross-sectional view illustrating one of a plurality of struts included in a vertical wafer boat of the present invention;
[0025] FIG. 2 is a plan view of a wafer support portion included in one shelf plate portion formed in the strut of FIG. 1 ;
[0026] FIG. 3 is a cross-sectional view of a conventional vertical low pressure CVD apparatus;
[0027] FIG. 4 is a perspective view of a conventional wafer boat;
[0028] FIG. 5 is a partially-enlarged cross-sectional view of a strut of the conventional wafer boat; and
[0029] FIG. 6 is a partially enlarged cross-sectional view of a strut of another conventional wafer boat.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] Hereinafter, embodiments of a vertical wafer boat according to the present invention will be described with reference to the drawings. The vertical wafer boat according to the present invention is different from a conventional wafer boat that has been already described with reference to FIGS. 3 and 4 in terms of only a configuration of a shelf plate portion which supports a silicon wafer, and thus, detailed descriptions for the other components will be omitted.
[0031] FIG. 1 is a partially enlarged cross-sectional view illustrating one of a plurality of struts of the vertical wafer boat (wafer boat 1 ) of the present invention.
[0032] As illustrated in FIG. 1 , a plurality of support grooves 2 a is formed at an inner side of the strut 2 with a predetermined interval along a longitudinal direction thereof. Further, plate-like shelf plate portions 2 b are formed by forming the plurality of support grooves 2 a. A wafer support portion 2 b 1 is formed at a distal end of the shelf plate portion 2 b so as to protrude upward by a predetermined height h (preferably, h=0.3 mm or more and 1.0 mm or less), and the wafer support portion 2 b 1 is formed in a horizontal plane having a predetermined area as illustrated in the plan view in FIG. 2 .
[0033] A silicon wafer W is held by the boat; that is, a lower surface of a peripheral edge portion of the silicon wafer W abuts on and is supported by the wafer support portion 2 b 1 of the shelf plate portion 2 b formed in each of the plurality of struts 2 .
[0034] The shelf plate portion 2 b is extended in a radial direction in a state in which an upper surface side and a lower surface side thereof are parallel to each other, and is inclined downward toward the center of the wafer boat. An inclination angle θ thereof is preferably 1° or more and 2° or less. This is because there is a risk that the upper surface of the wafer support portion 2 b 1 and a lower surface of a peripheral edge of the silicon wafer W may be brought into contact with each other at the time of conveying or loading the silicon wafer W when the inclination angle θ exceeds 2°. In contrast, when the inclination angle θ is less than 1°, there is a risk that an upper surface of the peripheral edge portion may be brought into contact with the lower surface of the wafer support portion 2 b 1 when the silicon wafer W is deformed, that is, when a warp occurs.
[0035] Further, a length d 1 of the shelf plate portion 2 b in the radial direction is formed to be 40 mm or more and 80 mm or less. An optimum value of the length d 1 in the radial direction is different depending on a diameter of the silicon wafer W to be supported. For example, when the diameter of the silicon wafer W is 300 mm, the length d 1 is preferably 80 mm. By adjusting the length of the shelf plate portion 2 b in the radial direction and setting a support position by the wafer support portion 2 b 1 in this manner, a position of the wafer support portion 2 b 1 moves to a radially inner side of the wafer from the peripheral edge end of the wafer; as a result, it is possible to reduce the amount of self-weight deflection of the silicon wafer W.
[0036] Further, right and left corners at the distal end of the wafer support portion 2 b 1 of the shelf plate portion 2 b are chamfered as illustrated in FIG. 2 . Preferably, a chamfering width d 3 is 0.5 mm or more and 2 mm or less, and R chamfering of 2 mm or more and 8 mm or less is carried out.
[0037] Further, a length d 2 of the wafer support portion 2 b 1 in the radial direction is formed to be 5 mm or more and 10 mm or less. A width d 4 in a circumferential direction may be formed to a desired length depending on a shape of the strut 2 .
[0038] The surface of the wafer support portion 2 b 1 is preferably roughened to have a surface roughness Ra of 0.2 μm or more and 0.8 μm or less. This roughening treatment prevents occurrence of scratches on a back surface of the wafer and slip, and further the wafer support portion 2 b 1 from sticking to the silicon wafer W.
[0039] With thus configured wafer boat, since the shelf plate portion 2 b is inclined downward toward the center of the boat, it is possible to secure a sufficient interval (clearance CL) from the upper shelf plate portion 2 b and to prevent contact between the peripheral edge portion of the silicon wafer W and the lower surface of the shelf plate portion 2 b even if the peripheral edge portion of the silicon wafer W is warped upward at the time of holding the silicon wafer W for heat treatment.
[0040] Further, since the wafer support portion 2 b 1 abutting on the silicon wafer W is provided at the distal end of the shelf plate portion 2 b, the support position of the silicon wafer W is located at the radially inner side of the peripheral edge end of the wafer, and the deflection amount can be reduced even if the center of the silicon wafer W having the large diameter is deflected downward by its own weight.
[0041] Further, since the wafer support portion 2 b 1 is formed in a horizontal plane and the inclined lower surface of the silicon wafer W due to self-weight deflection abuts on the wafer support portion, line contact is made in the abutment portion, and stress to the silicon wafer W is reduced, whereby the occurrence of slip can be prevented.
[0042] The vertical wafer boat according to the present invention will be further described on the basis of Examples. In these Examples, the vertical wafer boat illustrated in the above-described embodiment was manufactured, and the performance of the obtained wafer boat was verified.
[0043] Specifically, the plurality of support grooves configured to place the silicon wafer was formed on a SiC base material by a rotary cutting tool to form the strut.
[0044] Subsequently, an upper surface (engagement surface) of the shelf plate portion formed by the support groove was roughened by sandblasting treatment so as to have Ra of 0.5 μm.
[0045] Further, the obtained strut was washed with an acid, then washed out with pure water, and dried to obtain a complete form of the strut. A necessary number of the struts was formed in the same manner, and then, the top plate and the bottom plate were assembled to these struts, thereby manufacturing the assembly-type vertical wafer boat.
[0046] In addition, fifty silicon wafers having a diameter of 300 mm were loaded in the manufactured vertical wafer boat, and heat-treated in a furnace at 750° C. for one hour.
[0047] In Examples 1 to 8, verification was performed regarding a preferable length of the shelf plate portion in the radial direction and length of the wafer support portion in the radial direction by observing the number of particles adhering to the surface of the silicon wafer after the heat treatment (the number of particles of 0.2 μm or more that adhere on the surface of the silicon wafer of 300 mm in diameter) and a slip occurrence state of the back surface of the silicon wafer.
[0048] Table 1 shows conditions of Examples 1 to 8 and verified results thereof. In the verified results shown in Table 1, “Good” of “the number of adhering particles” indicates a state in which adhesion of particles of 0.2 μm or more was not observed on the surface of the silicon wafer of 300 mm in diameter, “Fair” indicates a state in which adhesion of a small amount (twenty or less of particles of 0.2 μm or more on the surface of the silicon wafer of 300 mm in diameter) of particles was confirmed, and “Poor” represents a result in which adherence of a lot (more than 20 and 50 or less of particles of 0.2 μm or more on the surface of the silicon wafer of 300 mm in diameter) of particles was confirmed. Further, “Good” in the “slip occurrence state” indicates a state in which no slip occurs, and “Poor” indicates a state in which slip has occurred.
[0000]
TABLE 1
Ex-
Ex-
Ex-
Ex-
Ex-
Ex-
Ex-
Ex-
ample
ample
ample
ample
ample
ample
ample
ample
1
2
3
4
5
6
7
8
Length of shelf plate
39 mm
40 mm
80 mm
81 mm
60 mm
portion in radial direction
Length of wafer support
7 mm
4 mm
5 mm
10 mm
11 mm
portion in radial direction
Inclination angle of shelf
1.5°
plate portion
Step height of wafer
0.6 mm
support portion
Surface roughness (Ra)
0.5 μm
of wafer support portion
Number of adhering
Fair
Good
Good
Fair
Fair
Good
Good
Fair
particles
Slip generation state
Good
Good
Good
Good
Good
Good
Good
Good
[0049] As shown in Table 1, particularly when the length of the shelf plate portion in the radial direction was 40 mm or more and 80 mm or less (the length of the wafer support portion in the radial direction was fixed at 7 mm), particles did not adhere, and good results were obtained as the results of Examples 1 to 4.
[0050] Further, particularly when the length of the wafer support portion in the radial direction was 5 mm or more and 10 mm or less (the length of the shelf plate portion in the radial direction was fixed at 60 mm), no particles adhered, and good results were obtained as the results of Examples 5 to 8.
[0051] In Examples 9 to 12, verification was carried out regarding a preferable inclination angle of the shelf plate portion by observing the number of particles adhering to the surface of the silicon wafer after the heat treatment and the state of slip occurrence.
[0052] Table 2 shows conditions of the inclination angle of the shelf plate portion and verification results thereof. In the verification results shown in Table 2, “Good” of “the number of adhering particles” indicates a state in which adhesion of particles of 0.2 μm or more was not observed on the surface of the silicon wafer of 300 mm in diameter, “Fair” indicates a state in which adhesion of a small amount (twenty or less of particles of 0.2 μm or more on the surface of the silicon wafer of 300 mm in diameter) of particles was detected, and “Poor” represents a result in which adherence of a lot (more than 20 and 50 or less of particles of 0.2 μm or more on the surface of the silicon wafer of 300 mm in diameter) of particles was detected. Further, “Good” in the “slip occurrence state” indicates a state in which no slip occurs, and “Poor” indicates a state in which slip has occurred.
[0053] Table 2 shows results of Comparative Examples that were carried out subsequent to Examples. In Comparative Example 1, the shelf plate portion is inclined, but the wafer support portion protruding upward is not provided. In Comparative Example 2, the shelf plate portion is not inclined but horizontal, and has the wafer support portion protruding upward at the distal end. In Comparative Example 3, the shelf plate portion is not inclined but horizontal, and has no wafer support portion protruding upward at the distal end.
[0000]
TABLE 2
Compar-
Compar-
Compar-
Ex-
Ex-
Ex-
Ex-
ative
ative
ative
ample
ample
ample
ample
Example
Example
Example
9
10
11
12
1
2
3
Length of shelf plate
60 mm
30 mm
60 mm
portion in radial direction
Length of wafer support
7 mm
None
20 mm
None
portion in radial direction
Inclination angle of shelf
0.9°
1.0°
2.0°
2.1°
1.5°
0°
plate portion
Step height of wafer
0.6 mm
None
0.6 mm
None
support portion
Surface roughness (Ra)
0.5 μm
of wafer support portion
Number of adhering
Fair
Good
Good
Fair
Poor
Poor
Poor
particles
Slip generation state
Good
Good
Good
Good
Poor
Good
Poor
[0054] As results of Examples 9 to 12, particularly when the inclination angle of the shelf plate portion was 1.0° or more and 2.0° or less, no particles adhered and good results were obtained as shown in Table 2.
[0055] Further, the deflection was large since the diameter of the silicon wafer was large, the surface contact with the shelf plate portion was made so that a lot of particles adhered, and the slip occurred in Comparative Example 1 (the shelf plate portion was inclined and the support portion was not protruded). In Comparative Example 2 (the shelf plate portion was horizontal and the protruding support part was provided), no slip occurred, but a large number of particles adhered. In Comparative Example 3 (the shelf plate portion was horizontal and the support portion was not protruded), a large number of particles adhered, and the slip occurred.
[0056] As a result of the above-described examples according to the configuration of the present invention, it has been confirmed that generation of particles and occurrence of slip can be prevented by reducing the risk of contact between the shelf plate and the warp of the outer peripheral portion of the silicon wafer while minimizing deflection of the silicon wafer.
REFERENCE SIGNS LIST (FOR TAIWAN)
[0000]
1 Wafer boat
2 Strut
2 a Support groove
2 b Shelf plate portion
2 b 1 Wafer support portion
3 Top plate
4 Bottom plate
W Silicon wafer | A vertical wafer boat includes a plurality of struts formed with a shelf plate portion configured to mount a silicon wafer, and a top plate and a bottom plate which fix upper and lower ends of the struts. The shelf plate portion is inclined downward toward the center of the boat, and a wafer support portion which protrudes upward and abuts on an edge portion of the silicon wafer is formed at a distal end of the shelf plate portion. To obtain the vertical wafer boat which supports a silicon wafer to be processed by a shelf plate portion provided in multiple stages, the vertical wafer boat being capable of reducing a risk of contact between a warped outer peripheral portion of a wafer and the shelf plate portion and suppressing deflection of the silicon wafer even when the silicon wafer has a large diameter. | 7 |
RELATED APPLICATION
This application claims the benefit of provisional application 60/571,457 filed 5/14/2004.
The invention was made with Government support under Contract DE-AC0576RLO 1830, awarded by the U.S. Department of Energy. The Government has certain rights in the invention.
TECHNICAL FIELD
This invention relates generally to a process for producing reagents to minimize NOx emissions derived from internal and external combustion engines. More particularly, the invention relates to a process for producing reagents using a three step process to transform fuel hydrocarbons into reagent species in a manner that allows for high activity and control over the selectivity of the resultant reagents.
BACKGROUND OF THE INVENTION
More stringent environmental regulations require novel approaches to minimize NOx emissions from major sources, such as on-road and off-road vehicles. Current logistic fuels, such as diesel, kerosene, JP-8, gasoline, and natural gas are the preferred choice as reductants for NOx reduction aftertreatment systems, such as hydrocarbon selective catalytic reduction (HC-SCR) and lean NOx traps (LNT). This is primarily due to the fact that such fuels are already carried on-board a vehicle as the combustion fuel for the engine and, therefore no special secondary treatment is required. However, the direct use of these fuels as reducing agents in catalytic aftertreatment systems is known. Hydrocarbon species which make up the fuel are not the actual reductant used in NOx reduction chemistry. Instead, most catalyst formulations contain one or more “promoters”, which are typically made up from precious metals or base metal oxides, whose function is to “convert” fuel hydrocarbons into partially oxidized species like alcohols, aldehydes or ketones. It is these oxygenates that are active in the chemical reduction of NOx on the surface of most lean-NOx catalysts.
Currently, some of the most active reductants for HC-SCR are aldehydes and alcohols such as methanol, ethanol, acetaldehyde, and formaldehyde. On-board production of these reductants would allow for better performance of the catalyst system to meet the more stringent environmental regulations for NOx emissions. The enhanced performance of aldehydes and alcohols over traditional hydrocarbons (propylene) is based on the broadening of the active temperature window, higher selectivity, and higher overall activity for reduction of NOx.
Accordingly, the ability to transform fuel hydrocarbons into oxygenated species in a manner that allows for high activity and control over the selectivity would be a break-through in the aftertreatment industry. The invention described herein provides for a method to produce specific oxygenates from diesel, natural gas, JP-8, and other hydrocarbon fuels.
SUMMARY OF THE INVENTION
One embodiment of this invention provides a process for producing reagents for a chemical reaction by introducing a fuel containing hydrocarbons into a flash distillation process, wherein the fuel is separated into a first component having a lower average molecular weight and a second component having a higher average molecular weight. In yet a further embodiment, the present invention provides a process to reform the first component to produce a mixture of predominately synthesis gas. In yet a further embodiment, the present invention provides a process to react catalytically the synthesis gas to produce desired reagent. The desired reagents may be selected from a group consisting of ethers, alcohols, and combinations thereof. Preferably, but not to be limiting, the ether may be dimethyl ether, and the alcohol may be methanol. The reagent may further be a mixture of dimethyl ether to methanol in approximately a 4:1-8:1 ratio on a molar basis. It is also contemplated that the reagents produced by this invention may be olefinic products, keytone products, aldehyde products, and combinations thereof, depending on the catalyst used in the chemical synthesis.
In another embodiment, the present invention provides a process as described herein, wherein the sulfur is reduced to at least 20 ppb before catalytically reacting the synthesis gas to desired reagent.
In still another embodiment, the present invention provides a process to create a fuel supplement feedstock for a power source. The power source may be a fuel cell, for example, but not to be limiting, a solid oxide fuel cell, molten carbonate fuel cell, a phosphoric acid fuel cell, a direct methanol fuel cell that may handle dimethyl ether, proton exchange membrane fuel cell, or an auxiliary power unit fuel cell. Another power source may be internal or external combustion engine, such as a rotary engine or stirling engine, or a heat pump wherein the DME is used to drive the thermal compression cycle.
In a further embodiment, the present invention provides a process for producing a feedstock as described herein for use in a lean-NOx exhaust system.
In a further embodiment, the present invention provides a reforming step as selected from a group consisting of partial oxidation, catalytic partial oxidation, autothermal, steam reforming, plasma reforming, super critical reforming, cracking, dry reforming and combinations thereof. Also, the invention may utilize catalysts selected from the group of precious metals, for example, but not to be limiting, ruthenium, rhenium rhodium, palladium, silver, osmium, iridium, platinum, and gold to achieve a desired reagent during the reforming step.
In another embodiment, the present invention provides a process described herein used for producing reagents for use in lean-NOx exhaust systems. In this embodiment, fuel containing hydrocarbons is introduced into a reforming unit operably connected offline from an engine exhaust system to produce a synthesis gas. The synthesis gas is then reacted catalytically to produce desired reagents. In this embodiment, the reagents may be selected from the group consisting of ethers, alcohols, and combinations thereof. More preferably, but not to be limiting, the ether may be dimethyl ether, and the alcohol may be methanol. It may also be desired to have the reagents comprise a mixture of dimethyl ether to methanol in approximately a 4:1-8:1 ratio on a molar basis. The reforming unit may incorporate one or more of the operations from the group consisting of partial oxidation, catalytic partial oxidation, autothermal, steam reforming, plasma reforming, super critical reforming, cracking, dry reforming and combinations thereof. As used herein and throughout this patent, reforming means producing synthesis gas from hydrocarbons.
In a further embodiment of this invention, the sulfur is reduced to at least 20 ppb before reacting catalytically the synthesis gas to produce desired reagents.
In a still further embodiment of this invention, the reagents are selected from a group consisting of olefinic products, keytone products, aldehyde products, and combinations thereof.
In another embodiment of this invention, the process described herein is used in a hydrocarbon selective catalyst reduction system.
In a still further embodiment of this invention, the process provides a method for reducing soot and NOx in the combustion process. In this embodiment, a fuel containing hydrocarbon is introduced into a first step comprising a flash distillation process. It is then separated into a first component having a lower average molecular weight and a second component having a higher average molecular weight. The first component is then reformed to produce a mixture consisting predominantly of synthesis gas. The synthesis gas is then reacted catalytically to produce a reagent. The reagent is then reintroduced into the combustion process. The reagent may be selected from the group consisting of ethers, alcohols, and combinations thereof. Preferably, but not to be limiting, ether is dimethyl ether, and the alcohol is methanol. It may also be preferred to remove any gas that may be present in the effluent during the catalytic reaction.
In another embodiment, the invention described herein provides a process for reducing sulfur contaminates and other additives from a liquid hydrocarbon fuel source. In this embodiment, the flash distillation process is used to separate the fuel into a first component having a lower average molecular weight and a second component having a higher molecular weight. Preferably, but not to be limiting, the additive, sulfur, and detergent compounds are thus removed from the first component because they have a partial pressure less than first component.
BRIEF DESCRIPTION OF THE DRAWINGS
The following detailed description of the embodiments of the invention will be more readily understood when taken in conjunction with the following drawing, wherein:
FIG. 1 is a schematic drawing of batch flash distillation process.
FIG. 2 is a schematic drawing of the millisecond contact time Pox reactor.
FIG. 3 illustrates the pressure and temperature effects on conversion and selectivity.
FIG. 4 illustrates Effect of GHSV on CO Conversion.
FIG. 5 illustrates the Nitrogen (N 2 ) Dilution Effects on DME Synthesis.
FIG. 6 illustrates the flash distillation with 1000 ppm Dibenzothiophene inlet.
FIG. 7 Illustrates the flash distillation with 3000 ppm Dibenzothiophene inlet
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Flash Distillation
A series of experiments were conducted to demonstrate various embodiments and advantages of the present invention. In the first of these experiments, a fuel containing hydrocarbons was introduced into a flash vessel as described herein. The flash distillation process separates the fuel into two streams, a vapor and a liquid. The vapor stream will contain predominantly lighter hydrocarbons, while the liquid product will maintain the heavier fraction including many of the sulfur laden molecules. The fuel is heated to a temperature in the range of about 100-400° C. under a pressure of about 5-80 atmospheres and “flashed” across a valve to a lower pressure between about 0.5 and 30 atmospheres (absolute). The vapor and liquids are thus separated in a flash vessel. The recovered lighter component of the hydrocarbon stream, by example and not to be limiting, has a molecular structure averaging between about five carbon atoms per molecule (C5) and about eight carbon atoms per molecule (C8). The recovered heavier component of the hydrocarbon stream, by example and not to be limiting, has a molecular structure averaging between about ten carbon atoms per molecule (C10) and about eighteen carbon atoms per molecule (C18). The lighter component also has a lower amount of sulfur than the heavier component.
Referring now to the drawings, FIG. 1 is a schematic view of the flash distillation process used in proof-of-principle experiments designed to demonstrate the advantages of certain embodiments of the present invention. The batch system is preferably made up of two high pressure vessels; the 75 ml flash vessel 10 and the 75 ml condenser vessel 12 , a solenoid valve 14 , a back pressure regulator 16 , and a microgear pump (Micopump-MZR-7205) 18 . Valves 20 , 22 , 24 , 26 , 28 are utilized to open and close the typical ⅛ in. stainless steel line while operating the system. A Julabo oil pump 30 , capable of pumping 14-18 lpm, may be used to heat the flash vessel 10 to approximately 320° C. In this embodiment, a fuel tank 29 containing diesel fuel of DBT, 4 methyl DBT and 4,6 methyl DBT with a concentration between about 50 and about 3073 ppmw of sulfur was connected to a ⅛′ stainless steel tube to allow the fuel to travel throughout the system. The fuel is pumped into the flash vessel 10 by the microgear pump 18 . The fuel was pressurized using a mass flow controller 32 (Brooks 5850 E), which pumped nitrogen gas throughout the system. The condenser vessel 12 was also jacketed, and a typical liquid pump 34 capable of pumping 14-18 lpm may be used to pump cooling water through the jacket to cool it. Cooling water was maintained between 13-15° C. The vessels and any stainless steel tubing which was to be contacted by the diesel were treated with Sulfinert™ (Restek Corp.). The Sulfinert™ coating passivated the stainless steel so that it would not adsorb sulfur while still enabling the tubing to be bent and shaped. This coating is stable to 400° C. in inert atmospheres.
After purging the system with nitrogen for several minutes, valve 24 was shut and 20 ml of fuel was fed to the flash vessel. The nitrogen purge was left on at 25 sccm while the fuel was pumped in. Valve 20 was then closed and the flash vessel was pressurized with the nitrogen to the desired pressure identified in Table 1. Preferably, but not meant to be limiting, the flash pressure at this point is lower than the final pressure desired. While the flash vessel 10 is being pressurized, it was also heated. A pressure transducer 36 was used to measure the pressure of the flash vessel 10 . The condenser vessel 12 was pressurized by closing valve 26 . Once the desired temperature was reached, additional nitrogen could be used to finish pressurizing the system as needed. The solenoid valve 14 is then opened for approximately 3 seconds for the flash to occur. A thermocouple 38 measured the light component being flashed off. The system is then cooled and the separated materials collected. The condenser vessel 12 temperature was maintained at approximately 13° C. The heavier component was captured in vessel 40 to be reintroduced back into the fuel 29 . The lighter component, which flashed off the fuel was captured in vessel 42 and then sent to a reformer to produce synthesis gas. Some typical results and conditions are shown in Table 1.
TABLE 1
P
%
Initial
P flash
T
condenser
%
Final
Re-
Sam-
sulfur
at T
flash
initial
Flashed
Sulfur
duced
ple
ppm
(psi)
(C)
(psi)
(%)
ppm
Sulfur
1
3073
211
297
6.6
5.3%
868
71%
2
3073
300
320
100
7%
1040
66%
3
3073
455
326
200
2%
1122
63.5%
4
1002.3
209
302
8.6
12.5%
419.3
58%
5
1002.3
303
314
102
4.9%
403.5
59%
6
1002.3
430
324
201
3.7%
385
61%
7
529.7
200.1
283
7.8
2.7%
189.4
64%
8
529.7
309.4
321
104.1
4.9%
198
63%
9
529.7
447
326
204
3.7%
191
64%
10
50.1
210
302
6.7
17.5%
20.6
59%
11
50.1
301.5
325
103
7.3%
21
58%
12
50.1
429.5
324
201
2.4%
26
48%
The present invention typically utilized a condenser pressure of imately 5-200 psi, depending on the operating parameters. Accordingly, lash vessel is heated to approximately 300-320° C., there needs to be a 200-250 psi pressure difference to recover approximately 5% of the fuel.
Reforming Process
In the first of these experiments, a partial oxidation process was used as the reforming process. The partial oxidation (POx) reaction is an exothermic process (methane: ΔH=−36 kJ/mol; decane: ΔH=−856 kJ/mol) and requires no additional energy for operation.
C n H m +(n/2)O 2 →nCO+(m/2)H 2
The POx process in the present invention typically produces a lower H 2 :CO ratio than is formed by steam reforming. It is not necessarily an equilibrium controlled process, and thus product distribution (H 2 :CO ratio) is under limited control beyond controlling the proper C/O ratio, the reforming catalyst formulation, and the catalyst contact time (space velocity [SV]). POx operates at higher temperatures (in excess of 600° C.) in comparison to steam reforming, and thus demonstrates increased sulfur tolerance. Additionally, one skilled in the art would recognize that the POx process has a greater resistance to carbon depositing and fouling, provided oxygen to carbon levels are sufficient.
The present invention employed a millisecond contact time reactor as a reformer to convert either diesel or natural gas to largely synthesis gas components in addition to minimal amounts of carbon dioxide. FIG. 2 shows a schematic of the millisecond contact time reformer employed in the initial investigations of the partial oxidation process.
In one typical embodiment. the POx reactor 105 facilitates the vaporization of fuel in air and then passes this air-fuel mixture over a Rh or Rh—Pt supported on γ-alumina or a Rh-Pt gauze (Johnson Mathey, Engelhard) which facilitates the fuel POx process. The reactor 105 consists of a 2 ft (610 mm) long, 25 mm OD quartz tube 110 surrounded by a cylindrical furnace 112 on the upper half of the tube and insulation 114 on the bottom half. Fuel vaporization is assisted by a fuel injector 116 that forms a spray to create a film of fuel on the inside of the quartz tube at the top of the reactor. The fuel injector is fasted inside a stainless steel “T” fitting 118 (Swaglock Company). The fitting 118 coupled together the top of the reactor tube with the fuel injector. The fitting was sealed to the reactor tube using a typical Teflon ferrule. Vaporization of fuel is facilitated by the cylindrical furnace 112 , and the fuel is sprayed forming a film on the inside of the reactor tube. The fuel vaporizes off the inside to the tube 110 and forms a boundary layer void of oxygen, in addition to the liquid film produced by the fuel injector 116 to avoid autothermal ignition of the fuel. The Rh-catalyst 120 consists of a γ-alumina layer deposited onto an 80-ppi reticulated ceramic support 122 (Hi-Tech Ceramics), with Rh deposited onto the γ-alumina layer via Rh-nitrate solution. Blank reticulated ceramic supports 122 are placed directly upstream and downstream so as to be in thermal contact of the catalyst for heat shielding, and another blank support 124 is placed in upstream to sufficiently promote mixing and facilitate plug flow. The catalyst 122 and blank supports 124 are wrapped in fiberfrax paper to hold each in place and avoid bypassing of flow around the supports. A mineral insulated thermocouple 126 (Watlow, type K) monitors the temperature on the back face of the catalyst 120 which is sealed with a graphite ferrule. A second stainless steel “T” fitting was sealed to the bottom of the reactor tube to divert the product stream for characterization. The “T” fitting was sealed using a typical graphite ferrule. The characterization of the POx product stream was performed with a typical gas chromatograph (GC) commercially available from Agilent Technologies equipped with a thermal conductivity detector (TCD) and a mass selective detector (MSD)( model number 5973).
In another typical embodiment, a steam reforming process was utilized as the partial oxidation step. Steam methane reforming (SMR) is a widely used catalytic commercial process in the chemical industry today. The SMR reaction consists of two main reactions, the SMR reaction [1] and the water-gas shift reaction [2].
C n H m +(n)H 2 O→(n)CO+(m/2+n)H 2 [1]
CO+H 2 O←→CO 2 +H 2 [2]
Net: C n H m +(2n)H 2 O=(n)CO 2 +(m/2+2n)H 2 [3]
The steam reforming reaction is highly endothermic (methane: ΔH==+206 kJ/mol; decane: ΔH=+1563 kJ/mol), while the water-gas shift reaction is slightly exothermic (ΔH=−41 kJ/mol). The combined process (3) is highly endothermic, requiring a high temperature for favorable equilibrium conversion. As contemplated by the present invention, the synthesis gas may further be processed by any of the methods including, but not limited to, methanol synthesis, ammonia synthesis, Fischer-Tropsch synthesis, and the manufacture of hydrogen (H 2 ): and the products then used either as fuels or as reagents in engines and/or fuel cells.
Chemical Synthesis
Synthesis gas typically comprises a mixture of CO and hydrogen and can be converted to a variety of fuels and chemicals using known chemistries. Methanol synthesis is typically conducted over Cu based catalysts at temperatures from 200 to 400° C. and pressures from approximately 20-100 atm. The catalysts typically contain 55 wt % CuO, 25 wt % ZnO, and 8 wt % alumina and are typically made by co-precipitation of Cu, Xn, and Al. High pressure and low temperature favor the equilibrium CO conversion to methanol. To overcome the equilibrium limitation, acid type catalysts such as acidic alumina or zeolites were added in the synthesis step to shift methanol to DME. DME can also be synthesized in a separate step from methanol by general dehydration of methanol to produce DME on acidic catalyst, such as acidic alumina and zeolites. This process is typically conducted at temperatures from 200-350° C. Synthesis gas can also be converted to high alcohols, such as ethanol, propanol, butanol, pentanol using alkali doped Cu catalyst, MoS2 catalyst, or Rh based catalyst for high alcohol synthesis. High alcohol synthesis is typically conducted at 200-400° C. and pressures approximately from 20-100 atm. Alternatively, synthesis gas can be converted to olefins on Co or Fe-based catalysts (SASOL) using Fichser-Tropsch synthesis at temperatures from 200 to 400° C. and typical pressures of approximately 20-100 atm. High alcohols can also be dehydrated over acidic catalysts like alumina or zeolite (UOP, Grace Division or Amberlyst) to form ethers or olefins at temperatures from 100-400° C. Alcohols can also be further converted to aldehydes over early transition metal oxides or commercially available Ag based catalysts (ABB Lummus, Globall, Haldor Topsoe) in the presence of oxygen in the temperatures from 200 to 750° C. For example, and not to be limiting, methanol can be selectively oxidized to form formaldehyde using oxygen over Fe—Mo catalysts at temperatures from approximately 300-500° C., and over the Ag catalysts at temperatures from 650 to 800° C.
A mixture of methanol synthesis and dehydration catalysts was used to test direct synthesis of synthesis gas to produce DME. The experiments were carried out in a microchannel reactor (316 stainless steel), with the dimensions of 5.08 cm×0.94 cm×0.15 cm. The methanol synthesis catalyst was CuZnAl, based and purchased from Kataco Corporation (F51-8PPT); and the dehydration catalysts can be either ZSM-5 zeolite with a Si/Al ratio of 30 (Zeolyst International) or acidic Al 2 O 3 (Engelhard Corporation) with ZSM-5. Both the methanol synthesis catalyst and the dehydration catalyst were crushed and sieved into 70-100 mesh. The catalyst mixture was prepared by mechanically mixing the two types of catalysts in a transparent vial at a desired ratio and charged in the microchannel reactor. Typically, 0.18 or 0.36 grams catalyst was used. The volume of the catalyst +Al 2 O 3 was approximately 0.366 cc and 0.731 cc, respectively.
In one embodiment, the experimental conditions comprised temperatures from 220-320° C. and pressure from 2-5 MPa. The catalyst mixture (mixture of methanol synthesis and ZSM-5 or acidic alumina) was reduced with 10% hydrogen in helium in the 220-350° C. temperature range at atmospheric pressure. A mixture of N 2 /H 2 was fed during startup to establish steady-state flow and to heat the reactor to the desired temperature. When the catalyst bed temperature reached the target, premixed synthesis gas at the desired ratio was fed into the reactor. After reduction was complete, the desired temperature was achieved by ramping it at 1° C./min. The pressure was also increased to the desired operating condition (between 100-300 psig). The feed was initiated at this time.
The ratio of typical feed composition was CO:H 2 :CO 2 :Ar=30:62:4:4. The presence of Ar served as the internal standard for conversion and selectivity calculation purposes. Total feed flow rate was set to achieve the desired gas hourly space velocity (GHSV). The reaction products were analyzed by on-line gas chromatography (HP 5890 GC) equipped with both TCD and FID detectors. GC column used is GS-Q 30 m manufactured by JW Scientific. Temperature program of 5° C./min to 300° C. was chosen for the analysis. Liquid products were collected in a cold trap at −3° C. and were also analyzed by GC-mass spectrometry. Carbon monoxide conversion and product selectivity were calculated, based on feed and product flow rates and carbon balance.
Primary or secondary alcohols can be dehydrogenated to form aldehydes or ketones on copper chromite or ZnO—Cr2O3, or alumina supported Pt or Raney Ni catalysts (Engelhard, Celanese, Johnson Mathey, or Sud-Chemie) from about 200 to 400° C.
Typical compositions of the effluents coming out of the chemical synthesis process were 60% DME, 30% CO 2 , and 10% methanol. FIG. 3 shows that the CO conversion increased with increasing temperature and pressure. FIG. 4 shows the CO increased with a reduction in the Gas Hourly Space Velosity (GHSV). As the GHSV is decreased (residence time is increased) CO conversion approaches equilibrium and will reach equilibrium at about 1400 1/hr at a pressure of 200 psig and a temperature of 260° C. Likewise, as the residence time decreases, so does the CO conversion. Since the feed gas is going to be the product from a POx, it will be diluted with nitrogen. FIG. 5 shows activity of CO conversion during the chemical synthesis process at various dilution of N2. Equilibrium shows that with an increase in dilution, there is a decrease in CO conversion. The present invention experimental data shows that it follows the equilibrium trend. FIG. 6 illustrates the flash distillation results for 1000 ppm sulfur in the form of DBT, 4 methyl DBT and 4,6 methyl DBT. 601 represents the theoretical fraction of residual sulfur in the lower molecular weight component. 602 represents the theoretical fraction of the lower molecular weight component of the feedstock fuel. 603 represents the experimental results from the present invention. FIG. 6 further illustrates the present invention achieved 0.32 fraction of residual sulfur, indicating that the amount of sulfur in the fuel was decreased by 68%.
FIG. 7 , shows flash distillation results for 3000 ppm sulfur in the form of DBT, 4 methyl DBT and 4,6 methyl DBT with a concentration between about 50 and about 3073 ppmw. 701 represents the theoretical fraction of residual sulfur in the lower molecular weight component. 702 represents the theoretical fraction of the lower molecular weight component of the feedstock fuel. 703 represents the experimental results from the present invention. FIG. 7 further illustrates the present invention achieved 0.3 fraction of residual sulfur, indicating that the amount of sulfur in the fuel was decreased by 70%. It is also expected that regardless of how much sulfur is present in the fuel, similar results can be achieved. | The present invention provides a process for producing reagents for a chemical reaction by introducing a fuel containing hydrocarbons into a flash distillation process wherein the fuel is separated into a first component having a lower average molecular weight and a second component having a higher average molecular weight. The first component is then reformed to produce synthesis gas wherein the synthesis gas is reacted catalytically to produce the desire reagent. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to a heating system and, more particularly, the invention relates to a mobile heating system which is uniquely adapted for use at construction sites and/or for various ground-thawing purposes.
In the northern climates there are a great many uses for a portable or mobile heating system, particularly in the construction industry, but also in the maintenance and correction of ground-freezing problems relating to preexisting structures. A common problem in the northern climate is the problem of frozen underground water and/or sewer pipes. This problem is caused by a combination of factors; in some cases the underground pipes are laid too close to the surface, and in other cases a severe cold spell without adequate snow cover causes ground freezing to unexpected depth. One general type of solution to this problem is to obtain access into the pipe and/or conduit which is frozen, and inject heated liquid into the conduit until the frozen portion becomes dislodged of ice. Another general type of approach which has been used, particularly in the case of metal underground pipes, is to apply a very high electrical current to the metal pipe casing, thereby heating it to a temperature which causes the interior to become thawed. A third general type of solution to this problem has been to insert heating pipes into the ground itself, and thaw the ground surrounding the pipe, thereby thawing the pipe. The present invention is directed to this third type of solution, at least with respect to the problem of thawing underground pipes.
A further problem exists in connection with outdoor construction projects in cold climates. For example, construction work such as bricklaying is severely hampered in cold weather, not only because the concrete tends to be difficult to maintain in usable form, but also because the sand mixtures and the bricks themselves tend to become frozen. The optimum temperature for laying brick or block materials is in the range of 40°-45° Fahrenheit. If the temperature drops below this range, the mortar used to bond the bricks and/or blocks will not properly adhere to the materials, leading to a weakened construction. In such situations, it would be helpful to heat up the temperature of such construction materials so as to improve the overall quality and efficiency of the finished construction project. The present invention is also useful on construction projects for heating construction materials in preparation of use.
SUMMARY OF THE INVENTION
A feature of the present invention is the provision, in a heating system for thawing frozen ground, of a line and a heater for heating fluid being circulated in the line by a pump, an elongate heater probe for being implanted in the ground, and an antifreeze reservoir connectable to the line for pumping antifreeze into the line to protect the line and probe from freeze damage.
Another feature is the provision, in such a heating system, of the heater, antifreeze reservoir, and pump being mounted on a mobile apparatus.
Another feature is the provision in such a heating system, of the elongate heating probe having inner and outer concentric tubes, and the heating fluid flowing against a large surface area of the outer tube to maximize heat transfer to the probe's outer environment.
Another feature is the provision in such a heating system, of the probe being utilized with a block of building material to heat the building material during a construction process.
Another feature is the provision in such a heating system, of the probe being utilized with a pile of sand used in mixing cement.
An advantage of the present invention is that a frozen water or sewer line may be easily thawed.
Another advantage is that the line and heater probes may be retained safely in place overnight or over the weekend without freeze damage.
Another advantage is that the present heating system may be transported readily from site to site.
Another advantage is that blocks of building material may be easily warmed before being cemented into place. Attendant advantages are stronger and truer structures, as the higher temperature of the blocks improves the bonding qualities and overall qualities of the job.
Another advantage is that piles of particulate building material such as sand used in cement may be easily warmed. Thus, the sand flows more readily and is easier to handle for the worker, and may contribute to a more accurate mixing of cement.
Another advantage is that the present heating system is easy and inexpensive to manufacture, install, operate, and maintain.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of the present heating system being utilized to thaw a frozen sewer line.
FIG. 2 is another diagrammatic view of the heating system of FIG. 1.
FIG. 3 is a detail section view of the elongate heating probe of the heating system of FIG. 1.
FIG. 4 is a plan, partially phantom view of the probes of FIG. 3 in a pile of sand used in the mixing of cement.
FIG. 5 is a perspective partially phantom view of the probes of FIG. 3 disposed in bricks used for construction purposes.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 1, the present heating system is indicated in general by the reference numeral 10 and includes as its principal components a mobile apparatus or trailer 11 with a hot water tank and heater 12 and an antifreeze reservoir 13, a fluid line 14, and elongate probes 15. Circulation of hot water from the heater 12 and through the planted probes 15 thaws a patch 16 of frozen ground and a frozen sewer or water line 17.
In more particularity with reference to FIG. 1, the trailer 11 includes a hitching frame 20 for being hitched to a car or truck, and a pair of wheels 21. Couplings 22, 23 for the line 14 lead into a valving arrangement (not shown) which in turn regulates flow of fluid to and from the hot water heater 12 and antifreeze reservoir 13.
As shown in FIG. 2, the hot water heater 12 includes a pump 30 for pumping the hot water or heating fluid through the line 14 and probes 15. The pump 30 is in fluid communication with the hot water heater 12 and with respective inlet and outlet portions 31, 32 of the line 14.
As also shown in FIG. 2, the antifreeze reservoir 13 includes a pump 40 for pumping an antifreeze fluid into the line 14 and probes 15. The pump 40 is in fluid communication with the antifreeze reservoir 13 and with the inlet and outlet line portions 31, 32 via respective inlet and outlet reservoir line portions 41, 42 and respective valves 43, 44. Valves 43, 44 are shut relative the antifreeze reservoir 13 and open relative the hot water heater 12 when hot water is being circulated in the line 14 and probes 15. Valves 43, 44 are open relative the antifreeze reservoir 13 and shut relative the hot water heater 12 when antifreeze fluid is being pumped into the line 14 and probes 15. The antifreeze fluid that is typically utilized is ethylene glycol.
As shown in FIG. 3, the elongate heating probe 15 includes respective inner and outer concentric steel tubes 50, 51. The inner tube 50 includes a proximal inflow end 52 for receiving hot water or antifreeze fluid and a distal apertured outlet end 53 for releasing via its apertures 54 the hot water or antifreeze fluid into the volume between inner tube 50 and outer tube 51. The outer tube 51 includes an egress port 55 disposed adjacent the proximal inflow end 52 of the inner tube 50 such that the hot water and antifreeze fluid flow a sufficient distance for heat transfer in a passage 56 formed by the outside surface of inner tube 50 and the inner surface of the outer tube 51. A plug 57 is secured such as by welding adjacent to the distal end 53 of the inner tube 50 to seal the probe 15.
As also shown in FIG. 3, the outer tube 51 is threadably connectable to a tee connection 60 about the egress port 55 and proximal end 52 of the inner tube 50 for being in fluid communication with the egress port 55. The tee connection 60 is also threadably connectable to a tubular elbow connection 61 that directs hot water or antifreeze fluid from the inlet line portion 31 to the proximal end 52 of the inner tube 60. The tee connection 60 is further connectable to the outlet line portion 32 or one of a number of medial line portions 62, which are disposed between probes 15. For being connected to outlet line portion 32 or one of the medial line portions 62, the tee connection 60 may include sealing ribs 63 for pinching the line portions 32, 62 in cooperation with a band 64 engaging one of the line portions 32, 62. The elbow connection 61 also includes like sealing ribs 65 and a like band 66 for sealing engagement with inlet line portion 31 or one of the medial line portions 62.
In operation, holes are drilled into the frozen patch 16 of ground surrounding the frozen sewer or water line 17 or the probes are driven into the ground, so that the probes are into the ground a reasonable depth. Antifreeze solution is then pumped via pump 40 through the line 14 and probes 15 until the probes and lines are warmed, and then hot water is pumped therethrough. Hot water conveyed into the elbow connection 61 flows into the proximal end 52 of inner tube 50, through inner tube 50, out the apertures 54 of distal end 53, upwardly through flow passage 56, out of the egress port 55, through the connection 60, and into the medial line portion 62 to a subsequent heater probe 15. If circulation of the hot water ceases either intentionally or unintentionally such as upon a breakdown of pump 30, it is advantageous to convey antifreeze solution into the line 14 and probes 15. When pumping antifreeze fluid into line 14 and probes 15, the valves 43, 44 are shut relative the hot water heater 12 and opened relative the antifreeze reservoir 13.
It should be noted that after pumping antifreeze solution into line 14, the antifreeze fluid in the reservoir 13 may be diluted somewhat by the hot water previously present in the line 14 and probes 15 and vice versa. If such dilution is not desired, the hot water may be blown from the line 14 and probes 15 with an air compressor. Conversely, before operation of the valves 43, 44 to allow hot water flow through the line 14 and probes 15, excessive antifreeze fluid may be blown from the line 14 and probes 15 by an air compressor. The lines and probes, and the ground surface around the area to be heated may be covered with plastic or other material.
As shown in FIG. 4, a pile 70 of sand used in a mixing of cement may be heated by a plurality of probes 15 attached to the heating system 10 through inlet and outlet line portions 31, 32. As shown in FIG. 5, the probes 15 may also warm a pile of bricks 72. The probes 15 are inserted in the aligned apertures 73 of the bricks 72. Plastic sheeting 74 placed over the bricks 72 or sand 70 facilitates a heating of the sand 70 or bricks 72.
Of course, the number of probes 15 may be varied to accommodate any particular work site situation, by either varying the spacing between consecutively positioned probes or by varying the number of such probes used at the work site. One of the unique advantages of the invention is the ability to adapt the system to a particular work site configuration, by merely connecting and/or disconnecting the medial line portion 62, varying the respective lengths of medial line portion 62, and by inserting greater or lesser numbers of probes 15 in the series flow circuit.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is therefore desired that the present embodiment be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention. | A mobile heating system for thawing frozen ground. The system includes a hot water heater, antifreeze reservoir, and pumps mounted on a mobile apparatus such as a trailer for being towed by a car or truck. A line is connectable to the heater and antifreeze reservoir and includes a plurality of elongate heater probes for being implanted in the ground, adjacent a frozen water or sewer line. Circulation of hot water through the line and probes thaw the ground. Alternatively, the probes may be used to heat building material such as bricks. | 4 |
GOVERNMENT PATENT RIGHTS
This invention was made with Government support at least in part under contract #W-7405-ENG-182 awarded by the Department of Energy. The Government may have certain rights in the invention.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a means and method for transmitting and receiving ultrasonic energy, and in particular, one which allows the use of a single ultrasonic transducer in a pulse/echo mode to generate and receive unipolar ultrasonic pulses over a wide frequency bandwidth.
2. Problems in the Art
Ultrasonic interrogation is a widely used and promising technique of nondestructive evaluation. Nondestructive evaluation allows analysis of the interior of materials or structures without physically opening up or breaking into the interior. The advantages of this are obvious.
It has been firmly established that ultrasound can be propagated into a material and that its returning echoes will contain information about the structure of the interior of the material. For example, ultrasonic waves directed into a solid, generally homogeneous material, should result in reflected echoes which are unperturbed. If, however, the material contain cracks, voids, discontinuities, or such things, the reflected echoes should give an indication of the existence of these types of things. Major problems exist, however, in obtaining reliable and pertinent information from the echoes, and interpreting the echoes.
A co-pending, co-owned application filed Feb. 8, 1990, by inventors Thompson and Hsu, entitled MEANS AND METHOD OF TRANSMITTING AND RECEIVING BROADBAND, UNIPOLAR ULTRASONIC PULSES FOR ULTRASONIC INSPECTION, (which is a continuation application from Ser. No. 181,094 filed Apr. 13, 1988) discusses in some detail the differences in the types of ultrasonic pulses that are used in ultrasonic nondestructive evaluation. It also discusses why what are called "unipolar pulses" are believed to be better than "bipolar pulses" in many cases of ultrasonic non-destructive inspection and evaluation.
The above referenced application discusses the significant problems encountered in generating and receiving unipolar ultrasonic pulses. It discloses one structure and method for doing so. Circuitry was used incorporating two what will be called "passive" switching elements to "switch" the circuitry between the transmit (or pulse) and the receive (or echo) portions of each cycle. These passive switches also ensure appropriate impedances in the circuit to maintain the unipolar nature of the ultrasonic pulses from their generation to their reception.
It has been found that there is room for improvement with regard to this design. For example, it required utilization of and connection to a discrete square wave generator device, which in actuality itself contained a switch which was needed to maintain the unipolar nature of the pulses. It would be advantageous to be able to incorporate the square wave generator into the circuitry of an instrument to avoid the necessity of a separate square wave generator.
Additionally, there is a need for a unitary instrument that has a quicker transition time between transmit and receive states and maintains or improves upon the excellent bandwidth and time resolution of the co-pending application.
While the device described in the above mentioned application does present a viable way of generating and receiving unipolar ultrasonic pulses, there is a need in the art for improvement of the procedure and instrument used for the procedure. It is therefore a primary object of the present invention to provide an ultrasonic unipolar pulse/echo instrument and method which improves over or solves the problems and deficiencies in the art.
Another object of the present invention is to provide an instrument and method as above described which maintains the unipolar nature of the ultrasonic pulses in both the transmit (pulse) and receive (echo) portions of each cycle.
A still further object of the present invention is to provide an instrument and method as above described which has an improved bandwidth without sacrificing time resolution.
A still further object of the present invention is to provide and instrument and method as above described which results in improved return echoes of the unipolar pulses.
A further object of the present invention is to provide an instrument and method which utilizes active switches to accomplish improved unipolar pulse/echo operation.
Another object of the present invention is to provide an instrument and method as above described which results in improved output voltage during transmission and fast transition between transmit and receive operations.
Another object of the present invention is to provide an instrument and method as above described which can be operated from a single unitary instrument.
Another object of the present invention is to provide an instrument and method as above described which is reliable, efficient, and economical.
These and other objects, features, and advantages of the present invention will become apparent with reference to the accompanying specification and claims.
SUMMARY OF THE INVENTION
The present invention relates to an instrument and method for transmitting and receiving ultrasonic pulses for nondestructive evaluation of materials. The invention represents an improvement over co-pending and co-owned U.S. Ser. No. 477,162, and parent application Ser. No. 181,094, now abandoned, referenced above and which are incorporated by reference with this disclosure.
The present invention utilizes a conventional ultrasonic transducer to transmit and receive ultrasonic pulses. The transducer operates in what is called a "pulse/echo" mode of both transmitting and receiving. The circuitry connected to the transducer therefore must time and control transmission and reception so that they do not overlap or conflict with one another, because they must be performed by the same transducer. At the same time, the present invention seeks to generate and maintain unipolar ultrasonic pulses. This requires that certain differences in impedances be set up in the circuitry at different times during the transmit and receive cycles.
The instrument contains within a housing a timing and drive circuit, several power supplies, a receive and amplify circuit, and three switch means. The instrument is connectable to a standard service alternating current power supply. The transducer element is contained with a holder which is connectable by coaxial connectors and coaxial cable to a coaxial connector on the instrument. The transducer can therefore be moved around to a considerable extent without having to move the instrument.
The power supplies convert the standard AC line voltage to desired direct current power supplies. One is a variable DC voltage supply that is used as the variable excitation voltage for charging the transducer. Another DC power supply is utilized by various components of the circuitry and is not variable.
The timing and drive circuitry controls the operation of the instrument. For example, it controls operation of a first switch means to allow the excitation voltage to charge the transducer. It then opens the first switch means and closes a second switch means which is connected to an extremely low impedance pathway. This discharges the transducer very quickly to produce the mechanical ultrasonic acoustic pulse. The third switch means opens and closes the pathway to the receiving and amplifying circuitry. This switch means closes after the ultrasonic pulse is transmitted so that the transducer can receive the reflected echo of the pulse, convert that mechanical energy into an electrical signal, and communicate that signal to the reception and amplifying circuitry where it can be prepared for output.
Each of the switch means is an "active" switch as compared to the "passive" switches utilized in the application incorporated by reference. The timing and drive circuitry gives the instructions to cause the actual switching elements to open or close, as compared to the diode configuration in the application incorporated by reference which served as passive switches depending on the particular electrical pathway.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an electrical schematic of a passive-switched unipolar pulse/echo circuitry.
FIG. 2 is a diagrammatical representation of the active switch pulse/echo circuitry of the present invention.
FIG. 3 is a block diagram of a preferred embodiment of the present invention depicting circuit cards or boards and elements for such a unipolar pulse/echo instrument.
FIG. 4 is a perspective drawing of a preferred embodiment of the invention.
FIG. 5 is an electrical schematic of a portion of the power supply according to the preferred embodiment of the present invention.
FIG. 6 is an electrical schematic of the timing and drive card shown in FIG. 3.
FIG. 7 is an electrical schematic of the S1 card of FIG. 3, which represents a first switching means of the invention.
FIG. 8 is an electrical schematic of the S2 card or second switching means of FIG. 3.
FIG. 9 is an electrical schematic of the S3 card or third switching means of FIG. 3.
FIG. 10 is an electrical schematic of the receiver card of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In order to assist in an understanding of the invention, a preferred embodiment of the invention will now be described in detail. It is to be understood that this is only a preferred embodiment of the invention, and does not describe all the forms the invention can take.
In this description, reference will be taken to the drawings. Reference numerals will be used to indicate parts and locations in the drawings. The same reference numerals will be used for the same parts and locations in all of the drawings, unless otherwise indicated.
It is important to an understanding of the invention to understand the predecessor to this invention. As previously discussed, the application incorporated by reference discloses and claims a unipolar pulse/echo means and method. With reference to that application, it becomes apparent that the circuitry is designed with what are called "passive switches", which by their nature allow for the very quick cycling of the single ultrasonic transducer between a transmit mode and a receive mode. Likewise, the circuitry involved with the transducer must perform different functions during those cycles, and those passive switches operate to allow these functions while at the same time presenting the appropriate impedances in the circuitry to create and maintain ultrasonic pulses which are unipolar in nature.
For comparison purposes to the present invention, FIG. 1 is a schematic representation of a circuit 10 representative of the unipolar pulse/echo circuit of co-pending and co-owned U.S. Ser. No. 477,162 and parent application Ser. No. 181,094. First, second, and third passive switches 12, 14, and 16 respectively, are indicated within dashed boxes. As can be immediately seen, the unique diode configurations in passive switch 1 (reference #12) and switch 3 (reference #16) can be seen.
It is to be understood that circuit 10 was designed specifically for use with a low output impedance commercial square wave generator. Circuit 10 could then be put into a package which could be directly connected to such a generator. It was determined that switch means 2 (reference #14) actually existed inside such square wave generator. A first, and significant difference with the present invention is that the square wave generator of the present invention is "built-in" to the circuitry, and no external square wave unit and hook ups are required.
Circuit 10 of FIG. 1 operates as follows. During each transmit portion of the pulse/echo of ultrasound from transducer 18, switch 1 (reference #12) is "closed" as the output of the square wave generator is high (about 50 volts). An electrical pathway therefore exists to transducer 18 so that it can be charged by permitting this high voltage to be applied to transducer 18.
In circuit 10, only one of the three switches is closed as any particular time. Therefore, during the transmit portion of the cycle, switch 12 is closed, whereas switches 2 and 3 are basically "open". For example, switch 3 is effectively open because any voltage above one diode drop (0.7 volts) is shorted out by the clipping diodes in that switch.
The next portion of the cycle involves closing switch 2 inside of the square wave generator which pulls down its output voltage in a very short time (10-20 nanoseconds or ns). The output of the square wave generator therefore quickly drops to 0. This causes transducer 18 to discharge electrical energy stored in it which produces a mechanical acoustic ultrasonic pulse which propagates away from transducer 18.
The immediate return echoes of the transmitted ultrasound are "received" by transducer 18. Just as electrical energy stored and discharged from transducer 18 produces a mechanical acoustical wave with certain properties, reflected mechanical acoustical waves that return into transducer 18 cause it to vibrate and produce an electrical signal. Such operation is well known by those of ordinary skill in the art. However, during this "receive" portion of the cycle, switch 1 is effectively open because the magnitude of the return echoes is almost always less than one diode drop in switch 1. This passive operation basically results in the electrical signals from transducer 18 being allowed to travel through the effectively "closed" switch 3 to receiving circuitry. The electrical signals caused by the return echoes effectively do not "see" the low impedance of the square wave generator, which are needed to drive the transducer which has a very small input impedance. This is discussed in detail in application Ser. No. 477,162. It was also pointed out that such an arrangement is an essential requirement for generation and reception of unipolar pulses. If this relationship did not exist, the return signal picked up by the transducer, having an extremely high output impedance, would be high-pass filtered by the low impedance elements of the square wave generator.
It can therefore be seen how the three "passive switches" of circuit 10 would "passively" cooperate to achieve the transmit/receive (pulse/echo) cycles while at the same time producing the unipolar pulses which are at the heart of such an invention. Such a circuit, however, proved to have some disadvantages and the need for improvements were recognized.
Therefore, the need was perceived for a total, unitary instrument which could more effectively produce pulse/echo operation of a conventional transducer while also generating maintaining, and receiving unipolar pulses. By referring to FIG. 2, a general block-form electrical schematic of circuit 20 according to the present invention is depicted. The primary differences from circuit 10 are as follows. First of all, circuit 20 requires a timing and drive circuit 22. This circuit 22 is basically the control center for operating three "active" switches 1, 2, and 3 (alternatively designated by reference nos. 24, 26, and 28 respectively). The need for connection to a separate square wave generator has been eliminated. A variable power supply 30 is incorporated into circuit 20. Additionally, a receiver circuit (32) which includes an amplification subcircuit is also present.
Transducer 18 (again a conventional piezoelectric transducer in the preferred embodiment) is incorporated into the circuit so that switch 1 is between it and power supply 30. Switch 1 functions to close the electrical pathway and allow electrical power from power supply 30 to charge transducer 18 during one portion of each pulse/echo cycle.
Switch 2 is positioned between transducer 18 and the receiver circuit 32. Again, switch 2 closes, upon instruction of circuit 22, to discharge electrical energy from transducer 18 to generate the ultrasonic pulse.
Finally, switch 3 is connected between transducer 18 and the receiver circuit 32 and closes, upon instruction, circuit 22, during the portion of the cycle where the reflected ultrasound is captured and converted into an electrical signal by transducer 18, passing those signals to the receiver circuit 32.
FIG. 2 also shows timing and device circuit 22 is directly connected to each of switches 1, 2, and 3. As will be discussed later, circuit 22 controls the opening and closing of each of these switches. As is easily understood, each of the switches therefore is an "active switch"; opening and closing according to external instruction (by circuit 22), as opposed to the "passive" nature of the switching described with respect to circuit 10.
FIG. 3 is a diagrammatic block layout of an instrument 34 according to the present invention. It is to be understood, that this is only one configuration the invention could take and is for illustrative purposes only.
Instrument 34 is connectable to a standard 128 VAC (volts/alternating current) external power supply (36). Internally, a first power supply 38 converts the line voltage (AC) to plus and minus 28 VDC (volts/direct current). A second power supply 40 converts plus 28 VDC to a 0-1,000 VDC variable power supply.
Both power supplies 38 and 40 are contained on the printed circuit boards which in turn are fastenable to a mother board 42, all such as is well known within the art.
A timing and drive printed circuit card 44 contains the timing and drive circuit 22. It is connectable to first power supply 38 and operates off of 28 VDC.
What will be called a switch board 46 contains separate printed circuit boards for each of active switches 1, 2, and 3 (reference nos. 24, 26, and 28). Additionally, switch board 46 is connectable to the first power of supply 38 and utilizes plus or minus 28 VDC. Additionally, a jack mount 48 is included on switch board 46 to allow connection and communication such as will be described later.
A fan 50, which can operate from the first power of supply 38, is included on the mother board to provide cooling circulation of air into and out of instrument 34, such as well know in the art.
FIG. 3 also diagrammatically depicts a receiver card 52 which would contain the receiving and amplifying circuitry for instrument 34. The front panel 54 of instrument 34 can include an on-off switch 56, a voltage readout display 58, a repetition rate control 60, an excitation voltage control 62, as well as an input jack for cable to transducer 18 (see reference #64), and a signal-out jack 66 so that the received signal, amplified by receiver circuit 32, can be communicated to additional equipment.
The arrangement depicted in FIG. 3 therefore shows a unitary unipolar pulse/echo instrument containing all needed circuitry. Instrument 34 is easily manufacturable and serviceable by nature of the design of all subcircuits on the printed circuit cards or boards. As is well appreciated in the art, the actual physical layout of circuit boards in instrument 34 has been carefully designed for optimal circuit performance in light of the fact of the presence of high frequency circuits. In the preferred embodiment, this layout has done away with problems such as slow switching times and poor noise immunity, with the result being instrument 34 has a signal to noise (S/N) ratio at least 20 dB higher than commercial units.
FIG. 4 depicts an example of how instrument 34 could look according to the preferred embodiment. A housing 70 would enclose all of the circuitry. Front panel 54 would contain display 58, on/off switch 56, repetition rate control 60, excitation voltage control 62, as well as input jack 64 and signal out jack 66. Also shown is an external trigger jack 72 and a sync jack 74. A gain control 76 could also be incorporated to control the amount of amplification of receiver circuit 32 on receiver card 52. An offset control 78 could also be utilized.
FIG. 4 also shows electrical plug 80 used to access 128 VAC, a vent 82 in the side of housing 70 for air circulation of fan 50, as well as labeling of the various front panel items and calibration figures for the controls. It is furthermore noted that there are two signal-out jacks 66 and 68 in this particular embodiment. One is associated with gain control 76; the other is not.
FIG. 4 also depicts cable 84 which can be used to connect transducer holder 86 (containing transducer 18) to the "T/R" or input jack 64 on the front panel 54. Cable 84 can be of sufficient length to allow transducer 18 to be positioned and moved during operation of instrument 34.
The basic makeup of instrument 34 has now been described. Specifics of the circuitry, shown in block form in FIG. 3, will now be discussed.
FIG. 3 illsutrates that in the preferred embodiment, instrument 34 consists of a mother board 42, a switchboard 46, four printed circuit boards 24, 26, 28, and 48 on switchboard 46, three printed circuit boards 38, 40, and 44 directly on mother board 42, a printed circuit board 52 attached to front panel 54, and then readouts, switches, controls, and a fan. This is all contained within or on housing 70. Instrument 34 also contains 10 to 1,000 VDC electrical power supply, and two 28 VDC electrical power supplies.
Below will be individual descriptions of pertinent portions of the printed circuit boards corresponding to those shown in FIG. 3, as well as how they function within the system.
FIG. 5 is an electrical schematic of power supply card or printed circuit board 38. The left side of the circuit provides inputs for plus and minus 28 VDC and a ground connection. The standard line 128 VAC is first converted to plus or minus VDC, and then introduced at this point.
As can be seen, voltage regulator components 88, 90, 92, 94, and 96 receive the plus or minus VDC and convert it into different output VDC usable by other parts of instrument 34. For example, component 88 along with diode D4 transform plus or minus VDC into 5 VDC which is available, for example, for miscellaneous digital equipment or components associated with the circuitry 34. Component 88 can be device identified by component part number LM7805 and, like all other parts in these schematics, is available under this number by a wide variety of electrical component manufacturers and/or suppliers.
Component 90 (which can be a device identified by LM7905) cooperates with diode D3 to produce an output of minus 5 VDC. Diode D3 is reversed from diode D4 and is connected to minus 28 VDC input. In the preferred embodiment, however, the minus 5 VDC is not used.
Component 92 (identified by #LM337) cooperates with diode D2, varistor P1, and the other shown components to take a minus 28 VDC and output an adjustable minus voltage DC (1.2-37 VDC). As can be seen, the output is used as a supply for card of printed circuit board 28 which contains active switch 3. As is further shown, connection can be made to a 3 pin molex connector, such as is well known in the art.
Component 94 (LM317) utilizes diode D5 and varistor P2 to convert a plus 28 VDC into a variable output positive voltage DC (1.2 to 37 VDC). This voltage is available through the indicated molex connectors to cards 26 and 28, containing active switches 2 and 3.
Finally, component 96 (also LM317) cooperates with diode D5 and varistor P3 to create a variable output voltage of a positive nature to fan 50.
FIG. 6 is an electrical schematic of timing and drive card or printed circuit board 44. The circuitry is fairly conventional. Four 74LS123 (or alternatively 7HC123) dual one shot trigger devices 98 (IC-TTL Low Power Schottky, Dual Retriggerable Monostable Multivibrators) are powered by regulated voltage through device 7805, which in turn is connected +28VDC from the appropriate power supply in instrument 34. The dual one shots cyclically self-trigger timing pulses which are output to 7TSC429CPA power MOSFET drivers 100 (available from Teledyne).
It can also be seen that the dual one shots utilize plus 5 volts DC and are connected to the repetition rate control potentiometer 60 on front panel 54 of instrument 34 which serves as a manual control for the rate of timing pulses.
The MOSFET drivers 100 in turn are connectable through outputs from card 44 to cards 24, 26, and 28, which contain active switches 1, 2, and 3. As will be further discussed, each of the active switches 1, 2, and 3 contain power MOSFETs which are used in a switching capacity. The MOSFET drivers 100 drive the gate junctions of the MOSFETs in switches 1, 2, and 3.
It is to be understood that in timing and drive card 44, ground plane construction, such as well known in the art, is required to maintain extremely fast pulse transition times and to enhance noise immunity of the circuit.
FIG. 7 depicts the electrical schematic of the preferred embodiment of card 24 containing active switch 1. Coaxial connector 102 is in electrical communication from the 0-1,000 VDC power supply 40. Coaxial connector 104 is in electrical communication with the S1 output of timing and drive card 44. Each of these inputs are referenced to a separate ground other than the ground plane for the rest of the card. These separated grounds are connected together at the source of the power MOSFET in card 26 by utilizing jack mount card 48. Such an arrangement is essential to eliminate ground loops which will degrade the switching time by two orders of magnitude. It is to be understood that the same is true for cards 26 and 28.
As previously discussed, card 24, containing active switch 1, controls connection of the high voltage DC power supply to piezoelectric transducer element 18. When a timing signal from timing and drive card 22 is received through connector 104, gate voltage to power MOSFET MF2 opens an electrical path to fire the gate of power MOSFET MF1, in turn opening the electrical pathway from the 0-1,000 VDC input to output 106 which goes to jack mount card 48, and in turn to transducer 18 to charge it in preparation for transmission of an ultrasonic acoustic wave.
It is to be understood that the section of the circuit comprised of MF1, MF2, resistors R2-R5, and diode D3 is based on a Siemann's application as is known in the art. The additional elements, namely diodes D1-D5, and the band pass filter comprised of resistor R1, inductor Il, and capacitor C2, are a novel configuration required of this active switch to maintain the unipolar nature of the pulse and echo created by the circuit.
These latter elements basically "decouple" the return echoes from the low impedance path to ground, which would otherwise be available through the huge parasitic capacitance in the gate-source junction of MF2, or the parasitic drain-source capacitance in MF1. Similar decoupling is required in active switches 2 and 3. Such decoupling maintains the broad band unipolar pulse/echo ability of instrument 34.
FIG. 8 is the electrical schematic for circuit card 26 containing active switch 2. Coaxial connector 108 provides connection to the S2 output from timing and drive circuit 22. It again has a separate ground as previously explained. Device U1 (product #DS0026) is designed to take the timing pulses and distribute them to power MOSFET's Q1 and Q2. Transistor Q3 is connected at connection 110 to transducer 18.
Active switch 2 (card 26) rapidly drains stored charge built up on piezoelectric element 18 while switch 1 (card 24) is closed. When switch 1 is opened by a pulse from timing drive card 22, switch 2 closes providing an extremely low impedance path for a charge on the piezoelectric transducer element 18. This circuit can be obtained from Directed Energies Corporation. Resistor RO and capacitor CO were added to perform the decoupling of low frequency elements of return ultrasonic pulses to ground through the gate drive circuitry.
FIG. 9 is an electrical schematic of card 28 containing active switch 3. An input 116 exists from jack mount card 48. Three power MOSFETs MF1, MF2, and MF3 are used in this circuit. Additionally, electrical device EL2004CG BA1 is utilized. A coaxial connector 112 provides electrical communication from the S3 output of timing and drive card 22. Coaxial connector 114 provides an output to receiver circuit and card 32.
The connection from the jack mount card 48 pertains to the ground plane connections and separate grounds discussed earlier with regard to card S1 (reference #24).
Card 28, shown in FIG. 9, allows instrument 34 to receive the returning ultrasonic echoes picked up by transducer 18, as well as provides current amplification required to drive long cables and gain block circuitry in the final output stages of instrument 34.
The configuration of the circuit of card 28 is such that it withstands the application up to 1,000 VDC to its input without damage. To overcome this problem, the invention utilizes a 1,000 volt power MOSFET.
As previously explained, a large parasitic capacitance exists in the drain-gate junction of each power MOSFET. As previously described, this presents substantial difficulties to the provision of a successful unipolar pulse/echo design.
In the other circuit cards, decoupling elements were introduced to solve the problem. In card 28, however, the circuitry is constructed to actually utilize the parasitic junction capacitance to the advantage of the circuit.
The circuit of card 28 couples return echoes into a buffer current amplifier (device EL2004CG BA1) with a limited voltage input range (plus or minus 20 volts). At the same time, the circuit protects the inputs of the amplifier from voltages up to 1,000 VDC, which may be used in exciting the transducer 18. This protection arises as a result of a characteristics of the drain/source junction of the power MOSFET which is fabricated to stand off voltages up to its rated specification (1,000 volts). It is important to hold the gate of this MOSFET (MF1) at ground during the time the 1,000 volt excitation is applied to the transducer element 18. Otherwise the gate junction will float up to the applied excitation voltage and destroy the buffer amplifier. It has been found that this type of coupling scheme passes the return echoes without measurable attenuation or distortion.
Moreover, the return echoes can be superposed on a nearly flat baseline. This is essential and very advantageous if the return echoes are to be amplified by up to 40 dB, because the presence of even a 20 mv/μs slope in the baseline of the unamplified return echoes will result in a 2v/μs slope in the baseline of the amplified return echoes. The presence of such a rapidly varying baseline will obscure the location and shape of return echoes. Even if the echoes can be identified in such a rf (radio frequency) trace, their subsequent analysis will be made much more difficult by the presence of the baseline.
Card 28, with active switch 3, therefore basically works as follows. After transmission of the ultrasonic pulse, the return echoes, captured by the piezoelectric transducer element 18 and converted into electrical signals, are channeled through a closed active switch 3 without attenuation or distortion, to the receiving circuit on card 32 where they are maintained and amplified. Pulses are maintained in their unipolar form and can then be output to an external device for viewing, analysis, or storage.
FIG. 10 is the electrical schematic for receiving circuit 32. Coaxial connector 118 is the connection from card 28 containing active switch 3, whereas coaxial connector 120 represents an output which can, in the preferred embodiment, be split into direct output 66 or a variable gain output 68.
Five EL2004CG devices are utilized, along with two CLC501 devices. An attenuator configuration 122 is utilized to vary the output gain of these amplifications.
It can therefore be seen how the invention meets at least all of its stated objectives. It will be appreciated that the present invention can take many forms or embodiments. The true essence and spirit of this invention are defined in the appended claims, and it is not intended that the embodiment of the invention presented herein should limit the scope of those claims. | An ultrasonic unipolar pulse/echo instrument uses active switches and a timing and drive circuitry to control electrical energy to a transducer, the discharging of the transducer, and the opening of an electrical pathway to the receiving circuitry for the returning echoes. The active switches utilize MOSFET devices along with decoupling circuitry to insure the preservation of the unipolar nature of the pulses, insure fast transition times, and maintain broad band width and time resolution. A housing contains the various circuitry and switches and allows connection to a power supply and a movable ultrasonic transducer. The circuitry maintains low impedance input to the transducer during transmitting cycles, and high impedance between the transducer and the receiving circuit during receive cycles to maintain the unipolar pulse shape. A unipolar pulse is valuable for nondestructive evaluation, a prime use for the present instrument. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present patent application claims the benefits of priority of commonly assigned Canadian Patent Application no. 2,668,501, entitled “Extracteur d'ancrage à angle variable” and filed at the Canadian Patent Office on Jun. 1, 2009.
FIELD OF THE INVENTION
The present invention is related to device used to remove anchorage or the like from the ground.
BACKGROUND OF THE INVENTION
The present invention is related to devices used to remove anchorage or post inserted in the ground. Currently, non-motorized or motorized devices are used for this purpose, but users of these devices are rather dissatisfied with the performance or conditions of use.
Regarding the motorized devices, their advantage is the strength that can be generated but they are often bulky and heavy and consequently difficult to handle. In the specific environment of the assembly and dismantling of marquees or capital, hooks or anchorages used to secure the capital are often placed in confined spaces and a large device is awkward to use. These devices also require fuel to operate. Moreover, it is necessary to provide special equipment, such as a truck or trailer for moving these devices because of their size and weight.
The non-motorized devices that are currently used provide a limited force and a substantial effort is required from the user to remove the anchorages that are fixed in the ground. Indeed, the anchorages used to fix capitals are often inserted using pneumatic systems and in grounds such as asphalt or pavement composed of different materials pressed mechanically. Thus, these anchorages are firmly anchored in the ground. In addition, multiple anchorages are sometimes used, multiple anchorages are composed of a L-shaped structure which comprises several holes to receive several anchorages. Each of the anchorage is inserted individually in one of the hole of the L-shaped structure and the different anchorages will not have exactly the same orientation relatively to the ground. The different orientation of each of the anchorages creates a very high resistance to remove them all at the same time by exerting a force on the L-shaped structure. Because of this, each anchorage must be removed individually.
There is thus a need for a non-motorized device that has the advantages of both types of devices currently used, non-motorized and motorized. These advantages are ease of use, lightness of the system and the extraction force of the system independent of the strength of the user.
OBJECTS OF THE INVENTION
A first object of this invention is to provide a non-motorized extractor for anchorages.
A second object of this invention is to provide a non-motorized extractor developing a large extraction force.
Another object of the invention is to provide an extractor that may be positioned at different angles.
A fourth object of this invention is to provide an extractor having an extraction force that is generally independent of the strength of the user.
Another object of this invention is to provide an anchorage extractor that is easily transportable.
Another object of this invention is to provide an anchorage extractor that is foldable or that may be dismantled.
SUMMARY OF THE INVENTION
The aforesaid and other objectives of the present invention are realized by generally providing an extractor for anchorages or the like, the anchorages being installed in the ground and the anchorages having a longitudinal axis, the extractor comprising: a main body; a rack slidably connected to the main body; a shaft rotatively connected to the main body; a sprocket connected to the shaft, the sprocket cooperating with the rack; a first lever, wherein the actuation of the first lever cause the rotation of the shaft and of the sprocket; a connector adapted to cooperate with the anchorage, the connector being connected to the rack; a base connected to the main body, the base being in contact with the ground; wherein the actuation of the first lever drives the sprocket, and wherein the sprocket drives the rack upwardly and the rack pulls and remove the anchorage from the ground.
In a preferred embodiment, the extractor further comprises a driving wheel, the driving wheel being connected to the shaft, the driving wheel being rotated by actuating the first lever. The extractor further comprise a first lever-lock cooperating with the driving wheel, wherein the actuation of the first lever cause the first lever-lock to rotate the driving wheel, and wherein the first lever-lock transmit the rotation of the driving wheel to the shaft. The extractor comprises a second lever to release the first lever-lock. The extractor further comprises a second lever-lock cooperating with the driving wheel, the second lever-lock blocking the rotation of the driving wheel. The extractor comprises a release lever, the release lever releasing the second lever-lock from blocking the rotation of the driving wheel.
In a still further embodiment, aforesaid and other objectives of the present invention are realized by generally providing an extractor for anchorages or the like, the anchorages being installed in the ground and the anchorages having a longitudinal axis, the extractor comprising a main body, the main body having an elongated shape comprising a elongated cavity, wherein the main body may be disposed parallely to the longitudinal axis of the anchorage; a rack slidably connected into the cavity of the main body; a driving mechanism comprising: a shaft rotatively connected to the main body; a driving wheel connected to the shaft; a sprocket connected to the shaft, the sprocket cooperating with the rack; a first lever; a first lever-lock, the first lever-lock cooperating with the driving wheel, wherein the actuation of the first lever causes the first lever-lock to rotate the driving mechanism; a base connected to the main body, the base being in contact with the ground; a guiding member having an elongated shape, the guiding member being connected to the main body; a sliding structure adapted to slide along the guiding member, the sliding structure comprising an opening to receive the guiding member; a plurality of positioning holes, each of the positioning hole corresponding to an angular position of the main body; a locking member having an elongated shape, the locking member being adapted to cooperate with the positioning holes; wherein the actuation of the first lever drives the driving mechanism, and wherein the driving mechanism drives the rack.
The possibility to position the extractor at an angle substantially parallel to that of the anchorage provides a device that is more efficient. Indeed, when a force perpendicular to the ground is applied to remove an anchorage that is not perpendicular to the ground, only the force component that is in the same axis as the longitudinal axis of the anchorage is involved in the extraction. If the extraction force is applied in the same axis as the longitudinal axis as the anchorage, almost all this force acts as a force for extraction. Consequently, the device works more efficiently. The extractor of the present invention comprises a system to modify the angle of the main body. An example of such a system is illustrated later.
The support surface of the base of the anchorage extractor must be large enough to provide increased stability during extraction and thus prevent the extractor base to be destabilized during use. A triangular shape for the base of the support surface provides a good lateral stability. In addition, the support surface provided by the base is constant regardless of the angle of the main body. It is however to be understood that the shape of the base is not limited to a triangle and could be rectangular, polygonal, etc. . . . without departing from the scope of the present invention.
The device described in the present invention includes security mechanisms that are operated by levers or handles by the user. It is important to note that these security mechanisms are an example and they could be embodied by a different mechanism with the same utility, i.e. that will lock the extractor in a selected position.
The anchorages in the present invention may be devices inserted into the ground to keep objects in place or to provide an attachment point. These anchorages can be stakes for signs, anchorages for tents. It may also be, for example, stakes for trees, tent pegs, anchorages for tent, etc. . . . It should be noted that the extractor can be used to remove other devices inserted into the ground without limiting to the previous examples.
It has been experienced that the anchorage extractor as described in the present invention can develop sufficient strength to remove multiple anchorages as the one used for big size capitals. The multiple anchorage is a L-shaped structure having multiple holes, each hole adapted to receive an individual anchorage. A large force is required to remove the multiple anchorages, indeed, when the individual anchorages are positioned in the ground at different angles, the force required to remove them all at the same time is greater. Also, the anchorages for capitals are often inserted in grounds that are very compact, such as rocky grounds, asphalt, etc. . . .
The anchorage extractor can be made of metal or polymer having sufficient rigidity to withstand the forces transmitted during the extraction of anchorages. Aluminum, for example, is a good choice because it offers strength and lightness.
The features of the present invention which are believed to be novel are set forth with particularity in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the invention will become more readily apparent from the following description, reference being made to the accompanying drawings in which:
FIG. 1 is a perspective view of the anchorage extractor.
FIG. 2 a is a perspective view of the anchorage extractor.
FIG. 2 b is an enlarged view of a portion of FIG. 2 a.
FIG. 3 is a top view of the safety mechanism of the anchorage extractor.
FIG. 3 b is a perspective view of the safety mechanism of the anchorage extractor.
FIG. 3 c is a perspective view of the position selector.
FIG. 4 is a schematic sectional view of the main body.
FIG. 5 is a perspective view of the lifting mechanism and of the release mechanism of the anchorage extractor.
FIG. 6 is a sectional view of the anchorage extractor.
FIG. 7 is an exploded view of a portion of the anchorage extractor.
FIG. 8 is a perspective close-up view of the angle selector mechanism.
FIG. 9 a is an exploded view of the angle selector mechanism.
FIG. 9 b is a cross-section view of the angle selector mechanism of FIG. 9 a.
FIG. 10 is a schematic cross-section of the main body.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A novel anchorage extractor will be described hereinafter. Although the invention is described in terms of specific illustrative embodiment(s), it is to be understood that the embodiment(s) described herein are by way of example only and that the scope of the invention is not intended to be limited thereby.
As shown in FIG. 1 , the anchorage extractor includes a first lever 104 , a main body 102 and a base 188 . The base 188 is formed, in this embodiment, by a first and a second section 190 and 191 which are arranged in a “V” shape or triangular shape one relative to another. These two sections 190 and 191 are connected by a third section 192 on which are fixed wheels 195 . Two pivoting members 193 and 194 are connected to the base and the main body 102 , the first extremity pivotally connected to the sliding structure and the second extremity connected to the base. The connections between members 193 and 194 with the base 188 and the main body 102 are of the pivot type, to change the angular position of the main body 102 relatively to the base 188 . The shape of the base 188 includes an enlarged portion (section 192 ) which provides a stable support surface when the anchorage extractor is in use. It should be noted that the base may have a shape other than triangular, the important aspect being to have a support surface sufficiently large and stable.
To minimize the space occupied when the anchorage extractor is not used, it can preferably be folded on itself or disassembled. As illustrated in FIG. 1 , the main body 102 , the base 188 and the pivoting members 193 and 194 are fixed to each other by using pivot connections 202 , 204 , 206 and 208 . By dismantling one or more of these connections it is possible to fold or disassemble the anchorage extractor. For example, if the pivot connection 202 or the pivoting members 193 and 194 are dismantled, the main body 102 can be disposed or folded on the base 188 . The pivot connections are typically composed of a rod with a bolt at each end to connect the main body 102 , the base 188 and the pivoting members 193 and 194 .
The main body 102 of the anchorage extractor 100 can be positioned in the same axis or almost the same as the longitudinal axis of the anchorage or stake to remove. A first embodiment of the mechanism for changing the angle of the main body is illustrated in FIGS. 2 a , 2 b , 3 a , 3 b and 3 c . It includes a sliding structure 122 , an angle selector 120 , a transmission member 121 , a locking rod or member 127 , a guiding member 123 , positioning plates 124 and a security device 126 . The angular position selector 120 is connected to the transmission member 121 which is itself connected to a locking member 127 . The sliding structure includes a hole 125 which is adapted to receive the guiding member 123 . The plates 124 extend on both sides of the main body 102 . The transmission member 121 is partially contained in the sliding structure 122 . The security device 126 , in a locked position, is partially inserted into the transmission member 121 , preventing the angle of the anchorage extractor to change during its use.
To change the angle of the main body 102 , the security device 126 is held in unlocked position and the angle selector 120 is activated. When the angle selector 120 is activated, it releases the locking member 127 and the sliding structure 122 is displaced along the main body 102 . The positioning plates 124 maintain the lateral position of the sliding structure 122 . When the angular position of the main body 102 is reached, the angle selector 120 is released and the locking member 127 is repositioned to its locked position, i.e. in one of the holes designed to receive the locking member 127 . The surface 128 of main body 102 , adjacent to the locking member 127 , comprises the positioning holes 129 . Each of these positioning holes 129 correspond to an angular position of the main body 102 . The number of positioning holes 129 determines the number of possible angular positions of the main body 102 .
As shown in FIGS. 4 , 5 and 6 , the main body 102 comprises a longitudinal cavity 118 and an opening 116 where the drive wheel 144 interacts with the rack 140 . A rack 140 and a plate 160 , which are fixed to each other, are located in the cavity 118 . In FIG. 10 , is it shown that the rack 140 is connected to the rack support structure 161 . The rack support structure 161 slide on the low-friction material block 221 .
FIG. 7 shows the driving mechanism 138 , which includes a first gear or drive wheel 144 , a first lever 104 , the rack 140 , a second gear (or sprocket) 142 , and a shaft 156 . The sprocket 142 and the drive wheel 144 are connected to the shaft 156 . The mounting blocks 180 and 182 are mounted on the shaft 156 . The rotating block 154 comprises a hole 155 that is adapted to receive the shaft 156 . The shaft 156 rotates in the hole 155 . The first lever 104 is connected to the rotating block 154 . A first lever-lock 146 , controlled by the second lever or handle 148 , is connected to the rotating block 154 .
Attachment means or connector such as a hook 170 and/or a jaw 172 , to which one or more anchorages are attached, is attached to the plate 160 , shown in FIGS. 4 and 6 . When the drive mechanism is actuated, by displacing upwardly and downwardly the first lever 104 , the rack 140 is driven upward and thereby removes the anchorage from the ground.
To displace the rack 140 , the first lever 104 is moved up and down. By lowering the first lever 104 , the first lever-lock 146 contacts one of the teeth of the drive wheel 144 and the latter rotates along the shaft 156 . The rotation of the drive wheel 144 causes the shaft 156 to rotate and this rotation is transmitted to the sprocket 142 . The sprocket 142 is engaged with the rack 140 and drives the latter upward. The reduction ratio depends on the diameters of the drive wheel 144 and of the sprocket 142 . In a preferred embodiment, the drive wheel 144 comprises less teeth than the sprocket 144 .
The handle 148 of the first lever-lock 146 is automatically held in a locked position using a spring (not shown in the figures). The second lever-lock 150 is adapted to interact with the teeth of the drive wheel 144 , it locks the drive wheel 144 , and consequently the rack 140 , to its current position and the first lever 104 may be raised again to transmit a further displacement to the rack 140 . When the anchorage is removed from the ground, the release mechanism 151 allows the rack 140 to be repositioned to the starting position. The release mechanism 151 comprises the release lever 152 and the second lever-lock 150 . By actuating the release lever 152 , the second lever-lock 150 is disengaged from the drive wheel 144 and allows the latter to rotate freely and allow the rack 140 to go back to its rest or starting position.
To reduce the friction occurring between the plate 160 and the main body, strips or block 219 of a material having a very low coefficient of friction are connected to the main body or on the plate. This material may be, for example, UHMWPE.
To remove an anchorage from the ground, the user positions the extractor near the anchorage to be removed. The user adjusts the angle of the main body 102 to place it substantially parallel to the angle of the anchorage. The anchorage is connected to the extractor through the hook 170 or the jaw 172 , or any other suitable means, depending on the physical configuration of the anchorage. It is possible to use an intermediary such as a chain to attach the anchorage to the hook 170 or the jaw 172 .
At the starting or rest position, the rack 140 is ideally located at its lowest position relatively to the main body 102 . The user moves the first lever 104 upwardly, this movement does not offer resistance, and then moves the first lever 104 downwardly, this movements driving the drive wheel 144 and moving upwardly the rack 140 within the cavity of the main body. Under the action of the sprocket on the rack, the rack slide upwardly.
To reposition the extractor to the starting position, the user actuates the release lever 152 , allowing the rack 140 to move down freely.
FIGS. 8 and 9 shows another embodiment of an angle selector for the main body. It comprises a sliding structure 222 , an angle selector 220 , a locking member 227 , positioning plates 224 and a spring 228 . The angle selector 220 is connected to the locking member 227 . The sliding structure 222 comprises a hole 225 which is adapted to receive the guiding member 223 . The plates 224 extend on both sides of the main body 102 . The locking member 227 is partially contained in the sliding structure 222 . The spring 228 is contained in a hole in the sliding structure 222 (shown at the exterior of the sliding structure in FIG. 9 ). The extremity of the locking member 227 is adapted to be received by one of the holes 229 in the guiding member 223 . To change the angle of the main body, a user pulls the position selector 220 , it will compress the spring 228 , and displaces the sliding structure 222 upwardly or downwardly. The user let go the angle selector 220 when the main body is at the appropriate angle and the spring will force the locking member 227 to move towards the guiding member 223 . When the locking member 227 faces one of the positioning holes 229 , the extremity of the locking member 227 engages with the hole and locks the main body at the selected position or angle. It is to be noted that the sliding structure may be made in one block or more, depending of the design.
While illustrative and presently preferred embodiment(s) of the invention have been described in detail hereinabove, it is to be understood that the inventive concepts may be otherwise variously embodied and employed and that the appended claims are intended to be construed to include such variations except insofar as limited by the prior art. | The present invention is directed to an anchorage extractor. The extractor is used to remove post, anchorage or stake from the ground without using a force generated by a motor. The anchorage extractor comprises a base disposed on the ground to provide a stable support. A lever is connected to a driving wheel that is connected to a rack. The anchorage is attached to the rack and when the lever is actuated, the drive wheel drives the rack upward, removing the anchorage from the ground. An advantage of the present invention is that the direction of the extraction force is parallel to the anchorage axis by adjusting the angle of the extractor. The extractor may be folded on itself or dismantled to be transported. | 4 |
FIELD OF THE INVENTION
This invention relates generally to devices that are used in the health care industries. More particularly, it relates to a holder device for use with a standard urine specimen collection cup, which holder is configured to securely hold the cup in a sanitary, sample-taking orientation relative to the patient as the urine specimen is taken. The holder is also configured to allow for the quick release of the cup and specimen contained within it upon completion of specimen collection.
BACKGROUND OF THE INVENTION
The physical, chemical or microscopic analysis of human urine, or urinalysis, is an essential tool in the health care industry. Urinalysis can provide a wide range of information concerning the health and well being of a patient. The examination of urine color and clarity, the measurement of urine acidity and the detection of the presence of protein, sugar, bacteria and other matters found in urine can tell a great deal about the physical condition of the subject patient.
Urinalysis is performed ideally by using a fresh urine specimen, preferably the first voiding of the day since such specimens are the most concentrated and therefore more likely to reveal abnormalities contained within the urine. All urine tests are performed ideally by using clean and uncontaminated collection vessels or containers. Additionally, it is recognized that microscopic urinalysis is best performed within the first one-half hour after collection of the specimen since allowing the sample to stand may cause bacterial overgrowth and even dissolution and dissipation of cellular elements. In short, collection protocol requires that all specimens be collected in sterile containers, then sealed against outside contamination and thereafter refrigerated as soon as possible after collection.
The bacteriological study of urine poses a particular problem due to the inevitable contamination caused by the presence of microorganisms that reside in the vicinity of the human urethral opening. This contamination can be avoided by catheterization of the urinary bladder, but such is obviously an extreme measure and clearly not one recommended for routine examinations. Very reliable bacteriologic urine studies are possible, however, without catheterization by utilizing the so-called “clean-catch mid-stream” technique. For women, collecting a urine specimen in this manner involves partial voiding and then placement of a urinary collection cup between the legs to catch the “mid-stream” urine during continued voiding. This technique is difficult to accomplish without the patient soiling her hands during the urine collection process and without the risk of the patient's hands contacting the collection cup during collection, thus risking inaccurate results due to bacteriologic contamination. In short, eliminating any contact with the urine stream simply provides greater hygiene for the patient and reliability for the health care provider charged with handling and measuring the specimen contained within the cup.
SUMMARY OF THE INVENTION
It is, therefore, a principal object of this invention to provide a new, useful and uncomplicated urine specimen collection cup holder that eliminates the inconveniences, unsanitary practices and ineffective results common with conventional urine collection devices. It is another object of this invention to provide such a cup holder that is manufactured to be disposable. It is still another object of this invention to provide such a cup holder that allows the patient to more easily hold the cup in specimen-collecting relation to her body and minimizes the risk of dropping the cup into the toilet. It is still another object of the present invention to provide such a cup holder that would make urine collection easier and more convenient and make patients feel more at ease with the process, thus reducing the stress associated with medical examinations. It is still another object of the present invention to provide such a cup holder that is particularly beneficial for pregnant or obese women who experience difficulty with reaching around the abdomen to hold a specimen cup. It is another object of the present invention to provide such a cup holder that can provide pediatric assistance for specimen collection from small children. It is still another object of the present invention to provide such a cup holder that minimizes the risk of contamination thereby avoiding the need to repeat the taking of urine samples at a reduced cost to patients and the health care industry in general. It is yet another object of the present invention to provide such a cup holder that allows for the quick attachment to a standard specimen cup and the quick release of the cup following collection of the specimen.
The present invention has obtained these objects. It provides for a disposable holder for use with urine specimen collection cups, the holder having a cup grasping extension incorporated and molded into it. In the preferred embodiment, the elongated extension is formed within a recess defined within the overall holder. The holder may be held firmly with one hand and the grasping extension actuated with the other hand. The holder is configured to be held and operated by right and left handed persons. When ready for use, the cup grasping portion of the holder is urged downwardly onto a portion of the perimeter of a cup edge. The specimen is firmly grasped thereby. Upon collection of the specimen, the extension is urged toward the handle so as to open cooperating and opposing cup holding members. In this fashion, the specimen cup and collected specimen are released and the holder is disposed of.
The foregoing and other features of the urine sample collection cup holder of the present invention will be further apparent from the detailed description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a right side elevational view of a urine sample collection cup holder constructed in accordance with the present invention.
FIG. 2 is a bottom plan view of the holder shown in FIG. 1 .
FIG. 3 is a top plan view of the holder shown in FIG. 1
FIG. 4 is a right side elevational and cross sectioned view of the holder shown in FIG. 1 and taken along line A—A in FIG. 3 .
FIG. 5 is an enlarged top plan view of the cup grasping portion that is detailed within line N of FIG. 3 .
FIG. 6 is a further enlarged right side and cross sectioned view of the cup grasping portion that is detailed within line B of FIG. 4 .
FIG. 7 is a reduced right side elevational view of the holder.
FIG. 8 is an enlarged front elevational view of the holder.
FIG. 9 is an enlarged rear cross sectioned view of the holder taken along line C—C of FIG. 7 .
FIG. 10 is an enlarged rear cross sectioned view of the holder taken along line M—M of FIG. 7 .
FIG. 11 is an enlarged top plan view of the cup grasping portion of the holder shown in FIG. 7 .
FIG. 12 is an enlarged right side elevational view of the cup grasping portion that is detailed within line E of FIG. 7 .
FIG. 13 is an enlarged rear cross sectioned view of the handle portion of the holder and taken along line D—D of FIG. 7 .
DETAILED DESCRIPTION
Referring now to the drawings in detail, wherein like numerals represent like elements throughout, FIG. 1 illustrates a holder, generally identified 10 , that is constructed in accordance with the present invention. The holder 10 is functionally adapted to be used for grasping and then releasing a urine specimen collection cup. As shown in the preferred embodiment, the specimen cup holder 10 includes a longitudinally extending main frame, generally identified 20 , having a distal portion, generally identified 40 , and a proximal portion, generally identified 60 . The distal portion 40 of the frame 20 serves generally as the “handle portion” of the holder 10 . The proximal portion 60 of the frame 20 serves generally as the “cup gripping portion” of the holder 10 .
The main frame 20 of the holder 10 includes a pair of longitudinally extending side members 26 , 28 . See FIG. 2 . The side members 26 , 28 lie generally parallel to one another. At the proximal end 22 of the frame 20 is a longitudinally extending aperture 30 that lays between the side members 26 , 28 . The proximal end 22 of the frame 20 terminates in the cup gripping portion 60 , the detailed construction of which is described below. The main frame 20 also includes a distal end 24 that is integrally formed with the handle portion 40 of the holder 10 . As shown, the handle portion 40 includes a somewhat concave member 42 having an upper surface 44 . See FIGS. 4 and 13 . This upper surface 44 is functionally adapted to receive a user's thumb therewithin, the purpose of which will become further apparent later in this detailed description. The concave member 42 is attached to the distal frame portion 24 by means of a connecting neck 46 . Proximal of the neck 46 and lying generally underneath the distal frame portion 24 is a finger recess 48 , the purpose of which will also become apparent later in this detailed description.
The aperture 30 defined within the main frame 20 has an extension portion, generally identified 80 , formed within it. That is, the extension portion 80 of the holder 10 is integrally formed as part of the holder, and more specifically as part of the main frame 20 . The extension portion 80 includes an extension member 82 having a proximal portion 84 and a distal portion 86 . To either side of the distal portion 86 is a nominal support member 88 , 90 . See FIGS. 2 and 3 . In the preferred embodiment, the specimen collection cup holder 10 is formed from a polystyrene, polypropylene or polyethylene plastic material which may be injection molded. Accordingly, the main frame 20 and the extension member 82 are integrally formed from a single piece of material. The nominal support members 88 , 90 are in the form of mold gates for material flowing between the frame side members 26 , 28 and the extension member 82 . In the holder 10 of the present invention, the nominal support members 88 , 90 are intended to prevent actuation of the device during shipping and handling. When used as intended, the nominal support members 88 , 90 essentially break away during use of the holder.
Referring now to FIG. 11 , it will be seen that a portion of the distal end 84 of the extension member 82 is integrally formed with the side members 26 , 28 . That is, the distal end 84 of the extension member 82 and the side members 26 , 28 are formed into one conjoined structure at this part of the holder 10 . As is specifically shown in FIG. 11 , it will be seen that, at the distal end 84 of the extension member, where the distal end 84 becomes an inner cup support 96 , a pair of arms 62 , 64 is provided to connect that distal end 84 to the side members 26 , 28 of the holder 10 . The function of the inner cup support 96 will be described in greater detail later in this description. In this fashion, the extension member 82 is actually configured to rotate slightly at this distal end 84 . This feature is what this inventor would term a “living hinge.” For example, as the lever 92 of the extension member 82 is urged slightly downwardly, the distal end 84 and the arms 62 , 64 of the side members 26 , 28 actually deform in a “twisting” or torque-like fashion. This twisting is not sufficient to fracture or break the arms 62 , 64 or to sever the continuity between the distal end 84 of the extension member 82 and the side members 26 , 28 , but it is sufficient to provide some resistance when the extension member 82 is urged downwardly. The resilient nature of the plastic material from which the holder 10 is formed allows for this deformation. More importantly, plastic material also possesses the quality of “memory” such that the extension member 82 maintains its original position prior to depression of the extension lever 92 . This maintains the various portions of the holder 10 in their original molded position, a position that they tend to want to return to after deformation. The significance of this feature will become apparent later in this detailed description.
As alluded to previously, the proximal cup gripper portion 60 of the holder 10 is really comprised of a number of elements common to the holder portions previously described. For example, a portion of the cup gripper 60 includes the distal end 84 of the extension member 82 and the side members 26 , 28 . See FIGS. 9 and 10 . Additionally, the cup gripper portion 60 also includes a plurality of outer cup support members 94 extending outwardly and downwardly from the side support members 26 , 28 . Cooperatively opposing the outer cup support members 94 is an inner cup support member 96 , as alluded to earlier. See FIGS. 5 , 6 , 11 and 12 . The inner cup support member 96 extends downwardly from the distal end 84 of the extension member 82 . As shown in FIG. 11 , the arms 62 , 64 effectively connect those two structures. The lowermost portion of the outer cup support members 94 includes a hook member 98 which is intended to ensure secure attachment of the holder 10 to the specimen cup, the cup typically including a rim (not shown).
In application, the holder 10 of the present invention could be used to hold one of many commercially available plastic specimen cups, such cups coming in different sizes but generally assuming the same shape. Although the precise size of the cup is not a limitation of the present invention, it would be desirable that the cups used with the holder 10 of the present invention have a top opening that includes a substantially circular rim.
In use, the user would grasp the distal handle portion 40 of the holder 10 with one hand. It should be noted that the holder 10 of the present invention is functionally adapted to be grasped by the left hand or the right hand, thus aiding in the functionality of the device since it need be made in one configuration to serve both right and left handed persons. More specifically, the user would place the thumb of her grasping hand over the concave top 44 of the handle 42 , the handle 42 being secured between the thumb and the first finger of that hand. The first or second finger of that same hand would comfortably fit within the recess 48 thereby stabilizing the holder 10 in the grasping hand. Assuming that a cup (not shown) was not already held within the grasping portion 60 of the holder 10 , the user would position the rim of the cup below the inner cup support member 96 and the outer cup support members 94 and urge the holder 10 downwardly to the point that the rim of the cup snaps into and is secured by the hook member 98 of the outer cup support members 94 . It should be noted here that the preferred embodiment illustrated herein is not the only configuration that would be used to accomplish this intended function. The cup is thereby secured and ready for specimen collection. It should also be noted here that the holder 10 is configured such that it is of sufficient strength to be weight bearing of the collected specimen yet lightweight enough to be disposable. It should also be noted that, during this cup engagement step, the outer and inner cup support members 94 , 96 are urged away from each other and the arms 62 , 64 are slightly twisted to allow that movement to occur. The plastic memory in the holder 10 allows the cup support members 94 , 96 to continue to press a portion of the cup between them. The hook end 98 as previously described ensures that the cup will not slip out from their grasp.
Once collected, the cup is released by the user exerting gentle downward pressure on the lever 92 of the extension member 82 . At this point, the nominal support members 88 , 90 break away and allow the extension member 82 its full range of movement. As pressure continues to push the lever 92 downwardly, the proximal end 84 of the extension member 82 and the arms 62 , 64 are slightly deformed in a “twisting” or torque-like fashion. Although this twisting is not sufficient to fracture or break the continuity between the proximal end 84 of the extension member 82 and the side members 26 , 28 , it is sufficient to provide some resistance when the extension member 82 is urged downwardly. The resilient nature of the plastic material from which the holder 10 is formed allows for this deformation. It also provides the necessary memory such that the extension member 82 maintains its original position prior to depression of the extension lever 92 . As this deformation takes place, the arms 62 , 64 are deformed and the inner cup support member 96 extending outwardly and downwardly from the side support members 26 , 28 is pushed away from the plurality of outer cup support members 94 so as to release the cup and the specimen contained within it. The holder 10 is then ready for disposal.
From the foregoing detailed description of the illustrative embodiment of the invention set forth herein, it will be apparent that there has been provided a new, useful and uncomplicated urine specimen collection cup holder that eliminates the inconveniences, unsanitary practices and ineffective results common with convention urine collection devices; that is manufactured to be disposable; that allows the patient to more easily hold the cup in specimen-collecting relation to their body and to avoid the risk of dropping the cup into the toilet; that makes urine collection easier and more convenient, allowing patients to feel more at ease with the process thereby reducing the stress associated with medical examinations; that is particularly beneficial for pregnant or obese women who experience difficulty with reaching around the abdomen to hold a specimen cup; and that minimizes the risk of contamination thereby avoiding the need to repeat the taking of urine samples at a reduced costs to patients and the health care industry in general. | A disposable holder for use with urine specimen collection cups has a cup grasping extension incorporated and molded into it. The elongated extension is formed within a recess defined within the overall holder. The holder may be held firmly with one hand and the grasping extension actuated with the other hand. The holder is configured to be held and operated by right and left handed persons. In use, the cup grasping portion of the holder is urged downwardly onto a portion of the perimeter of a cup edge. The specimen is firmly grasped thereby. Upon collection of the specimen, the extension is urged toward the handle so as to open cooperating and opposing cup holding members. In this fashion, the specimen cup and collected specimen are released and the holder is disposed of. | 0 |
FIELD OF INVENTION
[0001] The present invention is concerned with a system for the assembly and disassembly of articles and in particular is concerned with a process for the assembly and disassembly of textile based articles and with equipment and articles for such an assembly and disassembly process.
BACKGROUND ART
[0002] The vast majority of textile based products, which have been assembled from multiple components e.g. garments, shoes, furnishings, floor coverings, quilts, mattresses, bedding, automotive airbags, seat covers and safety belts are very difficult to recycle into useful products and/or be reused at the end of their useful or expected life. The majority of these products are either downcycled into low value products or discarded to municipal waste. Some garments, if in satisfactory condition may be suitable for reuse without additional re-manufacture and may be sold via charity shops or exported to developing countries where they are reused.
[0003] A common example of recycling is through use of fiber reclamation mills. Textile products may be shredded into fibers and blended with other fibers, depending on the intended end use. The recycled fibres may then be mechanically processed by processes such as carding or air-laying to produce a web, which is then converted into nonwoven fabrics using techniques such as needlepunching, stitchbonding, thermal bonding, chemical bonding and similar nonwoven bonding techniques. Alternatively, webs containing recycled fibres may be converted via other manufacturing processes in to yarns ready for weaving, knitting and similar fabric production processes. Recycled fibers may be used as components in the production of nonwoven fabrics for use in for example, mattress production (e.g. insulator pads above the springs) and sound insulator pads used in the manufacture of vehicles. Waste textile and clothing may also be shredded to make filling materials for insulation products, roofing materials such as felts, padding materials for furniture manufacture, fillers for composites and many other applications.
[0004] Textiles in municipal solid waste largely consist of discarded clothing, although other sources include furniture, mattresses, carpets, footwear, and goods such as sheets, towels, curtaining and other household fabric uses such as furniture. In the US alone it is estimated that eleven million tonnes per annum of textiles end up in landfill and in the United Kingdom it is approximately one million tonnes per annum.
[0005] Whilst various methods exist for recycling of textile-based products, many garments are difficult to recycle due to the complexity of their structure and the presence of multiple different materials including non-textile materials used in their manufacture.
[0006] Whilst the majority of textile-based articles being directed to municipal waste such as landfill have reached the end of their useful life a significant quantity of such textile based articles have not reached the end of their useful life and could be reused or redirected for use elsewhere. Significant quantities of clothing is rejected by retailers and brand owners because of flaws or because it is surplus to requirements or it is out of season/fashion. In addition, although large quantities of donated clothing are collected each year, not all of this clothing is suitable for re-sale or re-use.
[0007] Another major area where a significant quantity of reusable textile material is directed to landfill is in the area of corporate clothing and workwear. Many articles of corporate clothing including uniforms cannot be reused because there are potential security issues associated with the corporate identity. At present, identifying insignia or labels cannot be easily or economically removed to reduce the risk of such security issues. The main reason why the bulk of these articles are not reused is because they are difficult and expensive to process for the removal of labels and corporate insignia. Removal of labels and tax tabs prior to reuse is necessary often for security reasons, but is hampered because it often has to be done manually, which is not cost-effective. Also, the underlying fabric may be unavoidably damaged as the logo or insignia is removed. Embroidered logos and insignia are particularly difficult to remove in a cost-effective manner without damaging the base fabric in the process. The complex issues around the recovery and reuse of corporate clothing has recently been addressed in a paper entitled “Principles of the recovery and reuse of corporate clothing”, by Russell et al., in Waste and Resource Management, 163, Issue WR4, pages 165 to 173.
[0008] Another problem with many textile products is the heterogeneity of the composition and methods that are used to join the integral components, which are irreversible. Many textile products comprise of more than one material, for example, metal zips and fastenings are attached to the fabric. In addition it is common for textile components not to be comprised of homogeneous plastic materials. For example, a 100% cotton product may be sewn together with a sewing thread containing synthetic or man-made polymers such as polyester and the joint requires substantial energy to break. When such products are shredded, these different materials become intermixed and the separation of these individual components becomes very difficult. If an attempt is made to disassemble a conventional textile product in to its separate components by breaking stitches, seams or joints mechanically, substantial energy is required because these joints are not designed to be separated, for the same reason the separation may be incomplete due to tearing of the product due to the force involved resulting in some cross contamination of the material streams. The cost-effective disassembly and separation of the individual components of a textile product at the end of life is therefore problematic.
[0009] Recycling processes require effective means of separating textile components so that individual components of the product can be more cost-effectively separated and recycled without contaminating the various components. Examples include, the recycling of furniture, floorcoverings, mattresses, interior automotive components, seating, home furnishings, shoes, and soft luggage.
[0010] There is a growing need for safe and effective systems and methods of article assembly and disassembly, especially the assembly and disassembly of textile based articles.
DISCLOSURE OF THE INVENTION
[0011] Thus in accordance with the present invention there is provided a system for article material reuse or recycling, which system comprises the assembling of an article from at least two components, at least one of which comprises a textile material brought into communication with each other through one or more connecting means, wherein the assembled article is susceptible to automatic or semi-automatic disassembly through one or more of its connecting means being susceptible to a reduction in one or more mechanical properties under exposure of the article to electromagnetic energy.
[0012] The disassembly is facilitated by the reduction in one or more mechanical properties of the one or more connecting means and the disassembly process utilizes this reduction in one or more mechanical properties. In one embodiment one or more of the components of the article from the disassembly may be re-used in the assembly to make the same or similar type of article. In another embodiment the components of the article may be re-used in the assembly of a different type of article from the disassembled article. In another embodiment the components of the article from the disassembly are re-used or recycled via a process that does not require or use the connecting means susceptible to a reduction in one or more mechanical properties under exposure to electromagnetic energy.
[0013] The present invention further provides an article susceptible to automatic or semi-automatic disassembly, which comprises at least two components at least one of which comprises a textile material in communication with each other through one or more connecting means, wherein one or more mechanical properties of at least one of the connecting means may be reduced on exposure to electromagnetic energy.
[0014] The present invention further provides a method of manufacturing an article susceptible to automatic or semi-automatic disassembly, which method comprises securing at least two or more components at least one of which comprises a textile material to each other via one or more connecting means, wherein at least one of the connecting means is susceptible to a change in one or more of its mechanical properties under exposure to electromagnetic energy.
[0015] The present invention further provides a method of disassembly of an article comprising one or more components at least one of which comprises a textile material and one or more connecting means susceptible to a reduction in one or more mechanical properties under exposure to electromagnetic energy, which method comprises exposing the articles to electromagnetic radiation under conditions to achieve a reduction in one or more mechanical properties of one or more of the connecting means such that at least one component may be separated from the article.
[0016] The present invention further provides an article disassembly plant comprising at least one region for exposure of articles comprising at least one textile material for disassembly to electromagnetic radiation, means for introducing articles to this exposure region and means for extracting exposed articles from the exposure region.
[0017] The present invention further provides connecting means suitable for use in the assembly of an article, wherein the connecting means is susceptible to a reduction in one or more of its mechanical properties under exposure to electromagnetic energy.
[0018] The preferred articles of the present invention are articles comprising one or more textile materials. The articles may be exclusively based on textile materials but may also comprise a mixture of textile and non-textile materials. As an example the article may comprise a textile substrate with a non-textile based label secured to the textile substrate. As a further example, the article may comprise a non-textile material, such as a metal button or zip secured to the textile substrate. The article may be in the form of any product that is joined by the use of sewn, stitched, embroidered or stapled threads including garments and other items of clothing (e.g. hats, gloves, shoes, socks, etc) as well as non-clothing items such as badges, labels, seat-covers, seat furnishings, car headliners, mattress covers and tickings, bedding including pillows and duvets, sheets, parachutes, airbags, seat belts, composites, medical, healthcare, composite and industrial products. The present invention is especially useful in the disassembly of garments and other products whose assembly involves stitching or sewing. Garments meaning any form of human attire, preferably comprising one or more textile components. It is envisaged that non-textile based articles may used in the present invention, especially when the components of the articles are secured to each other by means of a filament, staple, yarn or thread. Preferably the form of the communication between article components is a join such as a seam, embroidery, or sewn, stitched or stapled joints.
[0019] In accordance with the present invention the connecting means may be in any form suitable for use in the assembly of the article. When the article comprises a textile component it is preferred that one or more of the connecting means is in the form of at least one filament, yarn or staple or a combination of these connecting means.
[0020] The filament, staple or yarn may be manufactured from any material that is susceptible to a reduction in one or more of its mechanical properties under exposure to electromagnetic energy. It is preferred that the material is such that upon exposure to electromagnetic energy there is a significant reduction in the physical integrity of the material such that the connector comprising the material may be disintegrated under relatively low applied force. The level of disintegration of the connector may be such that when the article is simply moved or handled after exposure the e.g. by hand, relevant component or components are separated from the article. In one embodiment disintegration is induced by a mechanically applied force to the connector and/or the components of the article. In a preferred embodiment the material properties of the connector are such that one or more mechanical properties of the connector is degraded to such a degree that disintegration occurs on exposure to the electromagnetic energy, with no need for an applied force to disintegrate the connector after exposure.
[0021] In a preferred embodiment the material of the connection means is such that on exposure to electromagnetic energy there is a rise in temperature of the material. It is preferred that it is the rise in material temperature on exposure, which results in the reduction in the mechanical properties of the material.
[0022] The electromagnetic energy may be any electromagnetic radiation, which may induce a reduction in the mechanical properties of one or more of the materials of the connection means. It is preferred that the electromagnetic radiation is in the radio frequency range or the microwave frequency range and most preferably the microwave frequency range.
[0023] The frequency of the emitted electromagnetic radiation may be in the range of 3 Hz to 300 EHz, most preferably in the range of 300 MHz to 300 GHz In the context of the present invention the term “microwaves” refers to electromagnetic radiation in the frequency range from 300 to 30,000 MHz (megahertz) and more preferably from 800 to 4,000 MHz
[0024] The microwave radiation may interact with a material in a number of ways. These may be referred to as resistive heating or dielectric heating.
[0025] With a material that is a conductor, electrons move freely in the material in response to an electric field and electric current results. Unless the material is a superconductor, the flow of electrons will heat the material through resistive heating (Joule heating). This relationship is described by Joules law:
[0000]
q=I
2
·R·t
[0026] Where: q is the heat liberated
I is current flowing through a material R is the resistance of the material t is time
[0030] Microwave induced electric currents in such materials results in resistive heating of the material.
[0031] Dielectric heating is the phenomenon, which can be experienced when, microwaves act upon an insulator; electrons do not flow freely, but re-orientation or distortions of induced, or permanent dipoles, can give rise to heating. Microwaves penetrate such materials and release their energy in the form of heat as the polar molecules (ones with positively and negatively charged ends—such as water) vibrate at high frequency to align themselves with the frequency of the microwave field. The microwaves interact directly with the object being heated. The interaction is related to the chemical properties of the material and it is possible to apply heat in ways that cannot be achieved by conventional means (convection heating, conductive heating or radiant heating).
[0032] It is therefore preferred that the connecting means comprise one or more materials that are susceptible to resistive or dielectric heating or a combination of these under exposure to microwave radiation and this results in the reduction in one or more of their mechanical properties.
[0033] It is preferred that the connection means materials on exposure to the electromagnetic radiation exhibit the desired reduction in one or more mechanical properties at a material temperature, which is below a temperature which would impart thermal damage to the components of the article. In this regard it has been found that certain connection means manufactured exclusively from metals that melt at a high temperature e.g. steel are not suitable as connector materials for most textile articles. This is because for many articles when steel is used it disintegrates at a temperature, which causes thermal damage to the article for disassembly.
[0034] The one or more connecting means susceptible to a reduction in one or more mechanical properties under exposure to electromagnetic energy may comprise two or more materials. The connecting means may comprise two or more materials as separate regions or layers or components of the connecting means with one or more of the connecting means components being susceptible to a reduction in one or more mechanical properties under exposure to electromagnetic radiation. Thus in one embodiment it is envisaged that the connecting means may comprise two components each of a different material, one being susceptible to being heated on exposure to electromagnetic radiation and the second being relatively unaffected by such exposure. In this embodiment the disintegration of the connecting means may be due to the mechanical degradation of one of its components resulting in disengagement of the components from each other. In another mode the disintegration may be due to the mechanical degradation of the component relatively unaffected by exposure to electromagnetic through heat transfer from the component heated on exposure to the electromagnetic radiation. It is possible that both the preceding modes of disintegration may occur.
[0035] In a preferred embodiment the filament, staple, or yarn connection means comprises a bi-component material wherein the electromagnetic radiation susceptible material is present in one or more of the constituent components.
[0036] In a preferred embodiment the connection means comprises one or more organic polymeric components (natural or synthetic) and a material that may be heated rapidly on exposure to electromagnetic radiation such that one or more mechanical properties of the connection means may be rapidly degraded by exposure of the connection means to electromagnetic energy.
[0037] The structure/form of the filament staple or yarn may take on a number of suitable forms.
[0038] The structure/form of the filament staple or yarn may comprise one or more organic materials coated and/or chemically bonded with one or more electromagnetic radiation susceptible or conductive additives or materials, which on exposure to electromagnetic radiation transfer heat to the organic materials degrading their mechanical properties.
[0039] The structure/form of the filament staple or yarn may comprise one or more organic materials chemically bonded with one or more electromagnetic susceptible or conductive materials, which on exposure to electromagnetic radiation transfer heat to the organic materials degrading their mechanical properties.
[0040] The structure/form of the filament staple or yarn may comprise a core/sheath structure with at least the sheath material comprising one or more materials susceptible to electromagnetic radiation, which on exposure to electromagnetic radiation transfer heat to the organic core materials degrading their mechanical properties.
[0041] The structure/form of the filament staple or yarn may comprise a core/sheath structure with at least the core material comprising one or more materials susceptible to electromagnetic radiation, which on exposure to electromagnetic radiation transfer heat to the organic sheath materials degrading their mechanical properties.
[0042] In a preferred embodiment the connection means comprises a plied yarn construction comprising at least one filament yarn susceptible to exposure to electromagnetic radiation, wherein the yarn is comprised of two or more filaments or combinations of filament and staple yarns. These include plied yarns comprising filaments containing at least one metallic compound (other than steel). Also envisaged are blended yarns containing a core of at least one filament or staple fibre yarn that is susceptible to exposure to electromagnetic radiation sheathed by organic fibres, or yarn mixtures containing any combination of the above described yarn related embodiments. This may take the form of a twisted yarn assembly containing at least one filament or yarn that it susceptible to exposure to electromagnetic radiation with one or more additional filaments or yarns wrapped or twisted around it so as it to cover it. The additional covering filament/s can be comprised of man-made or natural polymers that may be dyed or pigmented. Alternatively, the additional covering filament/s pre-dyed or pigmented so as to permit a range of different colours to be achieved without the need to dye or pigment the filament or yarn that it is susceptible to electromagnetic radiation.
[0043] In a preferred embodiment, the yarn containing at least one filament or yarn that it susceptible to exposure to electromagnetic radiation is covered (or sheathed) with staple fibre (e.g. cotton, viscose, lyocell, polyester, polypropylene, polyamide) so as to hide the core component. This is done by existing processes that are known in the art, for example, core-spinning, ring spinning, air-jet spinning or friction spinning. It has been found that such an arrangement facilitates the production of yarns that are compatible with high speed sewing or embroidery operations as well as providing a means of modifying the colour and appearance of the yarn. In a preferred embodiment the cover yarn has a yarn linear density of 50 dtex or more. Preferably the cover yarn is twisted in both the S-direction and Z-direction to produce a double-covered yarn assembly of balanced twist. By twisting two or more additional yarns around the yarn core, the core is mechanically protected from subsequent abrasion. Furthermore the core is also substantially hidden from view. The colour, handle, appearance, softness and general aesthetics of the final yarn is then principally dependent on the yarns twisted around the core. As a result of covering the core with yarns containing cotton, the resulting yarn surface may be soft and hydrophilic as well as being suitable for yarn colouration or chemical finishing. A particularly suitable construction for sewing thread use was produced by twisting at least two additional yarns composed of cotton around a “core” multifilament yarn or staple fibre yarn with a specific resistivity of 10 −2 -10 0 ΩQ*cm. The “core” multifilament or staple fibre yarn is composed of acrylic or polyamide fibre wherein the fibres and filament contain a chemically bonded layer of copper sulphide that is proximal to the fibre/filament surface. The copper sulphide layer is of the order of 300-1000 Å (angstroms) thick. It was determined that the “core” can comprise of a Thunderon™ polyamide multifilament yarn containing a layer of copper sulphide (sulfide). This “core” yarn could be hidden by the two or more yarns twisted around it. A particularly suitable grade of core material was Thunderon™ 110 dtex/24F.
[0044] The components of the connecting means may comprise one or more of the following materials: metal sulphides e.g. copper sulphide/sulfide including digenite (Cu 9 S 5 ), covellite, anilite, djurleite, chalcocite; various mixed valent oxides, such as magnetite, nickel oxide and the like; sulfide semiconductors, such as FeS 2 and CuFeS 2 ; silicon carbide; various metal powders such as powders of aluminum, iron and the like; various hydrated salts and other salts, such as calcium chloride dihydrate; aliphatic polyesters (e.g., polybutylene succinate and poly(butylene succinate-co-adipate), aromatic polyesters, polymers and copolymers of polylactic acid; various hygroscopic or water absorbing materials or more generally polymers or copolymers with many sites of OH groups. Examples of other suitable inorganic materials include, without limitation, aluminum hydroxide, zinc oxide, barium titanate. Examples of other suitable organic materials include, without limitation, polymers containing ester, aldehyde ketone, isocyanate, phenol, nitrile, carboxyl, vinylidene chloride, ethylene oxide, methylene oxide, epoxy, amine groups, polypyrroles, polyanilines, polyalkylthiophenes. Examples of other additives include, without limitation, the following: metallic particles such as aluminium, copper, gold, tin, zinc particles; metallic oxide particles such as barium dodecairon nonadecaoxide, diiron nickel tetra-oxide, manganese di-iron oxide, zinc diiron oxide, titanium carbide, silicon carbide, zinc oxide; and galvanic couple alloy particles, such as, aluminium-nickel alloy, aluminium-cobalt alloy and aluminium-copper alloy particles. It is preferred that the components do not comprise a carbon, carbon black or graphite core.
[0045] In a particularly preferred embodiment one or more of the connecting components comprises at least one component that is comprised of an organic material containing a metal sulphide, most preferably copper sulphide. Preferably at least one component comprises an acrylic, polyamide or polyester containing a metal sulphide, preferably copper sulphide material. A particularly preferred embodiment uses Thunderon® filament or staple fibre yarn comprised of an acrylic or polyamide material chemically bonded with a layer of copper sulphide wherein the thickness of its conductive layer is 300 - 1000 Å (angstroms) and the filament or yarn specific resistance is within the range 10 −3 -10 0 Ω.cm.
[0046] It is preferred that the connecting means comprises one or more materials having a specific resistance within the range of 10 −5 -10 11 Ω.cm., more preferably 10 −5 -10 5 Ω.cm., more preferably 10 −5 -10 0 Ω.cm., more preferably 10 −4 -10 0 Ω.cm., and most preferably 10 −3 -10 0 Ω.cm. Pseudo-conductive materials are preferred to reduce the potential for over-heating and damage to the surrounding textile fabric whilst at the same time providing sufficient heating to deteriorate mechanical properties. Thus it is preferred that in the present invention connecting means with a resistivity of less than 10 −3 Ω.cm are selected, which are not metals or metal containing. It is also preferred that in the present invention connecting means with a resistivity of greater than 10 0 Ω.cm are selected, which exclude elemental carbon and/or carbon black and/or graphite.
[0047] The connecting means may comprise a flexible joint or seam comprising one or more yarns in the form of one or more stitch classes (suitable stitch constructions are detailed in ISO 4915: 100's, 200's, 300's, 400's, 500's and 600's stitch classes); these are the preferred examples of a bi-component connection means.
[0048] Such stitch classes, without limitation, may include: 100 single thread chain stitch; 300 lock stitch; 400 multi-thread chain stitch; 500 over edge chain stitch; 600 covering chain stitches; or any combination of two or more of these stitch classes. The yarn may be used as, needle thread, bobbin thread, looper thread or any combination of these. According to the stitch class, to ensure joint failure following the exposure of the joint to electromagnetic radiation, it may be particularly advantageous to incorporate the thread susceptible to a reduction of its mechanical properties only as a bobbin thread of the bi-component stitch since the tensile strength requirements are frequently less critical for the bobbin component than for the needle-thread component where higher processing forces are encountered during manufacture of the joint. Microwave-induced failure of the lower thread component in the joint (delivered by the bobbin thread) is then the controlling factor in the mechanical failure of the bi-component joint, facilitating separation of the upper and lower components of the connection means and thus separation of the article components secured by the bi-component joint. This approach also minimizes the economic cost of the joint, since the microwave-sensitive yarn component is only required in part of the entire joint construction.
[0049] It is preferred that the mechanical property reduced on exposure to microwave and resistive or dielectric heating or a combination thereof is the tensile strength of one or more of the materials comprising the connecting means. The loss of tensile strength in one or more of the materials comprising the connection means enables that component of the connection means to fail resulting in loss of strength of the connection means and its consequential structural failure allowing disassembly to be achieved. The total reduction in tensile strength (breaking load) that is achieved as a result of microwave heating has been found to increase as the overall yarn or filament linear density (tex=weight in g of 1000 m of yarn) decreases.
[0050] When the connection means is a stitch based joint between two textile components of an article it is preferred that compromising of the mechanical properties of one or more of the components of the joint results in a joint strength reduction of at least 50%, more preferably at least 80% and most preferably at least 90%.
[0051] It is preferred that the reduction in the mechanical properties of one or more of the materials of the connection means is sufficient to enable disassembly of the article comprising the connection means using an applied force of 20 N or less, more preferably 15 N or less and most preferably 10 N or less. This may be tested according to standard test methods, e.g. EN ISO 13934-2;1999 Grab method for Tensile Strength, EN ISO 13935-1;1999 method for Seam Strength Strip and EN ISO 13935-2;1999 method for Seam Strength Grab method.
[0052] In a preferred embodiment the connection means is selected from materials that exhibit the required reduction in mechanical properties when exposed to a microwave power density of 0.060 w/cm −3 or less, more preferably 0.050 w/cm −3 or less, more preferably 0.047 w/cm −3 or less, more preferably 0.040 w/cm −3 or less, more preferably less than 0.040 w/cm −3 , and most preferably within the range of 0.001 w/cm −3 and 0.04 w/cm −3 . It has surprisingly been found that at such low power densities enough energy may be imparted to facilitate disassembly. This is the case when the one or more connecting means constitute less than 5% by weight, preferably less than 3% by weight, more preferably 2% or less by weight and most preferably between 0.5 to 2% by weight of the total article being disassembled.
[0053] The article disassembly plant of the present invention comprises at least one region for exposure of articles for disassembly to electromagnetic radiation, means for introducing articles to this exposure region and means for extracting exposed articles from the exposure region and is designed to ensure that a requisite and effective dose of electromagnetic radiation is delivered to articles for disassembly passing through the plant. The plant equipment is designed to enable the safe application of electromagnetic radiation to articles especially textile based articles.
[0054] In a preferred embodiment the equipment for exposure primarily comprises a chamber or cavity designed to contain electromagnetic radiation during exposure of the articles for disassembly. In the case of microwave irradiation the chamber is designed through appropriate screening design to ensure that microwave radiation is contained within the chamber and is unable to escape from the chamber and become potentially hazardous to operators of the plant. The equipment also comprises one or more electromagnetic field generators, preferably microwave field generators and associated control electronics under computer and appropriate software control. In addition the equipment may comprise opening doors to access the chamber interior and a system to transport articles into and/or through the chamber. The microwave field generators may be low power preferably 2 kW or less and more preferably 1 kW or less.
[0055] The chamber of the equipment is of sufficient volume to accommodate the required mass of one or more textile items. The required mass is governed in part by the power setting of the equipment, which is tailored to ensure that the required dose of radiation is imparted to the articles in the chamber to enable disassembly.
[0056] The articles for disassembly may be processed through the equipment singularly or in multiples, in bales or in rigid tote bins, flexible bags or other types of container compatible with the electromagnetic i.e. microwave environment. The process may take place in batch, semi-continuous or continuous operation. Preferably, the chamber, which may be an aluminium chamber, features an inner box liner, preferably polymeric in nature e.g. manufactured from polyurethane and sized to accept a particular tote bin pre-existing in the supply chain. The liner separates the working volume of the equipment from the associated technical workings of the chamber, specifically such workings as the mode stirrer and the three microwave apertures. This feature prevents accidental damage occurring to the mode stirrer or the microwave wave guides, as well as preventing dust contamination within the wave guides/microwave apparatus and simplifying general cleaning.
[0057] In a preferred embodiment the article or articles for disassembly contain relatively low levels of moisture before exposure to the electromagnetic radiation e.g. microwave radiation in the disassembly inducing phase of the process. Preferably the article or articles have a total moisture level of 0.1 to 25% by weight of the total weight of articles for disassembly, more preferably 0.1 to 15% by weight of the total weight, more preferably 0.1 to 10% by weight of the total weight, more preferably 0.1 to 5% by weight of the total weight, more preferably 0.1 to 2% by weight of the total weight, more preferably 0.2 to 2% by weight of the total and most preferably 0.4 to 2% by weight of the total weight. Thus in a preferred embodiment the plant or apparatus for implementing the process/system of the present invention further comprises a stage/unit before the exposure region/chamber, which reduces the moisture content of the articles or articles to the desired level for exposure to the radiation. This moisture reduction may be effected by any suitable means of moisture reduction that does not damage the components of the articles. In one embodiment the moisture reduction may be effected in the radiation exposure region or chamber prior to exposure to the radiation. The apparatus of the present invention preferably comprises means for detecting and monitoring the moisture level of the articles for disassembly, means of setting and controlling the moisture reduction stage to achieve the desired moisture level and means for controlling the radiation exposure conditions to effect reduction in the one or more material properties of the connecting means in the articles to be disassembled.
[0058] The openings to the chamber may feature doors to fully seal the opening during the electromagnetic field operation; these doors may be manual, semi-automatic or fully automatic in operation. The physical configuration of these doors and the sequence of their operation may be designed as to allow batch, semi-continuous or continuous operation. In a preferred embodiment on the inner face of the door there is mounted a choke seal to prevent any leakage of microwave fields when the door is closed. To make the choke seal effective while still allowing easy and rapid manual opening and closing of the door, the door is preferably held tightly closed by means of pneumatically actuated clamps, acting across the top and bottom edges of the door. The clamps are automatically activated when the door is pushed closed, as this action engages a pair of safety interlocks, one mounted either end of the door; receiving the engaged signal from both interlocks informs the control system to close the clamps.
[0059] The openings may take the form of an aperture, permanently open but of such a design as to prevent the egress of electromagnetic i.e. microwave radiation during operation of the equipment. Such an arrangement lends itself to a continuous mode of operation of the equipment. The articles may be transferred and transported through the chamber in a continuous manner, a conveyor belt being one method of achieving this.
[0060] The articles may be transported through the chamber by means of manual handling, electrically or mechanically-driven flat bed conveyor belt, vibratory conveyor, suspended from a pulley or chain, mechanically pushed or pulled, gravity fed with a suitable incline, suction or pressure, etc.
[0061] The articles may be stationary or in motion (either rotational or longitudinal) during exposure to the electromagnetic radiation.
[0062] The equipment may incorporate one or more individual electromagnetic radiation sources i.e. microwave sources directing radiation fields into a single chamber through one or more individual ports in the walls of the chamber. Preferably each electromagnetic radiation source comprises a microwave generator sub-assembly comprising an air-cooled magnetron, an electric cooling fan mounted in close proximity to the magnetron, a length of wave guide connecting to the magnetron outlet at one end and featuring a mounting flange at the other, the flange being used to bolt the subassembly to the corresponding flange on the side of the chamber. Also part of the assembly there may be included a circuit board for the local control functions and high voltage connections to the magnetron. Each sub-assembly may be protected in situ by a perforated stainless steel safety cover, this preventing any accidental contact with hot or high voltage elements while still allowing sufficient passage of cooling air around the electrical components. The wave guide exits into the chamber may be positioned in one or more of the side, top or bottom walls of the chamber. In a preferred embodiment the electromagnetic radiation sources and the associated wave guides are arranged such that the electric field direction of the wave guide exits are perpendicular to one another.
[0063] The equipment may also incorporate a mode stirrer. Preferably, this is mounted on the base of the equipment beneath the chamber, its function being to disrupt any standing waves occurring in the chamber by varying the effective internal height of the chamber as the paddle rotates. The mode stirrer paddle is mounted between the chamber's aluminium outface and the inner polyurethane liner. The mode stirrer is ideally driven by an electric motor and gearbox assembly mounted on the outside of the chamber. The mode stirrer preferably rotates sufficiently to move high field areas by more than a quarter wavelength. Preferably this is achieved by a rotating mode stirrer where the movement during the equipment operating cycle is at least π/2 radians. The diameter of the mode stirrer is preferably more than 5% of the length of the shortest side of the base of the microwave chamber.
[0064] The microwave sources preferably impart a power density to the chamber of 0.060w/cm −3 or less, more preferably 0.050 w/cm −3 or less, more preferably 0.047 w/cm −3 or less, more preferably 0.040 w/cm −3 or less, more preferably less than 0.040 w/cm −3 , and most preferably within the range of 0.001 w/cm −3 and 0.04 w/cm −3 .
[0065] The electromagnetic radiation sources may operate either individually in sequence, with one or more operating in parallel or a combination of these states.
[0066] It is preferred that the apparatus control systems operate to deliver an electromagnetic radiation i.e. microwave exposure time of between 0.5 and 1000 seconds, more preferably 0.5 and 700 seconds, more preferably, 0.5 and 500 seconds, more preferably 0.5 and 400 seconds and most preferably 0.5 and 300 seconds.
[0067] The preferred operating temperature within the chamber of the apparatus is within the range of −25° C. to 120° C., and most preferably −18° C. and 100° C.
BRIEF DESCRIPTION OF THE DRAWINGS
[0068] The present invention is exemplified and may be further understood upon reference to the following detailed description when read in conjunction with the accompanying drawing, wherein like reference characters refer to like parts throughout the several views, and in which:
[0069] FIG. 1 A to C are schematic views of various connection means according to the invention before and after exposure to microwave radiation;
[0070] FIG. 2 is a perspective view of an exposure apparatus according to the invention;
[0071] FIG. 3 is a perspective view of an exposure apparatus according to the invention as illustrated in FIG. 1 with exterior panels removed;
[0072] FIG. 4 is a perspective view of an exposure apparatus according to the invention as illustrated in FIG. 2 with the chamber door removed;
[0073] FIG. 5 is a front view of the exposure apparatus according to the invention as illustrated in FIG. 4 with the chamber door removed; and
[0074] FIG. 6 is a perspective view of an exposure apparatus according to the invention as illustrated in FIG. 4 with microwave housings removed.
DETAILED DESCRIPTION
[0075] With reference to FIGS. 1 A-C, various modes of disassembly are illustrated for one embodiment of the invention. In FIG. 1A there is illustrated a textile based article ( 1 ) comprising textile fabric ( 2 ) and a lockstitch with a locking thread ( 3 ) and a bobbin thread ( 4 ). The lockstitch is a connection means according to the invention, which is connecting two textile cloth components although only one is illustrated in the Figure. In this figure the bobbin thread ( 4 ) is susceptible to microwave-induced mechanical degradation, whilst the locking thread ( 3 ) is not susceptible or as susceptible to microwave irradiation. On exposure to microwave radiation the bobbin thread ( 4 ) is degraded by the microwave and the tensile strength of the bobbin thread ( 4 ) is reduced. This reduction in tensile strength of the bobbin thread ( 4 ) results in its failure at or near to ‘X’ when a force is applied to the joined components of the article ( 1 ). The locking thread ( 3 ) remains intact in this embodiment.
[0076] In FIG. 1 B there is illustrated a textile based article ( 1 ) comprising textile fabric ( 2 ) and a lockstitch with a locking thread ( 3 ) and a bobbin thread ( 4 ). The lockstitch is a connection means according to the invention, which is connecting two textile fabric components although only one is illustrated in the Figure. In this figure the locking thread ( 3 ) is susceptible to microwave irradiation, whilst the bobbin thread ( 4 ) is not susceptible or as susceptible to microwave irradiation. On exposure to microwave radiation the locking thread ( 3 ) is heated by the microwave and the tensile strength of the locking thread ( 3 ) is reduced. This reduction in tensile strength of the locking thread ( 3 ) results in its failure at or near to ‘Y’ when a force is applied to the joined components of the article ( 1 ). The bobbin thread ( 4 ) remains intact in this embodiment.
[0077] In FIG. 1 C there is illustrated a textile based article ( 1 ) comprising textile cloth ( 2 ) and a lockstitch with a locking thread ( 3 ) and a bobbin thread ( 4 ). The lockstitch is a connection means according to the invention, which is connecting two textile cloth components although only one is illustrated in the Figure. In this figure the locking thread ( 3 ) and the bobbin thread ( 4 ) are both susceptible to microwave irradiation. On exposure to microwave radiation both threads ( 3 , 4 ) are heated by the microwave and the tensile strength of both threads ( 3 , 4 ) are reduced. This reduction in tensile strength of the threads results in their failure at or near to ‘Z’ when a force is applied to the joined components of the article ( 1 ).
[0078] FIG. 1 C also illustrates what may happen when either of the threads are susceptible to microwave radiation and are heated on exposure to microwave radiation. Here the other thread is not susceptible or as susceptible to microwave radiation. Both threads have point contact with each other on the stitch environment.
[0079] The temperature of the susceptible thread on exposure is such that this heat is also transferred to the microwave resistant thread, which is thermally sensitive and its physical structure is compromised along with that of the susceptible thread.
[0080] In a further embodiment the susceptible thread remains intact and the joint fails through heat transfer from this thread to the thread which is not susceptible and the failure will look schematically similar to that illustrated in FIGS. 1 A and B.
[0081] With reference to FIGS. 2 to 6 an apparatus ( 100 ) according to the invention is illustrated comprising three mains assemblies. The first being the exposure unit ( 101 ) having a microwave chamber ( 102 ), with associated sub-assemblies of; sliding door ( 103 ); door clamping mechanisms (top and bottom) ( 104 , 104 ′); microwave generators ( 105 , 106 , 107 ); microwave mode stirrer ( 109 ). The second being an electrical control and power cabinet (not shown), with associated remote operator control panel. The third being a frame ( 108 ), onto which the microwave chamber ( 102 ) and electrical control and power cabinet are mounted. The frame ( 108 ) features; locking castors (not shown) for ease of movement on site; and safety panels to prevent accidental contact with moving or live electrical components.
[0082] The microwave chamber ( 102 ) consists of an aluminium box, which is closed on five faces, with the open side being the means to place articles within the chamber ( 102 ). The chamber ( 102 ) is designed to prevent the leakage of microwave radiation during operation; there are no gaps at the edges of the faces. Located within the chamber ( 102 ) is an inner box liner ( 120 ) manufactured from polyurethane.
[0083] On three of the closed chamber faces (specifically both ends and the top face ( 110 , 111 , 112 )) there is a rectangular aperture (only two illustrated 113 , 114 ) and corresponding flange onto which is bolted a microwave generator sub-assembly (not shown). The two opposing apertures are orientated with the 2 nd aperture rotated 90 degrees compared to the first, to introduce microwaves oscillating in both the X and Z-axis. The top mounted sub-assembly ( 112 , 114 ) provides microwaves in the Y-axis, ensuring that the articles in the chamber ( 102 ) are fully immersed in the microwave field, irrespective of their position within the chamber ( 102 ).
[0084] The chamber ( 102 ) is sealed by a sliding door assembly ( 103 ). The aluminium plate door ( 115 ) is mounted on runners ( 116 ), running across the top and bottom front edges of the chamber. Roller bearing assemblies (not shown) on the top and bottom edges of the door locate in tracks machined into the runners. Bump stops (not shown) at both extremities of the travel control the range of door movement.
[0085] Mounted on the inner face of the door is a choke seal (not shown) to prevent any leakage of microwave fields when the door ( 115 ) is closed.
[0086] The exposure process for treatment of garments to facilitate garment disassembly, can be either continuous or batch. In the former method, the assembled articles pass through an electromagnetic field (preferably a microwave field), by means of a conveyor system. The speed should be adjustable to ensure that the product will exit the field within 0.5 and 1000 seconds, preferably within 0.5 and 700 seconds, more preferably within 0.5 and 500 seconds, more preferably 0.5 and 400 seconds and most preferably within 0.5 and 300 seconds. The actuator should be designed accordingly to ensure that the size of the gap between the conveyor belt and the actuator has sufficient size for the products to pass through to the electromagnetic field, while, ensuring that there is no radiation leak that could affect personnel's health and safety. In the latter method, the actuator will have a door that can be opened manually. The products will be placed in a basket and then to the actuator. The actuator will be activated only when the door is closed and for similar time length as mentioned above. Following this process, the door will be opened and the basket containing the disassembled products will be removed.
EXAMPLES
Example 1
[0087] Various samples of embroidered logos, sewing yarns and backing fabric were obtained from Mathias & Sons Ltd. A yarn blend of Kevlar®/Acrylic and 50 micron steel wire (Dualtec® AISI 304L) was supplied by Saveguard Ltd, UK. Various article arrangements were prepared with this yarn and other yarns and the samples were subsequently exposed to microwave radiation in a microwave oven, (model Cookworks MM717CKA 700 Watt). The samples and conditions are as follows:
a) Metallic yarn, Dualtec AISI 304L was passed through an embroidered logo from rear side using hand stitching needle. The sample was exposed to microwaves for 10-20 seconds. b) Fabric sample sewn using a lockstitch with Dualtec AISI304L50 (incorporates 50 ∥m diameter steel yarn) as the understitch and 100% PET sewing yarn as the upper thread. This sample was exposed to microwaves for 5 seconds. c) Backing fabric lock stitched using Dualtec AISI304L50 as the understitch and 100% PET sewing yarn as upper thread. This sample was treated with microwaves for 5 seconds. d) Embroidery was performed using metallic yarn as bobbin thread and viscose sewing thread as embroidery thread. The sample was exposed to microwave for 5-10 seconds. e) Embroidery was performed using metallic yarn as bobbin thread and polyester sewing thread as embroidery thread. The sample was exposed to microwave for 5-10 seconds.
[0093] In all of the samples a) to e) the stitched joint or embroidery failed on exposure of the article to microwaves, however the components or the articles suffered severe heat damage and discoloration from the exposure due to the decomposing metal based yarn. These article components were unsuitable for reuse due to this damage.
Example 2
[0094] A commercially available yarn, Thunderon®, (Nihon Sanmo Dyeing Co., Ltd), was used to form a stitch based connection means for various textile based articles. Thunderon® is an acrylic or polyamide fibre or filament that contains a chemically bonded layer of copper sulphide. The fibre diameter is ˜4 μm, the thickness of its conductive layer is 300-1000 Å (angstroms) and it has a specific resistivity of 10 −2 -10 0 Ω.cm. A 110 dtex polyamide Thunderon® yarn was used as the bobbin thread in 301 lock stitch and 406 construction cover stitch to manufacture various garments, such as shirts, trousers, T-shirts, and jackets.
[0095] The prepared samples with interlock and overlock seams produced with
[0096] Thunderon® monofilament yarn had similar seam strengths to samples stitched with standard threads. The seam strength of seams containing Thunderon® yarn was similar to the standard samples. Five shirts and five pairs of trousers were successfully produced using commercial garment assembly techniques. Thunderon® thread was used as a bobbin thread in lockstitch seams and as a looper thread in chainstitch seams. Buttons, tags, pockets and zips were also sewed on the garments without any difficulties. Seam strength was sufficient for all the samples.
[0097] The garments were placed in a domestic microwave oven for 10 s, which caused the mechanical failure of all the textile joints of the garments without damage or discoloration to the garments. When the Thunderon® yarn was used only in the stitching of pockets on to base garments, these pockets could be readily removed after microwave irradiation with no signs of thermal damage to the underlying fabric.
[0098] In addition, metal zips and other metallic accessories that had been sewn in to the garment could be readily removed. No arching was observed during microwave irradiation, partly because of the short exposure time of 10 s.
Examaple 3
[0099] A metallised embroidery and decorative thread from Madeira UK Ltd, FS No. 50, was used as in example 1 with similar results. This 2-ply thread consisted 45% of Polyamide filament and 55% of a metallised polyester foil. Overlock stitch samples were also prepared that are commonly used in garment production using Madeira metallised thread FS 50. Samples with buttons were also prepared. Microwave testing for durations of ≦10 seconds led to a decrease in the detachment force (seam strength) of over 80% enabling the fabric pieces to be readily separated manually. There was no significant thermal damage and discoloration to the articles.
Example 4
[0100] Polyamide multifilament yarns containing a layer of copper sulphide were obtained with linear densities of 121 dtex/24F (filaments) and ca. 110 dtex/24F.
[0101] The specific resistance of these yarns was ca. 10 −1 -10 −2 Ω.cm and the filament tenacity was ca. 4.5 g/den (grams per denier). The yarn strength enabled these yarns to be utilized directly in sewing operations without end breakages. However, to facilitate high speed sewing or embroidery operation as well as provide a means of modifying the colour and appearance of the yarn, plied yarn assemblies were constructed. Using a hollow spindle up-twisting machine the 110 dtex/24F yarn was twisted with a 50 dtex textured polyester yarn in both the S-direction and Z-direction to produce a double-covered yarn assembly of balanced twist. A yarn linear density of 50 dtex was approximately the minimum required to satisfactorily disguise the core yarn component during the twisting operation. Thus, by twisting two or more additional yarns around the polyamide multifilament yarn containing a layer of copper sulphide, the filaments could be mechanically protected from subsequent abrasion and hidden from view, such that the colour, handle, appearance, softness and general aesthetics of the yarn were dependent on the yarns twisted around it. A particularly suitable construction for sewing thread use was produced by twisting at least two additional yarns composed of cotton around a Thunderon 110 dtex/24F polyamide multifilament yarn containing a layer of copper sulphide such that this yarn became a core hidden by the two or more yarns twisted around it. The linear density and number of covering yarns employed influences the extent to which the core is disguised. As a result of covering the core with yarns containing cotton, the resulting yarn surface was soft and hydrophilic as was suitable for yarn colouration or chemical finishing. Additionally, yarn strength exceeded 4.5 g/den with an elongation at break between 12-24% depending on twist level facilitating its use in sewing and embroidery operations.
[0102] Each of the filament samples and yarns were exposed to microwave energy operating at domestic wavelength and at power of 700 W for a duration of 10 s and were found to be subject to a reduction in tensile strength of >90%. The yarns having the lowest linear densities (g/1000 m) were found to produce the lowest residual breaking loads, and therefore enabled the largest decreases in seam strength after microwave exposure at domestic frequency for ≦10 seconds.
[0103] Garments manufactured with the cotton yarn covered polyamide multifilament containing copper sulphide thread were found to be more comfortable to users than those manufactured without the cotton yarn cover. Additionally, the cotton component could be dyed (prior to or after combination with polyamide multifilament containing copper sulphide thread) to match the base colour of the underlying fabric.
[0104] All of the features disclosed in this specification for each and every embodiment and arrangement (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.
[0105] Each feature disclosed in this specification (including any accompanying claims, abstract and drawings), may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
[0106] The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed. | There is described a system, article, method, connectors and apparatus for article reuse or recycling, which system including the assembling of an article from at least two components at least one of which has a textile material brought into communication with each other through one or more connectors and the subsequent disassembling of the article and use of one or more of the components in the assembling stage. The assembled article is susceptible to automatic or semi-automatic disassembly through one or more of its connectors being susceptible to a reduction in one or more mechanical properties under exposure of the article to electromagnetic energy especially microwave. The article may be a garment that has joins stitched with a microwave susceptible yarn. The yarn is ideally manufactured from pseudo-conductive materials and is metal free. | 8 |
[0001] This application is a national stage completion of PCT/FR2008/000724 filed on May 28, 2008 which claims priority from French Application No. 07/03779 filed on May 29, 2007.
TECHNICAL DOMAIN
[0002] The present invention concerns a device for handling a load such as a sheet iron coil comprising a holder capable of supporting the load, the holder moving rotationally on a frame between at least a first position in which the axis of the load is vertical, called the vertical axis position, and a second position in which the axis of the load is horizontal, called the horizontal axis position.
PRIOR ART
[0003] In the field of metallurgy, strip steel, sheet iron and so forth packaged on reels called “coils” are used to feed production lines for metal pieces obtained by cutting, stamping, shaping, etc. These production lines are supplied by reels located at the head of the line to which the coils are transported by chucks with horizontal axes in most cases. Reels less than 500 mm wide are stacked, separated by support beams, and arranged in circles on pallets or the like for storage and transportation with the coil axes vertical. Consequently, it is necessary to lift each coil and tilt or pivot it a quarter turn before it can be loaded onto a reel so as to change the position of its axis from vertical to horizontal.
[0004] This is a relatively dangerous operation. At the present time it is accomplished in different ways:
[0005] By suspending each coil from a hook at the end of a sling supported by a moving crane;
[0006] By turning over each coil with the fork of a forklift (a very dangerous operation);
[0007] By tilting the unit consisting of the pallet and the stack of coils on a machine equipped with a ferrule or turning bracket called a “tilting device,” which is a very large and expensive machine. The major disadvantage to this solution is that it requires turning over the entire stack of coils, whereas only one coil or a portion of it may be required for production.
[0008] U.S. Pat. No. 4,322,198 proposes an automated solution which uses a bent rotating arm to change the position of the axis of the coil of metal supported by the arm. U.S. Pat. No. 3,395,813 proposes another automated solution using the weight of the coil to tilt a holder from a vertical axis position to a horizontal axis position, and maintaining it in that position controlled by an actuator.
[0009] Whatever the means used to turn the coil, the equipment or machines used are utilized uniquely for that operation. Once turning has taken place, it is necessary to load the reel. This complementary operation consists of taking up the coil so that its axis is horizontal, positioning it, and engaging it on the chuck of the reel at a point beyond the mid-point of the chuck jaws before depositing it.
[0010] Therefore, current solutions are incomplete and unsatisfactory, particularly from the point of view of operator safety. This problem exists in other technical domains such as the paper industry, plastics industry, etc., where materials are packed on coils or similar devices and the products to be handled are heavy.
DESCRIPTION OF THE INVENTION
[0011] The present invention proposes a solution to the problem at hand with a handling device that is simple, economical, compact, reliable and secure, versatile, allows each coil to be turned individually, and combines the turning operation with the operations of loading and unloading any type of reel.
[0012] For this purpose, the invention concerns a handling device of the type indicated and characterized in that the frame is connected to a drive means allowing it to move so it is able to load and/or unload the load on another machine, such as a reel, and in that the support comprises a means of maintaining and positioning the load that grips the load while it changes position and deposits or takes up the load onto or from another machine.
[0013] According to variations of the invention, the rotational axis of the holder on the frame may be offset relative to the center of gravity of the holder including the load, the holder being designed to turn under the effects of gravity in a rotational direction that changes it from a vertical axis position to a horizontal axis position. In this case, turning the load in at least one direction of rotation is accomplished without using additional energy.
[0014] According to other variations of the invention, the axis of rotation of the holder on the frame may generally coincide with the holder's center of gravity inclusive of the load. In this case, the device advantageously comprises an additional driving means connected to the frame to turn it from its vertical axis position to its horizontal axis position and conversely.
[0015] In another variation, the frame may move translationally along guide rails and the drive means may comprise at least one actuator connected to the frame by a transmission.
[0016] The drive means is advantageously connected with the holder in order to turn it in the reverse direction of rotation so it passes from its horizontal axis position to its vertical axis position; this means may comprise a prop extending from a stop integral with the guide rails and an articulation integral with the holder opposite the axis of rotation.
[0017] In another embodiment, the actuation means may comprise a ramp with a fixed cam with a roller circulating on it that is integral with the holder opposite the rotational axis.
[0018] The guide rails are advantageously disposed in the extension of a reel and the actuation means, in this case, displaces the frame along a supplemental course for loading and unloading the reel when the holder is in horizontal axis position.
[0019] Preferably, the frame comprises a stop defining the holder's horizontal axis position.
[0020] The cam ramp may comprise a first inclined portion corresponding to the path of the frame while the holder rotates and a second horizontal portion corresponding to the supplemental loading and/or unloading path of the reel.
[0021] In another variation, the frame may be installed on a moving device that constitutes the drive means, and may comprise a lifting device for moving the frame upward.
[0022] The means of holding and positioning the load on the holder preferably moves in radial and/or axial translation and it may comprise a hook that contacts the interior bore in the load or a bed that contacts the exterior of the load.
[0023] The holder advantageously comprises a central opening to be traversed by the chuck of a reel during the operations of loading and unloading the load.
SUMMARY DESCRIPTION OF THE DRAWINGS
[0024] The present invention and its advantages will be more readily apparent from the following description of several embodiments provided as non-limiting examples, with reference to the attached drawings, wherein:
[0025] FIG. 1 is a perspective view of a first embodiment of a handling device according to the invention;
[0026] FIGS. 2A through 2C are side views of the device of FIG. 1 respectively in the horizontal axis position, in the intermediate position, and in the vertical axis position;
[0027] FIGS. 3A-3D are detailed views of four variations of the positioning means provided on the device of FIG. 1 ;
[0028] FIGS. 4A through 4D are schemas of a variation of the device of FIG. 1 showing the four operational sequences involved in loading a coil onto the reel;
[0029] FIGS. 5A through 5D are schemas of another variation of the embodiment of FIG. 1 showing the same operational sequences as FIGS. 4A through 4D ;
[0030] FIGS. 6A through 6D are schemas of a second form of embodiment of the device of FIG. 1 showing the same operational sequences; and
[0031] FIGS. 7A and 7B are perspectives of an indexing station for two coils respectively in the waiting position and during the loading process.
ILLUSTRATIONS OF THE INVENTION AND VARIOUS EMBODIMENTS
[0032] FIGS. 1 and 2 illustrate a first embodiment of a handling device 30 according to the invention designed to tilt a load C for a quarter turn and to also effect the loading and/or unloading of this load C onto another machine such as a reel D equipped with a chuck M for receiving load C. This load C may be a coil of sheet metal as shown in the drawings, deposited by a forklift or similar device, for the purpose of supplying a reel located at the head of a production line, or a partial coil of sheet metal to be removed from the reel. This load C may also consist of a stack of sheet iron coils as shown schematically in FIG. 3D for supplying a reel, the coils being deposited one after the other.
[0033] The handling device 30 comprises a frame 31 moving in translation along guide rails 313 attached to the floor in the axis of reel D, the frame being connected to a drive means 35 . It comprises a pedestal 310 equipped with a roller device housed in guide rails 313 , surmounted by a bracket 311 supporting at its free end a platform 312 defining rotational axis A. Frame 31 holds a holder 32 for receiving a load C such as a coil of sheet iron or the like. This holder 32 comprises a frame or similar piece rotationally movable about axis of rotation A between at least a vertical axis position V and a horizontal axis position H, and vice versa. Axis of rotation A in this example is offset from the center of gravity G of holder 32 such that turning holder 32 in clockwise direction R so it passes from its vertical axis position V to its horizontal axis position H is generated by the weight of load C on holder 32 by the pull of gravity G. This mechanism is not reversible, as turning in the opposite or counterclockwise direction R′ is generated by a driving means 35 detailed below.
[0034] Driving means 35 comprises an actuator 350 such as a reduction motor or similar means connected to frame 31 by a transmission such as a chain/pinion system 351 with the chain circulating in a closed loop within U-shaped guide rails 313 , although any other known system may also be used. It also comprises a prop 352 extending between a fixed stop 353 integral with guide rails 313 and an articulation 354 integral with holder 32 opposite the axis of rotation A. This prop 352 ensures that holder 32 is locked in position and it also drives the holder 32 to rotate in a counterclockwise direction R′ causing it to pass from its horizontal axis position H to its vertical axis position V as shown in FIGS. 2A through 2C .
[0035] The operation of handling device 30 is explained with reference to FIGS. 2A through 2C in which the device is shown empty. In the position shown in FIG. 2C , handling device 30 is awaiting a load C; it is distanced from reel D and holder 32 is in the vertical axis position V. When a load C is deposited on holder 32 , the holder remains blocked in its vertical axis position V by virtue of prop 352 contacting fixed stop 353 . Engaging actuator 350 displaces frame 31 towards reel D and allows holder 32 to rotate due to the pull of gravity G. Articulation 354 on prop 352 describes an arc in counterclockwise direction R centered on fixed stop 353 until holder 32 attains the horizontal axis position H shown in FIG. 7A defined by a stop 314 located on frame 31 in which load C faces reel D. This first portion of the course taken by frame 31 is called the approach course L 1 . From this position, frame 31 continues its displacement toward reel D, driving with it prop 352 , the base of which circulates in guide rails 313 as far as a block 355 at the end of the course that stops actuator 350 and defines the loading and/or unloading position of reel D. This second portion of the course taken by frame 31 is called the loading course L 2 . Load C can be transferred from holder 32 to chuck M as explained below.
[0036] Returning handling device 30 to its initial position illustrated in FIG. 2C is accomplished by reversing the rotational direction of actuator 350 to drive frame 31 in the opposite direction from reel D. Frame 31 retreats along course L 2 driving prop 352 to its fixed stop 353 (cf. FIG. 2A ). At this stage frame 31 pursues displacement opposite reel D and prop 352 causes holder 32 to rotate on its rotational axis A in counterclockwise direction R′ (cf. FIG. 2B ) to pass from its horizontal axis position H to its vertical axis position V (cf. FIG. 2C ).
[0037] Handling device 30 comprises a means 36 for maintaining and positioning load C on holder 32 to eliminate any risk of load C falling and to ensure its alignment with chuck M on reel D that will be loaded. For this purpose, holder 32 is preferably drilled to allow chuck M to pass through the holder 32 . In the examples shown holder 32 consists of a frame defining a central opening 33 large enough to receive chuck M; in the example in FIG. 3A , the maintenance and positioning means 36 are shaped like a hook 360 that contacts the interior bore in load C. The hook 360 slides along holder 32 and its radial position can be adjusted using threaded rods 361 that allow the axis of load C to be aligned with the axis of chuck M on reel D. Consequently, this adjustment is performed at the time handling device 30 is put into service. In this case, reel D is equipped with an automatically expanding chuck M and the jaws of chuck M are disposed so as to form a passageway P (cf. FIG. 1 ) for hook 360 while reel D is being loaded and unloaded.
[0038] If reel D is equipped with a manual expansion chuck M, the hook 360 must move in radial translation on holder 32 , for example, through the action of cylinders 362 , as illustrated in FIG. 3B . This radial translation allows load C to be vertically deposited on the jaws of chuck M.
[0039] If chuck M on reel D does not permit hook 360 to pass through, then a positioning means 36 is designed to contact the exterior of load C, perhaps using a bed formed of contact rods 363 , a V-shaped contact, or similar device. In this case the positioning means 36 also moves in radial translation on holder 32 , for example, through the action of cylinders 364 in order to adapt to the exterior diameter of load C.
[0040] Handling device 30 , according to the invention, can also be designed to turn a load C consisting of a stack of several coils of sheet iron C 1 , C 2 , C 3 , Cn, however they are packaged, as shown in FIG. 3D . In this example, the positioning means 36 move radially on holder 32 through the action of cylinders 364 and support the exterior diameter of load C using axially movable contact arms 365 . Contact arms 365 move axially so as to permit one single coil C 1 at a time to be deposited on chuck M of reel D. In a variation, the positioning means 36 may also support load C through its interior bore as in the examples of FIGS. 3A and 3B , and in this case, hook 360 also moves axially.
[0041] Other mechanisms may also be used associated with the drive means 35 to ensure displacement of frame 31 in two steps L 1 and L 2 , the first step L 1 corresponding to the approach course in which holder 32 is turned for a quarter turn to place the axis of load C in horizontal position aligned with the axis of chuck M of reel D, and the second step L 2 corresponding to the loading course loading load C on reel D. An example is shown schematically in FIGS. 4A through 4D , using a fixed cam ramp 356 along which a roller 357 or similar element circulates integral with holder 32 opposite rotational axis A. Cam ramp 356 comprises a first inclined portion corresponding to course L 1 during which frame 31 is displaced translationally toward reel D and holder 32 moves from its vertical axis position V to its horizontal axis position H (cf. FIGS. 4A and 4B ), followed by second horizontal portion corresponding to course L 2 during which frame 32 pursues translational displacement to place load C at a right angle to chuck M. of reel D (cf. FIGS. 4C and 4D ). FIG. 4D illustrates how handling device 30 of the invention allows reel D to be loaded without resorting to other handling equipment, thanks to holder 32 which allows chuck M to pass through its central opening 33 in order to deposit load C therein when chuck M is extended.
[0042] FIGS. 5A through 5D illustrate another variation of the handling device 30 of the invention in which rotational axis A of holder 32 generally coincides with the center of gravity G of the supplemental holder 32 for load C, and in which tipping the holder 32 between its vertical axis position V and its horizontal axis position H and vice versa is accomplished using an additional drive means 37 . This means comprises an actuator 370 such as a motor, a reduction motor, a cylinder connected either directly or through a rack and pinion or similar mechanical transmission to a drive shaft that coincides with rotational axis A. The vertical axis position V and horizontal axis position H are defined either by programming actuator 370 or by the course limits located on frame 31 and not shown. In this variation, frame 31 is attached to a moving device 38 and connected to reel D by rails or telescoping guides 380 which define the courses L 1 and L 2 followed by handling device 30 that are necessary for loading and unloading reel D. Naturally the displacement of frame 31 is controlled by actuator 350 and any type of mechanical transmission connected to the rails or telescoping guides 380 . Just as in the preceding embodiments, holder 32 comprises a central opening 33 for the passage of chuck M while reel D is being loaded, as well as a maintenance and positioning means 36 for load C, for example, in the shape of a radially adjustable hook 360 .
[0043] FIGS. 6A and 6D illustrate a second embodiment of a handling device 40 according to the invention in which frame 31 is on a mobile device 41 maneuvered by an operator, the mobile device 41 constituting the drive means for the frame 31 and offering the advantage of not being dedicated to one particular reel D, but capable of supplying different reels D with the same device. Frame 31 is similar to the preceding example and it also comprises a supplemental drive means 37 to turn holder 32 from a vertical axis position V to a horizontal axis position H and vice versa. Holder 32 is also like the preceding examples in that it comprises a central opening 33 for the passage of chuck M and a means 36 for maintaining and positioning load C. Mobile device 41 comprises vertical guide columns 410 or similar elements inside or upon which frame 31 and lifting means 411 slide, for example, in the form of cylinders, to displace frame 31 vertically and be able to position holder 32 relative to the axis of chuck M of a given reel D. This design allows handling device 40 to be versatile and adaptable to various types of reels D.
[0044] In this second embodiment it is possible to have indexing stations 50 near reels D (cf. FIGS. 7A and 7B ) to collect at least two coils C waiting alongside each other in vertical axis position to be lifted by handling device 40 : for example, one full coil waiting to be loaded onto reel D and one partial coil coming off reel D. This indexing station 50 comprises a receiving platform 51 supported by feet 52 . In the example shown receiving platform 51 comprises at right angles to each coil C a central opening 53 to allow holder 32 on handling device 40 to pass below coil C. Similarly, feet 52 define at right angles to each coil C an index housing 54 for receiving the feet of mobile device 41 in order to load a waiting coil. In this case, lifting means 411 of holding device 40 allows holder 32 to be lowered below the coil C that will be taken up.
[0045] Obviously, the exemplary embodiments in FIGS. 5 and 6 may comprise a holder 32 similar to the embodiments in FIGS. 1 through 4 with its center of gravity offset relative to rotational axis A in order to eliminate any additional drive means 37 .
[0046] It is clear from this description that the invention attains its stated objectives, that is, simple, economical, secure, and versatile handling devices that perform both the operations of loading and unloading one or more reels, as well as turning load C.
[0047] The present invention is not limited to the exemplary embodiments described, but extends to any modification and variation evident to a person skilled in the art while remaining within the scope of protection defined in the attached claims. | A device ( 30 ) for handling a load (C) such as a sheet iron coil comprises a holder ( 32 ) capable of carrying the load (C). The holder ( 32 ) is able to be rotated on a frame ( 31 ) between a first position, in which the axis of the load (C) is vertical, and a second position, in which the axis of the load (C) is horizontal. The frame ( 31 ) of the device ( 30 ) is coupled to a driving assembly ( 35 ) so as to be mobile in order to load and unload the load (C) on a reel (D). The holder ( 32 ) includes a mechanism for maintaining and positioning ( 36 ) the load (C), retaining the load (C) during a change of the position of the load, and depositing the load on and/or removing the load from the reel (D). | 1 |
RELATED APPLICATIONS AND PRIORITY CLAIM
[0001] The subject invention claims the benefit of and priority to U.S. Provisional Application No. 60/961,861, filed Jul. 24, 2007 which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This subject invention relates to armor.
BACKGROUND OF THE INVENTION
[0003] Armor configured to be added to a structure such as a vehicle is well known. The applicant hereof invented the idea of ceramic armor tiles removably attached to the outside of a vehicle. See U.S. Pat. Nos. 4,928,575 and 5,191,166 incorporated herein by this reference.
[0004] Typically, for armor inside of the vehicle, a flexible spall barrier or liner is used. See U.S. Pat. Nos. 5,170,690 and 5,333,532 incorporated herein by this reference.
[0005] Sometimes, for certain structures facing specific threats, armor on the outside of the structure is not possible or desirable and/or a flexible spall barrier or liner on the inside of the structure does not provide sufficient protection.
[0006] U.S. Pat. No. 4,664,967 discloses a more rigid spall liner with layers of fabric and steel. Published Patent Application No. 2003/0192426 discloses armor panels including ceramic designed to be placed on the inside of a vehicle door. See also published Patent Application No. 2007/0113729 and DE 3226476. All of these references are incorporated herein by this reference.
[0007] Despite the state of the art in armor design, a need still exists for a suitable armor system which can be placed on the inside of a structure for protecting the same from different threats.
BRIEF SUMMARY OF THE INVENTION
[0008] It is therefore an object of this invention to provide a new armor system for the interior of a structure.
[0009] It is a further object of this invention to provide such an armor system which is easily installed and removed without modification of the parent (existing) structure.
[0010] It is a further object of this invention to provide such an armor system which adequately protects against a number of different threats.
[0011] It is a further object of this invention to provide such an armor system which is easier to handle and transport.
[0012] It is a further object of this invention to provide such an armor system which is easier and less expensive to manufacture.
[0013] The subject invention results from the realization, in part, that, in one example, a better armor system for the interior of a structure such as a ground vehicle, aircraft, or watercraft includes suitable armor materials spaced from the interior of the structure by a spacer layer and all encapsulated in a polyurea/polyurethane coating resulting in panels which are easier to handle, transport, and install since hook and loop fasteners are used on the inside of the structure and on the panels. In one embodiment, the armor materials include a ceramic layer and one or more ballistic layers. In another example, the armor materials include ballistic layers but no ceramic.
[0014] The subject invention features an armor system for the interior of a structure to be protected. The typical system includes releasable fastener material secured to an inside wall of the structure and at least a first armor panel. One preferred panel includes an optional spacer layer, a ceramic hard face layer behind the spacer layer, ballistic material behind the ceramic hard face layer, an encapsulant about the spacer layer, the ceramic hard face layer, and the ballistic material, and releasable fastener material on the encapsulant adjacent the spacer layer for mating the panel to the inside wall of the structure.
[0015] In one example, the spacer layer includes foam and the ceramic hard face layer includes an aluminum oxide ceramic material. The ballistic material may include a composite laminate such as plies of aramid fibers. In one example, the ballistic material includes a thermoplastic matrix material or high performance and high molecular weight polyethylene. The typical encapsulant includes a polyurea/polyurethane. The typical releasable fastener material includes hook and loop fasteners.
[0016] The armor system may also include a second armor panel and a joint between the first armor panel and the second armor panel. In one example, the first panel includes a lap portion and the second panel includes a tongue portion receivable over the lap portion of the first panel. The lap portion of the first panel typically includes an edge without the spacer layer. The tongue portion of the second panel typically includes a ceramic layer and a ballistic layer. In another example, the first panel and the second panel include lap portions and the system further including a tongue member bridging the lap portions of the first and second panels. The lap portion of each panel includes an edge without a spacer layer and preferred tongue member includes a ceramic layer and a ballistic layer.
[0017] An armor panel in accordance with the subject invention includes an optional spacer layer, a ceramic hard face layer behind the spacer layer, ballistic material behind the ceramic hard face layer, an encapsulant about the spacer layer, the ceramic hard face layer, and the ballistic material, and releasable fastener material on the encapsulant adjacent the spacer layer for mating the panel to an inside wall of a structure.
[0018] Another armor panel in accordance with the subject invention includes an optional spacer layer, ballistic material behind the spacer layer, an encapsulant about the spacer layer and the ballistic material, and releasable fastener material on the encapsulant adjacent the spacer layer for mating the panel to an inside wall of a structure.
[0019] The subject invention also features a method of making an armor panel. In one example, a ceramic hard face layer is assembled on ballistic material, an optional spacer layer is assembled on the ceramic layer, and an encapsulant is sprayed about the layers to form a panel.
[0020] One method of protecting a structure features securing releasable fastener material to an inside wall of the structure, supplying an armor panel including an optional spacer layer, a hard face absorber layer behind the spacer layer, ballistic material behind the hard face absorber layer, an encapsulant about all the layers, and a releasable fastener material on an encapsulant adjacent the spacer layer, and mating the releasable fastener material on the panel to the releasable fastener material on the structure to secure the panel to the inside wall of the structure.
[0021] Another method of making an armor panel includes assembling an optional spacer layer on ballistic material and spraying an encapsulant about the spacer layer and the ballistic material to form a panel.
[0022] The subject invention, however, in other embodiments, need not achieve all these objectives and the claims hereof should not be limited to structures or methods capable of achieving these objectives.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0023] Other objects, features and advantages will occur to those skilled in the art from the following description of a preferred embodiment and the accompanying drawings, in which:
[0024] FIG. 1 is a schematic side view of a typical army vehicle with one or more door panels which may be protected via the armor panels of the subject invention;
[0025] FIG. 2 is a highly schematic cross-sectional side view showing an armor panel in accordance with the subject invention releasably attached to the interior of the door of the military vehicle shown in FIG. 1 ;
[0026] FIG. 3 is a highly schematic three-dimensional cut-away view showing the primary components associated with a typical armor panel in accordance with the subject invention; FIG. 4 is a schematic cross-sectional view showing two armor panels in accordance with the subject invention and a half lap joint therebetween;
[0027] FIG. 5 is a schematic cross-sectional view also showing two adjacent panels in accordance with the subject invention and a different kind of protected joint between the panels; and
[0028] FIG. 6 is a schematic cross-sectional view showing the primary components associated with an example of another embodiment of an armor panel in accordance with the subject invention.
DETAILED DESCRIPTION OF THE INVENTION
[0029] Aside from the preferred embodiment or embodiments disclosed below, this invention is capable of other embodiments and of being practiced or being carried out in various ways. Thus, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings. If only one embodiment is described herein, the claims hereof are not to be limited to that embodiment. Moreover, the claims hereof are not to be read restrictively unless there is clear and convincing evidence manifesting a certain exclusion, restriction, or disclaimer.
[0030] FIG. 1 shows one of many structures that may be protected by the armor system of the subject invention. The interior of the door panels of this military vehicle may be protected by the armor system hereof and so too may the floor, sides, rear and ceiling, if desired. Other structures to be protected by the subject invention include aircraft, vessels, and even fixed structures such as command centers, bunkers, barracks, and check stations. Typically, the armor panels are manufactured to match the overall shape of the interior of a structure. For example, one armor panel may be configured in the same shape as the interior of door 10 of vehicle 12 while another may be manufactured in general shape of a seat cushion or a floor area, or the like.
[0031] In FIG. 2 , wall 10 represents the door of the vehicle or some other portion of a structure. Releasable fastener material such as hook and loop fastener structure (e.g., the well-known material manufactured under the Velcro® brand name) of a first type (e.g., hooks) 14 a is secured (using an adhesive, a tape, or a glue) on the interior of door 10 . Hook and loop fastener material of a second type (e.g., loops) 14 b is on armor panel 16 a (again, using a tape, glue, or adhesive). In this particular example, as also shown in FIG. 3 , panel 16 a includes optional spacer layer 20 (e.g., open faced Elliot P300 foam), ceramic hard face layer 22 (e.g., a layer of aluminum oxide ceramic material), and ballistic material 24 . Ballistic material 24 may include plies of aramid or aromatic polyamide fibers, such as KEVLAR® aramid consolidated within a thermoset or thermoplastic matrix material. The ballistic material may also be high performance and high modulus polyethylene such as DYNEEMA® or Spectra Shield®, or other high strength ballistic fiber material in consolidated or unconsolidated (soft) form.
[0032] Irrespective of the internal construction of the armor panel, it is preferred that the individual components are secured together in a panel form by encapsulant 26 which is typically sprayed about the top, bottom, and sides of the lay-up completely covering it. In one embodiment, a grey polyurea/polyurethane material sold under the commercial name “Line-X” was used. This material is typically used to coat and protect the bed of a pick up truck. Other hardenable polymers may also be used.
[0033] In one 2′×2′ test panel, foam layer 20 was 1 inch thick, ceramic layer 22 was 16 mm thick, and ballistic material 24 was ½ inch thick. The grey encapsulant material was sprayed on to a thickness of 0.06 inches.
[0034] Sometimes, more than one panel is used to protect an interior wall or portion of a structure. FIG. 4 shows two panels 16 a and 16 b and one example of a joint 40 therebetween. First panel 16 a includes lap portion 42 and second panel 16 b includes tongue portion 44 received on lap portion 42 . In one particular example, lap portion 42 includes an edge of panel 16 a without foam layer 20 . Tongue portion 44 of panel 16 b includes ceramic layer 50 and ballistic material 52 . Again, all the layers are encapsulated in material 26 . Ceramic layer 50 may be 0.5 inches thick and ballistic material 52 may be 0.5 inches thick.
[0035] FIG. 5 shows two adjacent panels 16 a and 16 b in another example where both of the panels include an edge lap portion where an edge of each panel is devoid of foam layer 20 . Separate tongue member 60 is located so it bridges the lap portions of panels 16 a and 16 b as shown. Tongue member 60 may include ceramic layer 50 and ballistic material 52 encapsulated within polyurea/polyurethane layer 26 . Tongue member 60 can be secured to the panels 16 a and/or 16 b using an adhesive or hook and loop fasteners if desired. Also, separable fastener structure such as hook and loop fastener material 14 b can be added to tongue member 60 as shown.
[0036] In another example, panel 16 ′, FIG. 6 includes optional spacer layer 20 (e.g., foam) and ballistic material 24 encapsulated within polyurea/polyurethane coating 26 . Again, hook and loop fastener material 14 b is typically used to secure panel 16 ′ to the interior of a structure. In one specific test panel, foam layer 20 was 1.0 inches thick and ballistic material 24 included a high modulus polyethylene (DYNEEMA®) 1.0 inches thick.
[0037] The result, in any embodiment, is an armor system for the interior of a structure which is easily installed and removed and yet still provides adequate protection against a number of different types of threats. Due to the panel configuration of the armor system, a number of panels which could completely line in the interior of a structure are easier to handle and transport. The use of the encapsulation spray-on coating provides structural integrity to the panel while also making the panels less expensive and easier to manufacture.
[0038] Although specific features of the invention are shown in some drawings and not in others, this is for convenience only as each feature may be combined with any or all of the other features in accordance with the invention. The words “including”, “comprising”, “having”, and “with” as used herein are to be interpreted broadly and comprehensively and are not limited to any physical interconnection. Moreover, any embodiments disclosed in the subject application are not to be taken as the only possible embodiments. Other embodiments will occur to those skilled in the art and are within the following claims.
[0039] In addition, any amendment presented during the prosecution of the patent application for this patent is not a disclaimer of any claim element presented in the application as filed: those skilled in the art cannot reasonably be expected to draft a claim that would literally encompass all possible equivalents, many equivalents will be unforeseeable at the time of the amendment and are beyond a fair interpretation of what is to be surrendered (if anything), the rationale underlying the amendment may bear no more than a tangential relation to many equivalents, and/or there are many other reasons the applicant can not be expected to describe certain insubstantial substitutes for any claim element amended. | An armor system and method for the interior of a structure to be protected wherein releasable fastener material is secured to an inside wall of the structure and at least a first armor panel includes, in one example, a spacer layer, a ceramic hard face layer behind the spacer layer, a ballistic material behind the ceramic energy absorber layer, an encapsulant about the spacer layer, the ceramic energy absorber layer, and the ballistic material. Releasable fastener material is on the encapsulant adjacent the spacer layer for mating the panel to the inside wall of the structure. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to the joining of composite materials, and, more particularly, to the joining of composite materials by induction heating.
A composite material is a material formed from two or more constituent materials which retain their identities within the composite material. One important type of composite material is the fiber composite material, wherein continuous or discontinuous fibers of one material are embedded within a matrix of another material. Composite materials such as fiberglass have long been known, and have been used in a variety of applications.
In recent years, a number of high-performance composite materials of great interest in aerospace and other demanding applications have been developed. Some materials, such as carbon, can be made very strong and stiff if they are in an elongated fibrous form with a diameter of a few micrometers or less. Such very fine fibers cannot be used directly in structural applications, and instead are incorporated into a matrix which holds the fibers in the proper alignment and protects them from damage. Nonmetallic matrix materials such as thermoplastic or thermosetting resins are widely used in such composite materials. Both the fiber and the matrix can be selected to be quite low in density, with the composite material having a high strength-to-weight ratio. These materials have therefore become the leading candidates for specific structural applications in the next generation of aircraft, to replace aluminum alloys.
The fabrication of a structure using composite materials requires somewhat different procedures than the fabrication of the same structure using metal parts. When metals are used, individual parts are formed by machining, rolling, drilling, and similar procedures, and then joined with fasteners or adhesive. When composite materials are used, parts are prepared by laying up prepreg strips of the composite material or filament winding to form the structure directly. The composite material is then consolidated in an autoclave.
Even when composite materials are used, there must be a method for joining different pieces of composite structure. For example, if a wing of an airplane is to be formed from composite materials, the internal stiffening elements such as the ribs and spars are first prepared and joined together, and then the wing skin is joined to this structural framework. Typically, the length of each stiffener is much greater than the transverse dimension of its interface with the skin. For some of the bonded joints in such a fabricated piece, adhesives are readily applied and provide acceptable performance. However, adhesives cannot be readily applied in other bonded joints. Adhesives may be more brittle and less resistant to loss of properties at elevated temperature than the adherends, compromising their mechanical performance. Moreover, many adhesives require a further autoclave curing treatment, and an autoclave capable of holding the entire wing may not be available. Externally applied fasteners such as rivets are particularly disadvantageous with composite materials because of the high stress concentrations which they introduce into the joint.
An alternative approach that has been used in some bonding applications of thermoplastic-matrix fiber composite materials is co-consolidation, in which the matrix polymer is softened and the two adherends are caused to fuse together at their common interface. In one instance, the two parts are placed inside tooling and inside an autoclave and the entire extent of both parts is heated along with the interface. Application of pressure accomplishes the co-consolidation at the interface. However, the costs for tooling, equipment, and energy are high. Accordingly, another approach is to apply localized heating to cause only the interfacial region between the two composite pieces to become plastic and flowable, force the pieces together in this state, and then remove the heat. If this procedure is performed properly, the two composite pieces are fused into one piece. There is little or no evidence of the original interface, and the final part is a single integral piece. This approach is very promising, because premature failure sources associated with the interface or adhesives are not present.
One promising heating source used to provide localized heating is an induction heater. Such a heater typically includes a generally planar coil of tubing, through which cooling water flows, and to which a high frequency electrical primary alternating voltage is applied. The current in the induction coil causes induced currents to flow in electrically conducting portions of the composite materials, such as carbon or graphite fibers where they are used.
By experience it has been found that the composite structures fabricated by the induction heating process typically have nonuniformities in the form of unbonded regions, or regions in which the original adherends have become deconsolidated because of excessive local heating. These unbonded or deconsolidated regions are difficult or impossible to repair, and can lead to premature failure of the structure. There is therefore a need for an approach to the bonding of composite material pieces that achieves the benefits of induction bonding, but ensures a good quality fabricated part. The present invention fulfills this need, and further provides related advantages.
SUMMARY OF THE INVENTION
The present invention provides an apparatus and process for joining pieces of composite materials using induction heating. The joining operation is fast, controllable, and heats only the regions where the bonding is to be accomplished. The bonded joint is of high quality throughout, without unbonded regions that result from the cold spots observed when prior techniques are used. Tooling is simplified and is less costly compared to that required for autoclave co-consolidation, because tooling is only required at the joints. The approach of the invention is applicable to a variety of composite materials joining applications wherein the interface at which the joining is to occur is extensive and is relatively near a free surface. The approach is especially applicable to the joining of pieces along long interfaces.
In accordance with the invention, an apparatus for joining together two pieces of composite material comprises means for induction heating an interface between two pieces of composite material simultaneously throughout the lateral extent of the interface, the induction heating being produced by a primary alternating current adjacent to the interface that flows in a single direction at one longitudinal location along the interface at any moment.
Stated alternatively, an apparatus for the joining of two pieces of composite material throughout an interface between the two pieces comprises a means for inducing a global current flow in the pieces of the composite material simultaneously throughout the entire interface, there being no inversions of the current flow direction across the extent of the interface at any longitudinal location.
The composite pieces to be joined together are placed into contact along an interface. The pieces are normally at least partially supported laterally with tooling, and may have other tooling in the form of platens to apply a force normal to the interface containing the bonding region.
A specially configured induction coil is positioned adjacent to the interface and particularly the regions of the interface which are to be joined by induction heating. In the prior approach, a conventional "pancake" spiral induction coil or an oval coil was placed over the interface, with all or most of the coil overlapping the interface in a plan view. It has now been discovered that such conventional coil configurations and placement result in a "cold center" in the interfacial region below a portion of the induction coil. This cold center results from the multi-directional nature of the current flows induced by the coil in the composite material, and will be discussed in more detail subsequently. The cold center in turn results in the corresponding region of the composite material interface not being heated to the joining temperature, and produces the bonding defects seen in such composite structures joined by this procedure.
The present invention provides for induction heating throughout the entire bonded interfacial area simultaneously, with no unheated and unbonded regions caused by the cold center effect. This heating is achieved by configuring the induction coil so that the primary current through the induction coil flows in a single direction at any longitudinal location, or at least does not turn back through an arc of more than about 90 degrees, unlike the prior approach where pancake or oval coils are placed entirely over the bonding region.
In one type of application of the present approach, a multiturn, planar induction coil of dimensions larger than the bonding area is placed such that only a portion of the coil overlies the bonding area of the interface. The selected portion of the induction coil is that portion wherein the primary currents in the electrical conductors of the coil all run in the same direction. The number of turns and the plan view configuration of the coil are chosen so that the selected portion of the coil extends over the entire bonding area. Thus, the induction coil is custom selected for the interface to be bonded.
The global induced current produced in the composite material at any one longitudinal location by this configuration of induction coil is generally uniform in direction throughout the extent of the bonding region. There are no cold centers that can result in unbonded locations. The induction coil is preferably maintained stationary relative to the composite material workpiece, which is an advantage because it simplifies the bonding apparatus, but the two can be moved relative to each other if necessary.
This approach to induction coil design is applied to more complex structural configurations than a single bonded joint. For example, if two parallel stiffeners are to be joined to a sheet, the joining is accomplished for both stiffeners at the same time by using an oval induction coil dimensioned such that one side of the oval overlies the interfacial bonding region of one stiffener, and the other side of the oval overlies the interfacial bonding region of the other stiffener.
The present invention further provides a nonmetallic heat sink that is placed in contact with the external surfaces of the composite pieces being joined near the interface region being heated. The nonmetallic heat sink, preferably made of a ceramic such as alumina, accelerates the flow of heat out of the near-surface regions into the heat sink. The heat sink, being made of an electrically nonconducting material, is not itself heated by the induction coil nor does it interfere with the heating of the composite material. Thus, the heat sink permits the interfaces being joined to be heated to a higher temperature than the rest of the adherends.
Another problem found in the joining of composite materials by induction heating is that the fibers in the composite pieces being joined may not be optimally oriented to couple to the induction field and produce induction heating. Heating of the interfacial regions to the joining temperature therefore requires more power than would otherwise be the case, and an associated heating of unrelated parts of the structure. There have been attempts to place thin susceptors, such as metallic wire screens, into the interface in the bonding region to increase the coupling to the induction field, thereby localizing the heating in the parts of the composite material pieces proximate the interface. This approach has a serious drawback of permanently placing a foreign material into the interface, obviating the bondline-removal advantages otherwise attained with the induction technique.
In the present approach, a thin piece of composite material, having the conducting fibers oriented so as to strongly couple to the induction field and carry current to produce heating, is placed between the pieces being bonded. In most instances, the pieces being bonded are formed of the same or nearly the same materials, a particular type of conducting fiber in a particular type of matrix. The composite material susceptor is chosen to be of the same material, so that no foreign substance is introduced into the bonding region. The composite material susceptor is selected so that the conducting fibers are oriented parallel to the primary conductors of the induction coil that generate the induced field, so as to achieve a good induced current flow in the interfacial region. The presence of a small thickness of the composite material has little effect on the properties of the final structure, and provides a transition between the two bonded pieces.
The present invention thus provides a basic approach and several added features that permit the joining of pieces of composite materials by induction heating, while avoiding unbonded defects within the bonded regions and also avoiding unnecessary overheating of the composite material pieces at locations remote from the interface where bonding occurs. Other features and advantages of the 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
FIG. 1 is a perspective view of a piece of material being heated by an overlying induction coil;
FIG. 2 is a diagrammatic sectional view through the piece of material and induction coil of FIG. 1, taken along line 2--2, where the piece of material is a metal;
FIG. 3 is a perspective view of a piece of a composite material of electrically conducting fibers in a nonconducting matrix;
FIG. 4 is a diagrammatic sectional view like that of FIG. 2, where the piece of material is a cross-plied composite material;
FIG. 5 is a diagrammatic sectional view like that of FIG. 2, where the piece of material includes two pieces of cross-plied composite material meeting at an interface;
FIG. 6 is a diagrammatic plan view of apparatus for joining pieces of composite material;
FIG. 7 is a diagrammatic sectional view of the apparatus of FIG. 6, taken along line 7--7 of FIG. 6;
FIG. 8 is a diagrammatic sectional view of the apparatus of FIG. 6, taken along line 8--8 of FIG. 6;
FIG. 9 is a diagrammatic section view like that of FIG. 7, with a superimposed graph of temperature through the pieces being bonded;
FIG. 10 is a diagrammatic sectional view like that of FIG. 7, illustrating the use of a composite material interfacial susceptor;
FIG. 11 is a diagrammatic plan view of two composite material pieces being joined, with a global current loop closing; and
FIG. 12 is a diagrammatic perspective view of apparatus for joining multiple stiffeners to a wing skin.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The physics of the heating of composite materials formed of electrically conducting fibers in an electrically nonconducting matrix by induction heating is significantly different from the heating of metals by induction heating, as will be illustrated with reference to FIGS. 1-4. FIG. 1 is a perspective view of a generally planar piece 20 of material having a generally planar, induction heater 22 positioned thereabove. The induction heater 22 is formed from a planar coil of electrical conductors 24, in this case two turns of the conductors in the region of the piece 20. A power supply 26 applies a high frequency alternating current between the leads 28 of the induction heater 22, in turn applying the alternating current to the electrical conductors 24.
FIG. 2 presents a sectional view through the induction heater 22 and piece 20 of material, where the piece of material is a metal having a good electrical conductivity. Such heating of metal is the most common application of induction heating. The metal is a good electrical conductor, and the electrical conductivity is approximately independent of the direction of measurement.
The portion of the metal piece 20 directly below the electrical conductors 24 is strongly heated, as indicated by the symbol "VH" (for "very hot"). The heating occurs because the alternating current in the conductors 24 induces a responsive induced current in the electrically conducting metal piece 20, and that induced current in the piece produces ohmic heating of the piece. The induced current in the workpiece flows in a pattern whose size, shape, and direction of current flow roughly parallels the current flowing through the coil. Since the current flowing through the coil forms essentially a complete loop, the current in the workpiece does the same. This is the "global current loop" which is discussed subsequently. In the portion of the metal not directly below the electrical conductors 24 and therefore not directly heated by an induced current, but adjacent the strongly heated regions, the metal is heated to a lesser temperature "H" (for "hot") by thermal conduction from the VH region. At a greater distance from the induction heater 22, the piece 20 remains cool, indicated as "C". Significantly, if the size of the coil of the induction heater 22 is not too large, a central region 30 between the conductors 24 is heated by thermal conduction to a temperature H.
FIG. 3 illustrates a composite material having electrically conductive fibers 32 embedded in an electrically nonconductive matrix 34, which also has a low thermal conductivity. In one class of commercially important composite materials, the fibers 32 are carbon or graphite, and the matrix 34 is an organic thermoplastic polymeric material such as polyetheretherketone (PEEK) or a thermosetting polymeric material such as an epoxy. In FIG. 3, the fibers 32 are unidirectional and oriented parallel to a longitudinal direction L. The electrically conductive fibers 32 can be further characterized as occupying a particular fraction of the total volume of the material, which is typically in the range of about 20-70 volume percent. The direction perpendicular to the fibers 32 and in the plane of the piece 20 is termed the transverse direction T, while the direction perpendicular to the plane of the piece 20 is termed the normal direction N. The electrical conductivity of the composite piece 20 is dependent upon the direction of measurement, and is generally higher in the L direction than in the T or N directions, because the conductive fibers 32 are oriented parallel to the L direction.
When the piece 20 is a composite material such as shown in FIG. 3 (rather than a metal such as shown in FIG. 1), an induced current can flow along the length of the fibers 32 in the longitudinal direction L. There is essentially no induced current in the matrix 34, because it is electrically nonconducting. There is also essentially no induced current in the transverse direction T or the normal direction N, because there is no continuous electrically conducting path extending in those directions.
A unidirectional laminate or piece such as that in FIG. 3 can be placed adjacent to a pancake induction coil to attempt to heat it by induction. Because the fibers all run in the same direction, at some locations the fibers will be roughly parallel to the coil tubing, and at other locations the fibers will be roughly perpendicular to the coil tubing. At the locations where the fibers are parallel to the coil tubing, current can be induced in a direction parallel to the coil current (i.e., along the fibers), but at the other locations where the fibers are perpendicular to the coil tubing, the required current cannot be induced, because the composite workpiece has essentially no electrical conductivity in the required direction. Thus, if a unidirectional composite laminate such as that shown in FIG. 3 is placed under a pancake induction coil, the required global current loop will not form and the laminate will not heat.
In most applications of composites, fibers are placed in various directions in the plane of the laminate to confer stiffness and strength in multiple directions. Typically this is accomplished by placing separate unidirectional plies of the laminate in various directions during its fabrication. In such a "cross-plied" laminate, there are multiple in-plane directions having good electrical conductivity. FIG. 4 illustrates the response produced by the induction coil configuration of FIG. 1, where the piece 20 is a cross-plied composite material laminate. Because the fibers run in multiple in-plane directions, the global current loop mentioned above can form. The regions directly below the electrical conductors 24 of the induction heater are heated to a temperature H. The laterally adjacent regions of the piece 20 that are not below the electrical conductors 24 are not heated directly by induced currents and remain in the cool or C condition because there is little thermal conduction laterally from the H regions due to the low thermal conductivity of the polymeric matrix material. The central region 30 experiences very little if any heating, producing a "cold center" under the center of the induction heater 22 that is not present for the more common case of a metal heated by an induction heater because of the thermal conductivity of the metal.
The present invention is concerned with the joining of two pieces of composite material by induction heating. FIG. 5 depicts a key problem inherent in such joining, in the same view as FIG. 4. Two pieces of cross-plied composite material 40 and 42 are placed together along an interface 44. The electrical conductors 24 produce a heating pattern in the composite materials 40 and 42 somewhat similar to that depicted in FIG. 4, for the same reasons. The central region 30 is heated very little if at all.
The pieces of composite materials 40 and 42 are bonded together in those regions of the interface 44 that are heated to the H or high temperature. There is essentially no bonding in the central region 30, because it is not heated.
The present invention achieves complete bonding through the entire interface between the composite materials by avoiding unheated and cold spots at the bonding interface, through careful selection of the induction heater and, in some cases, ancillary tooling. In accordance with the invention, apparatus for the joining of two pieces of composite material throughout an interface between the two pieces comprises an induction heater positioned such that the induction coil overlies an entire interface between two pieces of composite material to be bonded together, the induction heater having at least one length of an electrical conductor; and a source of an alternating current applied to each length of the electrical conductor overlying the interface such that the direction of current flow in each conductor is the same at any moment at any longitudinal position along the interface.
More preferably, apparatus for joining of two pieces of composite material at an interface having a first end and an oppositely disposed second end in the plane of the interface comprises at least two substantially parallel lengths of electrical conductor disposed adjacent to the interfacial region of the composite material and extending from the first end to the second end; and an induction generator that drives a primary electrical alternating current through the lengths of electrical conductor at a frequency sufficient to induce secondary currents in the two pieces of the composite material proximate the interface, such that the primary current flows in the same direction in each of the lengths of electrical conductor at any moment at any longitudinal position along the interface.
FIGS. 6-8 illustrate an apparatus 50 used to join two pieces 52 and 54 of composite material together along an interface 55. In this case, one piece 52 is a sheet of composite material, and the other piece 54 is a localized stiffener (having a T configuration when viewed in cross section) to be bonded to the sheet. The apparatus 50 includes an induction heater 56 energized by a radio frequency (rf) generator 58. The rf generator 58 is of the type commercially available from several manufacturers, and supplies an alternating current at a frequency typically ranging from 200 kilohertz (KHz) to 3 megahertz (MHz), depending upon the specific type of machine utilized.
The induction heater 56 includes at least one, preferably at least two, and most preferably a plurality of electrically conducting loops 60, that are in electrical communication with the outputs of the rf generator 58 through leads 62. In FIGS. 6-8, there are six electrically conducting loops 60 arrayed over the interface 55 between the pieces 52 and 54.
The induction heater 56 is configured so that the primary electrical current applied by the induction generator 58 at any moment in time flows in the same direction through those portions of the electrical conductors 60 that overlie the interface 55. At the moment depicted in FIGS. 6-8, the direction of the primary electrical current is indicated by arrows 64 in FIG. 6, a dot 66 indicating a vector out of the plane in FIG. 7, and a cross 68 indicating a vector into the plane in FIG. 8.
In FIG. 7, which depicts the bonding region and interface 55, the current in each of the conductors 60 flows in the same direction, out of the plane of the drawing. The electrical conductors 60 of FIG. 7 are closely spaced together, and in this depiction stacked in two overlying rows to intensify the induced electrical current at the interface 55. At the interface 55, all regions are heated to a temperature H, and there is no cold center. As a result, the entire interface 55 is heated to the desired bonding temperature.
In FIG. 8, which depicts the region away from the interface and the bonding region, the electrical conductors 60 induce heating of the sheet piece 52, but the conductors 60 are spaced further apart from each other than in the region of the interface. The sheet piece 52 is subjected to less intense heating, and is only warmed as indicated by the letter W.
The induction heater of the invention is configured differently than heaters used in the art. The present induction heater is much larger in lateral extent than the interfacial area to be bonded, to permit the electrical conductors to be arranged such that the electrical current flows through them in only a single direction, over the interface being heated for bonding.
An alternative description of the approach of the invention is based upon the concept of a global current loop. With the induction heater arrangement of FIG. 6, at each moment when current is flowing, there is a macroscopic current flow path in the composite pieces 52 and 54 that roughly mirrors the current flow pattern of the electrical conductors 60 as depicted by the arrows 64, except in the opposite direction. This global current flow is depicted by the arrow 70 in FIG. 6. The global current 70 is unidirectional through a region 72 where the interface 55 between the pieces 52 and 54 is found. That is, the vector 70 indicating the global current flow direction does not reverse itself across the bonding region 72. This may be contrasted with the conventional prior situation depicted in FIG. 5, where the global current flow vector is out of the plane of the illustration for the two conductors 24 on the left hand side, and into the plane of the illustration for the two conductors 24 on the left hand side. In this case, there is a reversal of the global current flow vector through the interfacial region being bonded, contributing to the detrimental cold center effect.
FIGS. 9 and 10 illustrate other features of the present invention used to promote temperature control. In order to cause the two adherends to fuse together (co-consolidate) at the interface, the matrix polymer must be heated approximately to its melting temperature. However, since the adherends themselves are typically cross-plied laminates, heating the adherends to the melting temperature of the polymer tends to cause an undesirable deconsolidation of the adherends. Thus, it is desirable to maintain all regions of the adherends, except the interface to be joined, as cool as possible.
In the current approach, the temperature within the pieces 52 and 54 is regulated with tooling that is present to aid in the bonding of the interfaces. Although heating an interior interface 55 may be sufficient to effect bonding along the interface, it is preferred to also apply a compressive force 76 in the normal direction N to the interface 55. To apply that compressive force, electrically nonconducting but thermally conducting tooling is used.
In the particular configuration of FIGS. 7 and 9, the electrical conductors 60 are embedded in a block 78 of an electrically nonconducting material that has a reasonably good thermal conductivity, such as alumina (aluminum oxide) or other ceramic. Since water is passed through the electrical conductors 60 to cool them, heat is removed from the near surface 74 by conduction through the block 78. A back surface 80 of the stiffener piece 54 is supported by conforming tooling 82 made of the same type of material as the block 78. The tooling 82 may optionally be cooled by embedded cooling lines 84 through which water is passed, removing heat from the back surface 80. Alternatively, since typically the bonding is done in short times, the heat capacity of the tooling may be sufficient to keep it at a low temperature (relative to the interface) without requiring it to be cooled by water. Thus, it may be sufficient to place the induction coil adjacent to the tooling (on the side opposite from the workpiece) and not embed it within the tooling. Under such conditions, the extra cooling passages 84 are not needed. The compressive force 76 is applied to the interface 55 through the block 78 and the tooling 82.
Superimposed on FIG. 9 is a graph of temperature through the pieces 52 and 54 and the interface 55, as a result of the approach just described. Because the near surface 74 and the back surface 80 are cooled and the composite material between them is heated internally by induction, the maximum temperature is found at the interface 55. This is the desired result, as elevated temperature bonding at the interface 55 can be accomplished without degradation of the other regions of the composite pieces 52 and 54 resulting from overheating. For any particular configuration of pieces to be bonded, a thermal flow model can be constructed to ascertain the precise form of the temperature graph of FIG. 9 using known techniques.
Another obstacle to attaining sufficient and proper heating of the interface 55 for bonding can arise if the fibers of one or both of the composite pieces are either too sparse (i.e., of too low a volume fraction) to permit sufficient heating or are misoriented away from the longitudinal direction of the interface 55. In the first case, if the fraction of fibers in one or both pieces is very low, the total secondary or induced current is not sufficiently high to heat the interfacial region unless an unacceptably high power is applied to the induction heater. In the second case, there may be a high fraction of fibers, but if they are misoriented from the direction parallel to the electrical conductors of the induction heater the induced current is small. In the limiting case, if the conducting fibers lie in the transverse direction T, then there will be virtually no induced current. It is not sufficient to simply reorient the electrical conductors, because the fibers in each piece being bonded can be oriented in different directions. In the most general case, each composite piece may be formed of a number of layers of composite material, with the fibers in each layer lying in different orientations.
The heating intensity at the interface can be intensified by supplying an intermediate layer of composite material at the interface 55 between the pieces 52 and 54, termed herein an interfacial susceptor 86. The fibers in the composite material of the interfacial susceptor 86 are oriented such that a relatively large induced current is produced in the interfacial susceptor, thereby heating it to a higher temperature than would occur in the absence of the intermediate layer. The intermediate layer of the interfacial susceptor 86 is therefore preferably made of the same type of material as the pieces 52 and 54, that is, a composite of the same type of fibers and the same type of matrix. The intermediate layer can have either a higher fraction of the fibers than the pieces 52 and 54, or can be oriented differently with the fibers more nearly parallel to the global current vector, or both. With such an interfacial susceptor 86, the temperature profile through the pieces exhibits a sharper peak, as illustrated schematically in the inset graph of temperature as a function of position of FIG. 10. The interface is thus preferentially heated as compared with the pieces being joined. The use of the interfacial susceptor formed of the same materials as the composite pieces being joined avoids the introduction of foreign substances into the interface.
In some cases, the geometry of the pieces to be joined does not permit the desired global current loop flow, and conductive tooling must be provided to permit such flow. Otherwise, irregular current flows may result. FIG. 11 illustrates a configuration somewhat similar to that of FIG. 6, except that in FIG. 11 the composite pieces being joined are simply two small sheets 90, that are overlying each other. An induction heater 92, illustrated in FIG. 11 in phantom lines, is configured similarly to that of FIG. 6, with a portion of the electrical conductors overlying the sheets 90 so that the current flow in all the conductors is in the same direction, and the rest of each electrical conductor forming the remainder of the loop that does not overlie the sheets 90. This arrangement does not permit a smooth global current flow, of the same form as shown in FIG. 6.
To permit such a current flow, electrically conductive tooling 96 is placed under the portions of the induction heater 92 that do not overlie the sheets 90. The conductive tooling 96 is in electrical contact with the ends 98 of the sheets 90, so that a global current loop 94 may flow from one end of the sheets 90, through the tooling 96, and into the other end of the sheets 90.
The approach of the invention is applicable to the simultaneous formation of multiple interfacial joints in a single operation, as illustrated in FIG. 12. An aircraft wing section 100 requires stiffeners attached to the interior of the upper wing skin and the lower wing skin. As illustrated, two surfaces 102 of two composite stiffeners 116 are joined to the interior surface of a top wing skin 104, and two other surfaces 106 of these same composite stiffeners 116 are joined to the interior surface of a bottom wing skin 108. Two pieces of internal tooling 110 extend between respective stiffener surfaces 102 and 106.
An induction heater 112 is configured according to the principles discussed herein, so that the global current flow through each interface being bonded is substantially unidirectional. (Only a single electrical conductor is shown along each interface in FIG. 12 for clarity of illustration, although multiple conductors can be supplied according to the principles illustrated in FIG. 6.) The electrical conductors of the induction heater are embedded in external compressive tooling 114, in the manner illustrated in FIG. 7. The compressive pressure can be supplied by a press or other mechanical means, or by a vacuum bag (not shown) arranged over the external tooling. The global current loop for the interfaces between the upper stiffener surfaces 102 and the upper wing skin 104 is completed through the upper wing skin 104, or alternatively may be completed through external current flow paths (not shown, but as discussed in relation to FIG. 11). The global current loop for the lower stiffeners is similar.
Thus, using the approaches exemplified by FIGS. 6, 11, and 12, composite pieces can be readily joined along interfaces singly or in multiples, and with or without the need for a conductive susceptor to aid in formation of the global current loop. These teachings can be readily applied by those skilled in the art to a wide variety of simple and complex joining situations.
By the approach described above, adherends of cross-piled laminates of graphite-polyetheretherketone (gr-PEEK) have been joined together. In one case, a circular pancake coil was used to join together circular adherends along a circular annulus. In a second case, a rectangular pancake coil was used to join together adherends along a rectangular annulus. The joints have been inspected ultrasonically and found to be sound, and no deconsolidation of the laminates was observed. Instrumented tests of the type described above have proved that the surfaces of the adherends can be kept substantially cooler than the interface being bonded, and that the heat can be localized to the region of the induction coil.
Although particular embodiments of the invention has been described in detail for the purpose of illustration, various modifications may be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be limited except as by the appended claims. | Two pieces of composite material are simultaneously joined together throughout an interface between the two pieces, by induction heating the interface region with an induction coil placed, at least in part, adjacent to the bonding region, and forcing the composite material at the interface together while heating. The approach is particularly useful in joining pieces having "long interfaces" whose longitudinal dimension is substantially larger than its transverse dimension, for example the long interfaces between aircraft wing stiffeners and skins. The induction coil is configured so that, at any one longitudinal location along the interface, the primary current flowing therethrough does not flow in opposite directions in the portions of the coil overlying the interface, and preferably flows in substantially the same direction throughout the interface. Unheated "cold spots" in the interface being bonded, which would not bond properly, are thereby avoided. An electrically nonconductive but thermally conductive material may be placed between the induction coil and the composite material pieces to act as both a heat sink and a pressure-applying tool. Bonding may be enhanced by placing a susceptor made of the same materials as the composite materials being bonded but having a higher electrical conductivity, in the interface between the two composite material pieces prior to induction heating. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] A sulfur recovery plant is provided comprising a primary Claus reactor and a plurality of downstream reactor units, each reactor unit comprises a reactor that is selectively operable under Claus reaction conditions and cold bed adsorption (CBA) reaction conditions thereby permitting the plant to achieve greater than 99.5% average sulfur removal efficiency. The high sulfur removal efficiencies are obtained through sequencing the reactor units such that the reactor unit containing the coolest catalyst is positioned in the final spot in the series of reactor units. The order of reactor units within the sequence is periodically changed so as to permit catalyst regeneration. However, the reactor unit containing the newly regenerated catalyst is shifted to a middle position, as opposed to the final position in the sequence of reactor units. This manner of shifting the order of reactor units within the plant provides additional cooling time for the catalyst that has been most recently regenerated thereby ensuring that the final reactor unit in the series is capable of highly efficient cold bed adsorption operation.
[0003] 2. Description of the Prior Art
[0004] The processing of natural gas or petroleum products often results in the generation of acid gas streams comprising oftentimes significant quantities of sulfur, generally in the form of H 2 S. These acid gas streams are often of limited value and are commonly disposed of by incineration. However, environmental regulations restrict the amount of sulfur that can be released into the atmosphere. Therefore, a significant portion of the sulfur present in these waste product streams must be removed prior to incineration.
[0005] One approach to the removal of sulfur has been through the use of an extended Claus sulfur recovery plant, such as that disclosed in U.S. Pat. Nos. 5,015,459 and 5,015,460. In these plants, one catalytic reactor is operated under high temperature Claus conditions in series with one or more catalytic reactors each periodically operated under high temperature Claus and cold bed adsorption (CBA) conditions. Each catalytic reactor that alternates between Claus conditions and CBA conditions is associated with a sulfur condenser to comprise a reactor unit. The sequencing of the reactor units is periodically changed so that the reactor having freshly-regenerated catalyst is placed in the last position in the sequence.
[0006] The CBA plants have demonstrated average sulfur removal efficiencies of up to 99.2%. However, as environmental regulations become even more strict, CBA plants such as those described in the aforementioned patents have not thus far been able to achieve 99.5% or greater average sulfur reduction efficiencies. In order to achieve this level of efficiency, conventional CBA plants would need to be equipped with an additional tail gas treating unit, such as a hydrogenation/amine treating unit, thereby adding further capital and operating expense. Thus, it would be highly desirable if a CBA plant could be configured to achieve 99.5% or greater average sulfur removal efficiency without the need for additional tail gas treatment.
SUMMARY OF THE INVENTION
[0007] One embodiment according to the present invention comprises a process for recovering sulfur from a gas stream. A process gas comprising H 2 S and SO 2 is passed through a primary Claus reactor operable to convert at least a portion of the H 2 S and SO 2 present in the process gas into elemental sulfur. Next, the gas exiting the primary Claus reactor is passed sequentially through at least first, second, and third reactor units, each reactor unit comprising a catalytic reactor and a sulfur condenser. The catalytic reactors are capable of selective operation under both Claus reaction conditions and cold bed adsorption conditions. After a First period of operation of the reactor units, the sequence of the reactor units is rearranged such that the gas exiting the primary Claus reactor first passes through the third reactor unit, followed by the first and second reactor units.
[0008] Another embodiment according to the present invention comprises a process for recovering sulfur from a gas stream. A process gas comprising H 2 S and SO 2 is passed through a primary Claus reactor operable to convert at least a portion of the H 2 S and SO 2 present in the process gas into elemental sulfur. Next, the gas exiting the primary Claus reactor is passed sequentially through a series of reactor units, each reactor unit comprising a catalytic reactor and a sulfur condenser. The condenser of the final reactor unit in the series is operated so that the gas exiting the condenser is at or below the freezing point of sulfur.
[0009] Still another embodiment according to the present invention comprises a process for recovering sulfur from a gas stream. A process gas comprising H 2 S and SO 2 is passed through a primary Claus reactor operable to convert at least a portion of the H 2 S and SO 2 present in the process gas into elemental sulfur. Next, the gas exiting the primary Claus reactor is passed sequentially through a series of reactor units, each reactor unit comprising a catalytic reactor and a sulfur condenser. The catalytic reactor of the final reactor unit in the series has an inlet temperature that is within 10° F. of the freezing point of sulfur.
[0010] A further embodiment according to the present invention comprises a sulfur recovery unit. The sulfur recovery unit includes a primary Claus reactor and a series of reactor units located downstream from the primary Claus reactor. The primary Claus reactor is configured to receive a process gas comprising H 2 S and SO 2 and convert at least a portion of the H 2 S and SO 2 into elemental sulfur. Each of the downstream reactor units comprises a sulfur condenser and a catalytic reactor. The catalytic reactor of the final reactor unit in the series operates at the lowest average temperature of all of the catalytic reactors in the series.
[0011] Still a further embodiment according to the present invention comprises a sulfur recovery unit. The sulfur recovery unit includes a primary Claus reactor and a series of reactor units located downstream from the primary Claus reactor. The primary Claus reactor is configured to receive a process gas comprising H 2 S and SO 2 and convert at least a portion of the H 2 S and SO 2 into elemental sulfur. Each of the downstream reactor units comprises a sulfur condenser and a catalytic reactor. The condenser of the final reactor unit in the series operates at a temperature that is at or below the freezing point of sulfur.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a process flow diagram of a sulfur removal plant in which process gas exiting a primary Claus reactor is directed through a series of cold bed adsorption reactor units, the process gas first flowing through a condenser of the first unit prior to being directed through the reactor of the first unit;
[0013] FIG. 2 is a process flow diagram of a sulfur removal plant as depicted in FIG. 1 , except that the process gas exiting the primary Claus reactor bypasses the condenser of the first unit and is directed immediately to the reactor of the first unit;
[0014] FIG. 3 is a process flow diagram of a sulfur removal plant in which process gas exiting the primary Claus reactor is initially directed toward a third CBA reactor unit, and particularly through the condenser of the third unit prior to being directed through the reactor of the third unit, and wherein the second reactor unit from FIGS. 1 and 2 is now in the final position in the series of reactor units;
[0015] FIG. 4 is a process flow diagram of a sulfur removal plant as depicted in FIG. 2 , except that the process gas exiting the primary Claus reactor bypasses the condenser of the third unit and is directed immediately to the reactor of the third unit;
[0016] FIG. 5 is a process flow diagram of a sulfur removal plant in which process gas exiting the primary Claus reactor is initially directed toward a second CBA reactor unit, and particularly through the condenser of the second unit prior to being directed into the reactor of the second unit, and wherein the first reactor unit from FIGS. 1 and 2 is now in the final position in the series of reactor units; and
[0017] FIG. 6 is a process flow diagram of a sulfur removal plant as depicted in FIG. 5 , except that the process gas exiting the primary Claus reactor bypasses the condenser of the second unit and is directed immediately into the reactor of the second unit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] Turning to the Figures, an exemplary sulfur removal plant 10 is represented schematically. It is noted that each figure contains both solid and dashed process lines. The solid lines indicate conduit through which process gas is flowing and the dashed lines indicating conduit that is presently closed off by valves. Plant 10 comprises a primary Claus reactor 12 configured to receive a process gas stream via conduit 14 . The process gas stream may comprise the products of a thermal reaction step in which oxygen is introduced into byproducts from natural gas or petroleum processing, such as an acid gas stream, and combusted in, for example, a thermal reactor. The products of this thermal reaction step carried by conduit 14 comprise a sulfur compound, such as H 2 S, and one or more other components, such as CO 2 and water. Reactor 12 contains a Claus catalyst such as activated Al 2 O 3 or TiO 2 that catalytically converts H 2 S and SO 2 (produced by combustion of H 2 S within the reactor) into elemental sulfur. However, conversion of H 2 S to elemental sulfur in reactor 12 is often not as complete as many environmental regulations require. Therefore, additional reaction must be carried out.
[0019] The reacted process gas stream exits reactor 12 through conduit 16 and is directed toward a plurality of reactor units, depicted in FIG. 1 as units 18 , 20 , and 22 , for further H 2 S conversion. As discussed in greater detail below, the sequencing of the reactor units is variable so as to optimize average sulfur removal efficiency to a level of at least 99.5% for the cycle. In particular, a “front-middle-back” sequence for rotation of reactor units 18 , 20 , 22 is employed. Each reactor unit comprises a sulfur condenser 24 , 28 , 32 , and a reactor 26 , 30 , 34 , respectively. The reactor units themselves are of similar function, as each will be cycled through the various operational positions within plant 10 .
[0020] In certain embodiments, condensers 24 , 28 , 32 are located upstream from respective reactors 26 , 30 , 34 and comprise tube/shell heat exchangers employing, for example, water on the shell side as the cooling fluid for condensing the sulfur. The liquified sulfur is then recovered from the condensers. Reactors 26 , 30 , 34 are catalytic reactors containing similar Claus catalyst as primary reactor 12 . But unlike reactor 12 , reactors 26 , 30 , 34 selectively operate under both Claus reaction conditions and cold bed adsorption conditions. Under Claus reaction conditions, sulfur formed in the presence of the Claus catalyst is continuously removed from the reactor in the vapor phase due to the relatively high temperatures associated with the reaction. Under cold bed adsorption conditions, the sulfur formed is deposited and accumulated on the Claus catalyst, which must be regenerated from time to time. However, under both sets of conditions, the reactors catalyze the Claus reaction in which H 2 S and SO 2 are converted to elemental sulfur.
[0021] As depicted in FIG. 1 , the stream carried by conduit 16 is initially directed toward reactor unit 18 . Specifically, the process gas in conduit 16 is directed through a control valve 36 and into condenser 24 via conduit 38 . Within condenser 24 at least a portion of the sulfur generated by primary Claus reactor 12 is condensed and recovered from plant 10 . The process gas exits condenser 24 at about 260° F. via conduit 40 and passes through three-way valve 42 . The process gas is then directed toward reactor 26 via conduit 44 . In reactor 26 , additional H 2 S is reacted to form elemental sulfur. The process gas exits reactor 26 via conduit 46 and is directed toward reactor unit 20 .
[0022] Three-way valve 48 is positioned to direct the process gas into conduit 50 and eventually through sulfur condenser 28 . The process gas exits sulfur condenser 28 via conduit 52 at about 260° F. A three-way valve 54 directs the process gas toward reactor 30 via conduit 56 . Upon exiting reactor 30 , the process gas is directed toward reactor unit 22 via conduit 58 . Three-way valve 60 is positioned to direct the process gas into conduit 62 and eventually through sulfur condenser 32 .
[0023] Sulfur condenser 32 is operated at the lowest temperature of each of the three condensers in the process scheme depicted in FIG. 1 . In certain embodiments, the temperature of the process gas exiting condenser 32 is at or below the freezing point of sulfur, approximately 240° F. or less. The cooler temperatures in condenser 32 can be achieved by depressurizing the shell side of the condenser (in certain embodiments to about 9 to 10 psig) so as to lower the temperature of the steam exiting the condenser. When plant 10 is operated in this configuration, the steam pressure for condenser 32 is less than that of condensers 24 and 28 . In other embodiments, a liquid comprising a heat transfer fluid may be used in place of steam to provide the necessary cooling for the condensers used herein. The temperature and flow of the liquid may be adjusted to provide the desired operational temperature for the condenser and outlet temperature for the process gas.
[0024] Operating a condenser at such low temperatures generally defies conventional wisdom regarding Claus plant operation, as this will result in the accumulation of solidified sulfur in the tubes of condenser 32 , especially in the tubes adjacent the condenser outlet. However, the condensers utilized in this process are generally designed to accommodate high cooling duty demands. Therefore, when a reactor unit is located in the third position, as is reactor unit 22 in the configuration of FIG. 1 , its condenser possesses sufficient surface area to make up for loss of operating efficiency resulting from the solidification of sulfur within its tubes. Thus, accumulation of sulfur in the tubes for the period in which reactor unit 22 operates in the final position in the sequence of reactor units of plant 10 will not meaningfully affect the overall performance of the condenser.
[0025] The process gas stream exits condenser 32 via conduit 64 and is directed through three-way valve 66 and toward reactor 34 via conduit 68 . The much lower temperature of the process stream exiting condenser 64 also permits reactor 34 to operate at a much cooler temperature than reactors 28 and 30 . This lower operational temperature provides more efficient H 2 S conversion under cold bed adsorption conditions. In certain embodiments, reactor 34 , the final reactor in the series, has an inlet temperature that is within 10° F. of the freezing point of sulfur (e.g., between about 230° F. to about 250° F.), or even within 5° F. of the freezing point of sulfur (e.g., between about 235° F. to about 245° F.). The process gas exiting reactor 34 through conduit 70 can be directed by three-way valve 72 to conduit 74 , which feeds, for example, an incinerator or a tail gas treatment unit. Although, it is an advantage with certain embodiments of the present invention that further tail gas treatment can be avoided because the increased efficiency of plant 10 results in a sufficiently low sulfur content gas stream which would permit incineration without a need for further sulfur removal.
[0026] After operation of plant 10 in the configuration of FIG. 1 for a predetermined period of time, in some embodiments approximately 3 hours, the flow path of process gas through plant 10 is slightly altered so as to liberate sulfur that has been deposited on the catalyst present in reactor 26 . Turning to FIG. 2 , it can be seen that the position of valve 42 has been altered so that the process gas from conduit 16 now bypasses condenser 24 via conduit 76 and flows through valve 42 and directly into reactor 26 . The increased temperature of the process gas being introduced into reactor 26 vaporizes sulfur which may have accumulated on the catalyst inside reactor 26 thereby regenerating the catalyst. The remainder of plant 10 operates as described above for FIG. 1 . In certain embodiments, plant 10 is operated in this configuration for approximately 9 hours, at which time the flow path of process gas through plant 10 is again altered.
[0027] In preparation for a re-sequencing of reactor units, the flow path of process gas through plant 10 is changed from the configuration of FIG. 2 back to the configuration of FIG. 1 . Essentially, this involves bringing condenser 24 back on-line so as to cool the process gas being directed toward reactor 26 . Thus, the catalyst within reactor 26 is pre-cooled in advance of the re-sequencing of reactor units. The remainder of plant 10 continues to operate as previously described for FIG. 1 . In certain embodiments, plant 10 is operated in this configuration for approximately 3 hours.
[0028] Next, the sequencing of reactor units is changed so as to permit regeneration of catalyst in reactor 30 of reactor unit 20 . Conventionally, reactor unit 18 , having the “freshest” catalyst (i.e., having most recently undergone regeneration) would be slotted in the final position of the sequence of reactor units. However, it has been discovered that the sulfur removal efficiency of plant 10 can be improved if reactor unit 18 is not moved to the final position in the sequence of reactor units, but rather a middle position, namely the second position as shown in FIG. 3 . Because reactor 26 has not be operated (for the second time) in the configuration of FIG. 1 for long, the catalyst contained within reactor 26 is much warmer than the catalyst contained, for instance, in reactor 30 . Thus, the catalyst in reactor 26 will not perform as effectively as the catalyst in reactor 30 under cold bed adsorption conditions. Therefore, even though the catalyst contained within reactor 30 may contain more adsorbed sulfur, it has been discovered that its lower temperature renders it more effective under cold bed adsorption conditions than the catalyst in reactor 26 .
[0029] In the plant configuration depicted in FIG. 3 , valve 36 is closed thus diverting the flow of process gas from conduit 16 into conduit 76 . A valve 78 in reactor unit 20 also remains closed so that the process gas continues to flow toward reactor unit 22 , while a valve 80 has been opened. Thus, reactor unit 22 has assumed the first position in the sequencing of reactor units downstream of primary Claus reactor 12 . Process gas is directed through valve 80 and flows through sulfur condenser 32 . Sulfur condenser 32 is no longer operated to produce an outlet temperature at or below the freezing point of sulfur. The shell side steam pressure is now increased to 15 psig, for example, thereby increasing the outlet temperature of condenser 32 . Also, condenser 32 is receiving the hot process gas directly from primary Claus reactor 12 . Therefore, any sulfur that may have solidified in the tubes of condenser 32 from the immediately preceding operating configurations is at least melted. In certain embodiments, the process gas exiting condenser 32 via conduit 64 has a temperature of about 260° F. The process gas passes through three-way valve 66 and into conduit 68 where it is directed to reactor 34 . Three-way valve 72 has been repositioned so that the process gas exiting reactor 34 and carried by conduit 70 is diverted to conduit 82 and directed toward reactor unit 18 , which has been moved to the second position in the sequence of reactor units.
[0030] The process gas carried by conduit 82 is transferred to conduit 38 (due to the position of valve 42 ) and passed through condenser 24 . In certain embodiments, the process gas exiting condenser 24 has a temperature of about 260° F. The process gas is then directed through reactor 26 and toward reactor unit 20 as previously described above. However, because reactor unit 20 is now in the final position in the sequence of reactor units, condenser 28 is operated at or below the freezing point of sulfur, much like condenser 32 was operated when in the configuration shown in FIG. 1 . Likewise, in certain embodiments, the inlet to reactor 30 is within 10° F. of the freezing point of sulfur. Upon exiting reactor 30 , the process gas is carried by conduit 58 to three-way valve 60 . Valve 60 is positioned so as to divert the process gas into conduit 84 and then to conduit 74 to be finally disposed of.
[0031] After a period of operation in the configuration shown in FIG. 3 , approximately three hours in certain embodiments, the gas flow path is slightly altered so that condenser 32 is bypassed and the process gas flows directly toward reactor 34 . This configuration is depicted in FIG. 4 . Thus, reactor 34 is permitted to operate under higher-temperature Claus conditions while reactors 26 and 30 operate under cold bed adsorption conditions. Further, during this period of operation, the catalyst within reactor 34 is regenerated so as to vaporize sulfur that has accumulated thereon. In certain embodiments, this particular plant configuration is operated for a period of approximately 9 hours.
[0032] Subsequent to operating plant 10 according to the configuration shown in FIG. 4 , operation of plant 10 is reverted to the configuration shown in FIG. 3 . Namely, condenser 32 is brought back on-line so that process gas from primary Claus reactor 12 now flows through condenser 32 en route to reactor 34 . This transition begins cooling of the catalyst in reactor 34 in preparation for the next re-sequencing of reactor units. In certain embodiments, the process gas exiting condenser 32 has a temperature of approximately 260° F., and plant 10 is operated in this configuration for approximately 3 hours.
[0033] As shown in FIG. 5 , the sequencing of the reactor units is changed yet again. Reactor unit 20 assumes the first position, followed by reactor units 22 and 18 . In this configuration, the catalyst in reactor 26 is the coolest of all of the three reactor unit reactors and thus capable of most efficient operation under cold bed adsorption conditions. Valve 36 and 80 are now closed, while valve 78 has been opened so that process gas exiting primary Claus reactor 12 via conduit 16 is directed toward reactor unit 20 . Three-way valve 54 is positioned to that the process gas flows through condenser 28 . Process gas exits condenser 28 and is carried via conduit 52 , through three-way valve 54 and toward reactor 30 via conduit 56 . In certain embodiments, the process gas exiting condenser 52 has a temperature of approximately 260° F.
[0034] The process gas carried by conduit 58 is then directed toward reactor unit 22 through three-way valve 60 . The process gas flows through condenser 32 , exiting the condenser at approximately 260° F. in certain embodiments, and then onto reactor 34 . The process gas carried by conduit 70 is then directed toward reactor unit 18 by three-way valve 72 . The process gas flows through condenser 24 which is operated at or below the freezing point of sulfur. In certain embodiments, the process gas exiting condenser 24 via conduit 40 has a temperature of about 240° F. or less, thereby leading to a reactor 26 inlet temperature that is within 10° F. of the freezing point of sulfur. The process gas is then directed toward reactor 26 which operates under cold bed adsorption conditions. The process gas exits reactor 26 via conduit 46 and is directed toward conduit 74 by valve 48 and ultimately to the incinerator. In certain embodiments, plant 10 operates in this configuration for approximately 3 hours.
[0035] Next, the configuration of plant 10 is slightly altered so that reactor 30 is operated under Claus conditions and the catalyst contained therein is regenerated. As shown in FIG. 6 , the position of valve 54 is changed so as to cause the process gas from conduit 76 to bypass condenser 28 . In this manner, process gas from primary Claus reactor 12 is directly fed to reactor 30 without having undergone sulfur condensation. The remainder of the process remains essentially the same as depicted in FIG. 5 and described previously. In certain embodiments, plant 10 operates in this configuration for approximately 9 hours.
[0036] Following a period of operation of plant 10 in the configuration shown in FIG. 6 , the configuration of plant 10 is reverted to that shown in FIG. 5 in preparation of a change in reactor unit sequencing. In certain embodiments, this period of operation in the configuration shown in FIG. 5 is for approximately 3 hours.
[0037] At this stage, reactor units 18 , 20 , and 22 have completed a full cycle with respect to their sequencing order within plant 10 . Plant 10 continues to operate in this fashion with periodic re-sequencing of reactor units. As discussed above, during a change in reactor unit sequencing, the reactor unit immediately downstream from primary Claus reactor 12 is shifted to the second position. The reactor unit furthest downstream from primary Claus reactor 12 is shifted into the first position to be immediately downstream from reactor 12 . By following this sequencing of reactor units, it is ensured that the reactor having the coolest catalyst is last in the sequence and is capable of operating most efficiently under cold bed adsorption conditions. | A process for removing sulfur from a gas stream is provided in which a plurality of reactor units, each comprising a condenser and reactor, are selectively operable under Claus reaction and cold bed adsorption conditions. The arrangement of reactor units within the plant is periodically changed following a front-middle-back sequencing scheme. This ensures that the final reactor unit in the series utilizes fully cooled catalyst which is most efficient for operation under cold bed adsorption conditions. In addition, the condenser of the final reactor unit in the series operates at or below the freezing point of sulfur thereby permitting even greater sulfur recovery. | 2 |
FIELD OF THE INVENTION
The invention relates to electronic article surveillance systems in which an alternating magnetic field is applied in an interrogation zone.
BACKGROUND OF THE INVENTION
Electronic article surveillance (EAS) systems have, in recent years, become increasingly commonplace. Such systems are now installed in a majority of academic and public libraries and are so common in retail stores as to not even cause a second look.
One type of EAS system in which alternating magnetic fields are employed typically utilizes panels or lattices on both sides of an exit way, thereby defining an interrogation zone through which protected articles bearing the EAS markers must pass. Both drive coils and sense coils are generally located within each lattice. For example, U.S. Pat. No. 4,994,939 (Rubertus) discloses a previously-preferred lattice assembly for housing both types of coils side by side, and in which a nulling mechanism is provided, thereby minimizing inductive coupling between the respective coils. As the null condition is affected by both ferrous objects near the lattice and by ambient electric currents, that mechanism enables the null condition to be adjusted during installation. While that patent facilitates certain improvements in the ease of construction, ease of installation, and usefulness with various types of systems and coil configurations, it has not proven to be fully satisfactory.
SUMMARY OF THE INVENTION
In contrast to lattices supplied with prior art magnetic EAS systems, the present invention is directed to an improved and more universal, more rugged, magnetic EAS lattice assembly.
The improved universal lattice assembly of the present invention thus comprises a structural chassis having a bottom section adapted to be mounted on a floor and opposing parallel side sections rigidly secured to opposite ends of the bottom section. The lattice assembly also includes means for indexing and interlocking the chassis with other members of the assembly, together with a frame formed of two molded half shells which, when mated together, define a cavity within which may be mounted a coil assembly such as may include a drive coil and, preferably, also a detector coil.
The mated together half-shells thus form opposing spaced-apart vertical legs, a top, substantially horizontal section connected across the top of the legs, a middle section connected between the legs and spaced upward of the bottom thereof, at least one additional, substantially horizontal section extending between the legs intermediate between the top and middle sections, and a centermost vertical section connected between the respective horizontal sections.
A cavity is thus defined by and extends through the vertical legs, top section, middle section, all additional horizontal sections, and the centermost vertical section. Within the cavity are means for receiving and rigidly anchoring the coil assembly in place. The half-shells also include a substantially continuous plurality of interlocking tabs and notches extending around a major portion of the respective peripheries of each half-shell which are adapted to mate together when the half-shells are positioned facing each other and are pressed together, thereby attaching the respective half-shells together.
Finally, means are provided in the middle section for receiving portions of the respective coils and associated electronic sub-assemblies, and the like, and for mating with members of the chassis, the mating of the chassis and half-shells making up the frame thereby forming a completed composite lattice assembly of high integral strength suitable for use in a hostile-user environment without requiring additional bonding of the respective members.
Preferably, the assembly also includes a foot pad adapted to be permanently secured on a floor surface and which includes means for receiving and anchoring the chassis therein. The pad, preferably, includes a pair of upward projecting structural support pins adapted to be received into matching apertures in the chassis. Desirably, the pins are of unequal length, enabling the assembled frame and chassis to be temporarily positioned on the foot pad, adjusted for operation, and moved away from the shorter pin, allowing the pad to then be permanently attached to the floor.
And, in one embodiment, the topmost section of the frame is configured in a generally arched shape, and a topmost section of the detector coil is anchored within the cavity formed by said topmost section of the frame. The detector coil desirably comprises two sections connected in a lazy FIG. 8 configuration, thereby having two substantially vertical juxtaposed, but crossed-over, centermost sections, which sections are anchored within the cavity formed by the centermost vertical section of the frame.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a partially cut away perspective view of a pair of lattice assemblies of a preferred embodiment of the present invention as used in a magnetic electronic article surveillance system installation;
FIG. 2 is an exploded perspective view of a preferred lattice assembly of the present invention;
FIG. 3 is a top view of three lattice assemblies of the present invention positioned to provide dual interrogation zones;
FIG. 4 is a front view of the lattice assemblies shown in FIG. 3;
FIG. 5 is a perspective view of a brace for interconnecting the lattice assemblies of FIG. 1; and
FIG. 6 is a cross-section of the brace shown in FIG. 5, taken along the line 6--6.
DETAILED DESCRIPTION
FIG. 1 shows a partially broken-away perspective view of a magnetic electronic article surveillance (EAS) interrogator according to a preferred embodiment of the present invention. As there shown, such an interrogator 10 comprises two universal lattice assemblies 12 and 14, which are identical to each other, and within which may be installed specific electronic sub-assemblies. Each of the universal lattice assemblies 12 and 14 comprises a frame 16 or 16', a chassis 18 or 18', and a coil assembly 20, which preferably includes a field-producing coil 21 and a detector coil 22 (not shown on lattice assembly 14). Each of these respective components will be discussed in more detail hereinafter.
With respect to FIG. 1, the assembly 12 has installed within the middle section 19 portions of the EAS system electronics, such as capacitor 24. Both sides of that assembly may then be covered by flat, flush-fitting covers 28, so as not to impede passage next to the assembly. In a similar manner, the assembly 14 has attached to the inner side a flush-fitting cover 30, thereby maintaining a maximum corridor width. The outer side of the assembly, on the other hand, has mounted thereon an expanded cover 32 containing more bulky system components such as a cooling fan 34 and regulator circuits 36. Within the center section 19' are mounted signal processor circuits 23, etc. Connections from the respective circuits in either assembly to the various coil components, audible and visible alarms 37 and 39, respectively, may be made via a cable within the brace/raceway 38.
The respective lattice assemblies 12 and 14 are mounted via base members 40 and 42 to a respective floor surface. Such base units typically include a centrally positioned portion 44 with opening 46 to provide access for incoming electrical power leads and projections 48 contacting the floor surface, enabling the base to be mounted on a variety of floor coverings, carpets, tile and the like. As described in more detail herebelow, the bases also include a pair of vertically extending pins 50 and 51 which are adapted to be received into mating recesses 52 and 53 in the assemblies.
As shown in more detail in the exploded view of FIG. 2, a representative lattice assembly 12 includes two half-shells 54 and 56, which together make up the frame 16 shown in FIG. 1, the structural chassis 18, the coil assembly 20, and the base or foot pad 40.
The chassis 18 further comprises a bottom section 58 formed of a 0.5 inch (12.7 mm) thick aluminum plate, adapted to be secured to the floor mounted base 40. Opposing parallel side sections 60 and 62 formed of T-shaped aluminum beams are, in turn, welded to the bottom section 58. The side sections are adapted to be secured between mating flanges 64 and 66 on the lower leg of half-shell 54 and corresponding flanges 68 and 70 on half-shell 56. The bottom section 58 further has openings 72 and 74 to receive the mounting pins 50 and 51 and an opening 76 aligned with the opening 46 on the base 40.
The coil assembly 20 is further there seen to include the field-producing or drive coil 21 and detector coil 22.
The two identical, molded half-shells 54 and 56, when mated with the other, form opposing, spaced-apart vertical legs 78 and 80, a top, substantially horizontal section 82 connected across the top of the legs, and a middle section 19 connected between the legs and spaced upward of the bottom 86 thereof. Recesses are provided in the top section 82 for receiving an alarm 37 and cover 83. The shells further include at least one additional, substantially-horizontal section 86 extending between the legs intermediate between the top and bottom sections 82 and 84. Preferably, the frame includes at least two such upper horizontal sections, thus including an upper section 88. As shown, the middle section 19 of the frame includes variously angled ribs 90 adapted to receive a variety of coil configurations and defines a lower cavity for containing electronic components. A centermost vertical section 92 connected between the respective horizontal sections is also provided. The respective sections are interconnected and, thus, define the interior cavity within which the coils are anchored. As particularly visible in half-shell 56, the respective walls defining the cavity include projecting ribs 94 defining tapered recesses and saddles for receiving and rigidly anchoring the coil elements in place.
As also visible on half-shell 56, the frame includes a substantially continuous plurality of interlocking tapered tabs 98 and notches 100 extending around a major portion of the peripheries which are adapted to mate together when the half-shells are positioned facing each other and are pressed together. As the half-shells are identical, it will be recognized that the tabs 98 on one side of the half-shell are positioned to mate and form a taper lock with similarly positioned notches 100 on the other side, and vice versa. Thus, when two half-shells are positioned facing each other, all tabs are received by a matching notch. When appropriate screws are inserted, a completed lattice assembly of high integral strength is formed which is suitable for use in a hostile-user environment without requiring additional bonding of the respective members.
As shown in both FIGS. 1 and 2, the base or foot pad 40 includes a pair of vertically projecting pins 50 and 51. It is preferred that one of the pins 50 be approximately 4 inches shorter than the other, and may include an opening 53 in which another pin may be inserted to maintain the assembly in an elevated position. By so doing, installation of the lattices is considerably facilitated. For example, if the installation is to include a pair of lattices as shown in FIGS. 1 and 2, two base members 40 and 42 may be attached via the brace/raceway 38, thus forming a relatively stable platform. These three members may then be approximately positioned at a desired orientation, and the respective lattice assemblies may be set down over the pins 50 and 51. Electrical connections to the coil assemblies may be made so that the assemblies may be tested for electrical null and other system parameters. Once proper placement and operation has been verified, the lattice assemblies may be carefully raised to clear the shorter pin and rotated about the taller pin to clear the base members sufficiently to allow access thereto, allowing the members to be rigidly attached to a floor surface. When so attached, the lattice assemblies may be rotated back and lowered to the earlier established positions, thus retaining the desired electrical null, etc.
As further shown in FIG. 2, the coil assembly 20 desirably includes a field-producing coil 21 which includes at least a pair of substantially similarly configured coil segments 102 and 104 juxtaposed in substantially a coplanar orientation. Each coil segment has a pair of spaced apart and substantially vertical arms 106 and 108, a top, substantially horizontal section 110 and 112, respectively, connecting the upper ends of the vertical arms, and a bottom, at least partially diagonal section 116 and 118, respectively, connecting the lower end of the vertical arms. As there seen, the vertical arms of each coil segment are anchored within the cavity formed by the vertical legs of the frame, one of the respective top sections of the coil segments is anchored within the cavity formed by the horizontal frame section 88, and the other top coil segment is anchored within a cavity formed by a lower horizontal section 86 of the frame. The respective top coil segments are thereby located at different, predetermined heights. Preferably, the diagonal sections 116 and 118 of each coil segment are anchored within the cavity formed by the ribs 90 in the middle section of the frame, each diagonal being there positioned at an opposite diagonal angle with respect to the vertical arms.
Also as there shown, it is desired that at least the topmost section 82 of the frame be configured in a generally arched shape, and that the top section 120 of the detector coil 22 be anchored within the cavity formed by that topmost section 82. Desirably, the top section of the detector coil is thus positioned appreciably above the cavity within which the topmost horizontal section of the field-producing coil is anchored. The detector coil is also shown to include two sections connected in a lazy FIG. 8 configuration, thereby having two substantially vertically juxtaposed, but crossed-over, centermost sections 122 and 124. These sections are anchored within the cavity formed by the centermost vertical section 92 of the frame and are adjustable via the null mechanism 126.
Top views of a three-lattice assembly are shown in FIGS. 3 and 4 to include assemblies 130, 132 and 134, with only the outside of assembly 130 having mounted thereon an expanded cover 136, in which electronics controlling the coil assemblies in all three lattices are included. The lattices are shown to be coupled together by braces 138 and 140.
During installation, as discussed above, it may be desired that the assemblies be rigidly coupled together to facilitate alignment and positioning, such as by use of the bolts 142. However, it has also been found that such rigid coupling may not be desired during actual use, as a person walking on the brace may cause vibration, and that vibration may be coupled to the lattice assembly and thence to the coil assembly, causing a shift in the electrical balance. It is, therefore, preferred that after the initial installation, such that the lattices are rigidly anchored to the floor, the bolts 142 and shims 143 be removed. The assemblies and brace are thus isolated to prevent coupling of vibration.
As shown in detail in FIG. 5, brace 138 may be positioned adjacent bases 40 and 42, and flanges 144 screwed to the bases with shims 143 therebetween, thus rigidly coupling the assemblage together. The cross-section of FIG. 6 further shows that the brace 138 desirably includes a raceway 146 within which interconnecting cables and conduits may be positioned.
The lattice assembly of the present invention is particularly desirably provided and inventoried in a disassembled state without specific coil assemblies, electronic sub-assemblies and covers in place, thereby decreasing the number of components which must be separately stocked. Upon receipt of an order for a particular EAS system and configuration, the requisite coils assemblies, electronic sub-assemblies may then be installed in the half-shells, the shells locked together, and covers put in place. The completed system is then in condition for shipping to a customer for installation.
While the use of a base member and interconnecting brace has been described hereinabove, it will be appreciated that other suitable mounting and connecting arrangements may be used. For example, the chassis may be attached directly to the floor or a large metal plate. Interconnecting wires may be fed below the floor, thereby eliminating any need for a raceway. | A universal lattice assembly for use in a magnetic-type electronic article surveillance system is disclosed which comprises a frame formed of two identical molded plastic half-shells, a metal chassis within which specific electronic sub-assemblies may be positioned and a coil assembly including a field-producing coil and a detector coil. The frame includes a substantially continuous series of tabs and notches which are positioned to be inter-connected as the half-shells are pressed together, the resulting assembly becoming dimensionally rigid, thus firmly anchoring a coil assembly in place, preventing any relative movement as the assembled unit may be jostled in operation. | 7 |
RELATED APPLICATIONS
This application is a provision of 60/210,675 filed Jun. 10, 2000.
This application is related to the following U.S. patent applications:
U.S. application Ser. No. 09/878,985 entitled System and Method for Daisy Chaining Cache Invalidation Requests in a Shared-memory Multiprocessor System, filed Jun. 11, 2001, and U.S. application Ser. No. 09/878,984.
Multiprocessor Cache Coherence System and Method in Which Processor Nodes and Input/Output Nodes Are Equal Participants, filed Jun. 11, 2001, and
U.S. application Ser. No. 09/878,983 entitled Cache Coherence Protocol Engine And Method For Processing Memory Transaction in Distinct Address Subsets During Interleaved Time Periods in a Multiprocessor System, filed Jun. 11, 2001.
The present invention relates generally to multiprocessor computer system, and particularly to a multiprocessor system designed to be highly scalable, using efficient cache coherence logic and methodologies.
BACKGROUND OF THE INVENTION
High-end microprocessor designs have become increasingly more complex during the past decade, with designers continuously pushing the limits of instruction-level parallelism and speculative out-of-order execution. While this trend has led to significant performance gains on target applications such as the SPEC benchmark, continuing along this path is becoming less viable due to substantial increases in development team sizes and design times. Such designs are especially ill suited for important commercial applications, such as on-line transaction processing (OLTP), which suffer from large memory stall times and exhibit little instruction-level parallelism. Given that commercial applications constitute by far the most important market for high-performance servers, the above trends emphasize the need to consider alternative processor designs that specifically target such workloads. Furthermore, more complex designs are yielding diminishing returns in performance even for applications such as SPEC.
Commercial workloads such as databases and Web applications have surpassed technical workloads to become the largest and fastest-growing market segment for high-performance servers. Commercial workloads, such as on-line transaction processing (OLTP), exhibit radically different computer resource usage and behavior than technical workloads. First, commercial workloads often lead to inefficient executions dominated by a large memory stall component. This behavior arises from large instruction and data footprints and high communication miss rates that are characteristic for such workloads. Second, multiple instruction issue and out-of-order execution provide only small gains for workloads such as OLTP due to the data-dependent nature of the computation and the lack of instruction-level parallelism. Third, commercial workloads do not have any use for the high-performance floating-point and multimedia functionality that is implemented in modern microprocessors. Therefore, it is not uncommon for a high-end microprocessor to stall most of the time while executing commercial workloads, which leads to a severe under-utilization of its parallel functional units and high-bandwidth memory system. Overall, the above trends further question the wisdom of pushing for more complex processor designs with wider issue and more speculative execution, especially if the server market is the target.
Fortunately, increasing chip densities and transistor counts provide architects with several alternatives for better tackling design complexities in general, and the needs of commercial workloads in particular. For example, the Alpha 21364 aggressively exploits semiconductor technology trends by including a scaled 1 GHz 21264 core, two levels of caches, memory controller, coherence hardware, and network router all on a single die. The tight coupling of these modules enables a more efficient and lower latency memory hierarchy that can substantially improve the performance of commercial workloads. Furthermore, the reuse of an existing high-performance processor core in designs such as the Alpha 21364 effectively addresses the design complexity issues and provides better time-to-market without sacrificing server performance. Higher transistor counts can also be used to exploit the inherent and explicit thread-level (or process-level) parallelism that is abundantly available in commercial workloads to better utilize on-chip resources. Such parallelism typically arises from relatively independent transactions or queries initiated by different clients, and has traditionally been used to hide I/O latency in such workloads. Previous studies have shown that techniques such as simultaneous multithreading (SMT) can provide a substantial performance boost for database workloads. In fact, the Alpha 21464 (the successor to the Alpha 21364) combines aggressive chip-level integration along with an eight-instruction-wide out-of-order processor with SMT support for four simultaneous threads.
Typical directory-based cache coherence protocols suffer from extra messages and protocol processing overheads for a number of protocol transactions. These problems are the result of various mechanisms used to deal with resolving races and deadlocks and the handling of “3-hop” transactions that involve a remote node in addition to the requester and the home node (where the directory resides). For example, negative-acknowledgment messages (NAKs) are common in several cache coherence protocols for dealing with races and resolving deadlocks, which occurs when two or more processors are unable to make progress because each requires a response from one or more of the others in order to do so. The use of NAKs also leads to non-elegant solutions for livelock, which occurs when two or more processors continuously change a state in response to changes in one or more of the others without making progress, and starvation, which occurs when a processor is unable to acquire resources.
Similarly, 3-hop transactions (e.g., requestor sends a request, home forwards request to owner, owner replies to requester) typically involve two visits to the home node (along with the corresponding extra messages to the home) in order to complete the transaction. At least one cache coherence protocol avoids the use of NAKs and services most 3-hop transactions with only a single visit to the home node. However, this cache coherence protocol places strict ordering requirements on the underlying transaction-message interconnect/network, which goes even beyond requiring point-to-point ordering. These strict ordering requirements are a problem because they make the design of the network more complex. It is much easier to design the routing layer if each packet can be treated independent of any other packet. Also, strict ordering leads to less than optimal use of the available network bandwidth.
The present invention also avoids the use of NAKs and services most 3-hop transactions with only a single visit to the home node. Exceptions include read transactions that require two visits to the home node because of a sharing write-back that is sent back to the home node. However, the present invention does not place ordering requirements on the underlying transaction-message interconnect/network.
SUMMARY OF THE INVENTION
In summary, the present invention is a system including a plurality of processor nodes configured to execute a cache coherence protocol that avoids the use of NAKs and ordering requirements on the underlying transaction-message interconnect/network and services most 3-hop transactions with only a single visit to the home node. Each node has access to a memory subsystem that stores a multiplicity of memory lines of information and a directory. Additionally, each node includes a memory cache for caching a multiplicity of memory lines of information stored in stored in a memory subsystem accessible to other nodes. Further, a protocol engine is included in each node to implement the negative acknowledgment free cache coherence protocol. The protocol engine itself includes a memory transaction array for storing an entry related to a memory transaction, which includes a memory transaction state. A memory transaction concerns a memory line of information and includes a series of protocol messages, which are routed both within a given node and to other nodes. Also included in the protocol engine is logic for processing memory transactions. This processing includes advancing the memory transaction when predefined criteria are satisfied (e.g., receipt of a protocol message) and storing an updated state of the memory transaction in the memory transaction array.
BRIEF DESCRIPTION OF THE DRAWINGS
Additional objects and features of the invention will be more readily apparent from the following detailed description and appended claims when taken in conjunction with the drawings, in which:
FIG. 1 is a block diagram of a multiprocessor system.
FIG. 2 is a block diagram of an input (I/O) node of the multiprocessor system of FIG. 1 .
FIG. 3 is a block diagram of a intra-chip switch and the module interfaces used to couple the modules of a system node to the intra-chip switch.
FIG. 4 depicts a directory data structure for keeping track of which nodes of the system have copies of each line of memory data.
FIG. 5 is a block diagram of a protocol engine.
FIG. 6A depicts the instruction format of the instructions executed in one embodiment of the protocol engine of FIG. 5;
FIG. 6B is a block diagram of a portion of the TSRF selection logic of the protocol engine of FIG. 5; and
FIG. 6C depicts a subset of the fields of each TSRF entry in the Transient State Register File (TSRF) of the protocol engine of FIG. 5 .
FIG. 7A is a table indicating operations performed during Even and Odd cycles of the execution unit of the protocol engine;
FIG. 7B depicts Even and Odd logical pipelines in the protocol engine that share use of many circuitry components; and
FIG. 7C depicts a state transition diagram for any single one of the TSRF entries in the Transient State Register File (TSRF) of the protocol engine of FIG. 5 .
FIG. 8 is a block diagram of a portion the execution logic of the protocol engine of FIG. 5 .
FIGS. 9A and 9B depict two embodiments of the Tag-State and Data arrays of an L1 cache.
FIG. 9C shows the architecture of the L1 cache in more detail.
FIGS. 10A and 10B depict the duplicate tag, tag-state and data arrays of an L2 cache.
FIG. 10C shows the architecture of the L2 cache in more detail.
FIGS. 11A, 11 B, 11 C, 11 D and 11 E illustrate the exchange of protocol messages in the course of a read request.
FIGS. 12A, 12 B, 12 C and 12 D illustrate the exchange of protocol messages in the course of a write request.
FIG. 13 illustrates the exchange of protocol messages in the course of completing a write-back request.
FIGS. 14A and 14B illustrate the exchange of protocol messages in the course of executing an invalidation request when nodes are represented in a limited-pointer format or a coarse-vector format.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
All specific quantities (such as numbers of processors, number of nodes, memory sizes, bit sizes of data structures, operating speeds of components, number of interfaces, number of memory locations in buffers, numbers of cache lines), as well as the sizes and number of components in various data structures, disclosed in this document, are provided solely for purposes of explaining the operation of one particular embodiment. These quantities will typically vary, sometimes significantly, from one implementation of the invention to another.
The following is a list of abbreviations frequently used in the descriptions below:
CCP: cache coherence protocol;
FSM: finite state machine;
HPE: home protocol engine;
ICS: intra-chip switch;
I/O: input/output;
MC: memory controller;
PC: processor core;
RPE: remote protocol engine; and
TSRF: Transient State Register File.
Referring to FIG. 1, there is shown a multiprocessor system 100 including a multiplicity of processor nodes 102 and an I/O nodes 104 . Each processor node 102 is preferably implemented as a single chip multiprocessor. In a preferred embodiment, each processor node 102 has eight processor cores (PC) 106 ; however, other embodiments have two to sixteen PCs 106 . The PCs 106 , which may be comprised of a central processing unit, are processor cores since their caches, cache coherence logic and other supporting circuitry are shown separately.
Each processor core (PC) 106 is directly connected to dedicated instruction cache (iL1) 108 and data cache (dL1) 110 modules. These first-level caches (L1 cache modules) 108 , 110 interface to other modules through an intra-chip switch (ICS) 112 . Also connected to the ICS 112 is a logically shared second level cache (L2) 114 that is interleaved into eight separate modules 116 , each with its own controller, on-chip tag, and data storage. Coupled to each L2 cache 116 is a memory controller (MC) 118 that preferably interfaces directly to a memory bank of DRAM (dynamic random access memory) chips (not shown) in a memory subsystem 123 . In a preferred embodiment, each memory bank provides a bandwidth of 1.6 GB/sec, leading to an aggregate bandwidth of 12.8 GB/sec. Also connected to the ICS 112 are two protocol engines, the Home Protocol Engine (HPE) 122 and the Remote Protocol Engine (RPE) 124 , which support shared memory across multiple nodes 102 , 104 of the system. Multiple nodes are linked by a subsystem including a router (RT) 126 , an input queue (IQ) 128 , an output queue (OQ) 130 , a packet switch (PS) 132 , and a packet switched interconnect 134 . The router 136 sends and receives packets to and from other nodes via the interconnect 134 . The interconnect 134 physically links multiple nodes 102 , 104 . In a preferred embodiment the total interconnect bandwidth (in/out) for each node is 32 GB/sec. Finally, a system control (SC) module 136 takes care of miscellaneous maintenance-related functions (e.g., system configuration, initialization, interrupt distribution, exception handling, performance monitoring).
In a preferred embodiment, the various modules communicate exclusively through the connections shown in FIG. 1, which also represent the actual signal connections. This modular approach leads to a strict hierarchical decomposition of the single chip used to implement each node of the system, which allows for the development of each module in relative isolation along with well defined transactional interfaces and clock domains. While each processor node 102 uses a complete multiprocessor system on a chip, the processor nodes 102 do not have any I/O capability in this embodiment.
Instead, I/O is performed by I/O nodes 104 , one of which is shown in FIG. 2 . Each I/O node 104 is preferably implemented as a single chip that is relatively small in area compared to the chip used to implement the processor nodes 102 . Each I/O node 104 is a stripped-down version of the processor node 102 having only one PC 106 , one L2 cache 116 and one memory controller module 118 . The router 140 on the I/O node 104 is a simplified version of router 126 having support for only two links instead of four, thus eliminating the need for a routing table. The I/O node 104 includes an I/O interface 142 , called the PCI/X interface in a preferred embodiment because it provides an interface between a PCI bus and an I/O bus 144 .
From the point of view of a programmer, the PC 106 on the I/O node 104 is indistinguishable from a PC 106 included on the processor node 102 . Similarly, memory at the I/O node 104 fully participates in the global cache coherence scheme of the multiprocessor system 100 (FIG. 1 ). The presence of a PC 106 on the I/O node 104 provides several benefits. For instance, it enables optimizations such as scheduling device drivers on this processor for lower latency access to I/O, or virtualization of the interface to various I/O devices (e.g., by having the PC 106 interpret accesses to virtual control registers). Except for the PCI/X interface 142 , most of the modules on the I/O node 104 are identical in design to those on the processor node 102 . For example, the same first-level data cache module (dL1) 110 that is used with the PCs 106 is also used to interface to the PCI/X module 142 . The dL1 module 110 also provides the PCI/X interface 142 with address translation, access to I/O space registers, and interrupt generation. The I/O node 104 may also be customized to support other I/O standards such as Fiber Channel and System I/O.
Referring back to FIG. 1, the multiprocessor system 100 in a preferred embodiment allows for glueless scaling up to 1023 nodes 102 , 104 , with an arbitrary ratio of I/O nodes 104 to processing nodes 102 . The ratio of I/O nodes 104 to processor nodes 102 is adjustable to match the resource needs of any particular workload. Furthermore, the router 126 , 140 in each of the nodes 102 , 104 supports arbitrary network topologies and allows for dynamic reconfigurability.
The I/O nodes 104 of the system are treated the same as processor nodes 102 , that is, as full-fledged members of the multiprocessor system 100 . In part, this design decision is based on the observation that available inter-chip bandwidth is best invested in a single switching fabric that forms a global resource utilized for both memory and I/O traffic.
In an alternate embodiment, one or more of the I/O nodes 104 of the system have no processor cores and therefore no L1 caches other than the L1 cache for the interface 142 to an I/O bus or device. Furthermore, a first subset of the no-processor core versions of I/O nodes 104 may also lack a memory subsystem 123 , while other ones of the no-processor core versions of the I/O nodes do include a memory subsystem 123 .
Processor Core and First-Level Caches
In a preferred embodiment, the PC 106 uses a single-issue, in-order design capable of executing the Alpha instruction set. It consists of a 500 MHz pipelined datapath with hardware support for floating-point operations. The pipeline has 8 stages: instruction fetch, register-read, ALU 1 through 5, and write-back. The 5-stage ALU supports pipelined floating-point and multiply instructions. However, most instructions execute in a single cycle. The PC 106 includes several performance enhancing features including a branch target buffer, pre-compute logic for branch conditions, and a fully bypassed datapath. The PC 106 interfaces with separate first-level instruction and data caches designed for single-cycle latency.
As will be described in more detail below, the system uses 64 KB two-way set-associative, blocking caches with virtual indices and physical tags. The L1 cache modules 108 , 110 include tag compare logic, instruction and data translation lookaside buffers (TLBs) (each storing 256 entries, in a 4-way associative caching arrangement), and a store buffer (data cache only). The L1 cache modules 108 , 110 also maintains a 2-bit state field per cache line, corresponding to the four states in a typical MESI protocol. For simplicity, the L1 instruction cache modules 108 and L1 data cache modules 110 use virtually the same design. Therefore, unlike other Alpha implementations, the instruction cache is kept coherent by hardware. Treating all cache modules 108 , 110 in the same way also simplifies the implementation of a no-inclusion policy at the L2 level.
Intra-Chip Switch
Referring to FIG. 3, conceptually, the ICS 112 is a crossbar that inter-connects most of the modules 150 on a processor node 102 or I/O node 104 . The ICS 112 includes a switch fabric 152 and an arbiter 154 for determining which data transfer(s) to handle during each available data transfer period. The length of the data period depends on the number of transfers required to send one cache line across the ICS 112 . In a preferred embodiment, each connection provided by the switch fabric 152 of the ICS 112 has a path width of 64 data bits, plus eight parity bits, for a total of 72 bits. Each cache line transported through the ICS 112 has 512 bits of data and sixty-four parity bits. Memory lines are transported along with the corresponding sixty-four parity bits when they are transported through the ICS 112 . Parity bits for memory lines are also sent to and used in the L1 cache arrays. However, parity bits are not used in the L2 cache and they are also not used in main memory. Instead, in the L2 cache, 20 ECC bits are associated with each memory line, and more specifically a 10-bit ECC is associated with each 256-bit half memory line. In the L2 cache and main memory, the 64 bits otherwise available for use as parity bits are used instead to store the 20 ECC bits, as well as a 44-bit directory entry, which will be described in more detail below. Data transfers generally are sent with a command or transaction type indicator, which is transferred in parallel with the first 64 bits of data of the cache line. Each cache line sized data transfer requires eight clock cycles, with 64 bits of data and a proportional share of the parity and ECC bits being transferred during each clock cycle.
Arbitration and flow control are handled by the arbiter 154 . To better understand the arbiter it is helpful to first review the interface 156 presented by each module 150 (i.e., L1 cache modules 108 , 110 , L2 cache, protocol engine or system controller) to the ICS 112 . As shown in FIG. 3, the standard intra-chip interface 156 provided by each such module includes one or more input buffers 160 , one or more output buffers 162 , a first finite state machine (FSM) 164 for controlling use of the input buffer(s) 160 , and a second finite state machine (FSM) 166 for controlling use of the output buffer(s) 162 . The arbiter 154 , via the FSM 164 , 166 of each module 150 keeps track of the availability of buffer space in the output buffers 162 of the modules 150 at all times, and exercises flow control by deferring requests to transfer data to modules with full input buffers 160 . The arbiter 154 also receives all intra-chip data transfer requests from the interfaces 156 of the modules 150 , and arbitrates between the requests whose destinations have input buffers 160 with sufficient room to receive a data transfer (i.e., a cache line of data).
In a preferred embodiment three parallel communication lanes, also called queues, are implemented in the input buffers 160 and output buffers 162 of the ICS interface 156 , as well as in the input and output buffers of interfaces (not shown) to the packet switch 126 and interconnect 134 (see FIG. 1 ). These lanes or queues are labeled I/O, low priority and high priority, respectively. The high priority queues in the input and output buffers are used to store messages sent from a home node to another node of the system, replies from third party nodes to the home node or the requester node for a particular transaction, and messages internal to a node. The low priority queues are used to store messages going to the home node for a particular transaction. The low priority message are thus messages for initiating new memory transactions, while the high priority messages are messages for completing previously initiated memory transactions. The I/O queues are used for handling requests being sent to I/O devices. The messages in the I/O queues are given the lowest priority by the intrachip switch 112 and also by the packet switch 126 and interconnect 134 (see FIG. 1 ).
The use of multiple communication lanes generally increases the size of the input and output buffers in the interfaces to the ICS 112 , packet switch 126 and interconnect 134 . However, the use of multiple communication lanes is important for avoid deadlock conditions in the network, and in particular for ensuring that active memory transactions make forward progress even when the system is experiencing high levels of protocol message traffic. In alternate embodiments, four or more communication lanes are used instead of three. In particular, in one alternate embodiment the high priority lane is replaced by two separate communication lanes, one for messages sent from the home node of a memory transaction and the other for replies sent by third parties to either the home node or any other node in the system. Providing the additional communication lane helps to ensure that messages sent by the home nodes of transactions are not blocked by reply messages being sent by the same node(s) for transactions in which those nodes are not the home node, and vice versa.
From a philosophical viewpoint, the ICS 112 is the primary facility for decomposing the processor node 102 and I/O node 104 into relatively independent, isolated modules 150 . For instance, the transactional nature of the ICS 112 and the uniformity of the interfaces 156 presented by the modules 150 to the ICS 112 together allow different types of modules 150 to have different numbers of internal pipeline stages for handling various type of memory transactions.
The ICS 112 uses a uni-directional, push-only data transfer technique. The initiator of a memory transaction always sources data. If the destination of a transaction is ready, the arbiter 154 schedules the data transfer according to datapath availability. A grant is issued by the arbiter 154 to the initiator of the transaction to commence the data transfer at a rate of one 64-bit word per cycle without any further flow control. Concurrently, the destination receives a signal from the arbiter 154 that identifies the initiator and the type of transfer. Transfers across the ICS 112 are atomic operations.
Each port to the ICS 112 consists of two independent 64-bit data paths (plus additional datapath bits for eight parity bits) for sending and receiving data. The ICS 112 supports back-to-back transfers without dead-cycles between transfers. In order to reduce latency, in a preferred embodiment the modules 150 are allowed to issue a “pre-request” indicating the target destination of a future request, ahead of the actual transfer request. The pre-request is used by the ICS 112 to pre-allocate data paths and to speculatively assert a grant signal to the requester.
Directory Used in Cache Coherence Protocol
Referring to FIG. 4, within each node of the system that has a memory subsystem 123 , a cache state directory 180 is maintained by the home protocol engine (HPE) 122 . The memory subsystem 123 of a node is also called the main memory array of the node. The directory 180 for a node's memory subsystem 123 includes one directory entry 182 for each “memory line” 184 in the memory system 123 . A “memory line” is the unit of memory that fits into one cache line of the L1 cache modules 108 , 110 and L2 caches 114 . In a preferred embodiment, a memory line is 512 bits (64 bytes, or eight 64-bit words) of data; however, the size of the memory line will vary from one implementation to another. Each memory line 184 also includes two 10-bit ECC (error correction code) codes (one for each half memory line). The 20 bits of ECC codes and the 44-bit directory entry 182 occupy the same amount of memory, 64 bits, as would be required for one parity bit per byte. The ECC bits are used only in main memory and the L2 cache, to detect and correct errors in retrieved memory lines, while the directory entry is used by the home protocol engine (HPE) 122 to maintain cache coherence of the memory lines 184 corresponding to the directory entries 182 .
Each directory entry 182 includes a state field 186 for indicating the state of the corresponding memory line 184 , and a sharer-information field 188 for identifying nodes 102 , 104 that have or might have a shared copy of the corresponding memory line 184 . A directory entry 182 in a preferred embodiment contains 44 bits, with the state field 186 comprising a 2-bit field that is repeated (i.e., stored twice in each directory entry 182 ) and the sharer-information field 188 comprising a 40-bit field that is split into two 20-bit fields 188 - 1 , 188 - 2 . In a preferred embodiment there are two possible formats for the sharer-information field 188 , with the format of the sharer-information field 188 in a given directory entry 182 being determined by the number of nodes 102 , 104 sharing the memory line 184 corresponding to the directory entry 182 . Generally, a node 102 , 104 is said to “share” a memory line 184 if it maintains a read-only copy of the memory line 184 —typically stored in a cache array 108 , 110 , 114 within the respective node 102 , 104 .
In a preferred embodiment (with a 40-bit sharer-information field and a maximum of 1023 nodes), when the number of nodes 102 , 104 currently sharing a memory line 184 is four or less, a first sharer-information field 188 format called the “limited-pointer” format is used. In this format, the 40-bit sharer-information field 188 is divided into four 10-bit sub-fields, each of which is used to store a “direct node pointer” that identifies a node 102 , 104 that is a sharer of the memory line 184 . A predefined null pointer value (e.g., 0×000 or 0×3FF) is stored in one or more of the 10-bit sub-fields to indicate that the respective 10-bit field does not identify a node 102 , 104 (e.g., when fewer than four nodes 102 , 104 share a memory line 184 ). More generally, the size of the sharer-information field 188 and the number of bits required for each direct node pointer determines the maximum number (DP) of direct node pointers that a sharer-information field 188 can store. Additionally, the node pointers (i.e., identifiers) included in the 10-bit sub-fields are obtained from requests to share a corresponding memory line of information 184 . Thus, each request to share a memory line of information 184 (described in detail below), includes a 10-bit identifier of the requesting node.
Also, in a preferred embodiment, when the number of nodes 102 , 104 sharing a memory line 184 is more than four, a second sharer-information field 188 format called the “coarse vector” format is used. In this format, each bit in the sharer-information field 188 corresponds to one or more nodes 102 , 104 . More specifically, when the number of nodes 102 , 104 in the multiprocessor system 100 is more than four but less than forty-one, each bit of the sharer-information field 188 either corresponds to one node 102 , 104 or does not correspond to any node 102 , 104 . Thus, a set bit (zero or one depending on the specific implementation) in the sharer-information field 188 of a given directory entry 182 indicates that the one node 102 , 104 corresponding to the set bit shares the memory line 184 corresponding to the directory entry 182 . And when the number of nodes 102 , 104 in the multiprocessor system 100 is more than forty, one or more of the bits in the sharer-information field 188 correspond to a plurality of nodes 102 , 104 . Thus, a set bit (zero or one depending on the specific implementation) in the sharer-information field 188 of a given directory entry 182 indicates that the one or more nodes 102 , 104 corresponding to the set bit share the memory line 184 corresponding to the directory entry 182 .
Because only one bit is used to identify one or more nodes 102 , 104 when the sharer-information field 188 is in the coarse-vector format, each node 102 , 104 in the multiprocessor system 100 must be mapped to a bit in the sharer-information field 188 . The node to bit assignment table 189 of FIG. 4 illustrates a mapping of a plurality of nodes to a number of bits in a preferred embodiment (preferred embodiments of the invention do not actually utilize a table, which is included here merely for illustration). Specifically, table 189 shows 76 nodes 102 , 104 mapped to respective bits in a 40-bit sharer-information field 188 . Each column in table 189 is associated with a bit in the sharer-information field 188 . Thus, according to table 189 the first bit in the sharer-information field 188 is associated with the node 102 , 104 identified (and addressed) as 40. Since only 76 nodes 102 , 104 are included in the multiprocessor system 100 of this example, table 189 includes only two rows. But if the number of nodes 102 , 104 included in the multiprocessor system 100 in this example exceeded 79, 119, 159, etc., additional rows would be included in the table 189 . In other words, additional nodes 102 , 104 would be associated with one or more of the bits in the sharer-information field 188 .
As indicated above, the numbers included in each entry of table 189 are node identifiers. The brackets around “0” is meant to indicate that 0 is not a valid node identifier in the embodiment illustrated in table 189 . In this embodiment, zero is used in the limited-pointer format to indicate that a particular sub-field of the sharer-information field 188 does not identify a node 102 , 104 . To maintain consistency between the two formats, zero is not a valid node identifier in either format.
Determining the node identifiers for nodes 102 , 104 associated with a given bit in sharer-information field 188 (which permits the home node 102 , 104 to send out invalidation requests when a given sharer-information field 188 is in the coarse-vector format), is divided into two basic steps. Assuming that a given bit is set and associated with column 3 of table 189 (FIG. 4 ), the first node 102 , 104 associated with this bit is simply the column number, i.e., 3. To calculate subsequent node identifiers of nodes 102 , 104 associated with this bit, the system adds to the column number positive integer multiples of the number of bits included in the sharer-information field 188 to the column number. For example, for column three of the sharer-information field, the associated system nodes are 3 , 43 , 83 and so on. The second step (i.e., adding multiples of the number of bits in the sharer-information field 188 ) is continued until the calculated node identifier exceeds the total number of nodes 102 , 104 in multiprocessor system 100 , in which case, the previously calculated node identifier is the identifier of the final node 102 , 104 associated with a given bit.
As noted above, each directory entry 182 includes a state field 186 . In a preferred embodiment, the state field 186 is set to one of the following defined states:
invalid: indicates that the corresponding memory line 184 is not shared by another node 102 , 104 ;
exclusive: indicates that a node 102 , 104 has an exclusive copy of the corresponding memory line of information 184 , and thus may make changes to the memory line of information 184 ;
shared: indicates that the sharer-information field 188 is configured in the limited-pointer format described above and that the number of nodes having a non-exclusive (i.e., shared) copy of the corresponding memory line of information 184 is less than or equal to DP;
shared-cv: indicates that more than DP nodes 102 , 104 have a non-exclusive (i.e., shared) copy of the corresponding memory line of information 184 and that the sharer-information field 188 is configured in the coarse vector format described above.
Protocol Engines
The basic architecture of each of the protocol engines 122 , 124 (FIG. 1) is shown in FIG. 5 . The protocol engines are responsible for handling memory transactions, such as the sharing of cache lines, the exclusive assignment of a cache line to a processor in a particular node of the system, remote read and write operations. The protocol engines 122 , 124 are responsible for maintaining cache coherence of cache lines among the nodes 102 , 104 of the multiprocessor system 100 .
Each of the protocol engines 122 , 124 , as shown in FIG. 5, includes an input controller 190 , preferably implemented as a finite state machine used in connection with a set of input buffers 192 for receiving data (inbound messages) from the ICS 112 and the PS 132 . Received messages, some of which include a full cache line of data and the associated parity bits, are stored in the input buffers 192 . In a preferred embodiment, sufficient input buffers 192 are provided to store inbound, received data for up to sixteen ongoing memory transactions. A test and execution unit 194 (herein called the execution unit) executes instructions obtained from an instruction memory 196 , also called the microcode array, so as to advance memory transactions, also called cache coherence transactions. The currently selected instruction, obtained from the instruction memory 196 , is held in a current instruction buffer 197 for decoding and execution by the execution unit 194 . Output messages generated by the execution unit 194 are stored in a output buffers 198 , the operation of which are controlled by an output controller 200 , preferably implemented as a finite state machine. The output messages are transferred from the output buffers 198 to specified destinations within the same node 102 , 104 as a protocol engine 122 , 124 via the ICS 112 or to specified destinations within other nodes 102 , 104 of the multiprocessor system 100 via the PS 132 .
While the processor nodes 102 and I/O nodes 104 of a preferred embodiment use two protocol engines, including a home protocol engine (HPE) 122 (FIG. 1) for handling memory transactions where the node 102 , 104 in which the protocol engine 122 resides is the home of the memory line that is the subject of the memory transaction, and a remote protocol engine (RPE) ( 124 , FIG. 1) for handling memory transactions where a remote node 102 , 104 is the home of the memory line that is the subject of the memory transaction, for most purposes the two protocol engines 122 , 124 maybe considered to be logically a single protocol engine.
FIG. 6A shows the format of each of the instructions stored in the instruction memory 196 and instruction buffer 197 . As shown, each instruction includes an operator, two operands, and a next program counter field. The operator indicates the type of operation to be performed by the execution unit 194 when executing the instruction, the two operands provide parameters that affect the execution of an instruction.
The current state of multiple memory transactions is stored in a set of registers collectively called the Transient State Register File (TSRF) 202 . Each memory transaction has a memory line address (sometimes called the global memory address) that identifies the memory line that is the subject of the memory transaction. More specifically, the memory line address identifies the node 102 , 104 that interfaces with the memory subsystem 123 that stores the memory line of information 184 (i.e., home node) and a specific position within the memory subsystem 123 of the memory line of information 184 . In a preferred embodiment, the top M (e.g., 10) bits of the memory line address identify the home node 102 , 104 of the memory line of information 184 , while the remainder of the address bits identify the memory line 184 within the identified node. In a preferred embodiment, the memory line address for a memory line does not include any of the address bits used to identify sub-portions of the memory line, such as individual 64-bit words of individual bytes within the memory line of information 184 . However, in other embodiments that support transactions on sub-portions of memory lines, the memory line addresses used may include bits for identifying such memory line sub-portions.
Referring to FIG. 6B, each memory transaction has a respective entry 210 stored in the Transient State Register File (TSRF) 202 that indicates the state of the memory transaction. In a preferred embodiment, the TSRF 202 has registers for storing sixteen entries 210 as well as access circuitry for reading and updating the contents of the TSRF entries 210 . Obviously the number of entries in the TSRF 202 is a design choice that will vary from one implementation to another. Typically, the TSRF 202 will include at least as many entries as the number of PCs 106 included in a processor node 102 .
Referring to FIG. 6B, the entries 210 of the TSRF 202 are divided into two groups—“even” TSRF entries 210 and “odd” TSRF entries 210 . The “even” TSRF entries 210 are used for memory transactions associated with memory lines of information 184 that have “even” memory line addresses (i.e., memory line addresses ending in a “0” bit), while the “odd” TSRF entries 210 are used for memory transactions associated with memory lines of information 184 that have “odd” memory line addresses (i.e., memory line addresses ending in a “1” bit).
Referring to FIGS. 6B, 7 A- 7 C, and 8 , the sequence of operations required to execute an instruction so as to advance a memory transaction is: reading the TSRF entries, scheduling one of the transactions represented by the TSRF entries, retrieving from the instruction memory the instruction identified by the TSRF of the scheduled transaction, and executing the instruction. As shown in FIGS. 7A and 7B, this sequence of four operations is pipelined and is furthermore performed by two “logical pipelines” that are parallel but offset from each other by one clock cycle. One logical pipeline is for the odd TSRF entries and the other is for the even TSRF entries. However, the two logical pipelines are implemented using a shared scheduler 212 , a shared microcode array 196 and access circuitry (see FIG. 8 ), and shared execute logic 240 , which along with the scheduler 212 is part of the test and execution unit 194 . Only the TSRF registers and access circuitry 202 have distinct even and odd circuits.
Alternating clock cycles of the test and execution unit 194 are called Even and Odd clock cycles. As shown in FIG. 7A, during each even clock cycle the following operations are performed, simultaneously, by the circuitry modules identified in FIG. 7 B:
reading the Odd TSRF entries, including comparing the address in each of the Odd TSRF entries with the addresses of messages received from the packet switch and intra-chip switch;
scheduling a next Even transaction (by selecting an Even TSRF entry) to be advanced by executing an instruction identified by the “next PC” field of one of the Even TSRF entries;
reading the microcode instruction identified by (A) the Odd transaction scheduled in the immediately previous Odd clock cycle and the condition code (CC) bits stored in the TSRF entry for the scheduled Odd transaction; and
executing the instruction for the currently scheduled Even transaction, where the instruction is identified by the “next PC” field of the Even transaction selected by the scheduler two clock cycles ago as well as the condition code bits stored in the TSRF of the currently scheduled transaction.
Similarly, as shown in FIG. 7A, during each Odd clock cycle the following operations are performed, simultaneously, by the circuitry modules identified in FIG. 7 B:
reading the Even TSRF entries, including comparing the address in each of the Even TSRF entries with the addresses of messages received from the packet switch and intra-chip switch;
scheduling a next Odd transaction (by selecting an Odd TSRF entry) to be advanced by executing an instruction identified by the “next PC” field of one of the Odd TSRF entries;
reading the microcode instruction identified by (A) the Even transaction scheduled in the immediately previous Even clock cycle and the condition code (CC) bits stored in the TSRF entry for the scheduled Even transaction; and
executing the instruction for the currently scheduled Odd transaction, where the instruction is identified by the “next PC” field of the Odd transaction selected by the scheduler two clock cycles ago as well as the condition code bits stored in the TSRF of the currently scheduled transaction.
The scheduler 212 selects the next Even (or Odd) transaction at the same time that the current Even (or Odd) transaction is being executed. In some circumstances, it is important for the current transaction to remain active and to be executed during two or more successive even clock cycles. For example, this is the case when a transaction needs to send two or more messages to other nodes in the system. The scheduler is able to determine whether the current Even (or Odd) transaction should be scheduled to execute again during the next Even (or Odd) clock cycle by inspecting the state, counters and condition codes in the TSRF of the currently executing transaction to determine if they satisfy predefined criteria for continuing execution of the current transaction for an additional execution cycle.
By interleaving instruction fetch and instruction execute cycles, the bandwidth and computational resources of the test and execution unit 194 and the microcode memory 196 are fully utilized.
As shown in FIG. 6B, the test and execution unit 194 (FIG. 5) of the protocol engine includes a scheduler 212 that selects an even TSRF entry 210 and an odd TSRF entry 210 , corresponding to the next even memory transaction and the next odd memory transaction to be processed or advanced by the execution unit 194 . The selections by the scheduler 212 are conveyed to a pair of multiplexers 214 , 215 that transfer information from selected even and odd TSRF entries 210 to a pair of latches 216 , 217 for storing the state of the currently running memory transactions. The TSRF entries stored in latches 216 , 217 are used by the execution logic 242 (FIG. 8) of the execute unit 194 (FIG. 5 ).
Referring to FIG. 6C, each TSRF entry 210 includes many fields, a small subset of which are identified and described below:
a state field 220 : indicates the state of the associated memory transaction if any;
an address field 222 : stores the memory line address associated with a memory transaction if any;
a next program counter field 224 : identifies the next instruction to be executed by the execution unit when certain preconditions required for continued execution of the memory transaction are satisfied; and
a set of counter fields 226 : are used to store count values that, for example, control repeated execution of an instruction (e.g., when a transaction needs to send out N identical protocol messages to other nodes 102 , 104 , one of the counter fields 226 is initially to a value corresponding to N, and is then decremented or incremented after each execution of the instruction until a predefined terminal count value is reached, at which point the memory transaction is either complete or a next program counter for the transaction is determined). The counter fields 226 and the state field 220 together form an overall or more specific state of an associated memory transaction.
In a preferred embodiment, the set of defined states for the state field 220 include:
vacant (also called invalid): indicates that the TSRF entry 210 does not store information related to a memory transaction;
active: indicates that the associated memory transaction is available for scheduling/execution;
running: indicates that the associated memory transaction is currently running (i.e., is currently being executed by the execution unit 194 , or was the transaction for which an instruction was executed during the last available even or odd execution cycle);
waiting: indicates that the associated memory transaction is stalled/deferred, waiting for a protocol message from another node 102 , 104 to be delivered via the PS 132 ;
local_waiting: indicates that the associated memory transaction is stalled, waiting for a protocol message from within the same node 102 , 104 to be delivered via the ICS 112 ; and
suspended: indicates that the associated memory transaction is suspended because there is a memory address conflict with a previously allocated memory transaction having the same memory line address.
FIG. 7C shows all defined state transitions for each of the TSRF entries 210 . A Vacant TSRF entry 210 becomes Active when a message initiating a new memory transaction is received and there is no unfinished transaction having the same memory line address and that blocks activation of the new memory transaction. A Vacant TSRF entry 210 becomes Suspended when a message initiating a new memory transaction is received and there is unfinished memory transaction having the same memory line address that blocks activation of the new memory transaction.
When an Active transaction is scheduled for execution it enters the Running state. If the execution of the transaction completes the transaction, the TSRF returns to the Vacant state. The Running Transaction remains in the Running state until it was sent all the protocol messages required for handling a current portion of the transaction. If execution of the transaction does not complete the transaction, the state of the TSRF becomes Waiting if the transaction is waiting for one or more messages from one or more other nodes to be able to continue the transaction, and becomes Local_Waiting if the transaction is waiting only for one or more messages from the local node to be able to continue the transaction.
The scheduler 212 includes arbitration logic for selecting the next even TSRF entry and the next odd TSRF entry to be sent to the execution unit 194 in accordance with (A) the states of the TSRF entries, (B) the buffered received messages received via the PS 132 and the ICS 112 and which TSRF entry, if any, corresponds to each of the buffered received messages, and (C) a set of prioritization rules. Each TSRF entry and each buffered received message identifies the memory line associated therewith, and the arbitration logic of the scheduler includes an array of comparators for comparing the memory line addresses in the TSRF entries with the memory line addresses in the buffered received messages so as to produce a corresponding set of status update signals. The status update signals are used for “upgrading” TSRF entries from the Waiting and Local_Waiting state to the active state, as well as for downgrading the TSRF entry for the last running transaction to the waiting, local waiting or vacant state, depending on whether the transaction is finished, and if not finished, what type of message (i.e., from the local node or a remote note) the transaction needs to receive in order to ready to resume execution.
The status update signals are also used to determine when a buffered received message has the same address as a previously allocated TSRF, but is for a different memory transaction. When this condition is detected by the arbitration logic, one of three actions is performed: (A) a new TSRF entry is allocated for the transaction associated with the received message, and the new transaction is suspended, (B) the received message is merged into previously allocated transaction and modifies its state, or (C) the message is temporarily left in the input buffer because the previously allocated transaction is not currently in a state allowing the received message to be merged with it, and the received message is then either merged with the previously allocated transaction or, if that transaction completes, a new TSRF is allocated for the new message and that TSRF is placed in the Active state. When the received message is of the type that could potentially be merged with a previously allocated transaction, the previously allocated transaction must be in the Waiting or Local_Waiting state before the merger can be performed. When a Receive instruction is executed, the transaction enters a Waiting or Local_Waiting state. The transaction can not enter the Active state until either (A) one of the predefined messages required to advance the transaction, or (B) one of the predefined messages that can be merged with the transaction is received.
Referring to FIGS. 6B and 8, the scheduler 212 selects between continued execution of the currently Running transaction and any of the other Active transactions, if any. FIG. 6B shows a portion of the logic for selecting an Active transaction. FIG. 8 shows logic for continuing execution of a currently Running transaction. On the right side of FIG. 8 is shown a current instruction buffer 197 for holding the current instruction for Running transaction.
The operator and arguments of the current instruction are passed to the execute logic 242 , which also has access to all the fields of the TSRF of the Running transaction. The execute logic computes a set of condition codes, labeled “Curr_CC” in FIG. 8, as well as new State and Next PC for the TSRF of the running transaction. The Next PC, to be stored in the TSRF of the current Running transaction, is obtained from the current instruction stored in buffer 197 . The execute logic 242 may also update one or more counters in the TSRF of the current Running transaction as well as other fields of the TSRF.
When the scheduler 212 determines that the current Running transaction should continue to run, the next instruction for the transaction is determined as follows. The current instruction in buffer 197 includes a “Next PC” field that specifies the base address of a next instruction. Predefined bits (e.g., the four least significant bits) of the “Next PC” address are logically combined (by logic gate or gates 244 ) with the condition codes (Curr_CC) generated by the execute logic 242 so as to generate a microcode address that is stored in microcode address latch 246 . Multiplexers 248 and 250 are provided to facilitate selection between the current Running transaction and another Active transaction. Multiplexers 248 and 250 operate during both Even and Odd clock cycles so as to perform separate instruction retrieval operations during Even and Odd clock cycles (See FIG. 7 A).
When all the Even (or Odd) TSRF entries are in the Vacant state, meaning that there are no running, active or waiting Even (or Odd) memory transactions, there are no Even (or Odd) memory transactions for the scheduler to select for execution, and thus the corresponding logical pipeline is unused. More generally, when none of the Even (or Odd) TSRF entries are in the Running or Active state (see discussion of FIG. 6 C), meaning that there are no Even (or Odd) memory transactions that are ready to be processed by the execution unit of the protocol engine, the corresponding logical pipeline is unused. During the corresponding clock periods instructions are not fetched from the instruction memory and the test and execution unit remains dormant.
The operation of the protocol engine while handling various specific memory transactions will be described in more detail below. Additional aspects of the scheduler and execution logic will also be described in more detail below.
L1 Cache
Referring to FIG. 9A, for simplicity a direct mapped version of the L1 cache 260 will be explained before explaining the two-way set associative version, shown in FIG. 9 B. Each L1 cache 260 , whether it is a data or instruction cache (see FIG. 1) includes a data array 262 for storing cache lines, a tag array 264 and a state array 266 . Each entry 268 of the L1 cache 260 includes a cache line, a tag and a state value. The cache line consists of the data from one memory line, and in a preferred embodiment this consists of 64 bytes (512 bits) of data plus parity and ECC bits corresponding to the 64 bytes.
The tag of each entry 268 consists of the address bits required to uniquely identify the cache line, if any, stored in the entry. Each address used to access memory consists of a string of address bits, ABCD, where A, B, C and D each consist of different groups of the address bits. The D bits are used to identify specific words (or bits, or bytes, depending on the implementation) within the cache line. The B and C bits, herein called BC, identify the entry 268 into which the memory line at address ABC 0 is stored within the L1 cache. The BC bits are called the index or cache index of the address. The A bits comprise the tag of the cache line, which together with the cache index uniquely identify the memory line. The only reason for dividing the cache index bits, BC, into two groups is for purposes of explaining the embodiment shown in FIG. 9 B.
The state of each L1 cache entry 268 is represented by two bits, which for each cache line represent one of four predefined states:
invalid, which means that the cache entry 268 is empty, or that the data in it is invalid and should not be used;
shared, which means that other processors or other nodes in the system have non-exclusive copies of the same memory line as the one stored in the cache entry;
clean_exclusive, which means that this L1 cache has the only copy of the associated memory line, has been allocated exclusive use thereof, and that the value of the cache line has not been changed by the processor coupled to the L1 cache; and
dirty_exclusive, which means that this L1 cache has the only copy of the associated memory line, has been allocated exclusive use thereof, and that the value of the cache line has changed by the processor coupled to the L1 cache.
Referring to FIG. 9B, there is shown a two-way associative version of the L1 cache, which is a preferred implementation. Only the differences between the L1 caches of FIGS. 9B and 9A will be described. In particular, the set associative L1 cache 270 has the same number of entries 278 as the direct mapped L1 cache 260 , but in this version there are two cache lines mapped to each cache index instead of just one. As a result, there are only half as many cache index values, and therefore the cache index is represented by just the C bits of the ABCD address bits. In this embodiment of the L1 cache, the B address bit of each memory line address is included in the tag of the entry, and thus the tag array 274 is one bit wider in this embodiment than in the direct mapped L1 cache embodiment. If the L1 cache were a four-way associative cache, the tag array 274 would be two bits wider than in the direct mapped L1 cache embodiment. A two-way associative L1 cache is preferred over a direct mapped cache because it reduces cache evictions caused by cache index conflicts.
L1 Data Paths and Control Logic
FIG. 9C shows the data paths and primary components of the L1 cache 108 , 110 . Some of the connections between the various finite state machines of the L1 cache and some of the connections between those finite state machines, the tag and state arrays 274 , 266 and other components of the L1 cache 108 , 110 that are described below are not shown in FIG. 9C in order to avoid undue cluttering of this figure.
The L1 cache receives data (PC_L1_data) and a virtual address (PC_vaddr) from the processor core coupled to the L1 cache. Other signals received by the L1 cache from the processor core are a read request signal (PC_RdRq), which signals that the processor core is requesting data from the L1 cache, and a write request (PC_WrRq), which signals that the processor is requesting to write data into the L1 cache. The signals sent by the L1 cache to the processor core include data output by the L1 cache (L1_PC_data), a replay signal (PC_replay) requiring the processor to retry the last request sent by the processor core to the L1 cache, and an inhibit signal (PC_inhibit) to inform the processor core to inhibit its memory accesses because the L1 cache is busy (e.g., servicing a cache miss).
The L1 cache receives data from and sends data to the L2 cache, main memory, and other devices via the intra-chip switch 112 . Received data is temporarily buffered by a data in buffer 310 , and data being sent elsewhere is output via an output finite state machine (Output FSM) 312 . The output buffer for sourcing data to the ICS 112 is called the Fwd/Evt buffer 366 .
Input logic 314 receives control signals sent via the ICS 112 and conveys those control signals to either a fill FSM 316 or a synonym FSM 318 . The fill FSM 316 controls the loading of a cache line received from the ICS 112 into the L1 cache data array 262 . The synonym FSM 318 controls the movement of a cache line from one L1 cache slot to another when the L2 cache instructs the L1 cache to do so. Multiplexer 320 routes cached data from a slot of the L1 cache data array 262 back to the data array input multiplexer 322 under the control of the synonym FSM 318 . Input and output staging buffers 321 , 323 are preferably used in this data path, for instance to facilitate delivery of successive portions of the data in a cache line over the data path.
When the synonym FSM 318 is not active, multiplexer 320 sources data from the data input buffer 310 to the data array input multiplexer 322 . The movement of a cache line from one L1 cache slot to another is required when the cache line index derived from a virtual address does not match the physical location of a cache line in the L1 cache. A tag information input multiplexer 324 is also controlled by the synonym FSM 318 to enable tag information for the L1 tag array 274 to be sourced by synonym information from the synonym FSM 318 when the synonym FSM 318 is activated. When the synonym FSM 318 is not activated, the tag information input multiplexer 324 sources tag information for the L1 tag array 274 from the virtual address (PC_vaddr) provided by the processor core.
An inhibit FSM 330 receives signals from the fill FSM 316 and synonym FSM 318 when those finite state machines are activated and sources the PC_inhibit signal to the processor core while either of these finite state machines is servicing a cache fill or synonym cache line relocation operation.
When the processor core sends either a read or write request to the L1 cache, the processor core provides a virtual address, PC_vaddr. The virtual address and information derived from it, such as a valid tag match signal, are stored in a series of staging buffers 332 , 334 , 336 . Additional staging buffers, beyond those shown in FIG. 9C, may be required in some implementations. The virtual address is translated into a physical address (PA) by a translation lookaside buffer (TLB) 340 at the same time that a tag and state lookup is performed by the tag and state arrays 274 , 266 . The resulting physical address and tag lookup results are stored in a second staging buffer 334 and are then conveyed to a tag checking circuit 342 that determines if there is a tag match for a valid cache line. The results of the tag check, which includes state information as well as tag match information and the virtual address being checked, are stored in yet another staging buffer 336 . The information in the staging buffer 336 is conveyed to a data write FSM 360 when a valid match is found, and is conveyed to the output FSM 312 when a cache miss is detected. The final staging buffer 336 also stores a “replay” signal, generated by the tag checking circuit 342 , and the replay signal is conveyed to the processor core to indicate whether the L1 read or write operation requested by the processor core must be resubmitted to the L1 cache after the PC_inhibit signal is deactivated.
When a data write is being performed, the write request signal (PC_WrRq) and the results of the tag lookup are used by a data write FSM 360 and a cache access Arbiter 362 to determine if (and when) the data sourced by the processor core is to be written into the L1 cache data array 262 . The data sourced by the processor core is buffered in a series of staging buffers 352 , 354 , 356 so that the data to be written is available at the data array input multiplexer 322 at the same time that the tag check results become available to the data write FSM 360 . The data write FSM 360 stalls the data pipeline 352 , 354 , 356 if the arbiter 362 determines that the L1 cache is not ready to store the sourced data into the L1 cache data array 262 .
When a data read is being performed, the read request signal (PC_RdRq) is received directly by the arbiter 362 and the virtual address is used to directly read a cache line in the data array 262 even before the results of the tag lookup and check are ready. The data read from the data array is temporarily buffered in staging buffer 321 and is discarded if a cache miss is detected. If the read data is being read in response to a processor core request and a cache hit is detected, the read data is sourced from the staging buffer 321 to the processor core via the data path labeled Array_Out Data (L1_PC_data). If the read data is being read in response to a request received via the ICS 112 , the read data is sourced from the staging buffer 321 to the Fwd/Evt buffer 366 , and from there it is conveyed to the output FSM 312 for transmission to the requesting device via the ICS 112 .
L2 Cache With Duplicate L1 Tags
Referring to FIG. 10A, the L2 cache includes a set of “duplicate L1 tag and state arrays” 280 . These “DTag” arrays 280 contain exact copies of the tag arrays of all the L1 caches in the same node as the L2 cache, and furthermore contain state information that is similar to, but not identical, to the state information in the L1 cache state arrays 266 (FIG. 9 A). Thus, each entry 288 of the DTag arrays 280 corresponds to exactly one of the L1 cache entries 268 in the L1 caches of the node. The relationship between the state information in the L1 cache, the state information in the DTag arrays 280 of the L2 cache, and the state information in the L2 cache (see FIG. 10B) is as follows:
Possible
L1 state
DTag-L1 state
corresponding L2 states
invalid
invalid
invalid, clean, clean_nodex,
dirty
shared
shared_clean
invalid, clean, clean_nodex,
dirty
shared_clean_owner
invalid
shared_clean_owner_nodex
invalid
shared_dirty
invalid
clean —
exclusive
invalid
exclusive
dirty —
invalid
exclusive
As shown in the above table, the L2 cache keeps additional information in the DTag arrays regarding the ownership of shared cache lines. For instance, the shared_clean_owner_nodex state for any particular cache line indicates that the cache line in the L1 cache has not been modified, and that this node is the exclusive owner of the cache line. The clean_nodex state in the L2 cache means the same thing.
An L1 cache line with a DTag state of exclusive, shared_dirty, shared_clean_owner or shared_clean_owner_nodex is the owner of the cache line. If the L2 cache has a valid copy of the cache line, it is the owner of the cache line, and the only possible DTag states for that cache line are invalid or shared_clean. An L1 cache always performs a write-back when it replaces a cache line of which it is the owner. The written back cache line is loaded into the L2 cache, possibly victimizing another L2 cache line.
The L1 cache owner of a cache line responds to other L1 misses on the same cache line. In this case the requester of the cache line become the new owner and the previous owner's DTag state for the cache line is changed to shared_clean.
If a cache line is present in a particular node, node-exclusive information is kept in either the L2 state of in the DTag state of the owner L1 cache. The L2 states clean_nodex and dirty, and the DTag states shared_clean_owner_nodex, shared_dirty and exclusive all indicate that the node is the only node in the system that is caching the identified memory line (i.e., identified by the tag and cache index of the cache line). In a preferred embodiment, dirty (i.e., modified) cache lines are never shared across nodes. Thus, if a node has cache line that has been modified with respect to the memory copy, no other node in the system can have a copy of the line. As a result, when a node requests a shared copy of a cache line that has been modified by another node, the memory transaction that satisfies the request will always write-back the modified data to memory. Within a single node, however, a preferred embodiment allows sharing of a modified cache line among the processor cores. In this case, the DTag state of the L1 owner is set to shared_dirty and any other sharers have their DTag state set to shared_clean.
Referring to FIG. 10B, the main L2 cache array 290 includes a data array 292 for storing cache lines, a tag array 294 and a state array 296 . The L2 cache array is preferably distributed across eight interleaved arrays, but for purposes of this explanation, the interleaved array structure is not shown, as it does not affect the logical organization and operation of the L2 cache. Each entry 298 of the L2 cache 260 includes a cache line, a tag and a state value. The cache line consists of the data from one memory line, and in a preferred embodiment this consists of 64 bytes (512 bits) of data plus parity and ECC bits corresponding to the 64 bytes.
The tag of each entry 268 consists of the address bits required to uniquely identify the cache line, if any, stored in the entry. Because the L2 cache is typically much larger than the L1 caches, a different subset of the address bits of a memory line address is used to identify the cache index and a different subset of the address bits is used as the tag compared with the address bits used for those purposes in the L1 caches.
The L2 cache line state value for each L2 cache entry is selected from among the following state values:
invalid, which means that the cache entry 268 is empty, or that the data in it is invalid and should not be used;
clean, which means that the value of the memory line has not been changed and is therefore the same as the copy in main memory, and furthermore means that copies of the cache line may be stored in (A) one or more of the L1 caches of the same node as the L2 cache and/or (B) the L1 or L2 caches in other nodes of the system, and that these copies are non-exclusive copies of the same memory line as the one stored in the L2 cache entry;
clean_nodex (clean node-exclusive), which means that the L2 cache has a clean copy of the associated memory line (i.e., the memory line has not been changed and is the same as the copy in main memory), and that there may be cached copies of this memory line in local L1 caches in the same node as the L2 cache, but there are no copies of the memory line in any other nodes of the system; and
dirty, which means that this L2 cache has the only copy of the associated memory line, and that the value of the cache line has been changed by one of the processor cores coupled to the L2 cache.
L2 Data Paths and Control Logic
FIG. 10C shows the data paths and primary components of the L2 cache 116 . As described earlier with respect to FIG. 3, the L2 cache has an interface to the intra-chip switch 112 . This interface includes one or more input buffers 160 , one or more output buffers 162 , an input finite state machine (In FSM) 164 for controlling use of the input buffer(s) 160 , and an output finite state machine (Out FSM) 166 for controlling use of the output buffer(s) 162 . Similarly, the L2 cache 116 has an interface to the memory controller 118 (see also FIG. 1) that includes one or more input buffers 400 , one or more output buffers 402 and a memory controller interface finite state machine (MC interface FSM) 404 for controlling the use of the MC interface input and output buffers 400 , 402 .
A set of pending buffers 406 are used to store status information about memory transactions pending in the L2 cache. For instance, the pending buffers 406 keep track of requests made to the memory subsystem (see FIG. 1) via the memory controller 118 . A set of temporary data buffers 408 are used to temporarily store cache line data associated with pending memory transactions, including data being sourced to the L2 cache, data sourced from the L2 cache, and data transported through the L2 cache (i.e., from the memory subsystem 123 to the L1 cache). Data sent by the L2 cache in response to an L1 cache miss bypasses the temporary data buffers 408 and is sent via a bypass data path 410 so as to reduce latency when the L2 cache contains the data needed to satisfy a cache miss in an L1 cache (which is coupled to the L2 cache via the ICS 112 ).
The duplicate tag (DTag) arrays 280 and L2 tag and state arrays 294 , 296 have been discussed above with reference to FIGS. 10A and 10B. Access to and updating of these arrays is handled by the main L2 finite state machine 412 . The main L2 FSM 412 includes DTag and tag lookup, DTag and tag checking, and DTag, tag and state updating logic.
When an L1 cache miss is serviced by the L2 cache 116 , and the L2 cache does not have a cached copy of the memory line required by the L1 cache, the request is forwarded to the memory subsystem 123 via the MC interface FSM 404 . The memory line of information provided by the reply from the memory subsystem 123 is not stored in the L2 cache 116 . Instead the memory line is sent directly to the L1 cache, bypassing the L2 data array 292 . More specifically, the reply from the memory subsystem is directed through multiplexer 414 to the Din2 input port of the temporary data buffers 408 . The reply is then output at the Dout1 port of the temporary data buffers 408 to the interface output buffer 162 via output multiplexer 416 .
When an L1 cache evicts a memory line from the L1 cache, the victim memory line is sent to the L2 cache for storage via the ICS 112 and the interface input buffer 160 . The victim memory line is received at the Din1 input port of the temporary data buffers 408 and temporarily stored therein. The victim memory line is then sent from the temporary data buffers 408 to the L2 data array 292 , via the Dout2 port of the temporary data buffers 408 and a staging buffer 418 , for storage in the L2 data array 292 .
When the L2 cache sources a memory line to an L1 cache, the memory line read from the L2 data array 292 is conveyed via bypass line 410 to output multiplexer 416 , and from there to the ICS interface output buffer 162 . The output FSM 166 handles the transfer of the memory line from the output buffer 162 to the ICS 112 , and from there it is sent to the L1 cache.
Duplicate tags (DTags) are used by the L2 cache to determine which L1 caches have cached copies of an identified memory line. The duplicate tags in the DTag arrays 280 are accessed by the main L2 FSM 412 , and information derived from the duplicate tags is used to send messages via the output FSM 166 to one or more of the L1 caches in the same node as the L2 cache, or to other components of the node.
Cache Coherence Protocol
The present invention includes a cache coherence protocol (CCP) that enables the sharing of memory lines of information 184 across multiple nodes 102 , 104 without imposing protocol message ordering requirements or requiring negative acknowledgments (NAKs). Because invalidation NAKs are not used in this invention, the CCP includes an assumption that the various requests (e.g., read request) discussed below always succeed. Additionally, the CCP is invalidation based, so shared copies of a memory line of information 184 are invalidated when the memory line of information 184 is updated.
As noted above, memory transaction relates to a memory line of information. Completion of a memory transaction requires a plurality of protocol messages, which are generated in part by instructions. Preferred embodiments of the present invention use seven instruction types: SEND, RECEIVE, LSEND (to local node), LSEND_REC (combined send/receive to/from local node), TEST, SET, and MOVE. The actual protocol code is specified at a slightly higher level with symbolic arguments, and C-style code blocks. A sophisticated microcode assembler is used to do the appropriate translation and mapping to instruction memory 196 .
Typical memory transactions require only a few instructions at each node 102 , 104 for completion. For example, a memory transaction including a read request of a memory line of information 184 stored in a memory subsystem interfaced with a remote node 102 , 104 requires a total of four instructions at the requesting node 102 , 104 : a SEND of the read request to the remote node 102 , 104 ; a RECEIVE of the read reply; a TEST of the state of the memory transaction (e.g., state field 220 and counters field 226 ); and an LSEND that sends a protocol message based on the read reply to the PC 106 that initiated the memory transaction. The CCP supports read, read-exclusive, exclusive, and write-back request types. A number of other protocol messages are supported as well in order to implement the requests.
The request types are now discussed in greater detail. FIG. 11A illustrates steps executed to satisfy a read request for a memory line of information 184 . In a first step, a PC 106 issues the read request for the memory line of information 184 (step 1100 ). If the memory line of information 184 is stored locally (step 1102 -Yes), the state of the memory line of information 184 is checked by reference to a corresponding entry 182 in the directory 180 (step 1104 ). If the directory entry 182 does not indicate that a remote node 102 , 104 has an exclusive copy of the memory line of information 184 (step 1106 -No), the memory line of information 184 is retrieved directly from the memory subsystem 123 (FIG. 11B, step 1108 ).
If the memory line of information 184 is not stored locally (step 1102 -No), the read request is routed to the RPE 124 (step 1110 ). The RPE 124 adds an entry 210 in the TSRF 202 (step 1112 ). The new entry 210 indicates that a read reply is required to advance the state of this memory transaction. The new entry 210 also indicates that until the read reply is received, incoming requests related to the memory line of information 184 are stalled, which means that a TSRF entry 210 is added to the TSRF 202 for the incoming requests. Once the read reply is received, the state of the TSRF entry 210 is updated by the RPE 124 so that these incoming requests are processed.
The RPE 124 then sends a read request to the home node (step 1114 ). The home node is the node 102 , 104 to which the memory subsystem 123 storing the memory line of information 184 is interfaced.
The read request is received by the home node 102 , 104 , and routed internally as described above to the HPE 122 (step 1116 ). The HPE 122 responds by adding an entry 210 in the TSRF 202 (step 1118 ) and checking the state of the memory line of information 184 in a corresponding entry 182 in the directory 180 (step 1120 ). If the entry 182 does not indicate that a node 102 , 104 has an exclusive copy of the memory line of information 184 (FIG. 11C, step 1122 -No), the HPE 122 updates the entry 210 in the TSRF 202 so that it indicates that the memory transaction requires an internal response to a request for the memory line of information 184 in order to advance to another state (step 1124 ). The HPE 122 then submits an internal request for the memory line of information 184 from the memory subsystem 123 (step 1126 ). Upon receiving the memory line of information 184 (step 1128 ), the HPE 122 sends a read reply to the requesting node 102 , 104 (step 1130 ), updates the state of the memory line of information (step 1131 ), and removes the TSRF entry 210 (step 1132 ).
As noted above, the state of the memory line of information 184 is embodied in a corresponding entry 182 in the directory 180 . Included in the entry 182 is a state field 186 and a sharer-information field 188 . If the state field 186 indicates that the state of the memory line of information is shared-cv, the HPE determines which bit in the bits of the sharer-information field 188 the requesting node 102 , 104 is mapped to. If the bit is not already set to indicate that a node 102 , 104 mapped to that bit is sharing a copy of the memory line of information 184 , the bit is so set.
If the state field 186 indicates that the state of the memory line of information is “shared”, the HPE 122 determines if the requesting node 102 , 104 is already identified as sharing the memory line of information 184 in the sharer-information field 188 . If so, the sharer-information field 188 and state field 186 are not changed. If the requesting node 102 , 104 is not already identified as sharing the memory line of information 184 , the HPE 122 determines if any of the sub-fields within the sharer-information field 188 is set to indicate that it does not identify a sharer node 102 , 104 (e.g., set to zero). If such a field is found, the HPE 122 sets it to identify the requesting node 102 , 104 . As noted above, the identity of the requesting node 102 , 104 is included in the original request to share the memory line of information 184 . If no such sub-field within the sharer-information field 188 is set to indicate that it does not identify a sharer node 102 , 104 , the HPE 122 must set the state field 186 to “shared-cv”. Additionally, the HPE 122 must identify and set the bits in the 40-bit sharer-information field associated with (A) the four nodes 102 , 104 previously identified by the sharer-information field 188 and (B) the requesting node 102 , 104 . The HPE 122 then removes the entry 210 from the TSRF 202 (step 1132 ).
If the entry 182 indicates that a node 102 , 104 (i.e., owner node) has an exclusive copy of the memory line of information 184 (step 1122 -Yes), the HPE 122 updates the entry 210 in the TSRF 202 so that it indicates that the memory transaction requires a share write-back in order to advance to another state (FIG. 11D, step 1134 ). The state also indicates that any requests related to the memory line of information 184 received while the HPE 122 is waiting for the share write-back should be deferred (i.e., stalled) until after receipt of the share write-back. This is accomplished by adding a new entry 210 to the TSRF 202 for such requests, and setting the state of these new entries 210 to indicate that the associated memory transaction is eligible for processing once the share write-back is received.
The HPE 122 then sends a read forward to the owner node 102 , 104 (step 1136 ). The read forward is received by the owner node 102 , 104 , and routed to the RPE 124 (step 1138 ). The RPE 124 responds by adding an entry 210 in the TSRF 202 indicating that the memory transaction requires an internal response to a request for the memory line of information 184 in order to advance to another state (step 1140 ). The RPE 124 then sends an internal request for the memory line of information 184 from L1 or L2 cache 110 , 114 (step 1141 ). Upon receiving the memory line of information 184 (step 1142 ), the RPE 124 sends a share write-back to the home node 102 , 104 (FIG. 11E, step 1144 ) and a read reply to the requesting node 102 , 104 (step 1146 ), both of these protocol messages include an up-to-date copy of the memory line of information 184 . The RPE 124 also removes the entry 210 from the TSRF 202 (step 1148 ).
Upon receiving the share write-back (step 1150 ), the HPE 122 updates a copy of the memory line of information 184 (either in the memory subsystem 123 initially or a local cache initially and the memory subsystem 123 subsequently) (step 1152 ). HPE 122 then updates the state of the memory line of information 184 in the directory 180 to indicate that both the requesting node 102 , 104 and the former owner node 102 , 104 are both storing a shared copy of the memory line of information 184 (step 1154 ). The HPE 122 also updates the state of any entries 210 in the TSRF 202 for a request relating to the memory line of information 184 and received while waiting for the share write-back to indicate that the associated memory transaction may be executed. The HPE 122 then removes the entry 210 in the TSRF 202 related to this memory transaction (step 1155 ).
Upon receiving the read response (whether sent by the home node 102 , 104 or an owner node 102 , 104 ) (step 1156 ), the RPE 124 forwards the shared copy of the memory line of information 184 to the PC 106 that initiated the memory transaction (step 1158 ). The RPE also removes the entry 210 in the TSRF 202 related to the memory transaction (step 1160 ).
The read request steps described above with reference to FIGS. 11A-11E are subject to an optimization in preferred embodiments of the present invention. Specifically, if the memory line of information requested by the requesting node 102 , 104 is not shared or owned by any nodes 102 , 104 , the HPE 122 returns an exclusive copy of the memory line of information 184 . In other words, the response to a request for a shared copy of the memory line of information 184 is “upgraded” from a read reply to a read-exclusive reply. Thus, the requesting node 102 , 104 is identified in the directory 180 as exclusive owner of the memory line of information. However, this optimization does not affect the home node's 102 , 104 response to a request for a memory line of information that is comprised of an instruction since an instruction is never written to by a requesting node. Thus, there is no reason to provide an exclusive copy.
FIG. 12A illustrates steps executed to satisfy a request for an exclusive copy of a specified memory line of information 184 , which permits the node 102 , 104 requesting the memory line of information 184 (i.e., requesting node) to modify the memory line of information 184 . In a first step, a PC 106 issues the request for an exclusive copy of the memory line of information 184 (step 1200 ). The request is routed to the RPE 124 (step 1210 ), which adds an entry 210 in the TSRF 202 (step 1212 ). The new entry 210 indicates that a read-exclusive reply and a number (zero or more) of invalidation acknowledgments are required to advance the state of this memory transaction. The RPE 124 then sends a read-exclusive request to the home node (step 1214 ). At this point the memory transaction in the RPE 124 enters the Waiting state, where it remains until it receives the aforementioned read-exclusive reply and (zero or more) invalidation acknowledgments. When these messages are received by the RPE 124 , the memory transaction it will made Active and then Running in order to receive and process these protocol messages so as to advance and complete the memory transaction. The new entry 210 also indicates that until the aforementioned replies are received, incoming requests related to the memory line of information 184 are stalled, which means that a TSRF entry 210 is added to the TSRF 202 for the incoming requests. Once the aforementioned replies are received, the state of the TSRF entry 210 is updated by the RPE 124 so that these incoming requests are processed.
The read-exclusive request is received by the home node 102 , 104 , and routed to the HPE 122 (step 1216 ) of the home node, which adds an entry 210 in the TSRF 202 (step 1218 ). The HPE 122 then checks the state of the specified memory line 184 in a corresponding entry 182 in the directory 180 (step 1220 ). At this time, the HPE also sends a request to the L2 cache to locate and invalidate any copies of the specified memory line that may be present on the home node. The L2 cache uses the information in its L2 tag array and DTag arrays to determine if any copies of the specified memory line are present in the L2 cache or any of the L1 caches in the home node. If a copy of the specified memory line is found in the L2 cache, it is invalidated by the L2 cache, and if a search of the DTag arrays locates any copies of the specified memory line in the home node's L1 caches a command message is sent by the L2 cache to the identified local L1 cache or caches instructing those L1 caches to invalidate their copies of the specified memory line. Each L1 cache that receives the invalidate command respond to this command by setting the state of the corresponding cache line to “invalid”. It should be noted that when the requester for exclusive ownership of the specified memory line is a processor core in the home node of the memory line, L2 cache invalidates all cached copies of the specified memory line except for the copy (if any) held by the L1 cache of the requesting processor.
If the directory entry 182 for the specified memory line does not indicate that a node 102 , 104 has an exclusive copy of the memory line of information 184 (FIG. 12B, step 1222 -No), the HPE 122 updates the entry 210 in the TSRF 202 to indicate that the memory transaction requires an internal response to a request for the memory line of information 184 in order to advance to another state (step 1224 ). The HPE 122 then sends a request for the memory line of information 184 from the memory subsystem 123 (step 1226 ). Upon receiving the memory line of information 184 (step 1228 ), the HPE 122 determines the number of nodes 102 , 104 that have a shared copy of the memory line of information by reference to an entry 182 in the directory 180 corresponding to the memory line of information 184 (step 1230 ). The HPE 122 then sends a read-exclusive reply to the requesting node 102 , 104 (step 1232 ). The read-exclusive reply includes a copy of the memory line of information and indicates the number of invalidation acknowledgments to expect. HPE 122 then sends an invalidation request to each node 102 , 104 , if any, that has a shared copy of the memory line of information 184 (step 1233 ). The HPE uses the information in the directory entry for the memory line to identify the nodes having a shared copy of the memory line. HPE 122 then updates the state of the memory line of information 184 in the directory 180 to indicate that the requesting node 102 , 104 is an exclusive owner of the memory line of information (step 1234 ) and removes the TSRF entry 210 in the TSRF 202 related to this memory transaction (step 1235 ). Thus, from the perspective of the home node 102 , 104 , the entire memory transaction (including activity at other nodes 102 , 104 ) is now complete, though other nodes 102 , 104 must process protocol messages relating to this memory transaction.
The invalidation request is received by the sharer node(s) 102 , 104 , and routed to the RPE 124 (step 1236 ) in each of those nodes, which respond by adding an entry 210 to the TSRF 202 (step 1237 ). The RPE 124 responds initially by sending an invalidation acknowledgment to the requesting node 102 , 104 (step 1238 ). Additional steps taken by the RPE 124 depend upon whether the RPE is waiting on any requests related to the same memory line of information 184 (step 1239 ). See the discussion below, in the section entitled “Limited Fanout Daisy-Chaining Invalidation Requests,” for a description of another methodology of sending and handling invalidation requests and acknowledgments.
If the RPE 124 is waiting for a response to a read request, the invalidation request is merged with the outstanding read request transaction. To do this the RPE updates the TSRF entry 210 corresponding to the outstanding read request to indicate that an invalidation request related to the same memory line of information 184 has been received. Once the response to the read request is received, the PC 106 that initiated the read request/memory transaction is given a read-once copy of the memory line of information. In other words, the PC 106 is not permitted to cache a copy of the memory line of information 184 . This situation (receiving an invalidation request while waiting for a response to a read request) occurs because the CCP does not order protocol messages. More specifically, the home node 102 , 104 received the read request and sent a response to the read request before receiving the read-exclusive request and sending the invalidation request, but the invalidation request is received before the response.
If the RPE 124 is waiting for a response to a read-exclusive request or an exclusive request, the invalidation request is acknowledged as noted above and no additional steps are taken (e.g., there is no limitation to a read-once copy).
Once these additional steps are complete, the RPE 124 removes the TSRF entry 210 related to this memory transaction (step 1240 ).
If the directory entry 182 indicates that a node 102 , 104 has an exclusive copy of the memory line of information 184 (step 1222 -Yes), the HPE 122 sends a “read-exclusive forward” message to the owner node 102 , 104 (step 1241 ), updates the state of the memory line of information 184 in the directory 180 to indicate that the requesting node 102 , 104 is exclusive owner of the memory line of information 184 (step 1242 ), and removes the TSRF entry 210 in the TSRF 202 related to this memory transaction (step 1243 ). Thus, from the perspective of the home node 102 , 104 , the entire memory transaction (which includes activity at other nodes 102 , 104 ) is now complete, though other nodes 102 , 104 continue to process this memory transaction.
The read-exclusive forward is received by the owner node 102 , 104 , and routed to the RPE 124 (step 1244 ). The RPE 124 responds by adding an entry 210 in the TSRF 202 indicating that the memory transaction requires an internal response to a request for the memory line of information 184 in order to advance to another state (step 1245 ). The RPE 124 then sends a request for the memory line of information 184 from the L1 or L2 cache 110 , 114 in which the memory line is locally stored (step 1246 ). Upon receiving the memory line of information 184 (step 1247 ), the RPE 124 sends a read-exclusive reply to the requesting node 102 , 104 (step 1248 ). This protocol messages includes an up-to-date copy of the memory line of information 184 . The RPE 124 then invalidates the local copy of the memory line of information 184 (step 1249 ) and removes the entry 210 from the TSRF 202 (step 1250 ).
When the home node is the owner node, there is no need for the HPE of the owner node to send a read-exclusive forward to the owner node. Instead, the HPE sends a message to the L2 cache requesting that it forward a copy of the specified memory line and that it furthermore invalidate all cached copies of the memory line in the L2 cache and/or the L1 caches in the home node. The HPE would then send the read-exclusive reply message to the requesting node (i.e., steps 1246 through 1250 would be performed by the home node, since it is also the owner node in this example).
Upon receiving the read-exclusive response (step 1252 ), the steps taken depend upon the content of the response. As noted above, a read-exclusive request can result in a number of invalidation acknowledgments from nodes 102 , 104 that have or had a shared copy of the memory line of information 184 . Additionally, the CCP does not requires protocol message ordering, so invalidation acknowledgments can arrive at the requesting node before a read-exclusive reply. If the response is an invalidation acknowledgment (step 1253 -Yes), RPE 124 updates the TSRF entry 210 in the TSRF 202 associated with this memory transaction to reflect that the invalidation acknowledgment was received (step 1256 ). More specifically, RPE 124 increments or decrements a counter in the counter fields 226 of the TSRF entry 210 .
If the response is not an invalidation acknowledgment (step 1253 -No), it is a read-exclusive reply, in which case the RPE 124 forwards the memory line of information 184 included in the reply to the PC 106 that requested the memory line of information (step 1254 ). If the read-exclusive reply indicates that a number of invalidation acknowledgment are to be received, the reply to the PC 106 also indicates that the memory transaction is not complete (unless the number of invalidation acknowledgments have already been received). RPE 124 then updates the TSRF entry 210 to reflect that the read-exclusive reply has been received and to indicate the number of invalidation acknowledgments, if any, to be received as well (step 1256 ).
Whether an invalidation acknowledgment or a read-exclusive reply is received, RPE 124 then determines if another protocol message is due (e.g., an invalidation acknowledgment or a read-exclusive reply). If no additional protocol messages are due, (step 1258 -Yes), RPE 124 removes the TSRF entry 210 from the TSRF 202 (step 1260 ). Otherwise, the entry 210 is not removed immediately, but is updated and eventually removed as additional, related protocol messages are received. Additionally, the RPE 124 sends an additional message to the PC 106 to indicate that the memory transaction is complete if the RPE 124 indicated to the PC 106 in its earlier reply that the memory transaction was not complete.
Until the TSRF entry 210 in the TSRF 202 is removed, incoming requests (read, read-exclusive, exclusive protocol messages) related to the memory line of information 184 are merged with the existing TSRF entry 210 related to this memory line of information 184 and put in the Suspended state. Once the read-exclusive reply and all invalidation acknowledgments, if any, are received, the state of the TSRF entry 210 is updated to the Active state so that it will be selected by the scheduler and the merged requests will be processed by the test and execution unit 194 .
Additionally, the write request steps described above with reference to FIGS. 12A-12D are subject to an optimization in preferred embodiments of the present invention. Specifically, if the requesting node 102 , 104 already has a copy of the memory line of information, the RPE 124 of the requesting node sends an “exclusive request” to the home node 102 , 104 instead of a “read-exclusive request.” If the requesting node 102 , 104 is unambiguously listed as a sharer node 102 , 104 in the entry 182 of the directory 180 , the steps are the same as those described above with reference to FIGS. 12A-12D, with the exception that the home node 102 , 104 does not include the memory line of information 184 with the exclusive reply (a protocol message sent instead of a read-exclusive reply).
A given node is unambiguously listed as a sharer node if the sharer-information field 188 is in the limited-pointer format and includes the identifier of the given node or in coarse-vector format and only the requesting node is associated with a particular set bit. Thus, a given node is not unambiguously listed as a sharer node 102 , 104 if (1) the sharer-information field 188 is in the limited-pointer format but does not include the identifier of the given node, or (2) the sharer-information field 188 is in the course-vector format and the bit associated with the given node 102 , 104 is also associated with other nodes.
If the requesting node 102 , 104 is not unambiguously listed as a sharer node 102 , 104 in the entry 182 of the directory 180 , the HPE 122 converts the exclusive request to a read-exclusive request, which is then processed as described above. Alternatively, the HPE 122 sends a protocol message to the RPE 124 at the requesting node 102 , 104 directing it to send a read-exclusive request to the home node. In another alternate embodiment, the RPE of the requesting node is configured to recognize when the number of nodes in the system is sufficiently great that the coarse vector bit used to represent the requesting node in the sharer information field 188 of directory entries also represents at least one other node. In this alternate embodiment, the RPE of the requesting node is further configured to not send exclusive requests when it recognizes, detects or knows this of this system status, and to instead send a read-exclusive request. In other words, in this situation the “exclusive request” optimization is suppressed or not used.
FIG. 13 illustrates steps taken to support a write-back request protocol message. A write-back request is initiated by a PC 106 when, for example, space is needed in the caches 110 , 114 (step 1300 ). As an exception to the general rule described above, the write-back request is a high-priority protocol message. This exception is required because of a potential for the race condition described below.
The request is routed to the RPE 124 , which responds by adding an entry 210 in the TSRF 202 (step 1302 ) and sending a write-back request to the home node 102 , 104 (step 1304 ). The entry 210 indicates that a write-back acknowledgment is required to advance the memory transaction to a next state. Additionally, the RPE 124 maintains the memory line of information 184 until the write-back acknowledgment is received and, if necessary, a forwarded request is received. If a forwarded request is received (e.g., read forward), it is handled as described above; however, the RPE 124 updates the state of the TSRF entry 210 to indicate that the forwarded request was received.
Upon being received at the home node 102 , 104 , the write-back request is routed to the HPE 122 (step 1306 ) of the home node, which responds by adding an entry 210 in the TSRF 202 (step 1308 ). HPE 122 responds by checking the state of the memory line (step 1310 ). In particular, the HPE 122 determines if the directory entry 182 corresponding to the memory line of information still indicates that the “owner” node 102 , 104 is the owner of the memory line of information 184 . If so (step 1312 -Yes), the HPE 122 updates the memory line of information 184 in the memory subsystem 123 (step 1314 ) and the state of the associated directory entry to indicate that the memory line of information 184 is no longer shared or owned by the former owner node 102 , 104 (step 1316 ). HPE 122 then sends a write-back acknowledgment to the former owner node 102 , 104 indicating that the memory transaction was successful (step 1318 ). The HPE then removes the TSRF entry 210 related to this memory transaction (step 1320 ).
If the directory entry 182 corresponding to the memory line of information does not indicate that the “owner” node 102 , 104 is the owner of the memory line of information 184 (step 1312 -No), HPE 122 sends a write-back acknowledgment to the former owner node 102 , 104 indicating that the write-back request was stale (i.e., that the memory transaction was not successful) (step 1318 ). More specifically, the write-back acknowledgment indicates that the home node 102 , 104 forwarded a request related to the memory line of information 184 to the former owner node 102 , 104 before receiving the write-back request. The HPE then removes the TSRF entry 210 related to this memory transaction (step 1320 ).
Upon receiving the write-back acknowledgment (step 1324 ), the RPE 124 of the former owner node determines if a race condition exists and whether it has been satisfied. As noted above, the write-back acknowledgment will indicate whether a race condition exists (i.e., whether the home node has forwarded a request related to the memory line that is the subject of the write-back request). The TSRF entry 210 in the RPE of the former owner node will indicate if the forwarded request has already been received and processed by the former owner node 102 , 104 . If so, the RPE 124 removes the TSRF entry 210 for the memory transaction (step 1326 ). If not, the RPE 124 updates the state of the TSRF entry 210 to indicate that the forwarded request is required in order to advance the state of the memory transaction to a final state, and thus remove the TSRF entry 210 .
Limited Fanout Daisy-Chaining Invalidation Requests
In the above described embodiments, the home node 102 , 104 always sends invalidation requests to sharer nodes 102 , 104 individually. Each sharer node 102 , 104 then sends an invalidation acknowledgment to the requesting node 102 , 104 . Accordingly, the maximum number of invalidation requests and invalidation acknowledgments is entirely dependent upon the number of nodes 102 , 104 sharing a given memory line of information 184 and bound only by the number of nodes 102 , 104 in the multiprocessor system 100 . To reduce the number of protocol messages (e.g., invalidation requests and invalidation acknowledgments) active at any given moment, the invention configures directory entries (see FIG. 4 and the above discussion of the directory data structure 180 ) using the above described limited-pointer format and coarse-vector format, and furthermore employs a limited fanout, daisy-chaining invalidation methodology that ensures that no more than a specified number of invalidation requests and invalidation acknowledgments are active at any given moment, which avoids deadlocks.
The maximum number of invalidation requests and acknowledgments, resulting from a request for exclusive ownership of a particular memory line, that are active at any given moment is herein called the maximum fanout. In the preferred embodiments, the maximum fanout is a number between four and ten. The protocol engines of the present invention are configured to ensure that the number of invalidation requests and/or acknowledgments simultaneously active in a system as a resulting of a single a request for exclusive ownership of a particular memory line never exceeds the maximum fanout.
In preferred embodiments, the maximum number of invalidation requests and invalidation acknowledgments is set to four. Thus, the sharer-information field 188 of each directory entry 182 (FIG. 4) is configured to identify a maximum of DP (e.g. four) nodes when using the limited-pointer format. Similarly, the bits (e.g., 40-bits) of the sharer-information field 188 are grouped into DP (e.g., four) groups (e.g., 10-bit groups) when in the coarse-vector format. While the operation of the invention will be described with respect to an embodiment in which the sharer-information field 188 contains four groups of 10-bits for a total of 40 bits, in other embodiments the total number of bits in the sharer-information field, the number of groups of bits, and the number of bits per group, may vary substantially from those used in the preferred embodiment.
As described in more detail below, the home node 102 , 104 sends at most one invalidation request for each of the four 10 bit groups. In particular, the home node sends an invalidation request to the first node, if any, identified as being a potential sharer by each 10-bit group within the sharer-information field. Thus, a home node 102 , 104 sends at most four invalidation request messages to other nodes. Further, a subsequent set of invalidation request messages, if needed, are sent by the nodes that receive the initial invalidation request messages, this time to the second node, if any, identified as being a potential sharer by each respective 10-bit group within the sharer-information field. This process is repeated by each node receiving an invalidation request until the last node identified as being a potential sharer by each respective 10-bit group within the sharer-information field has received an invalidation request. Only the last identified node for each respective 10-bit group sends an invalidation acknowledgment to the requesting node 102 , 104 . Using this limited fanout, daisy chaining-like methodology, the maximum number of invalidation request messages and invalidation acknowledgment messages that are active at any one time as the result of a request for exclusive ownership of a particular memory line never exceeds four, which is the maximum fanout in a preferred embodiment. In other preferred embodiment, the maximum fanout varies from four to ten.
In some embodiments of the present invention, the bits are grouped, for example, as follows: the first 10-bits, the second 10-bits, the third 10-bits, and the fourth 10-bits of a 40-bit sharer-information field 188 are groups 1-4 respectively. But in preferred embodiments of the invention, the bits within each group are interleaved. Specifically, in the preferred embodiment, the bits (and table 189 columns) 0 , 4 , 8 , 12 , 16 , 20 , 24 , 28 , 32 , and 36 form one group; bits (and table 189 columns) 1 , 5 , 9 , 13 , 17 , 21 , 25 , 29 , 33 , and 37 form a second group; bits (and table 189 columns) 2 , 6 , 10 , 14 , 18 , 22 , 26 , 30 , 34 , and 38 form a third group; bits (and table 189 columns) 3 , 7 , 11 , 15 , 19 , 23 , 27 , 31 , 35 , and 39 form a fourth group.
Though group identifiers (e.g., first group, second group, etc.) are not required for a node 102 , 104 to determine which group it is in (since each node 102 , 104 has access to its identifier) the number of bit groups and the number of bits in the sharer-information field 188 are required to establish the bit membership of each group (i.e., to determine the position of the bits of a given group within the sharer-information field 188 ) or equivalently, to establish the identity of a first node 102 , 104 associated with each bit and additional nodes 102 , 104 associated with each bit of a given group.
This aspect of the invention is now described in greater detail with reference to FIGS. 14A and 14B. The steps taken by the home node 102 , 104 before and after an invalidation request is sent to a sharer node 102 , 104 as described above are not changed in this embodiment of the invention.
In a first step, the home node 102 , 104 determines the state of a given memory line of information 184 by reference to a corresponding directory entry 180 (step 1402 ). As described above, each directory entry 180 includes a state field 186 , which is preferably set to one of four values—including invalid, exclusive, shared, and shared-cv. Accordingly, this determination is made by reference to the state field 186 . If the state field 186 is set to shared, the format of the sharer-information field 188 is the limited-pointer format. If, however, the state field is set to shared-cv, the format of the sharer-information field 188 is the coarse-vector format.
If the state field 186 indicates that the sharer-information field 188 is in the limited-pointer format (step 1406 -Yes), the home protocol engine 122 extracts the node identifiers directly from each of the four sub-fields of the sharer-information field 188 (step 1410 ). The node identifier in each sub-field is valid if it is not the predefined null identifier. As noted above, in preferred embodiments the null identifier value is zero. The home protocol engine 122 then sends an invalidation request to each node 102 , 104 identified in the sharer-information field 188 as a sharer node 102 , 104 (step 1414 ).
If, however, the state field 186 indicates that the sharer-information field 188 is in the coarse-vector format (step 1406 -No), the home protocol engine 122 identifies for each group of bits within the sharer-information field 188 the first set bit (step 1418 ). Note that it is possible that one or more the groups may have no bits that are set.
Once the first set bit, if any, in each group of bits is identified, the home protocol engine 122 identifies the first node 102 , 104 that corresponds to each of the identified first-set-bits using the techniques described above (step 1422 ). The above described techniques are extended somewhat in preferred embodiments however. If the first node 102 , 104 that corresponds to a given identified first-set-bit is the requesting node or the home node, the home protocol engine 122 identifies the second node 102 , 104 that corresponds to the identified first-set-bit. This step is repeated until a node 102 , 104 that is neither the home node nor the requesting node is identified. If it is determined that none of the set bits in the group correspond to a node other than the home node and requesting node, an invalidation request is not sent by the home node for this particular group of bits in the sharer-information field 188 . In alternative embodiments, this step is not taken by the home node 102 , 104 . Instead, the HPE 122 of the home node and the RPE 124 of the requesting node are configured to process these messages as described above without ever responsively invalidating the memory line of information 184 .
Once one or more nodes 102 , 104 are identified (i.e., up to one node per group of bits in the sharer-information field of the directory entry), the home protocol engine 122 sends an invalidation request to each of the identified nodes 102 , 104 (step 1426 ). Included each invalidation request is a sharer group field containing the 10-bit group of bits associated with the designated recipient of a given invalidation request and possibly an identifier of the 10-bit group. (The sharer group field is not included in an invalidation request if the sharer-information field 188 is not in the coarse-vector format.) This sharer group field is required because the sharer nodes do not maintain information about the nodes 102 , 104 that share a given memory line of information 184 . The 10-bit group of sharer information that is sent along with the invalidation request permits each node that receives the invalidation request to identify the next node 102 , 104 to receive an invalidation request as described above or to determine that there is no next node 102 , 104 (i.e., that an invalidation acknowledgment should be sent to the requesting node 102 , 104 ).
Additionally, the group identifier of the 10-bit group permits the sharer node 102 , 104 to identify the position of each bit within the 10-bit group in the sharer-information field 188 , which also permits the sharer node 102 , 104 to identify the next node 102 , 104 (if any) to receive the invalidation request, as described above, or to determine that there is no next node 102 , 104 . In an alternate embodiment, the group identifier is not included in the invalidation request and instead the protocol engines in each node are programmed to know the sharer group in which each such node resides. Since all the invalidation requests received by any particular node would always have the same sharer group identifier, the sharer group identifier is not strictly needed.
Upon receiving an invalidation request (step 1430 ) and adding a related entry 210 in the TSRF 202 (step 1432 ), a sharer node 102 , 104 determines a next node, if any, by analyzing the sharer group field of the invalidation request. If all of the bits of the sharer group field are set to zero, there is no sharer information in the request ( 1434 -No) and therefore there is no next node to which to send the invalidation request. Instead, the remote protocol engine 124 in the sharer node 102 , 104 sends an invalidation acknowledgment to the requesting node (step 1438 ). The sharer-node then processes the invalidation request as described above with reference to step 1238 (step 1458 ).
If the sharer group field in the received invalidation request includes any set bits (i.e., includes sharer information) (step 1434 -Yes), the remote protocol engine 124 in the sharer node 102 , 104 determines the next node, if any, to receive an invalidation request (step 1442 ). The remote protocol engine in the sharer node identifies the next node by first determining the bit in the sharer group field that corresponds to the node identifier of the sharer node, and then determining if there is a next node (e.g., with a higher node identifier) that (A) also corresponds to that same bit of the sharer group field, and (B) is neither the home node (which is identified by the address of the memory line to be invalidated) nor the requesting node (which is identified by a requesting node field in the invalidation request). If not, the remote protocol engine looks for a next set bit (if any) in the sharer group field and determines if that next set bit corresponds to a node 102 , 104 that is neither the home node 102 , 104 nor the requesting node 102 , 104 . This process continues, processing the bits of the sharer group field in a predetermined order (e.g., from left to right) until the remote protocol engine either identifies a next node, or determines that there is no next node.
If a valid next node 102 , 104 is identified (step 1446 -Yes), the sharer node 102 , 104 sends an invalidation request to the next node (step 1450 ). The sharer node 102 , 104 includes in this invalidation request the same 10-bit sharer group field (and possibly a group identifier) that was included in the invalidation request received by the sharer node 102 , 104 . The sharer node 102 , 104 then processes the invalidation request as described above with reference to step 1238 (step 1458 ). The sharer node 102 , 104 then removes the related entry 210 from the TSRF 202 (step 1460 ).
If, a valid next node is not identified (step 1446 -No), this means that the sharer node is the last node in the invalidation request daisy chain. In this case the sharer node sends an invalidation acknowledgment to the requesting node (step 1454 ). The sharer node then processes the invalidation request as described above with reference to step 1238 (step 1458 ). The sharer node 102 , 104 then removes the related entry 210 from the TSRF 202 (step 1460 ).
Because each of the bits of the sharer group field may be associated with more than one nodes, the remote protocol engines in the nodes of the system are unable to determine which of the associated nodes (other than itself) are actually sharer nodes. When a node receives an invalidation request for a memory line of information 184 that it does not share, the node nevertheless sends an invalidation request (step 1450 ) or acknowledgment (step 1454 ) as described above. However, the processing of the received invalidation request at step 1458 comprises determining that the node is not a sharer of the specified memory line, and therefore no cache lines in the node are invalidated in response to the received invalidation request.
In other preferred embodiments, the bits of the sharer information field of the directory entries are divided into a larger number of groups of bits (e.g., four to ten groups). The number of such groups of bits corresponds to the maximum fanout of the daisy chained invalidation messages in these embodiments.
Alternate Embodiments
While the present invention has been described with reference to a few specific embodiments, the description is illustrative of the invention and is not to be construed as limiting the invention. Various modifications may occur to those skilled in the art without departing from the true spirit and scope of the invention as defined by the appended claims. | The present invention relates generally to multiprocessor computer system, and particularly to a multiprocessor system designed to be highly scalable, using efficient cache coherence logic and methodologies. More specifically, the present invention is a system and method including a plurality of processor nodes configured to execute a cache coherence protocol that avoids the use of negative acknowledgment messages (NAKs) and ordering requirements on the underlying transaction-message interconnect/network and services most 3-hop transactions with only a single visit to the home node. | 6 |
FIELD
The embodiments hereby disclosed relate generally to drywall tools, and more specifically to hand-held compound containers used to hold compound in drywall construction.
BACKGROUND
Compound containers, also known as mud pans, are available in various sizes, and are used to provide workers with easy access to the compound necessary for drywall construction projects. Workers generally carry a compound container in one hand, and a taping knife in the other. In this way, a worker can use the knife both to remove compound from the container and to mix the compound as necessary.
SUMMARY
Some embodiments of a compound container can be constructed to include a hand support member attached to a bottom of the compound container, allowing a user's hand to be extended between the hand support member and the bottom of the compound container and thereby enhancing a holding of the compound container by the user's hand. For example, the hand support member can be an expandable hand support member. When not in use, the hand support member is in a relaxed configuration without being under tension. When in use, the user's hand is extended between the hand support member and the bottom of the container body, and the hand support member can be stretched to an expanded configuration, applying an elastic force on the user's hand and thereby enhancing a holding of the compound container by the user's hand. It is to be understood that the hand support member can be made of materials other than elastic material. In such configuration, the hand support member can include buttons to allow the length of the hand support member to be adjusted to secure the user's hand to the bottom of the container body.
Moreover, the compound container can be constructed with a tool holder including a friction holding tab for holding a taping knife. The friction holding tab can be formed as a part of a side stand located at an end of the compound container such that the taping knife can be secured at the end of the compound container when not in use.
Moreover, the compound container can be constructed with two side stands, allowing the compound container to stand on a flat surface regardless whether the container body has a flat bottom or rounded bottom. The side stands can be spaced away from the bottom of the container body, allowing the compound container to be stackable for economical point of purchase display.
Moreover, the compound container can be constructed with a rounded corner on one side of its bottom and an edged corner on the other side of its bottom. The rounded corner allows easy gripping of the bottom of the container body by the user's hand, while the edged corner allowing a blade of a taping knife to be maintained at the corner when the taping knife is placed inside a spaced defined by the container body.
In particular embodiments, a compound container includes a container body having a side wall and a bottom wall, an interior space defined by the side wall and the end wall, an opening defined by an upper edge of the side wall; and an elongated hand support member having a first attachment section and a second attachment section for attaching the hand support member to a bottom surface of the bottom wall. The hand support member is positioned generally parallel to the opening defined by the upper edge of the side wall.
In some embodiments, a compound container kit includes a container body having a side wall and a bottom wall; an interior space defined by the side wall and the end wall; an opening defined by an upper edge of the side wall; an elongated hand support member having a first attachment section and a second attachment section for attaching the hand support member to a bottom surface of the bottom wall; and instructions for attaching the hand support member to the bottom surface of the bottom wall. The bottom wall is configured generally parallel to the opening defined by the upper edge of the side wall.
Other embodiments may include a method of using a compound container. The compound container in the method includes a container body having a side wall and a bottom wall; an opening defined by an upper edge of the side wall; and an elongated hand support member having a first attachment section and a second attachment section for attaching the hand support member to a bottom surface of the bottom wall. The method includes extending extend a hand between the hand support member and the bottom surface of the bottom wall; and holding on an outer surface of the side wall to manipulate the orientation of the compound container.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects and advantages of the invention will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The following is a brief explanation of embodiments herein using drawings and embodiments:
FIG. 1 is a bottom perspective view of a compound container with an edged bottom design with a hand support member of FIG. 4 attached.
FIG. 2 is a sectional view of the compound container of FIG. 1 .
FIG. 3 is a perspective view of the compound container of FIG. 1 .
FIG. 4 is a perspective view of a hand support member attachable to a compound container.
FIG. 5 is a sectional view of the compound container of FIG. 1 without a hand support member attached.
FIG. 6 is a sectional view of a compound container with a rounded bottom design on one of the two long edges with the hand support member of FIG. 4 attached.
FIG. 7 is a further sectional view of the compound container of FIG. 1 .
FIG. 8 is a sectional view of a compound container with a rounded bottom design on both of the two long edges without a hand support member attached.
FIG. 9 is a perspective view of two compound containers of FIG. 1 stacked together.
DETAILED DESCRIPTION
Embodiments disclosed herein relate to a compound container including an elongated body and a hand support member. The elongated body has an opening, two long edge sides opposing each other, two short edge sides opposing each other, and a bottom. The elongated body of the compound container may have a flat rectangular bottom with two edged corners along the long edges, or it may have a rounded bottom with an edge corner and a rounded corner along the long edges, or it may have a rounded bottom with two rounded corners along the long edges. The hand support member is attachable to the bottom of the compound container, allowing a user's hand to extend between the hand support member and the bottom of the compound container, and thereby enhancing the holding of the compound container by the user's hand. The length of the hand support member can be adjustable.
As shown in FIGS. 1-3 , a compound container 100 includes an elongated body 1 (referring to FIG. 3 ) used to hold drywall compound. The elongated body includes an opening 2 (referring to FIG. 3 ), two long edge sides 4 , 5 opposing each other, two short edge sides 3 , 6 opposing each other, and a bottom 7 . The opening 2 and the bottom 7 are both defined by the long edge sides 4 , 5 and the short edge sides 3 , 6 . The opening 2 may be in a rectangular shape. The bottom 7 may be flat in a rectangular shape. An area of the bottom 7 may be smaller than an area defined by the periphery of the opening 2 . As shown in FIG. 7 , the long edge sides 4 , 5 may be inwardly inclined when extending toward the bottom 7 , forming two edged corners 401 , 501 . As shown in FIG. 2 , the short edge sides 3 , 6 may be straight, inwardly inclined when extending toward the bottom 7 , forming two edged corners. A compound container with a flat, rectangular bottom may be more stable when placed on a flat surface.
Alternatively, in another embodiment as shown in FIG. 6 , a rounded bottom design may be used. A rounded bottom 701 has an edged corner 402 and a rounded corner 502 connecting to the long edge sides 4 , 5 respectively along the long edges of the rounded bottom 701 . The rounded corner 502 allows the elongated body 1 to have a more ergonomic design with more grips. Thus one may hold the compound container more easily and more comfortably for an extend period of time. In the meantime, the edged corner 402 allows a paint tool, such as a taping knife blade, to stay at the edged corner 402 . At the same time the rounded bottom may allow a taping knife blade to be placed along the long edge side 4 connected with the edged corner 402 without flipping over when in use.
Yet in another embodiment as shown in FIG. 8 , the elongated body 1 may have a rounded bottom 702 . The rounded bottom 702 has two rounded corners 403 , 503 connecting to the long edge sides 4 , 5 along the long edges of the rounded bottom 702 , providing more grips and comfort when one is holding the compound container.
As shown in FIG. 5 , two holding members 15 , 16 are placed on the bottom surface of the bottom 7 , in generally parallel with each other along two short edges 301 , 601 of the bottom 7 and near the two short edges 301 , 601 of the bottom 7 respectively. The holding members 15 , 16 allow a hand support member 40 to be attached to the bottom 7 of the compound container 100 .
In an embodiment as shown in FIG. 1 , the holding members 15 , 16 may be in a curved shape, curving away from the short edges 301 , 601 of the bottom 7 . The curved design allows more connection space with a hand support member 40 , while avoiding the hand support member 40 intruding out of the short edges 301 , 601 of the bottom 7 and adversely affecting the stackability of the compound container. Two retaining members 17 , 18 may be placed in the center of each of the holding members 15 , 16 , in order to further secure the hand support member 40 using screws. It is understood that other fastening meanings may be utilized to secure the hand support member.
FIG. 4 shows a hand support member 40 including an elongate body 19 . It is to be understood that the hand support member 40 can be configured in various configurations, as long as it has an elongate body and can be used to support the back of the user's hand when the hand holds on long edge sides 4 , 5 or bottom 7 of the compound container 100 . The hand support member 40 can have a strap shape or a string shape, and in some embodiments, a plurality hand support members 40 can be attached to the bottom surface of the bottom 7 of the compound container 100 .
The hand support member 40 may also include two holding members 20 , 21 to both ends of the hand support member 40 engageable with the corresponding holding members 15 , 16 . The holding members 20 , 21 may be curved away from the short edges 301 , 601 of the bottom 7 . The curved design allows more connection space with the body 1 , while avoiding the hand support member 40 intruding out of the short edges 301 , 601 of the bottom 7 and adversely affecting the stackability of the compound container. Each of the holding members 20 , 21 may have a cavity 201 , 211 , respectively, in a shape which tightly fits the above disclosed holding members 15 , 16 respectively, allowing the holding members 20 , 21 to be able to be plugged in and fixed securely. Two retaining members 22 , 23 may be placed in the center of each of the holding members 20 , 21 , further securing the hand support member 40 on to the bottom 7 using screws. The elongate body 19 has an expansion rib 191 in the center of the elongate body 19 . The expansion rib 191 may use stretchable materials, connecting the two body pieces 19 A, 19 B together. When a hand is placed between the bottom 7 and the elongate body 19 , the two body pieces 19 A, 19 B may bend outwardly, and the expansion rib 191 may be stretched. Thus the expansion rib 191 allows the length of the elongate body 19 to be adjustable to the size of one's hand holding the compound container. In another embodiment, the elongate body may include buttons and buttonholes allowing the length of the elongate body 19 to be adjustable. It is to be understood that the length of the elongate body 19 can be adjusted by other means as long as the intended function is attained.
As shown in FIGS. 1 and 2 , the hand support member 40 is attached to the bottom surface of the bottom 7 of the compound container 100 . When the hand support member 40 is attached to the bottom surface of the bottom 7 of the compound container 100 , the two holding members 20 , 21 tightly hold the two holding members 15 , 16 . To further secure the attachment between the hand support member 40 and the compound container 100 , screws may be placed through the retaining members 17 , 18 of the holding members 15 , 16 and the retaining members 22 , 23 of the holding members 20 or 21 .
When the hand support member 40 is attached to the compound container 100 , the ends of the two holding members 20 , 21 are in a position not extending beyond the two short edges 301 , 601 of the bottom 7 respectively, such that the total length of the hand support member 40 including the two holding members 20 , 21 is no longer than the length of the long edge of the bottom 7 , allowing the compound containers stackable while the hand support members are attached.
As further shown in FIG. 7 , when the hand support member 40 is attached to the bottom surface of the bottom 7 , a distance between the elongate body 19 and the bottom surface of the bottom 7 of the compound container 100 is large enough for holding the compound container 100 comfortably using the hand support member 40 ; however the length added to the bottom surface of the bottom 7 by attaching the hand support member 40 is within a range of distance within which the stackability of the compound containers is not affected by attaching the hand support member 40 .
In another embodiment as shown in FIGS. 1 to 3 , the compound container 100 may also include two side stands 8 , 9 extending from two opposing edges of the opening 2 . The vertical length of the side stands 8 , 9 may be longer than the vertical length from the edges of the opening 2 to the lowest point of the hand support member 40 when the hand support member 40 is attached to the compound container 100 , allowing the side stands 8 , 9 to support the elongated body 1 even when the hand support member 40 is attached. The side stands 8 , 9 may have a leg design to reduce material used for manufacturing and to help keep the compound container 100 in balance when placed on a flat surface.
Still referring to FIGS. 1-3 , in one embodiment, the side stands 8 , 9 may be outwardly inclined when extending toward the bottom 7 , forming an angle relative to the vertical direction. One side stand 8 has a tool holder including a blade slot 12 with a friction holding tab 13 , allowing a taping knife blade 80 to be placed in the blade slot 12 and held tightly when the taping knife is not in use. The friction holding tab 13 is carved out from a convex 24 bulging slightly out of the plane of the side stand 8 , and the top part of the friction holding tab 13 includes a tongue 25 having a free edge 42 extending inwardly toward the elongated body 1 generally parallel to the horizontal surface plane of the compound container 100 . The tongue 25 provides more friction when the taping knife blade 80 is placed into the blade slot 12 . It is to be understood that the blade slot 12 may be placed in either one of, or both of the side stands 8 , 9 .
In another embodiment as shown in FIGS. 3 and 7 , the compound container 100 may further include two lips 10 , 11 extending outwardly from the two long edge sides 4 , 5 of the opening 2 . The lips 10 , 11 may extend from the two opposing long edges of the opening 2 , and further curl downwardly so that there are no sharp edges formed along the periphery of the opening 2 and thus the hands of one who is using the compound container may be protected from being cut. Curled lips may also add strength and stiffness to the long edge sides 4 , 5 . One of the lips 10 , 11 may have a scraping blade slot 14 . The scraping blade slot 14 may have a narrow and deep vertical opening, the width and length of which may be large enough to allow a scraping blade 90 to be placed in the scraping blade slot 14 and to stay stably therein. It is to be understood that the scraping blade slot 14 may be placed in either one of, or both of the lips 10 , 11 . In such circumstances, the compound container 100 further includes the one or more scraping blades 90 placed in the scraping blade slot(s) 14 . In some embodiments, the scraping blades 90 can be removed for cleaning after use of the compound container 100 .
As shown in FIG. 9 , two compound containers each with a hand support member attached are stacked together by placing one compound container on top of another. When stacked together, the short edge sides 3 , 6 of the compound container 100 placed atop cling firmly to the short edge sides of the compound container placed underneath, allowing sufficient friction so that during movement stacked compound containers remain firmly stacked without being unintentionally separated. The side stands 8 , 9 and the short edge sides 3 , 6 close to the side stands 8 , 9 respectively may connect with each other at the short edge of the opening 2 in an acute angle. When two compound containers are stacked together, the side stands 9 , 8 of the compound container in below are placed underneath the side stands 3 , 6 of the compound container 100 on top; the side stands 8 , 9 in below are pressed and slightly bent inwardly, producing more friction between the compound containers when stacked together. The elongated body 1 of the compound container 100 including the holding members 15 , 16 may be molded using one or multiple embodiments herein disclosed. Elastroplastic with sufficient strength and durability, or other material with equivalent characteristics may be used for the elongated body 1 including the holding members 15 , 16 , and for the holding members 20 , 21 of the hand support member 40 . Soft materials like vinyl or thermal plastic elastomer may be used for the elongate body 19 of the hand support member 40 .
The above are merely preferred embodiments of this application, and it is understood that by a person skilled in this art, several alternations and improvements are still considered within the scope of this application so long as they do not differ from the structure in this application. Such alternations and improvements shall not affect the practicability and utility of this application. | A compound container includes a container body having a side wall and a bottom wall; an interior space defined by the side wall and the end wall; an opening defined by an upper edge of the side wall; and an elongated hand support member having a first attachment section and a second attachment section for attaching the hand support member to a bottom surface of the bottom wall. The hand support member is positioned generally parallel to the opening defined by the upper edge of the side wall. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to a developer composition which is useful in providing visible images through reaction with an electron donating color precursor and which is useful in providing transparencies or in providing reproductions having a glossy finish. It more particularly relates to a developer sheet which is capable of providing a controlled degree of gloss ranging from matte to high gloss and which exhibits a combination of high image density and abrasion resistance.
The developer sheet of the present invention can be used in conjunction with imaging systems in which visible images are formed by image-wise transferring a color precursor to the developer sheet such as conventional pressure-sensitive or carbonless copy paper, photosensitive, and thermal recording papers.
Pressure-sensitive copy paper is well known in the art. It is described in U.S. Pat. Nos. 2,550,446; 2,712,507; 2,703,456; 3,016,308; 3,170,809; 3,455,721; 3,466,184; 3,672,935; 3,955,025; and 3,981,523.
Photosensitive imaging systems employing microencapsulated radiation sensitive compositions are the subject of commonly assigned U.S. Pat. Nos. 4,399,209 and 4,416,966 to The Mead Corporation as well as copending U.S. patent application Ser. No. 320,643 filed Jan. 18, 1982. These imaging systems are characterized in that an imaging sheet, which includes a layer of microcapsules containing a photosensitive composition in the internal phase, is image-wise exposed to actinic radiation. In the most typical embodiments, the photosensitive composition is a photopolymerizable composition including a polyethylenically unsaturated compound and a photoinitiator and is encapsulated with a color precursor. Exposure imagewise hardens the internal phase of the microcapsules. Following exposure, the imaging sheet is subjected to a uniform rupturing force by passing the sheet through the nip between a pair of pressure rollers in contact with a developer sheet whereupon the color precursor is image-wise transferred to the developer sheet where it reacts to form the image.
In applications in which the aforementioned pressure-sensitive and photosensitive imaging systems are used to reproduce photographic quality images, a high degree of gloss is often desired in the reproduction. Where a transparency is desired, the reproduction must also transmit light efficiently. These objectives are difficult to achieve using conventional developers.
SUMMARY OF THE INVENTION
With the introduction of imaging systems described in U.S. Pat. No. 4,399,209 and thermal transfer systems of the types described in Japanese Published Application No. 62-60694, a need has arisen to produce photographic quality reproductions by transfer of a color precursor to a developer sheet. The reproduction must possess a desired degree of gloss and, in addition, it must not easily crack, delaminate or abrade when handled in a manner analogous to a conventional photograph.
In two previous commonly assigned patent applications, developers which are capable of glossing are described. These applications are U.S. application Ser. No. 905,727, filed Sept. 9, 1986 and U.S. application Ser. No. 086,059, filed Aug. 14, 1987. Both applications describe the use of finely divided thermoplastic acidic resin particles as developer materials. These resins color a color precursor and upon heating coalesce into a gloss-imparting film. In the former application the resins are phenolic resins. In the latter they are microparticles containing (meth)acrylic or vinylic resins having pendant developer moieties (e.g., pendant phenolic or salicylic acid moieties).
The present invention relates to an improved composition wherein these two resins are used in combination. The phenolic resins described in the former application provide high density but are tacky, exhibit a high yellowing index, poor adhesion and cohesion, and tend to scratch easily. The acrylic resins described in the latter application exhibit excellent abrasion resistance but it is difficult to design acrylic resins which provide the high densities available with phenolic resins. In accordance with the present invention these two resins are used together and modifications are made in the acrylic and vinylic resins to make them sufficiently compatible with the phenolic resins such that the two materials will coalesce and form a continuous and optionally transparent film.
Accordingly, a principal object of the present invention is to provide a novel developer composition which is useful in providing photographic quality images.
A more particular object of the present invention is to provide a developer composition useful in forming high gloss images and which provides high density and abrasion resistance.
Another object of the present invention is to provide a developer composition which is a mixture of finely divided thermoplastic microparticles which are capable of reacting with a color precursor and subsequently coalescing into a thin transparent uniform film upon heating to their film forming temperature.
The developer composition of the present invention is a mixture of first and second finely divided thermoplastic developer materials wherein the first developer material is a finely divided thermoplastic phenolic resin and the second developer material is a finely divided thermoplastic vinylic or acrylic polymer having pendant developer moieties; the first and the second developer materials are each capable of reacting with an electron donating color former to produce a visible color and subsequently coalescing with each other and forming a continuous film. The combination of the first and second developer materials provides high density and film strength to resist abrasion and cracking.
In accordance with another embodiment of the invention, a developer sheet useful in providing transparencies is provided in which the developer composition is coated on a transparet substrate. In this embodiment, the indices of refraction of the first and second developer materials are sufficiently equal that the coalesced film is transparent or essentially transparent. If the indices of refraction are not sufficiently equal, an opaque or translucent film results because the size of the emulsion particles is close to visible light region and there is a lack of mixing during the fusion step. The latter film is satisfactory for use on a paper substrate where transparency is not required but it is not desirable for use in making transparencies.
In accordance with the present invention, the vinylic or acrylic developer resin must be compatible with the phenolic developer resin such that the two will coalesce into a strong film (i.e., a melt of the two resin forms a single phase). In transparencies, the index of refraction of the acrylic or vinylic resin must match that of the phenolic resin. However, it is difficult to have both compatibility and refractive index matched in an emulsion particle of homogeneous composition. To facilitate glossing and manufacture, the vinylic or acrylic resin and the phenolic resin should have a low melt flow temperature (MFT) such that the resins can be coalesced with heating but a sufficiently high minimum film forming temperature (MFFT) that they do not coalesce upon drying. As explained below these two properties are not consistent with one another.
The vinylic or acrylic developer material is preferably a microparticle formed by multi-stage emulsion or dispersion polymerization. This enables one to provide a developer having this unique combination of properties. By using a multi-stage emulsion or dispersion polymerization technique, a developer particle having a core-shell construction can be obtained in which the composition of the core of the particle is different than the composition of the shell(s). Compatibility with the phenolic resin can be built into the outer or outermost shell(s). In addition the shell(s) can be provided with a sufficiently high MFFT that the particle does not melt as the developer sheet is dried during its manufacture. The shell can also be provided with a higher capacity for hydrogen bonding and a higher concentration of developer moieties which favor compatibility and higher density. On the other hand, the core can be designed with a low MFT, which lowers the temperature and total amount of heat (e.g., heating time) required to coalesce the developer. In addition, in making developers for transparencies, the core composition is controlled to provide an index of refraction which essentially matches the index of refraction of the phenolic resin.
Accordingly, one manifestation of the present invention is a developer composition comprising a first and second developer material, said first developer material being a finely divided thermoplastic phenolic resin and said second developer material being a finely divided thermoplastic vinylic or acrylic resin containing pendant developer moieties.
Another manifestation of the present invention is a developer sheet carrying a layer of the developer composition described above.
Still another manifestation of the present invention is a developer composition useful in preparing transparencies wherein the indices of refraction of said first developer material and the core of the second developer materials are essentially equal such that upon coalescing said developer materials a transparent film is formed.
A still further manifestation is a developer composition wherein said second developer material is a microparticle prepared by emulsion or dispersion polymerization such that said second developer material has a core-shell construction wherein said shell is designed to be compatible with said first developer material and said core is designed to have a low MFT to reduce the temperature required to melt said second developer material and when the developer is used in making transparencies the core is designed to have an index of refraction which essentially matches the index of refraction of said first developer material.
Definitions
The term "core-shell" refers to a microparticle having a core portion and one or more concentric shell portions.
The term "developer moiety" refers to phenolic or salicylic moieties or derivatives thereof.
The term "(meth)acrylic" means acrylic or methacrylic in the alternative.
The term "compatible" means that upon coalescence the developers form essentially a single phase.
"Minimum film forming temperature" is determined in accordance with ASTM D5354.
DETAILED DESCRIPTION OF THE INVENTION
The phenolic developers used as one component of the developer composition of the present invention preferably range from about 0.1 to 25 microns in particle size and have a minimum film forming temperature greater than about 60° C. and a melt flow temperature less than about 135° C.
Many phenolic resins conventionally used as developer materials in pressure-sensitive recording materials are useful in the present invention. These resins may be the condensation product of phenols (including substituted phenols) and formaldehyde. The resins may be further modified to include amounts of salicylic acids or substituted salicylic acids to enhance image density in a manner known in the art.
Examples of phenolic resins useful in the present invention are described in U.S. Pat. Nos. 3,455,721; 3,466,184; 3,762,935; 4,025,490; and 4,226,962.
Another class of phenolic resin useful in the present invention is the product of oxidative coupling of substituted or unsubstituted phenols or biphenols. Oxidative coupling may be performed using various catalysts but a particularly desirable catalyst is the enzyme, horseradish peroxidase. A particularly desirable phenolic resin is described in commonly assigned U.S. Pat. No. 4,647,952. A still more particularly useful resin is prepared by oxidative coupling Bisphenol A with hydrogen peroxide in the presence of horseradish peroxidase. This reaction can be carried out in a mixed solvent of water, acetone, and ethylacetate. After reaction the resin can be pulverized and ground in water with zinc salicylate and salicylic acid to prepare a finely divided particle useful in the present invention.
Another preferred phenolic developer is a condensation product of formaldehyde and an alkylphenol, such as an alkylphenol monosubstituted by an alkyl group which may contain 1 to 12 carbon atoms. Examples of alkyl phenols are ortho- or para- substituted ethylphenol, propylphenol, butylphenol, amylphenol, hexylphenol, heptylphenol, octylphenol, nonylphenol, t-butylphenol, t-octylphenol, etc. These resins are preferably metallated by reaction with a metal salt selected from the group consisting of copper, zinc, aluminum, tin, cobalt and nickel salts. Most typically, the resins are zincated to improve development. The metal content of the resins generally is about 1 to 5% by weight but may range up to 15%. Examples of these resins are provided in U.S. Pat. Nos. 4,173,684 to Stolfo and 4,226,962 to Stolfo.
Another class of thermoplastic phenolic developer material is a resin-like condensation product of a polyvalent metal salt, such as a zinc salt, and a phenol, a phenol-formaldehyde condensation product, or a phenolsalicylic acid-formaldehyde condensation product. Examples of this developer material are available from Schenectady Chemical Inc. under the designations HRJ 4250, HRJ 4252, and HRJ 4542. These products are reported to be a metallated condensation product of an ortho- or para-substituted alkylphenol, a substituted salicylic acid, and formaldehyde.
Phenolic developer materials useful in the present invention may be formed into particles useful in the present invention by several processes. A developer material can be prepared in a conventional manner and ground, or a melt of the material can be atomized. Alternatively, a melt of the developer material can be injected into a rapidly agitated aqueous medium whereupon the melt is solidified as droplets which are recovered. The developer material can also be dissolved in a solvent/non-solvent system and the solvent (which is lower boiling than the non-solvent) removed. Other materials such as Schenectady HRJ 4250, HRJ 4252 and HRJ 4542 resins are obtained commercially in a dispersed form.
The (meth)acrylic or vinylic developers are preferably polymers or copolymers having a repeating unit of the formula (I), (II), or (III) in their structure: ##STR1## where R is a hydrogen atom or a methyl group;
L is a direct bond or a spacer group;
X is --OH, --COOH, --OM, COOR' or a group of the formula (IV): ##STR2## Y is an alkyl group, an aryl group, or an aralkyl group; X' is --OH, --COOH, --OM, or --COOR';
W is --O-- or --COO--;
Z is --OH or a hydrogen atom;
M is a metal atom;
M' is a divalent metal atom;
R' is a hydrogen atom, an alkyl group, or a metal atom as defined for M;
n is 1 or 2 and when n is 2, X or X' may be the same or different; and
m is 0, 1, or 2 and when m is 2; Y may be the same or different.
They may consist of units of the formulae (I)-(III) above but they are preferably copolymers of units of the formulae (I)-(III) and units derived from other copolymerizable monomers as discussed below in more detail. They preferably have a melt flow temperature (MFT) less than about 135° C. and a minimum film forming temperature (MFFT) (ASTM D5354) greater than about 60° C.
Preferred developer resins are copolymers derived from one or more monomers of the following formulae: ##STR3## where R, Y, L and M are defined as above. The aforementioned monomers can be reacted as starting materials or, as explained below, they can be formed in situ by ligand exchange between an acidic monomer (e.g., acrylic or methacrylic acid) and a zinc salt (e.g., zinc salicylate, zinc 3,5 di-t-butyl salicylate, and the like) during polymerization of the acidic monomer.
The preferred (meth)acrylic or vinylic resins are thermoplastic copolymers obtained as microparticles by emulsion polymerization. The microparticles may range from about 0.01 to 20 microns in diameter.
Emulsion polymerization is used herein to design acrylic developers having unique combinations of properties.
In making coalescable thermoplastic microparticles it is desirable to form particles which are compatible with the phenolic resin and which have a low melt flow temperature but a high MFFT. A high MFFT prevents the particles from fusing together during drying. A low melt flow temperature enables the particles to be coalesced for glossing with minimum heating. As a general rule, a polymer which has a high MFFT will also have a high MFT, and a polymer having a low MFT will also have a low MFFT.
By forming the developer particles through a multistage emulsion polymerization process it is desirable to form particles having a core-shell construction in which:
(a) The core has a lower MFFT and MFT than the shell. Upon drying, the higher MFFT of the shell prevents the developer particles from coalescing. Upon glossing, on the other hand, the lower MFT of the core enables the core to melt readily, plasticize the shell and thereby reduce the temperature and the amount of heat required to gloss the developer.
(b) The shell composition is compatible with the phenolic resin such that when the two resins melt, they coalesce into a film. Typically, compatibility is established by incorporating a substantial amount of selected monomers into the shell composition of the acrylic microparticle. Concurrently, the composition of the core and shell are controlled such that they also are compatible. In this manner a continuity of properties is achieved which yields uniform film formation. For compatibility, quantities of the following can be: incorporated into the shell (i) functional monomers which form hydrogen bonds with phenolic resins such as units of the formulas I-III, 2-methoxyethyl (meth)acrylate, etc.; (ii) salicylic or phenolic moieties; or (iii) lower alkyl (meth)acrylates such as methyl (meth)acrylate.
(c) The refractive index of the core essentially matches the refractive index of the phenolic resin when making transparencies. Because the refractive index of (meth)acrylates is about 1.45 to 1.50 and a typical refractive index of a phenolic resin is about 1.55, in order to match refractive indices it is necessary to form copolymers of meth(acrylic) acid or esters with comonomers providing higher refractive indices. Polystyrene has a refractive index of 1.59. Hence, copolymers of styrene and (meth)acrylic acids and/or esters are good candidates for this purpose. On the other hand, polystyrene is not compatible with many phenolic resins. Therefore, to match refractive indices and at the same time maintain compatibility, a core-shell particle has been designed containing a high concentration of styrene in the core polymer and no styrene in the outermost compatible shell polymer. In this manner a particle is obtained having the necessary compatibility for coalescence and the matching refractive index for transparency. While the refractive index of the particle shell may not match exactly the refractive index of the phenolic resin, this does not appear to compromise transparency. Apparently the mixing of the phenolic and acrylic resin at the interface minimizes any effect due to the difference in refractive index.
The developer composition contains about 5 to 90% (solids) of acrylic or vinylic resin based on the total weight solids of the developer resins and preferably 20 to 50% of acrylic or vinylic resin based on total developer resin. The exact amount will vary depending on the nature of the resins used, the nature of the color formers, and the properties (density vs. abrasion resistance) required in a particular application. Generally, the good strength characteristics desired from the addition of the acrylic or vinylic resins are achieved with 25 to 35% acrylic or vinylic resin.
With reference to Formula (I), (II) and (III), X, Y, and M can be any of the substituents or metal ions found in phenolic, hydroxybenzoic acid or benzoic acid type developers. Representative examples of these developers are described in U.S. Pat. Nos. 3,864,146 to Oda; 3,924,027 to Saito et al.; 3,983,292 to Saito et al. and 4,219,219 to Sato.
X is typically selected from the group consisting of --OH, --COOH, --OM and --COOM where M is a metal atom selected from the group consisting of zinc, magnesium, calcium, copper, vanadium, cadmium, aluminum, indium, tin, chromium, titanium, cobalt, manganese, iron, and nickel. M is preferably zinc. X is preferably located ortho and/or para in formula (I) meta or para in formula (II). When the metal atom defined for M has a valency greater than 1, it is chelated with more than one developer moiety. In this case, the developer resin is crosslinked through the metal atom. For example, when X is COOZn in formula (I), the crosslinked unit can be represented by the formula (Ia): ##STR4## where R, L, Y and m, are defined as above.
In accordance with another embodiment of the present invention X is represented by the formula (IV) ##STR5## where W, M', X'Y, m and n are defined above.
Y is typical an alkyl, an aryl or an aralkyl group such as a methyl, n-butyl, t-butyl, t-amyl, cyclohexyl, benzyl, α-methylbenzyl, α,α-dimethylbenzyl, diphenylmethyl, diphenylethyl, chlorophenyl, etc. Y is most preferably an oil solubilizing group such as an alkyl group containing 4 or more carbon atoms or a group containing a monocyclic or bicyclic carbon ring of 6 to 10 carbon atoms. Y is preferably located in positions corresponding to the 3 and 5 positions in salicylic acid.
The spacer group, L in formula (I) and (II), has two functions when it is not a direct bond, namely to stabilize the resin to hydrolysis and to improve developer activity by reducing steric hindrance. By inserting the spacer group L between the aromatic moiety and the carboxyl group the resulting monomer is more resistant to hydrolysis and thermal degradation.
The other function of the spacer group is simply to displace the developer moiety from the acrylic or vinylic polymer chain and reduce the glass transition temperature (Tg) of the polymer. If the developer moiety is coupled directly to the polymer chain, steric hindrance and rigidity of the chains may reduce the activity of the polymer as a developer and reduce film-forming ability.
Those skilled in the art will appreciate that a number of divalent atomic groups can be used as the spacer group L. The exact definition of the spacer group will vary with the nature of the reactants forming the developer moiety. For example, where the developer moiety is derived from a salicyclic acid, the spacer will include the phenolic oxygen atom from the acid. Where it is derived from phthalic acid, the spacer group will include one of the carboxyl groups from the acid. Representative examples of spacer groups are --CH 2 CH 2 O--, --CH 2 CH(OH)CH 2 --, --O--CH 2 CH(CH 2 OH)--O--, and --(CH 2 )n'--OCO-- where n' is an integer of 1 or more and preferably 2 to 6. These spacer groups result from reacting hydroxyalkyl esters or glycidyl esters of acrylic or methacryl acids with the developer compound, e.g., the aromatic acid or phenol. Other spacer groups are alkylene bridges having 3 or more carbon atoms and alkylene oxide bridges having 2 or more carbon atoms and one or more oxygen atoms.
Subject to compatibility with the phenolic resin and any requirements regarding refractive index, the acrylic resin may contain 1 to 100 wt % of the unit of formulae (I)-(III). The developer resins preferably contain about 10 to 60 wt. % of the unit of formulae (I)-(III) and still more preferably 15 to 40 wt. %. If the acrylic or vinylic resin consists of or contains a high amount of the moiety of formulae (I)-(III), it is very rigid and usually must be ground and dispersed in a binder for application herein.
The repeating unit of the formula (I) is typically derived from a monomer which is prepared by reacting acryloyl or methacryloyl acid chloride, or acrylic or methacrylic acid esters such as hydroxyalkyl esters or glycidyl esters with a metallated phenol or a metallated or non-metallated aromatic or hydroxyaromatic acid. One monomer useful in preparing developer resins in accordance with the present invention can be prepared by reacting phthalic anhydride with hydroxyethyl methacrylate in tetrahydrofuran (THF) to yield methacryloyloxyethyl monophthalate. Another monomer can be prepared by reacting a zinc 3,5-disubstituted disalicylate with glycidyl methacrylate or methacryloyl chloride in THF in the presence of a base (e.g., triethylamine in the case of methacryloyl chloride), or a Lewis acid (e.g. ZnCl 2 in the case of glycidyl methacrylate) to yield zinc o-methacryloyloxy(hydroxypropyl)oxybenzoate or zinc o-methacryloyloxy benzoate which is filtered, the THF removed, redissolved in ethyl ether and washed with 2% NaHCO 3 , 0.5% HCl and saturated NaCl. Where X is represented by the formula (IV) above, the monomer is prepared as above but only one mol of the ester or acid chloride is reacted per mol of a difunctional metal salt.
Specific examples of monomers useful in providing the repeating unit of formula (I) are monomers of the formula (Ib)-(Ie) ##STR6##
The repeating unit of formula (II) is derived from a mixed metal salt. The monomers yielding (II) can be prepared by reacting acrylic or methacrylic acid with a divalent metal salt of an aromatic acid in a ligand exchange reaction. The molar ratio of the monomer to the salt is such that the monomer displaces one but not both of the basic groups on the salt. This reaction can be conducted in situ as shown in Example 1 below. Alternatively, the monomers yielding (II), can be prepared by dropwise adding zinc chloride or zinc sulfate solution to a mixture of sodium (meth)acrylate and sodium salicylate (the sodium (meth)acrylate) solutions added in slight excess). The mixed salt will precipitate out.
Specific examples of monomers useful in providing unit (II) are monomers of the formula (IIa) ##STR7##
The repeating unit of formula (III) is derived from monomers such as 3-vinylsalic-vlic acid, 3-vinylbenzoic acid, 4-vinylsalicylic acid, 4-vinylbenzoic acid and 5-vinylsalicylic acid. These compounds may be metallated. They are particularly desirable for incorporating into the acrylic resin when high resistance to ultraviolet radiation is desired.
Substantially any monomer which is copolymerizable with acrylic or methacrylic acid, acrylates, or methacrylates may be reacted with the aforesaid monomers to produce copolymers useful in the present invention. Copolymerizable monomers that may be used to provide the copolymers of the invention are most typically acrylic or methacrylic acid and vinyl monomers such as styrene, vinylacetate, vinylidene chloride, and acrylic or methacrylic acid esters having 1 to 12 carbon atoms in the ester moiety. The monomer is preferably but not necessarily water insoluble.
Monomers useful in increasing refractive index of a (meth)acrylate copolymer include styrene, phenylacrylate, benzyl methacrylate, vinylidine chloride, and others. These latter monomers are generally selected on the basis that homopolymers of the monomers have refractive indices greater than about 1.55.
Representative examples of acidic co-monomers include acrylic acid, methacrylic acid, maleic acid and itaconic acid. Examples of acrylates and methacrylates include methyl methacrylate, isobutyl methacrylate, n-butyl methacrylate, ethylhexyl acrylate, ethyl acrylate, etc. Diacrylate and triacrylate monomers such as hexane diacrylate, zinc diacrylate and zinc dimethacrylate may be used if crosslinking is desired.
Monomers of the formulae (I) or (II) can be compolymerized with a low molecular weight zincated monomer. This is advantageous because it increases the concentration of zinc in the developer resin. Zinc concentrations greater than 4% by weight and preferably greater than 5% by weight are desirable for the acrylic or vinylic developer resin. Useful examples of such zincated monomers are zinc dimethacrylate, zinc diacrylate, zinc itaconate and zinc maleate. These monomers are preferably reacted in an amount of 1 to 20% by weight and preferably 1 to 10% by weight. In selecting from these monomers, zinc diacrylate and zinc dimethacrylate are difunctional and crosslink the resin. They can be used to crosslink the microparticle core to give it a degree of elastomeric character. On the other hand, zinc itaconate and zinc maleate are non-crosslinking monofunctional monomers and as such they can be used to increase the effective zinc concentration in the shell without crosslinking.
The copolymerizable monomer and the amount in which it is used as well as the nature of the monomers yielding formulae (I)-(III) can be varied to provide the desired developing activity, film forming temperature and degree of tack. It is known in the art that properties such as tack, film forming temperature and glass transition temperature (Tg) can be controlled by polymerizing blends of monomers. For example, a copolymer of a monomer associated with a high Tg and a monomer associated with a low Tg produces a copolymer having an intermediate Tg.
By selecting the appropriate comonomers, in different stages of the core-shell emulsion polymerization, acrylic and vinylic resins can be prepared with specified melt flow temperatures (MFT), e.g., 100° to 130° C. (pressure free, 1 minute) and with specified minimum film forming temperatures (MFFT, ASTM D5354) e.g., 60°-80° C. Water based coatings of these resins can be oven dried at temperatures of about 60°-80° C. without coalescence and the developer can still be readily coalesced after reaction with the color former by heating to temperatures of about 100°-130° C.
The composition of the acrylic and vinylic developer resins between the core and the shell of the microparticle and optionally at intermediate points in an emulsion polymerization process can be controlled by varying the nature and the amounts of the monomers reacted, however, the surfactants and initiators can also be varied to produce modifications in the properties of the microparticle. Emulsion polymerization processes have been conducted in from 2 to 6 stages. It is desirable to conduct the polymerization in a large number of stages in order to achieve a gradual transition from the properties and composition of the core polymer to the properties and composition of the shell polymer.
It has been found to be particularly desirable to form the acrylic or vinylic microparticle with a relatively soft, resilient core and a relatively hard, higher melting thermoplastic shell. In this manner, a coalescable developer particle can be formed which does not coalesce upon drying but readily coalesces upon heating to the melt flow temperature of the shell. Not only does this assist drying but these microparticles also require substantially less heat to coalesce than a homogeneous microparticle prepared from monomers having a lower Tg and the resulting coalesced film is durable and resists crazing.
Cross-linking the core, while optional, improves flexural resistance and reduces the tendency for a film of the developer resin to crack. About 0.5 to 5 wt % of a difunctional or polyfunctional crosslinking monomer may be used to crosslink the core. In this regard, in repeating units of the formula (I), when X is COOM or OM, and M is a polyvalent metal atom, the developer resin is crosslinked via the polyvalent metal atom. This can also be used in the core. Difunctional monomers are preferably not used in forming the shell polymer which must be thermoplastic.
Additionally, it is also desirable to form the microparticle such that the zinc (or metal) concentration is higher in the shell than in the core. The zinc enhances the reactivity of the resin and hence image density. The principal site for reaction of the developer resin and the color precursor is the shell and for this reason a high concentration of zincated compounds (preferably about 20 to 50 wt %) in the shell is preferred. However, to match refractive indices in the core and shell and improve resin transparency and core-shell compatibility, some zincated compound is generally used in forming the core as seen in the example.
The shell and core properties are easily adjusted during the emulsion polymerization process. The microparticle core is formed in the initial stage(s) of the emulsion polymerization process. During this stage or stages it is preferred to use monomers providing a low melt flow temperature.
The shell polymer preferably has a melt flow temperature of about 100° to 150° C. and preferably about 115° to 125° C. This enables the developer layer to be dried efficiently, limits tack, and allows the developer layer to be coalesced readily at temperatures below 130° C. If the shell polymer has a substantially lower melt flow temperature, the developer microparticles may coalesce prematurely at the time of drying. If the melt flow temperature is too high, excessive time and heat may be required to coalesce the microparticles. A typical shell monomer composition is about 25-30 wt % monomer yielding the unit of formulas (I)-(III), about 60-65 wt % methyl methacrylate, about 5 to 10 wt. % butyl acrylate, and about 1 to 5 wt. % of methacrylic acid.
The shell polymer composition should be optimized to provide good developing activity, prevent coalescence upon drying, provide good handling characteristics and provide compatibility with the phenolic resin. In addition to including high concentrations of the developer moiety containing monomer and zinc in the shell, it is also desirable to include higher concentrations (e.g., about 3 to 5 wt %) of acrylic or methacrylic acid. The latter monomers are desirable because they are ionic and stabilize the emulsion and they also catalyze dye development during image formation.
As discussed later, a metal (e.g., zinc) salt can also be post-mixed with the acrylic or vinylic developer to enhance its activity. By providing acrylic or methacrylic acid groups in the shell, the zinc salt can chelate with the developer particle and thereby enhance its activity.
Emulsion polymerization usually also requires the use of an appropriate surfactant and/or protective colloid to stabilize the emulsion and control the size of the microparticles. These materials are commonly referred to as emulsion stabilizers and dispersing agents. Those surfactants or protective colloids which are normally used in the emulsion polymerization of acrylates may be used herein. Representative examples include sodium dodecylbenzene sulfonate, ethylene oxide adducts of alkylphenols. Hydroxyethyl cellulose and polyviny pyrrolidone (PVP) are particularly desirable.
Conventional catalysts or initiators for the polymerization of acrylates are useful herein such as benzoyl peroxide, potassium persulfate, t-butyl peroxide, etc. Catalyst concentration may range from about 0.1 to 1% by weight.
The acrylic and vinylic developer resins of the present invention can be synthesized by several pathways. For example, in one method, aromatic developer moieties may be added to preformed acrylate or methacrylate homopolymers or copolymers and particularly polymers having acrylic or methacrylic acid or acid chloride derived units by reacting the polymer with phenols or salicylic acid compounds. However, this method is relatively expensive. In another method, a developer-moiety containing monomer is prepared and reacted in a free radical polymerization process. A third method is to react a zincated phenol or aromatic acid with acrylic or methacrylic monomers to produce a polymer in situ from which the developer moieties are pendant.
With regard to the latter two methods, phenolics are known inhibitors of free radical polymerization. It has been found, however, the monomers containing a phenolic moiety can be polymerized if the phenol is metallated. The same metal salts which are known to enhance the developing activity of phenols can also be used to prevent inhibition of polymerization. Accordingly, in accordance with the preferred embodiments of the invention, monomers useful in preparing the developer resins of the present invention are prepared from zincated or similarly metallated phenolics. The metallated phenolic must be carefully prepared and purified such that no unchelated phenolic material is present. A particularly useful phenolic purification technique is to dissolve the metallated phenol in chloroform or ether, filter, and wash first with 2% NaHCO 3 and then with saturated sodium chloride.
In accordance with another modification of the invention, nonpolymerizable developers can be post added directly to an emulsion of the acrylic or vinylic developer resin. These compounds may be compounds which are soluble in the developer resin such as zinc 3,5-di-t-butyl salicylate. If the polymer contains acid, ester or acid chloride groups, the zinc salts may react with the polymer in a ligand exchange reaction.
In another method, developer materials which are monomer soluble but not soluble in the developer resin can be added to an emulsion polymerization system prior to polymerization such that the compounds become entrained in the acrylic or vinylic developer resin during the polymerization process. Water soluble materials such as zinc chloride or zinc acetate can be added directly to the emulsion prior to coating. Generally, these materials may be added in an amount ranging from about 0 to 10 parts per 100 parts resin. They increase density, improve abrasion resistance and reduce tackiness.
Where the developer composition is mixed with a binder for coating, useful binders include butadiene copolymers, styrene copolymers, α-methylstyrene copolymers, polyvinyl chloride and vinylidene chloride copolymers, carboxylated styrene-butadiene copolymers, styrene alkylalcohol copolymers, etc. The developer resins may be incorporated in the binder in an amount of about 5 to 10,000 parts by weight developer per 100 parts binder.
In the case of developer resin emulsions, a water soluble binder of polyvinyl alcohol, hydroxyethyl cellulose, carboxymethyl cellulose, polyacrylic acid, polyvinyl phenol copolymers, etc. is used. A typical binder/resin ratio is about 0.5/100 to 5/100.
The acrylic and vinylic resins used in the present invention can also be prepared by other known methods for polymerizing acrylates or vinyl compounds including bulk polymerization and suspension polymerization, however, the preferred method is emulsion polymerization. Emulsion polymerization of acrylates is well known.
Useful substrates for developer sheets of the present invention include paper, synthetic papers, and transparent films such as polyethylene terephthalate film. Paper weight and film thickness will vary with the particular application.
The resin is preferably applied to the substrate in a dry coat weight of about 5 to 20 g/sq.cm.
While the present invention is particularly directed to developer compositions in which the acrylic or vinylic resin particle is an active developer, there are applications in which an inactive acrylic or vinylic resin may also be useful. If the phenolic resin is sufficiently active to compensate for any potential loss in density due to the inactivity of the acrylic or vinylic resin, an inactive acrylic or vinylic resin may be used to improve adhesion and cohesion without unfavorably compromising density.
The present invention is illustrated in more detail by the following non-limiting example.
EXAMPLE 1
The following emulsions and catalyst solutions were prepared:
______________________________________ Pre-emulsion Initial charge I II III (g) (g) (g) (g)______________________________________Styrene 9 23 14.41 --Methyl methacrylate -- 6.9 14.41 18.36Butyl acrylateN--dodecyl 16.1 1.17 2.74Methacrylic acid 0.75 1.45 1.08 0.84N-dodecyl mercaptan 0.054 0.138 0.09 0.063Zinc bis(3,5-di-t-butyl salicylate) 0.9 2.3 6 6.4Abex 18S* (10% solution) 17.9 15.9 11.35 8.13Deionized water 30 34 31 23Hydroxyethylcellulose(2% solution) 1.5 -- -- --______________________________________ W-1 W-2 W-3 W-4Catalyst Solution (g) (g) (g) (g)______________________________________Ammonium persulfate 0.4 0.07 0.07 --t-Butylhydroperoxide(10% solution) -- -- 0.6 --Sodium bisulfite -- -- -- 0.01Deionized water 4 3 3 3Hydroxyethyl cellulose -- -- 1.5 --(2% solution)______________________________________ *Abex 18S: an anionic surfactant available from Alcolac, 3440 Fairfield Road, Baltimore, Maryland 21226.
The Initial Charge was heated to 73°-75° C. under nitrogen and stirred at 300-400 rpm. With continued stirring, catalyst solution W-1 was added. Thereafter, Pre-emulsion I was dropwise added to the reactor over a period of one hour and the reaction vessel was allowed to reach 80° C. and maintained at this temperature. After completing the addition of Pre-emulsion I, catalyst solution W-2 was added dropwise over a period of one hour followed by the addition of catalyst solution W-3. With the addition of catalyst solution W-3 completed, Pre-emulsion III was added dropwise over a period of one hour and maintained at a temperature of 80° C. for an additional hour. The reaction vessel was then allowed to cool to 65° C. and catalyst solution W-4 was added. The vessel was maintained at 65° C. for 30 minutes and then allowed to cool to room temperature. [The properties of the emulsion change as the polymerization advances and the catalyst solution is adjusted in the course of the reaction in response to these changes. For example, a more oil soluble catalyst is used in the third state of the polymerization because the water soluble catalyst used in the early stages will not dissolve in the polymer droplet which has grown substantially larger by the third stage. A different surfactant (HEC) is also used in the later stages as the zinc compounds are used in higher amounts since the zinc compounds complex with the surfactant used in the early stage and inactivate it.]
30 parts (solids) of the resulting emulsion was mixed with 70 parts (solids) phenolic resin dispersion HRJ 4542, commercially available from Schenectady Chemical, Inc. This mixture was applied to a transparent substrate and dried at 60° to 80° C.
The developer sheet was assembled with an imagewise exposed imaging sheet prepared in accordance with U.S. Pat. No. 4,399,209 and passed through a nip between a pair of pressure rollers. The developer sheet was separated from the imaging sheet and heated to 120°-130° C. for 1 minute to form a glossy image.
Having described the invention in detail and by reference to preferred embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined by the following claims. | A developer composition comprising first and second developer materials, said first developer material being a finely divided thermoplastic phenolic resin and said second developer material being a finely divided thermoplastic vinylic or acrylic resin containing pendant developer moieties, said first and second developer materials being sufficiently compatible that upon heating they coalesce to form a non-tackey, and scratch resistant film. | 1 |
BACKGROUND OF THE INVENTION
[0001] I. Field of the Invention
[0002] This invention generally relates to the use of a barrier coating to prevent the migration of copper in basis metal to overplate.
[0003] II. Description of the Prior Art
[0004] Jewellery products such as fashion watch bracelets, watch cases, imitation jewellery etc. are often made from copper or copper alloy. These products are often coated with fine gold or gold alloy. It is undesirable to deposit gold directly on copper or copper alloy. When gold is in intimate contact with copper or its alloys, a solid solution of gold-copper is formed. Copper will migrate in gold even at room temperatures. When copper atoms reach the gold top surface they react with atmospheric oxygen and tarnish the attractive appearance of these ornamental products.
[0005] To overcome this migratory problem, a copper diffusion barrier layer is coated between the basis metal and the top gold coating. A number of high melting metals are known to be effective copper diffusion barriers, such as nickel, cobalt, chromium, tungsten or molybdenum. Various factors have to be considered on the suitability of a metal to act as an effective diffusion barrier. The adhesive properties of gold overplate on the barrier coating, the capacity to reduce the thickness of the gold coating, volatility of the barrier coating on further treatments under high temperature and high vacuum; and its corrosion resisting properties are important elements for consideration of its suitability.
[0006] When these jewellery products are in prolonged contact with human skin during use, human perspiration penetrates the gold overplate and may corrode the diffusion barrier underneath to release metal ions as corrosion products. These corrosion products mix with the perspiration and may irritate the skin. The allergic effects of several metals used in plating has been studied and published. These results have been used as one of the references for the selection of diffusion barriers (see for example, “Reinst-Palladium als Ersatz fur Palladium/Nickel. Einsatz. fur Endschichten und als Diffusionssperre”, K.-P. Beck, Glavanotcchnik, vol. 47, no. 1; 1993; pp.20-).
[0007] Nickel has been widely used as the barrier coating for engineering applications. Until the implementation of the EEC Directive 76/769/EEC in 1994 controlling the use of nickel in consumer articles and the liberation of nickel(II) ions, it was also used as the barrier coating for jewellery products intended for prolong contact with the skin (see for example, “Control of nickel emission in jewellery and related items”, R. V. Green and J. F. Sargent, Transactions of the Institute of Metal Finishing, vol. 75, no.3; 1997; p.B51-52). The above mentioned Directive stipulates that metal objects with the intent for prolonged contact with human skin and are made of nickel-containing alloys or coated with nickel-containing substances, should not release nickel(II) in excess of 0.5 μg/cm 2 /week. The specifications for monitoring the said release rate are documented in the standards, EN1811 and EN12471 adopted by the European Committee for Standardization (CEN) in late 1999.
[0008] Various barrier coatings have been suggested to replace nickel including chromium and palladium. Palladium is used to overcome the allergy problem but the cost of the metal can be prohibitive. Copper-tin alloy is another alternative but its internal stress properties and relative high vapor pressure pose a lot of production problems.
SUMMARY OF THE INVENTION
[0009] The invention provides a barrier layer of cobalt-molybdenum-phosphorus, CoMoP.
[0010] The invention further provides a process for electrolytic depositing a cobalt-molybdenum-phosphorus alloy, which possesses excellent barrier property for copper. The use of this alloy as a barrier coating on copper or copper alloy base metal significantly inhibits the diffusion of copper atoms into the gold overplate at moderate temperatures over a long period of time and at high temperatures over a shorter period of time. It is a corrosion resistant alloy which can withstand corrosion on prolonged contact with the human skin.
[0011] The presence of cobalt in the alloy contributes to the inhibition of diffusion of copper. The presence of molybdenum in the alloy inhibits the corrosion of cobalt. It forms a passive film on the surface in the presence of an oxidizing agent such as oxygen in air, and protects the alloy.
[0012] The oxy salts of molybdenum are a potential replacement for chromium, especially the hexavalent ion function of chromium (see for example, “Molybdenum—A Corrosion Inhibitor”, E. Groshart, Metal Finishing, January 1989; p53-54). Molybdenum cannot be deposited in aqueous solution because of its high overpotentials. However, it can be electrolytic and electrolessly deposited with iron groups elements.
[0013] The presence of phosphorus favors the formation of amorphous characteristics in the alloy. It reduces grain boundaries and inhibits corrosion. The introduction of phosphorus thus enhances diffusion barrier properties.
THE DRAWING
[0014] The accompanying FIGURE is a schematic section through an ornamental article prepared in accordance with this invention.
DETAILED DESCRIPTION
[0015] The brass substrate is prepared for the electrolytic deposition in the following manner. The total area of the workpiece is determined. It is degreased; it then undergoes ultrasonic emulsification and cathodic cleaning. These cleaning processes are conducted in accordance with methods known in the art. The workpiece is then subjected to an acid rinse of 10% sulfuric acid, rinsed in water, followed with acid copper electroplating. The acid activation and the acid copper electroplating processes are conducted with the methods known in the art.
[0016] The copper plated workpiece is activated in a 10% sulfuric acid bath, rinsed in water and immersed in a bath of the following composition:
cobalt sulfate 50-70, preferably 60 g/l sodium molybdate 25-45, preferably 35 g/l sodium hypophosphite 15-25, preferably 20 g/l citric acid 160-200, preferably 180 g/l ammonia to pH 3-4, preferably about 3
[0017] The baths having such compositions are also the subject of this invention.
[0018] The temperature of the bath is kept at 55-75° C., preferably 65-75° C., more preferably about 65° C. The workpiece is electroplated at current density 0.1 to 50 A/dm 2 , preferably 6-40 A/dm 2 , more preferably about 10 A/dm 2 . Molybdenum alloys are well known for the relatively low hydrogen overpotentials during electrolysis. Thus, the electroplating efficiency of the said bath is about 30%. The rate of hydrogen evolution during electrolysis is so intense that the popular art of incorporating wetting agent during plating in order to avoid the formation of pitting, resulting from the formation of small hydrogen bubbles securely attached to the surface of the piece, can be eliminated
[0019] The workpiece after plated with the thin coating of cobalt-molybdenum-phosphorus, is now ready for electrodepositing gold or other decorative coatings after prior activation with 10% sulfuric acid for 10 seconds.
[0020] After electroplating the workpiece for 5 minutes at electric current density of 6 A/dm 2 , the coating is about 3 microns in thickness. The composition of the alloy coating is: 82% Co, 12% Mo and 6% P. A schematic cross-section of the finished article is shown in FIG. 1. A coating of an amorphous-microcrystalline alloy 32 of CoMoP is deposited onto the surface of a substrate 33. The coating impedes the migration of copper atoms to the top decorative gold or gold ally coating.
[0021] The workpiece is subjected heat in a hot air oven at 120 2 C for 14 days or at 500° C. for 12 hours. Copper has not migrated to the surface of the alloy coating.
[0022] The coating consists of a mixture of microcrystalline and amorphous metal alloy of Co, Mo and P. The presence of Mo in the coating promotes the formation of a passive film, protecting the attack of Co in hostile environment, such as perspiration. Deposit with amorphous structure reduces intercrystalline boundaries, enhancing its capacity to resist corrosion. Workpiece coated according to the above mentioned technique was subjected to CASS corrosion test (ASTM B368) treatment for 24 hours. The coating was graded 9-10 according to the method described in ASTM B537. When the coated workpiece was subjected to artificial perspiration for 24 hours. The formulation of the artificial perspiration was formulated according to the recipe listed in the European Standard EN1811. The workpiece was graded 10 according to the grading system of ASTM B537 after the treatment of artificial perspiration.
[0023] At low temperatures, copper migrates through the barrier coating via crystal boundaries at a much faster rate than through the metal grains. In the amorphous state of the barrier coating, the amount of boundaries is greatly reduced, affecting the total amount of copper migrating to lower chemical potential regions. At high temperatures, intergranular migration dominates. However, the low solubility of copper atoms in cobalt reduces the total amount of migratory process even at high temperatures. | Techniques are provided for electrolessly depositing and electrodepositing CoMoP barrier coating onto copper or copper alloys to prevent copper diffusion when forming layers on articles such as watch bracelets, watch cases, imitation jewellery, spectacle frames and metal buttons. | 2 |
This is a continuation, of application Ser. No. 903,236, filed 9/3/86, abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to grazing yards suitable for grazing farm animals such as dairy calves or kids. In particular, the present invention concerns such grazing yards which may be readily moveable or relocatable.
Prior art calf yards generally comprise large sheds and/or enclosures. These may contain 100-200 calves at a time. Keeping so many animals in one place gives rise to particular problems such as pollution and additionally presents difficulties in maintaining healthy conditions. If housed in sheds the animals have to be put out to pasture at regular intervals. If housed in enclosures the ground quickly becomes trodden and soiled and the animals must be put to pasture if they are to graze on clean ground.
SUMMARY OF THE INVENTION
The grazing yard of the present invention is adapted to be readily relocatable eg. on a daily basis, so that the animals always have fresh clean ground to graze on. The animals thus have clean healthy grazing conditions and a relatively pollution free environment. Frequent relocation has additional benefits in that the ground is able to recover quickly for reuse.
The grazing yard of the present invention preferably is modular in construction. In one form, the grazing yard may comprise a plurality of modular sub-units. The modular sub-units may be interconnected as desired, thus permitting grazing yards of any convenient shape and/or size to be readily constructed. Modular construction should also facilitate economical manufacture.
The grazing yard of the present invention includes a plurality of wall units. The wall units preferably are interconnected such that they can be moveable or relocatable as an assembly.
Each wall unit may include a frame member. The frame member preferably includes a pair of vertical elements. The frame member may include at least one horizontal element. In one form the frame member may include an inverted U having a pair of leg members. Each wall unit may include at least a further horizontal element. The further horizontal element may be located adjacent a lower portion of the wall unit. Each wall unit may include further vertical elements. The further vertical elements may be located between leg members. The frame member may be formed from tubular material. The tubular material preferably comprises metal. The tubular material may be rectangular in cross-section or any other suitable cross-section. Particularly economical construction may be achieved with tubular material of circular cross-section. At least one wall unit preferably includes a gate eg. between a pair of vertical elements.
Each wall unit may include a skirt member. The skirt member may be adapted to extend from a lowermost portion of a frame member substantially adjacent ground level to reduce clearance therebetween. A skirt member preferably is provided at least on the leading and trailing wall units. In one form the or each skirt member may be pivotably or swingably mounted on the wall unit to minimize fouling during relocation. The degree of pivoting preferably is limited to ensure that smaller animals do not exit via the skirt member.
Each wall unit may include a barrier element. In one form the barrier element may comprise steel mesh or `chicken` wire. The barrier element may include wind proofing if desired. The barrier element may be attached to the frame member in any suitable manner e.g. the barrier element may be spot welded or it may be bound to the frame member by means of metal wire. Each wall unit may be formed in any convenient size and/or shape. Preferably, the wall units are substantially rectangular in outline. In one form each wall unit be substantially one meter high and 4.3 meters wide.
The grazing yard of the present invention includes a plurality of base units. The base units may be coupled or attached to the leg members of a wall unit to maintain the wall units in a substantially vertical position. The base members preferably are non-rigidly flexibly coupled to the leg members so as to permit at least a degree of movement or pivoting between a leg member and base unit in the plane of the wall unit. Each base unit may include a vertical recess or slot for receiving at least one leg member of a corresponding wall unit. The recess or slot preferably is formed so as to permit movement or pivoting in the plane of the wall unit between a leg member and its base unit.
The mouth of the recess or slot preferably is rectangular in shape. The long side walls of the recess i.e. those running parallel to the wall units may be substantially parallel. The distance between the long side walls may be substantially equal to the width of a corresponding leg member. The long side walls preferably extend in a substantially vertical direction when the base unit is placed on the ground.
The short side walls of the recess i.e. those joining the long side walls preferably are spaced sufficiently to permit the abovementioned movement or pivoting of a leg member relative to the base unit. Such lateral movement or pivoting accomodates relative movement of the wall units during relocation. The latter feature is of assistance when the grazing yard is being moved over an uneven surface.
The short side walls of the recess may be parallel or they may flare outwardly from a minimum cross-section within the base unit to a maximum cross-section at the mouth of the recess. The minimum cross-section preferably is dimensionally similar to the cross-section of a pair of leg members when place side by side.
In the case of corner base units the abovementioned short side walls of the recess may be parallel and more closely spaced so that little or no movement of corner leg members takes place. In other words, the distance between the short side walls may be twice the distance between the long side walls of the recess or slot. This may ensure that a pair of corner leg members may be received in the slot or recess side by side with minimum front-to-back and side-to-side movement.
The base units may be formed of any suitable material. The material of construction preferably is sufficiently dense so that base units of adequate mass can be constructed within relatively compact dimensions. In one form the base units may comprise concrete. The base units may be cast in any convenient shape or configuration. Preferably the base units include substantially a smooth lower surface so that they may slide over the ground with minimum resistance. Alternatively, the lower surface may include elements capable of rolling, such as wheels or rollers.
In one form the base units may be substantially circular in horizontal cross-section. The base units preferably have sufficient mass to maintain the wall units in a substantially upright position. The base units may include curved side walls to enhance self-righting capability of the base units eg. in the event that a wall unit has front-to-back or side-to-side pressure applied to it.
Conveniently, a pair of base units may be associated with each wall unit. The base units preferably are spaced such that they are located substantially at the ends of a wall unit.
The wall units may be used to construct a grazing yard of any convenient shape and/or dimensions. In one form a substantially rectangular grazing yard may be formed which is two wall units wide and three wall units long. This would require ten wall units in all.
The base units preferably are interconnected to minimize strain on the wall units, particularly during relocation. In one form the base units may be interconnected via a flexible link such as a metal chain. A further interconnection such as by means of metal chain may be provided between the tops of adjacent wall units.
To minimize stress on wall units the base units may be further interconnected via one or more rigid members. The or each rigid member preferably comprises light weight material such as timber.
Relocation of the grazing yard may be performed with the aid of a prime mover such as a tractor. A rigid towing beam or bar member may be attached to a short side of the grazing yard. Preferably, the rigid towing beam is attached to the base units of the grazing yard. The rigid beam may be permanently attached to the grazing yard. Alternatively, the rigid beam may be secured to the base units prior to relocation being carried out. The rigid beam may be subsequently attached to a tractor via towing lines for towing to a fresh location. In one form a pair of towing beams or bar members may be provided, one each on the leading and trailing end of the grazing yard respectively. The towing beam not in use may be secured to the base or wall units by means of clips or chains.
With wider grazing yards two or more towing beams may be used in tandem at each end of the grazing yard. To reduce the tendency for the sides of the grazing yard to fold together during relocation the clips or chains located in the middle of the towing beams may be a little shorter than the outer clips or chains. The pull on the leading sides of the grazing yards should thus be a little ahead of the middle of the yard.
The grazing yard of the present invention may include an optional shelter unit. The shelter unit may be constructed in any suitable manner. The shelter unit preferably includes a floor and a roof section. The shelter unit preferably also includes three fixed walls. The shelter unit may be located at one end of the grazing yard. The shelter unit may be used to replace a pair of wall units, for example at a short side of the grazing yard.
The shelter unit may be attached to the grazing yard in any suitable manner. The shelter unit may be detachable from the grazing yard for separate towing or it may be towed with the grazing yard. In the latter case, towing lines may be attached directly to the shelter unit. The rigid towing beam also may be dispensed with. The shelter unit may include wheels or other means permitting easy relocation of the shelter unit. The shelter unit may optionally include a feeding station along one wall thereof. A pair of shelter units could be provided, alternatively one at each end of the grazing yard.
A feed receptacle could be prepared (cleaned and filled) in a preparing area and delivered to the grazing yard. The feed receptacle may be of any suitable design e.g. circular. The receptacle may be lowered into the grazing yard by means of a tractor.
According to one aspect of the present invention there is provided a wall unit suitable for use with a relocatable enclosure including a plurality of base units, said wall unit including at least one leg member adapted to be received by a base unit such that said wall unit is maintained in a substantially vertical position.
According to a further aspect of the present invention there is provided a base unit suitable for use with a relocatable enclosure including a plurality of wall units said base unit being adapted to receive a leg member of a wall unit and being adapted to maintain said wall unit is a substantially vertical position.
According to a still further aspect of the present invention there is a relocatable enclosure comprising:
a plurality of wall units, each wall unit including at least one leg member,
a plurality of base units, each base unit including at least one recess for receiving a leg member of a wall unit,
said wall units being arranged to form said enclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the present invention will now be described with reference to the accompanying drawings wherein:
FIG. 1 shows an erected grazing yard according to a preferred embodiment of the present invention;
FIG. 2 shows side wall units of the grazing yard according to one embodiment of the present invention;
FIG. 3 shows base units of the grazing yard according to a preferred embodiment of the present invention; and
FIG. 4 shows the recess or slots arrangement of the base units according to a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIG. 1, there is shown a grazing yard according to the present invention comprising a plurality of wall units 10-19 and a further plurality of base units 20-29. Base units 20, 21 are associated with wall unit 11, base units 21, 22 are associated with wall unit 12 and so on.
The grazing yard is assembled by placing the leg members of each wall unit so that they are received in corresponding slots in the base units. The wall units are maintained in a substantially vertical position by the base units.
Base units 20-23 and 25-28 are interconnected via respective chain elements 30-32 and 33-35 to reduce stress on wall units 11-13 and 16-18 during relocation. Chain elements 30-32 and 33-35, comprise single lengths of chain secured at the base units. Base units 20, 29, 28 and 23, 24, 25 are interconnected via rigid timber members 36, 37 and 38, 39. A pair of corner water troughs 40, 41 are fitted over horizontal elements associated with wall units pairs 13, 14 and 15, 16 respectively.
When it is desired to relocate the grazing yard, towing chains 42-44 are attached to base units 20, 29, 28. Chains 42-44 are then linked to a tractor and the whole grazing yard is advanced to a new grazing position.
Integrity of the grazing yard may be further improved especially during towing, by providing a chain link between base units 24 and 29. Chain 43 may be kept a little longer so that base units 20 and 28 can be towed a little in advance of base unit 29.
Referring to FIG. 2, the wall unit shown generally at 12 comprises: a frame including an inverted U-shaped member 50, a pair or vertical elements 51, 52 and a horizontal element 53. Inverted member 50 includes a pair of leg members 54, 55. The frame comprises welded square section tubular steel elements. A barrier element comprising steel mesh 56 is attached to the frame member by spot welding.
FIG. 3 shows a pair of circular base units 21, 22 in plan view. The base units include respective recesses 57, 58. Recesses 57, 58 are adapted to receive leg member pairs 54, 59 and 55, 60 respectively of adjacent wall units. Base units 21, 22 comprise pre-cast concrete units. The lower portions of base units 20, 21 are gently rounded as shown. The base units 21, 22 are interconnected via chain element 31 to reduce strain on the wall units during towing.
Further chain or similar linking elements, of which chain element 69 is typical, may be connected between chains (31) linking the base units (21, 22) and a lower portion (53) of corresponding wall units. The further chain elements are located adjacent the leading ends of the base units to cause at least partial lift of the leading ends thereof to assist movement of the base units during towing.
FIG. 4 shows a detailed view of slot arrangements in corner base units 20, 21, 29 shown in FIG. 1. The slot arrangement in base unit 21, for example comprises an insert 60 which is embedded in the concrete base unit. Insert 60 includes extremities which communicate with the external surface of base unit 21.
Insert 60 includes rectangular tubular elements 61, 62 which communicate with the top surface of base unit 62. Tubular elements 61, 62 receive leg members of wall units 11, 12. Tubular elements 61, 62 are spaced by a substantially square tubular element 63. Insert 60 includes horizontal tubular elements 64, 65 which communicate with the curved surface of base unit 21. Tubular elements 64, 65 are arranged to communicate with each other via suitable openings in tubular element 63. Tubular elements 64, 65 are inclined to the horizontal such that the inner ends thereof which communicate with tubular element 63 are elevated above the free ends thereof. This facilitates flushing of the tubular elements should these become polluted. Inclination of tubular elements 64, 65 in the manner described additionally facilitates the abovementioned partial lift of the leading ends of the base units. Flushing of pollution is further facilitated by arranging suitable openings in tubular elements 64, 65 which communicate with tubular elements 61, 62 respectively. Insert 60 is constructed by welding tubular elements 61-65 together as shown.
A chain is introduced into and passes through tubular elements 64, 65. The chain is secured with respect to insert 60 by dropping a fastening element 66 into tubular element 63. Fastening element 66 is bifurcated at one end thereof for engaging links of the chain thereby securing the chain with respect to insert 60.
The slot arrangement in corner base unit 20 comprises insert 70. Insert 70 differs from insert 60 primarily in the right angle orientation of the long side walls of tubular elements, 71, 72. It will be appreciated that other arrangements of tubular elements 70, 71 are possible whilst retaining the right angle relationship between the long side walls of tubular elements 70, 71.
Horizontal tubular elements 74, 84 of inserts 70, 80 respectively, slidably receive tubular elements 76, 86 therein. Tubular elements 76, 86 include plate members 77, 87 thereon to which is secured rigid beam 36.
It will be appreciated that various modifications and/or alterations may be introduced into the construction and arrangements of parts previously described without departing from the spirit or ambit of the present invention. | A relocatable grazing enclosure suitable for grazing farm animals such as dairy calves or kids. The enclosure comprises a plurality of wall units each of which includes at least one leg member. The enclosure also comprises a plurality of base units, each base unit including at least one recess for receiving a leg member of a wall unit. The wall units are arranged to form the enclosure. | 4 |
This is a continuation of application Ser. No. 08/292,468, filed Aug. 18, 1994, U.S. Pat. No. 5,525,663.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention generally relates to reactive hot-melt adhesive and/or sealing compositions containing a particulate filler providing improved toolability, wettability and cure profile times, among other things. The invention also relates to a method of using such a sealing composition to fill a cavity or recess in a substrate or between substrates, and the filled articles formed thereby.
2. Description of the Related Art
Adhesive sealants, caulks, and the like, are generally known which incorporate fillers in order to adjust certain physical characteristics of the material such as viscosity and other rheological features such as slumping, weight, toughness, flexibility, resilience, and so forth. Fillers and reinforcing agents generally are selected to have such chemical and temperature resistance so that they might be unaffected by processing with either reactive or thermoplastic systems.
However, in general, prior adhesive sealants are not thought to be entirely satisfactory. For instance, prior adhesive sealants do not have the capability of being shaped or tooled into intricate shapes and/or, if curable, the sealant material cures too slowly. Examples of such needed intricate shapes are seams observed where doorskins are attached to door frames on some new automobiles or the body side seam on some new models of leisure vans. Further, a fast curing adhesive sealant would be highly desirable, such as in the automotive aftermarket, so that as it can be handled more immediately after application without being too tacky, or leaving fingermarks, and so that it can be overpainted without delay.
Regarding previously proposed sealant formulations in more detail, U.S. Pat. Nos. 4,214,019 and 4,252,712 to Donnermeyer et al. describe a block copolymer hot melt adhesive composition and a method for filling a cavity in a substrate with the adhesive. The adhesive composition contains a block copolymer, aluminum powder, glass fiber and hollow inorganic silicate microspheres. The microspheres are said to be required in a minor amount sufficient cause further increase in the melt viscosity with the amount limited so that flow and workability are not impaired. To meet these objectives, an amount microspheres of generally up to about 10 volume percent of the total composition is stated as being required.
As a slight variant to the above, U.S. Pat. Nos. 4,214,019 and 4,217,376 to Donnermeyer et al. describe a block copolymer hot melt adhesive composition and a method for filling a cavity in a substrate with the adhesive, wherein the adhesive composition contains a block copolymer, particulate inorganic reinforcing agent, glass fiber and hollow inorganic silicate microspheres. Again, an amount microspheres of generally up to about 10 volume percent of the total composition is stated as being required. Also, the Donnermeyer et al. patents all relate to nonreactive adhesive systems.
U.S. Pat. No. 4,388,424 to Kennell et al. describe an ambient or room temperature caulk or sealant composition that is extrudible or trowellable. The caulk or sealant composition contains an acrylic copolymer latex binder, glass microballoons, plasticizer, solvent, water adhesion promoters, mineral filler and/or coloring pigments, and the like. The microballons are said to increase the thermal insulation properties and decrease the shrinkage properties in the dried caulk seam as well as impart good extruding characteristic during application and curing of the caulk at ambient temperatures.
As known, setting or hardening of adhesives, including adhesive sealants, into a solid form occurs in three different basic ways: by cooling, by solvent removal, or by a chemical reaction. Of the three, it is generally understood that solvent-based adhesives, such as described by Kennell et al., typically suffer the greatest shrinkage during solidification (solvent removal). Such shrinkage can greatly undermine the performance of an adhesive sealant since the sealant needs to make and maintain intimate contact with the surfaces of the cavity or recess being filled. Kennell et al. does not relate to adhesive sealants which set by cooling and/or chemical reaction. Also, unlike hot melts, solvent-based sealant systems cannot be formulated as 100% solids, and thus have associated higher costs and ecological drawbacks.
U.S. Pat. No. 4,005,033 to Geogeau et al. discloses a solvent-based pasty mastic adhesive or sealant containing organic hollow microspheres, preferably heat expandable thermoplastic spheres. Thermoplastic microspheres generally soften at too low a temperature to be applicable for hot melt applications. The use of thermosetting plastic microspheres in hot melts would be contraindicated due to the risk of the spheres reactivity in the system.
PCT Application WO 92/09503 to Garvey et al., published Jun. 11, 1992, describes a microwave package containing a quantity of hot melt adhesive, where the hot melt adhesive may be of a type which is activatable without microwave susceptors, i.e., of a water retaining type, or may be of a type including microwave susceptors. The microwave susceptor particles include nonsusceptor particles, such as microbubbles or flakes, which are coated with a microwave susceptor layer including a metal or metal -oxide, -silicide, -boride and -phosphide. A hot melt adhesive is exemplified which is loaded with glass microbubbles coated with tungsten.
European Patent Applicant No. 0 455 400, published 6 Nov. 1991 (Kangas et al.), and PCT Application WO 92/13017 (Kangas), each disclose an adhesive coating or sealant formulation formed of a blend of isocyanate-terminated polyurethane prepolymers. In the case of Kangas et al, this blend consists essentially of a first isocyanate-terminated polyurethane based on the reaction product of a polyhexamethylene adipate and a polyisocyanate and a second isocyanate-terminated polyurethane based on the reaction product of poly(tetramethylene ether) glycol and a polyisocyanate. Kangas disclose a similar adhesive coating but also requiring a third prepolymer comprising the reaction product of an essentially amorphous hydroxy-functional material and polyisocyanate. Kangas et al. and Kangas each disclose the optional use of other adjuvants in amounts up to 50% weight of the composition either individually or alone. Examples of such adjuvants are listed as being chain extension agents, fillers, metal oxides, minerals, thermoplastic resins, plasticizers, antioxidants, pigments, U.V. absorbers, and adhesion promoters. As examples of fillers, Kangas et al. and Kangas each similarly list carbon black and glass, ceramic, metal or plastic bubbles; although no bubbles of any kind are demonstrated in the examples of either reference.
Also, conventional plastic (PVC) plumbing drain pipe and joint fixtures, e.g., ells, tees, and the like, are usually joined and, sealed using solvent-based adhesives. The solvent-based adhesives set very rapidly and allow only a short period of time to accurately align of the fixtures before the adhesive sets. Also, the solvent-based adhesives have low viscosity and body which can make it difficult to fully seal the joint.
Also, in the conventional construction industry, there is a need for an adhesive and/or sealant which is flexible yet strong upon cure and has a relatively long open time to permit facile tooling in cracks between adjoining concrete slabs, boards, sheet rock, plywood and the like.
It is not thought that the field heretofore has disclosed the use, nor appreciated the advantages, that can be gained by filling hot melt adhesives and reactive or curing hot melt adhesive systems with hollow objects made of inorganic silicate having a certain thermal conductivity.
SUMMARY OF THE INVENTION
The present invention relates to reactive hot-melt adhesive compositions having a heat of crystallization (ΔH) in joules/gram of -2 or lower, where particulate fillers of a certain type and amount are added effective to provide an overall thermal conductivity in the composition of less than 0.30 Watts per meter per degree Centigrade (Watts/m.°C.).
For purposes of this application, the terms below have the following meanings:
"hot melt adhesive" means a polymeric composition which is a solid at room or ambient temperature (20° to 30° C.), which melts to a viscous yet flowable liquid state when heated, and, upon cooling, sets into a firm solid state;
"reactive", as used to further characterize a hot melt adhesive, means a hot melt adhesive material containing at least two different co-reactive monomers, oligomers or prepolymers capable of being polymerized after application to a substrate to form a three-dimensional polymeric network;
"curable" has the same meaning as "reactive";
"prepolymer" means a polymer having a number average molecular weight less than the entaglement molecular weight;
"particulate" means a flowable material is characterized as formed of separate fine solid particles, inclusive of hollow solid particles;
"filler" means a particulate material generally possessing such temperature resistance that it is unaffected by processing with reactive polymeric systems;
"cellular" means an object having a solid wall or walls enclosing partially or completely at least one cavity or space;
"wetting" means the process in which a liquid spontaneously adheres to and spreads on a solid surface;
"toolable" means the capability of an applied bead of adhesive or sealant to be shaped out of its original form with pressure exerted by a trowell or like device without substantial removal, transfer or loss of adhesive material from the bead;
"open time" means the time after the adhesive or sealant bead is applied, till it is no longer toolable.
"thermal conductivity" or "λ" means the heat passing, in unit time, through unit cross-sectional area of a substance when there is unit temperature gradient between the opposite faces. λ is measured according to industrial standard ASTM C 518; and
"heat of crystallization" or "ΔH" means the quantity of heat liberated (negative values) or adsorbed (positive values) upon crystallization in joules/gram of the composition. ΔH is measured according to industrial standard ASTM E 793 using a Perkin-Elmer #7 series Thermal Analysis System.
The reaction adhesive/sealant composition of the present invention provided with an overall thermal conductivity in the composition of less than 0.30 Watts/m.°C. by virtue of the added filler shows many advantages, including improved wettability, adherability, flexability and toolability over adhesives filled with conventional fillers, such as calcium carbonate.
For instance, the adhesive/sealant composition of the invention has an unexpectedly superior open time behavior for tooling of the bead, as it can be successfully tooled even after a delay of 30 minutes without losing adhesion.
Also, the use of types of fillers, for example, hollow inorganic silicate (glass) objects, in amounts providing an overall thermal conductivity in the adhesive/sealant composition of less than 0.30 W/m.°C., provides unexpectedly improved heat transfer control to provide reduced back melting with "melt-on-demand" capability, i.e., the adhesive/sealant melts more quickly with less back-melting, and less sag due to lower density. These advantages are realized such as where the adhesive/sealant of the present invention is loaded in stick form or cartridge form in a dispenser gun and applied in a melted state to a substrate. The adhesive has improved wettability and, thus, it can be more facilely spread and tooled out into the desired configuration over a substrate. These advantages, are attributable, at least in part, to the inventive use of fillers as an additive to the adhesive providing the thermal conductivity value of less than 0.3 W/m.°C., and more preferably less than 0.2 W/m.°C. These fillers impart unexpectedly advantageous thermal properties as compared to metal spheres, metal-coated glass bubbles, and the like without impairing the adherability (tack) of the adhesive. Also, the glass bubbles do not separate out of the adhesive system and reduce by about a half the cost of the adhesive. Further, as the adhesive/sealant of the present invention can be used as 100% solids, and thus avoids problems associated with the use of solvent.
It is thought that upon application and cooling of the adhesive/sealant composition of the present invention from a molten state that the heat of crystallization, also known as the enthalpy of fusion, of the semi-crystalline adhesive component provides a source of heat, which in combination with low thermal conductivity of the particulate filler, extends the open time of the adhesive facilitating polymer orientation processes taking place at the substrate surface which increase the strength of the adhesive bond. However, the presence of filler such as glass bubbles in this adhesive system imparts surprising improvements thereto. While not desiring to be bound by any theory at this time, the particulate filler is thought to behave like a slow drying solvent in extending the mobility of the polymer chains as they slowly come together and interact as the solvent evaporates from the coating. Examples of such polymer orientation and wetting processes include, but are not limited to, the displacement of air from, and filling of the micro-contours of the substrate surface by, liquid adhesive, and the orientation of adhesive molecules near the surfaces of both the substrate and reinforcing filler particles. The particulate, reinforcing filler reduces adhesive density, thermal conductivity, and cost while increasing adhesive strength.
In one further embodiment, the adhesive/sealant composition of this invention, as filled by the aforesaid filler providing an overall thermal conductivity in the adhesive/sealant composition of less than 0.30 W/m.°C. involves a blend of isocyanate-terminated polyurethane prepolymers having an overall crystallization temperature of from about 25° C. to about 70° C. and a heat of crystallization in joules/gram of -2 or lower. In this embodiment, the adhesive blend comprises (a) a first prepolymer which is the reaction product of an at least essentially semicrystalline hydroxy-functional material and a polyisocyanate and (b) a second prepolymer which is a reaction product of an at least essentially amorphous hydroxy-functional material and a polyisocyanate. The semicrystalline material, in addition to serving as a heat source, adds strength to the adhesive by virtue of crystalline bonds between and within the polymer molecules comprising the semi-crystalline material. The amorphous material imparts flexibility and lowers brittleness. The adhesive blend (a) and (b) is loaded with the particulate filler (c). This adhesive blend cures upon exposure to water moisture and/or vapor. In one preferred embodiment, the blended adhesive composition has components (a), (b), and (c) present in the weight proportions of: 6 to 37% (a), 27 to 80% (b), and 5 to 55% (c), with the proviso that the sum of (a)+(b)+(c) equals 100%, and the weight ratio of (b)/(a) is greater than 1.2. The filled adhesive/sealant composition of the invention preferably has a toolability time of from 5 to 50 minutes before cure.
Further, the adhesive/sealant composition of this invention is extremely versatile and can be used to bond a wide variety of substrate materials including metal, wood, concrete, cellulosic paper, plasterboard, sheet rock, and plastics such as polyvinyl chloride ("PVC"), polystyrene, and acrylonitrile-butadiene-styrene (ABS) rubbers under a wide variety of conditions. In one embodiment, the reactive hot melt system system is effective to bond plastic (e.g. PVC) plumbing and drain fixtures. In another embodiment, the reactive system is is useful in the building construction field such as a sealant applied into crevices between adjoining pieces of sheet rock and tooled smooth, or to bond wood paneling, or as a sealant/adhesive for fiber board and particle board products. As the reactive hot melt sysytem of the present invention is substantially nonshrinkable upon and after cure, it especially well-suited for filling of crevices and holes in substrates which filled adhesive/sealant can be tooled smooth with the adjoining substrate surfaces before cure.
Other features, advantages, and further methods of practicing the invention will be better understood from the following description of the preferred embodiments of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reactive hot melt adhesive systems, such as reactive hot melt urethane systems, can combine the rapid set or crystallization times of conventional nonreactive hot melt adhesives with the high bond strengths of a curing system. For example, like conventional hot melts, the reactive hot melt urethane adhesives are solid at room temperature (about 25° C.), melt to a viscous liquid when heated to moderate temperatures (82°-121° C.), and are applied in the molten state. The adhesive then cools to a solid state to provide initial bond strength. The urethane-based reactive hot melt systems, in particular, are superior to conventional noncuring hot melt adhesives which lack resistance to solvents and heat, have lower bond strengths, and which creep under load because they are non-curing.
However, it was observed by the present inventor that prior reactive hot melt adhesive caulks and sealants, in particular, have peculiar difficulties in terms of back-melt problems in the delivery device, poor wetting characteristic, poor adhesion if tooling is not performed immediately, and long cure time requirements. It has been discovered that the inclusion of filler providing an overall thermal conductivity in the adhesive/sealant composition of less than 0.30 W/m.°C. in reactive hot melt adhesive systems having a heat of crystallization in joules/gram of -2 or lower provides heretofore unreported control over the thermal and curing properties of the adhesive. For instance, while not desiring to be bound by theory, it nonetheless is believed that the extended toolability time achieved by the glass bubble filled adhesives of this invention provides additional time for the prepolymer adhesives to orient at the adhesive-substrate interface; thereby increasing the strength of the adhesive bond to the substrate, among other advantages.
In general, the particulate filler includes cellular glass or ceramic materials loaded into the adhesive in relatively high amounts by volume, generally 30 to 90% by volume of the total volume of the adhesive system. In one preferred embodiment of the invention, the particulate filler is devoid of any thermoplastic or thermosetting materials. For example, thermoplastic bubbles can be undesirable as being too susceptible to heat damage from the heat of the molten adhesive and during cure. On the other hand, thermosetting bubbles can be undesirable as they can interfere with the cure reaction mechanism of the adhesive in manners which cannot be controlled.
One preferred filler is Glass bubbles used in an amount of 30 to 90%, preferably 40-80%, by volume, of the overall adhesive/sealant composition. If the amount of glass bubble filler becomes less than 30% volume of the overall adhesive/sealant composition, the peel adhesion property of the adhesive/sealant tends to become unsatisfactorily low. The glass bubbles are selected of a material and wall thickness and are added in an amount to provide the requisite thermal conductivity of less than 0.30 W/m.°C., preferably less than 0.20 W/m.°C., when added in amounts of from 30 to 90% by volume. The glass bubble material can be an alkali or alkaline silicate material. The glass bubbles have a specific gravity of from about 0.1 to about 2.2, and a bulk density of about 0.1 to about 0.90 g/cc. The average wall thickness of the glass bubbles can be in the range of 0.5 to 2.0 micrometers. The glass bubble particle size can be from about 5 to 125 micrometers. The microballons are preferably less than 80 microns in external diameter. Smaller diameters can raise the viscosity of the adhesive to levels difficult to handle and tool. Again, the glass bubbles are used in amount sufficient to constitute about 30 to about 90 volume percent, and preferably 40-80 volume percent based on total volume of the adhesive and additives, inclusive of the glass bubbles.
Suitable glass bubbles as the filler used in the adhesive composition of the present invention include soda-lime-borosilicate glass bubbles having the trade designation Scotchlite™ K-20 Glass Bubbles and are available from 3M Company, Saint Paul, Minn. 55144. The Scotchlite™ K-20 glass bubbles are about 60 micrometers in external diameter and have a specific gravity of 0.20.
Another suitable glass bubble filler have the trade designation Scotchlite™ S-22 glass bubbles available from 3M Company, Saint Paul, Minn. 55144. Scotchlite™ S-22 glass bubbles are soda-lime-borosilicate glass bubbles of about 30 micrometers in external diameter and having a specific gravity of 0.22. Yet another suitable glass bubble filler have the trade designation Scotchlite™ S-60 Glass Bubbles and are available from 3M Company, Saint Paul, Minn. 55144, which are soda-lime-borosilicate glass bubbles of about 30 micrometers in external diameter and having a specific gravity of 0.60.
The filler can also be a ceramic material. For example, suitable ceramic filler include filler having the trade designation Zeeospheres™ type 850 and available from Zeelan Industries, Inc. Saint Paul, Minn. 55101. Zeeospheres™ type 850 are hollow, ceramic (silica-alumina alloy) spheres with relatively thick walls having a median particle size (by total population) of 17 micrometers in external diameter. Another suitable ceramic filler has the trade designation Z-Light™ W-1012 spheres also available from Zeelan Industries, Inc. Saint Paul, Minn. 55101. Z-Light™ W-1012 are hollow, ceramic (silica-alumina alloy) spheres having an average particle size of 100 micrometers in external diameter and a specific gravity of 0.7. Low density ceramic spheres containing a multiplicity of minute, independent, closed air cells surround by a tough outer shell are useful, such as the filler having the trade designation Macrolite™ ML 3050 and available from 3M Company, Saint Paul, Minn. 55144, which have a median particle size of about 450 micrometers in external diameter.
As to the reactive hot melt curable resins susceptible to improvement by the addition of the filler, such as glass bubbles, imparting the herein-mentioned requisite thermal conductivity, the resin should have a crystallization temperature of between about 25° C. to about 70° C. Also, the reactive hot-melts contemplated for use in the present invention have a heat of crystallization in joules/gram of -2 or lower (meaning -2 and negative values greater in absolute magnitude than the integer 2). The reactive hot melt versions of the adhesive-sealant of the present invention can be light-curing, moisture-curing or heat-curing when they meet the aforesaid crystallization temperature.
As one illustration of suitable resin for the present invention, there is a blend of certain isocyanate-terminated polyurethane prepolymers which provide a moisture-curable hot-melt adhesive system. The blend comprises first and second prepolymers. That is, the blend comprises a first isocyanate-terminated polyurethane prepolymer (hereinafter referred to as "the first polyurethane prepolymer" or "the first prepolymer") a second isocyanate-terminated polyurethane prepolymer (hereinafter referred to as "the second polyurethane prepolymer" or "the second prepolymer"). Each of the first and second prepolymers comprises the reaction product of a hydroxy-functional material and a polyisocyanate.
More particularly, the first prepolymer comprises the reaction product of an at least essentially semicrystalline hydroxy-functional material and a polyisocyanate. By "essentially semicrystalline" it is meant that the first hydroxy-functional material exhibits both a crystalline melting temperature (Tm) and a glass transition temperature (Tg). The at least essentially semicrystalline hydroxy-functional material preferably has an essentially linear, saturated, aliphatic structure, a crystalline melting temperature between about 5° C. and 120° C. (more preferably between about 40° C. and 105° C.) a glass transition temperature less than about 0° C. and has a heat of crystallization (ΔH) of lower than -2 joules per gram. Included within the scope of "at least essentially semicrystalline" materials are those materials which may be regarded as essentially crystalline.
The polyester polyol used to prepare the first prepolymer typically has a number average molecular weight (Mn) of at least about 1000, preferably at least between about 1000 and about 5000, and most preferably between about 1500 to about 3000. At a Mn below about 1000, the resultant prepolymer is soft and may lack cohesive strength in the uncured state. At a Mn above about 5000, the resultant prepolymer tends to be viscous which increases the difficulty of depositing acceptably thin lines of adhesive on a substrate.
If the hydroxy-functional material of the first prepolymer is provided in the form of a polyester polyol, it may comprise the reaction product of a polyol, for example, a diol, and a polyacid, for example, a dicarboxylic acid.
The at least essentially semicrystalline hydroxy-functional material may comprise the reaction product of an alphatic diol having from about 2 to 10 methylene groups and a dicarboxylic acid having from about 2 to 10 methylene groups. Diols useful in forming the at least essentially semicrystalline hydroxy-functional material may comprise, for example, those having from 2 to 10 methylene groups such as ethylene glycol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,8-octanediol, and 1,10-decanediol. Cycloaliphatic diols such as, for example, 1,4-cyclohexanediol and 1,4-cyclohexanedimethanol may also be employed.
Dicarboxylic acids useful in preparing the hydroxy-functional material of the first prepolymer include, for example, those having from about 2 to 10 methylene groups such as succinic acid, glutaric acid, adipic acid, sebacic acid, azelaic acid, and 1,12-dodecanedioic acid, derivative thereof, and mixtures thereof. Included within the scope of useful acids are acid derivatives such as acid anhydrides, acid halides, and alkyl esters such as, for example, the methyl and ethyl esters.
Suitable essentially semicrystalline polyester polyols useful in the invention include, for example, polyhexamethylene adipate, polybutylene adipate, polyepsilon-caprolactone, and combinations thereof. Preferably, the essentially semicrystalline polyester polyol is polyhexamethylene adipate and most preferably, 1,6-polyhexamethylene adipate. 1,6-polyhexamethylene adipate is the reaction product of 1,6-hexanediol and adipic acid.
Examples of commercially available essentially semicrystalline polyester polyols useful in the invention include, for example, FORMREZ 66-20, an adipate polyester diol (poly 1,6 hexane adipates! (OH=20.8)) available from Witco Chemical Company; LEXOREZ 1130-30P from Inolex Chemical Co.; RUCOFLEX 105-37 from Ruca Polyair Corporation; DYNACOLL 7360 from Hulls America; TONE 1271 from Union carbide, and combinations or mixtures thereof.
It has been noted hereinabove that the semicrystalline polyester polyols may be defined in part with reference to whether they display a Tg and/or a Tm. The presence and/or absence of a glass transition temperature and a crystalline melting point are techniques often used to characterize semicrystalline and amorphous (glassy) polymers. The two thermal transitions, Tg and Tm, can be quantitatively determined by measuring changes in specific volume and heat capacity through accepted analytical procedures such as differential scanning calorimetry (DSC). More particularly, Tg and Tm were measured with a Perkin-Elmer 7 Series Thermal Analysis System programmed to scan at,a rate of 20° C./min. The midpoint of the endothermic peak was considered to be the Tg. Tm was considered to be the temperature at the apex of the endothermic peak. These techniques are described more fully in Thermal Characterization of Polymeric Materials, edited by Edith A. Turi (published 1981 by Academic Press, York, York).
The essentially amorphous material used in the preferred adhesive of the invention is preferably a polyether polyol, more preferably, a polyoxyalkylene polyol where the alkylene is C 2 -C 3 . Representative polyoxyalkylene polyols include poly(1,2 and 1,3-propylene oxide) glycol. A suitable commercial source of polyoxyalkylene polyol for use in this invention as the essentially amorphous material in the adhesive are the "POLY G" polyether diol series from Olin Corp. Among this series, there are "Poly G 55-112" having a molecular weight of 1,000; "POLY G 55-56" which is a 2000 MW polyether diol with 70-88% primary --OH's; "POLY G 55-37" having a molecular weight of 3,000; "POLY G 55-28" having a molecular weight of 4,000. Another useful polyether diol is "PPG-2025", a 2,000 MW polyether diol with secondary --OH's available from ARCO Chemicals. One preferred hydroxy-functional material for the second prepolymer is the polypropylene oxide ether glycol Poly G 55-56 (2000 MW polyether diol/70-88% primary-OH, Olin Corp.
Polyisocyanates which can be reacted with the hydroxy-functional materials to form the first and second prepolymers used in one preferred embodiment of the instant invention may be aliphatic or aromatic. Preferably, they are aromatic diisocyanates such as diphenylmethane-2,4'-diisocyanate and/or diphenylmethane 4,4'-diisocyanate (MDI); tolylene-2,4-diisocyanate and -2,6-diisocyanate (TDI) and mixtures thereof. Other examples include: naphthylene-1,5-diisocyanate; triphenylmethane-4,4',4"-triisocyanate; phenylene-1,3-diisocyanate and -1,4-diisacyanate; dimethyl-3,3'-biphenylene-4,4'-diisocyanate; diphenylisopropylidine-4,4'-diisocyanate; biphenylene diisocyanate; xylylene-1,3-diisocyanate and xylylene-1,4-diisocyanate.
A list of useful commercially available polyisocyanates is found in the Encyclopedia of Chemical Technology, Kirk-Othmer, 2nd Ed., vol. 12, pp. 46-47, Interscience Pub., N.Y. (1967), which is incorporated herein by reference. Especially preferred isocyanates include diphenylmethane-4,4'-diisocyanate and its isomers and mixtures thereof.
Isocyanate-functional derivative(s) of MDI and TDI may be used, such as liquid mixtures of the isocyanate-functional derivative with melting point modifiers (e.g., mixtures of MDI with polycarbodiimide adducts such as ISONATE 143L, commercially available from Dow Chemical Company). Small amounts of polymeric diphenylmethane diisocyanate, preferably 10% or less by weight of the total isocyanate components, (e.g., PAPI, and the series PAPI 20, commercially available from Dow Chemical Company, the MONDUR M, MR and MRS series of isocyanates commercially available from Mobay Chemical Corp., and RUBINATE M, commercially available from ICI Chemicals, Inc.) may be included. Blocked isocyanate compounds formed by reacting aromatic isocyanates or the above-described isocyanate-functional derivatives with blocking agents such as ketoximes and the like are also included within the invention. Such blocked isocyanate-functional derivatives will, for convenience, be regarded herein as isocyanate-functional derivatives of MDI and TDI.
In one preferred embodiment of the invention, the reactive hot melt adhesive/sealant includes an essentially semicrystalline hydroxy-functional material comprising polyhexamethylene, adipate, a polyether glycol comprising polyether diol, and a polyisocyanate comprising diphenylmethane diisocyanate. Further, this composition preferably contains the polyether diol and the polyhexamethylene adipate in a weight ratio of 15:85 to 85:15, respectively, more preferably, 25:75 to 75:25, respectively, and the diphenylamine diisocyanate is present in an excess of hydroxyl equivalents. If the amount of polyether diol exceeds 85 per 100 parts of the combined polyether diol and polyhexamethylene adipate, the adhesive properties are adversely affected and decreased. On the other hand, if the amount of polyhexamethylene adipate exceeds 85 per 100 parts of the combined polyether diol and polyhexamethylene adipate, the adhesive/sealant crystallizes too rapidly and tooling time becomes severely shortened.
The prepolymers useful herein may be prepared by techniques that are well known in the art. For example, prepolymers suitable in the invention may be formed by reacting a mixture of the hydroxy-functional polymers and the polyisocyanate(s) in a suitable vessel. Alternatively, the prepolymers may be prepared by reacting each of the hydroxy-functional polymers separately with the polyisocyanate(s) followed by blending of the resultant prepolymers. Still further, the prepolymers may be prepared by forming one prepolymer and subsequently forming the other prepolymer or prepolymers in the first.
Typically, the components are mixed at an elevated temperature using conventional mixing techniques. It is preferred to mix the components under anhydrous conditions. Generally, the prepolymers are prepared without the use of solvents although solvents may be employed if desired.
The isocyanate equivalents should be present in the reaction mixture in an amount greater than the hydroxyl equivalents. The equivalent ratio of isocyanate-to-hydroxyl (NCO/OH), sometimes referred to hereinafter as the isocyanate index, is preferably from about 1.2/1 to about 10/1 and especially preferably from about 1.5/1 to 2.2/1.
The compositions of the invention may further include isocyanate-terminated polyurethane prepolymers other than the prepolymers described above. The additional prepolymers may be added to the prepolymer blends of the invention for a variety of purposes such as to further adjust the open time, green strength build-up, tack, final strength, compatibility, adhesion etc. of the resultant mixture.
Similarly, other monomeric materials may also be included in the polymerization mixture so as to incorporate them directly into either the hydroxy-functional materials of the prepolymers or the prepolymers themselves. Examples of such monomeric materials which may be used to modify the polyester polyols include neopentyl glycol, ethylene glycol, butanediol, hexanediol, succinic acid, sebacic acid, terephthalic acid, orthophthalic acid, etc. The exact level of "other monomer" utilized is not critical to the invention provided it does not materially negatively affect the adhesion of the composition. Typically, the other monomers may comprise up to 50 mole percent of the polymerization mixture.
Also, the inventive adhesive compositions may include an effective amount of catalyst or reaction accelerator such as tertiary amines; metal-organic compounds, such as dibutyl tin dilaurate; co-curatives, and the like. An effective amount of a catalyst is preferably from about 0.005 to 2 percent by weight of the total prepolymer weight. More preferably, the catalyst is present at a level of about 0.01 to about 0.5 percent, based on the total weight of the prepolymers employed. Preferred catalysts are tertiary amines. Especially preferred catalysts are the tertiary amines known as bis 2-(N,N-dialkylamino)-alkyl!ether(s) (sometimes known as "bis ethers"). Suitable bis ethers are described, for example, in U.S. Pat. No. 3,330,782, and include, for example, bis 2-(N,N-dimethylamino)ethyl! ether, bis 2-(N,N-dimethylamino)-1-methylethyl!ether, and 2-(N,N-dimethylamino)ethyl-2-(N,N dimethylamino)-1-methylethyl ether. A preferred bis ether is bis 4,4'-morpholino)-2-ethyl!ether (DMDEE) commercially available from Texaco Chemical Company, Houston, Tex. 77227, under the designation THANCAT DMDEE.
The mode of application of the adhesive formulations of the present invention include hand-held guns and valved dispensing nozzles. In addition to hot-melt bonding, the adhesive composition may be applied, cooled and later heat-activated, i.e., remelted.
Sodium borate exudes from the surfaces of borosilicate glass microballoons when used as the particulate filler. Therefore, in the practice of the present invention, a strong acid, such as phosphoric acid or sulfuric acid, should be added to the adhesive formulation to inhibit the alkalinity imparted by the sodium borate to prevent an undesired problem of inadvertent isocyanate trimerization in the adhesive otherwise caused by the presence of the sodium borate in the adhesive composition. For example, about 1 gram to about 3.2 grams of 86.7% J. T. Baker reagent grade phosphoric acid per kg of the unfilled adhesive is used in this regard. The amount of phosphoric acid can vary depending on the weight amount of borosilicate glass bubbles employed in the adhesive. For example, at a lower addition level of from about 10 to about 20% by weight borosilicate bubbles based on the total weight of filled adhesive, the phosphoric acid is added in amounts of about 1 gram per kg of unfilled adhesive, while, at an upper addition level of from about 30% to about 40% by weight borosilicate glass bubbles based on total weight of filled adhesive, the phosphoric acid is added in amounts of about 3 grams per kg of unfilled adhesive, to ensure that the alkalinity inhering to the borosilicate bubble material is adequately neutralized. Also, it is preferrable to add trace amounts of moisture scavengers to the strong acids, if used. Suitbale moisture scavengers include molecular sieves, such as zeolite, and anhydrides compounds such as maleic anhydride or acetic anhydride.
Other ingredients or adjuvants also may be employed with the blends of the invention to impart to or modify particular characteristics of the composition but only to the extent that the additives do not interfere with or prevent the composition from achieving the physical properties of a thermal conductivity of less than 0.3 W/m.°C. and a heat of crystallization of -2 grams/joule or lower. These ingredients are included in the overall blends or mixtures of the invention rather than being incorporated into the constituent components thereof. The adjuvants should be added only at a level that does not materially adversely interfere with the adhesion of the composition. The adjuvants may comprise up to 50 weight percent of the composition either individually or in combination. For example, chain-extension agents (e.g., short chain polyols such as ethylene glycol or butanediol); fillers (e.g., carbon black); metal oxides such as zinc oxide; and minerals such as talc, clays, silica, silicates, and the like), thermoplastic resins; plasticizers; antioxidants; pigments; U.V. absorbers; and adhesion promoters such as silanes, and the like may be included to modify set time, open time, green strength build-up, tack, flexibility, adhesion and the like.
EXAMPLES
All parts, percentages, ratios, and the like, are by weight in the following examples unless indicated otherwise.
General Preparation Procedure for the Isocyanate-Terminated Polyurethane Prepolymers
4,4'-Diphenylmethane diisocyanate (MDI) was added to a 500 ml--four (4) neck resin flask fitted with a gas inlet, gas outlet, stirrer and thermometer. The MDI was heated to 50° C. until completely melted with efficient stirring under a nitrogen atmosphere. After the MDI was melted, the hydroxy-functional materials were added sequentially (although their addition as a premixed blend also is within the scope of the invention). That is, the preferred order of addition is the essentially semicrystalline polyester polyol, and then the polyether glycol; although this sequence can be reversed. In any event, for purposes of the examples described herein, the semicrystalline polyester polyol was added first followed by adding the amorphous polyether glycol. Stirring and heating at 110° C. under a dry nitrogen purge were continued for about 30 minutes after the addition of each of the semicrystalline polyester polyol and the polyether glycol. Then, sequentially, phosphoric acid and 4,4'-(oxydi-2,1-ethanediyl) bis-morpholine (THANCAT DMDEE, an endcapping and cure promoting catalyst available from Texaco Chemical Co.) were added with about 5 minutes of mixing conducted after the addition of each of these two components. The reaction conducted and maintained throughout at a heated temperature 110° C. and under a dry nitrogen purge. Stirring was continued under vacuum for about 5 minutes at 110° C. A particulate filler, if any as indicated in the examples, then was added to the above mixture at 100° C. in a four neck resin flask fitted with a stirrer, nitrogen inlet and outlet, and thermometer, and mixed for 30 minutes and degassed. Then, the resulting mixture was poured into nitrogen-purged 24 oz. (680 grams) aluminum squeeze tube containers which were then sealed.
Comparative Examples 1-3 and Example 1
A series of isocyanate-terminated polyurethane prepolymers was made generally as described above in the General Preparation Procedure. The specific components and their amounts of addition are described below. The prepared compositions were tested for various properties such as bead characteristics, toolability, shore A hardness, viscosity, flex and/or adhesion to metal and polymeric substrates as indicated. Component values are reported in parts by weight.
Comparative Example 1
A prepolymer was prepared with the components and protocol indicated in Table 1.
TABLE 1______________________________________Addition AmountSequence (grams) Component Mix Time______________________________________1 42.2 Mondur M.sup.1 Until Melted2 100.0 Formrez ® 66-20.sup.2 30 minutes3 150.0 Poly G ® 55-56.sup.3 36 Minutes4 0.3 H.sub.3 P.sub.O.sub.4 .sup.4 5 Minutes5 0.56 DMDEE.sup.5 5 Minutes______________________________________ .sup.1 Diphenylmethane4,4diisocyanate (MDI) available from Miles Inc., Pittsburgh, PA 15205 .sup.2 Adipate polyester diol poly(1,6 hexane adipates)! having a hydroxyl number of 20.8 available from Witco Corp., Chicago, IL. .sup.3 2000 MW polyether diol with 70-88% primary hydroxyl functionality available from Olin Corp., Stamford, CT 06904 .sup.4 86.7 wt % reagent grade phosphoric acid available from J. T. Baker Chemcial Co., Phillipsburg, NJ 08865 .sup.5 Bis(4,4morpholino-2-ethyl) ether available from Texaco Chemical Company, Houston, TX 77227
The resulting prepolymer had a viscosity of 3700 Centipoise at 120° C. (measured using a Brookfield Thermo Cell at 10 rpm with a number 27 spindle) and a toolability time of from about 45 to 120 minutes as shown in Table 2.
Toolability time was determined by extruding a series of 15 centimeter diameter long substantially round beads of adhesive onto base coat-clear coat painted steel test panels designated Code: APR21553, Batch #: 50712312 available from ACT Laboratories, Inc., Hillsdale, Mich. 49242. At various elapsed cooling times (reported in minutes), the adhesive beads were tooled to a produce a 7 millimeter radius semi-circular cross-section by running a tooling wheel back-and-forth over the bead. The tooling wheel is comprised of a 5 centimeter diameter, 7 millimeter thick polyethylene wheel having a 7 millimeter radius semi-circle machined into the outer circumference of the wheel.
Example 1
Comparative Example 1 was repeated except that 53.3 grams of K-20 soda-lime-borosilicate glass bubbles were added to the prepolymer following the DMDEE charge. K-20 glass bubbles (about 60 micrometers in diameter) have an average particle density of 0.20 grams per cubic centimeter are designated Scotchlite™ K-20 Glass Bubbles and are available from 3M Company, Saint Paul, Minn. 55144. The resulting composition was mixed for 30 minutes at 110° C. It had a viscosity of 40,000° Centipoise at 120° C. (measured using a Brookfield Thermo Cell at 0.5 rpm equipped with a number 29 spindle) and a toolability time of from about 5 to 50 minutes as shown in Table 2.
Comparative Example 2
For additional comparison purposes, a commercially-available prepolymer having no glass bubble filler was tested which was obtained under the trade designation Jet Melt 3792-TC, a hot melt adhesive available from 3M Company, Inc., Saint Paul, Minn. 55144.
Comparative Example 3
For additional comparison purposes, a commercially-available prepolymer having no glass bubble filler was tested which was obtained under the trade designation TS-230, a moisture curable hot melt adhesive available from 3M Company, Inc., Saint Paul, Minn. 55144.
The bead quality was rated as unacceptable, marginal, and acceptable. An "unacceptable" bead cannot be tooled at short times before the adhesive cools to the crystallization temperature because it is too "runny" to maintain the semi-circular tooled shape and in some cases sticks to the tooling wheel. At long times, the adhesive cools below the crystallization temperature and becomes so stiff and hard it cannot be shaped by hand tooling. Such unacceptable beads were given a rating of 0 in Table 2 below. A "marginal" bead is defined as one that is able to hold or assume part of the semi-circular profile. Such marginal profiles have flat tops with circular arcs defining the profile between the flat top and painted substrate surface. Marginal beads were given a rating of 1. An "acceptable bead" is defined as bead that develops the full semi-circular profile when tooled with moderate hand pressure and does not stick to the tooling wheel. Acceptable beads were given a rating of 2. After the adhesive cooled and hardened to the point it could no longer be shaped with the tooling wheel, it was given a rating of 0, and the test was terminated.
TABLE 2______________________________________Time Comparative Comparative Comparative(Min.) Ex. 1 Example 1 Ex. 2 Ex. 3______________________________________5 0 2 1 010 0 2 1 115 1 2 0 020 1 2 0 025 1 2 Test Test Terminated Terminated30 1 235 1 245 2 250 2 260 2 Not Measured90 2 Not Measured120 2 Not Measured150 0, No flow Not Measured180 0, No flow Not Measured______________________________________
Examples 2-6
Using the procedure of Example 1, the ratio of polyether to polyester diol was varied to observed what effect changing the ratio had on viscosity (in centapoise), toolability time, and hardness increase at each of 10 minutes and after 2 hours. The results are shown in Table 3.
TABLE 3______________________________________ Ether/ Hardness Ester Tool Shore A Increase (% wt. Viscosity Time (10 (After 2Run ratio) (Cp.) (Min.) min.) hours)______________________________________2 70/30 28,000 5 to 50 28.9 52%3 65/35 34,000 5 to 50 34.6 64%4 66/40 40,000 5 to 60 55.8 28%5 55/45 74,000 5 to 60 69.8 29%6 50/50 116,000 5 to 15 76.4 14%______________________________________
Examples 7-11
In this series of runs, the polyether diol was changed to 1000 MW polyether diol designated Poly G® 55-112 available from Olin Corp. The polyester diol was not changed, i.e., it remained Formrez® 55-56 available from Witco Corporation.
TABLE 4______________________________________ Ether/ Hardness Ester Tool Shore A Increase (% wt. Viscosity Time (10 (After 2Run ratio) (Cp.) (Min.) min.) hours)______________________________________7 70/30 14,000 5 to 25 * --8 65/35 10,000 5 to 50 35.1 46%9 60/40 18,000 5 to 50 41.4 44%10 55/45 30,000 5 to 50 56.4 35%11 50/50 32,000 5 to 25 61.5 37%______________________________________ *Too soft to measure Shore A. Also, test terminated without hardness increase measurement.
Examples 12-16
In this series of runs, the polyether diol was changed to 3000 MW polyether diol designated Poly G® 55-37 available from Olin Corp. The polyester diol was not changed, i.e., it remained Formrez® 55-56 available from Witco Corporation.
TABLE 5______________________________________ Ether/ Hardness Ester Tool Shore A Increase (% wt. Viscosity Time (10 (After 2Run ratio) (Cp.) (Min.) min.) hours)______________________________________12 70/30 44,000 5 to 50 16.9 136%13 65/35 92,000 5 to 50 38.1 52%14 60/40 120,000 5 to 50 51.7 26%15 55/45 112,000 5 to 15 65.9 29%16 50/50 102,000 5 to 15 70.6 30%______________________________________
Examples 17-21
In this series of runs, the polyether diol was changed to 4000 MW polyether diol designated Poly G® 55-28 available from Olin Corp. The polyester diol was not changed, i.e., it remained Formrez® 55-56 available from Witco Corporation.
TABLE 6______________________________________ Ether/ Hardness Ester Tool Shore A Increase (% wt. Viscosity Time (10 (After 2Run ratio) (Cp.) (Min.) min.) hours)______________________________________17 70/30 34,000 too soft -- --18 65/35 38,000 too soft -- --19 60/40 86,000 too soft 6.5 129%20 55/45 104,000 5 to 50 11.3 145%21 50/50 124,000 5 to 50 35.6 39%______________________________________
For runs 17 and 18, the adhesive/sealant was too soft to measure tool time and 10 minute Shore A.
Examples 22-26
In this series of runs, the polyether diol was changed to 2000 MW polyether diol containing secondary hydroxyls designated ARCOL® PPG 2025 available from ARCO Chemical Company, Newtown Square, Pa. 19073. The polyester diol was not changed, i.e., it remained Formrez® 55-56 available from Witco Corporation.
TABLE 7______________________________________ Ether/ Hardness Ester Tool Shore A Increase (% wt. Viscosity Time (10 (After 2Run ratio) (Cp.) (Min.) min.) hours)______________________________________22 70/30 18,000 15 to 50 15.3 91%23 65/35 34,000 5 to 50 45.0 11%24 60/40 76,000 5 to 50 62.1 5%25 55/45 50,000 5 to 15 66.3 38%26 50/50 143,000 5 87.6 >14%______________________________________
The results of these runs show that maximum toolability of 5 to 50 minutes, acceptable initial hardness (10 minute), and hardness increase are achieved for the most economical 70/30 Ether/Ester % weight ratio for isocyanate terminated ether prepolymers having number average molecular weights of 2,000 and 3,000.
Examples 28-35
These examples investigated how toolability affects the range of 180° peel adhesion. A large, (about 3.2 kilogram) master-batch of unfilled adhesive was made using the General Procedure for Making the Prepolymer of Comparative Example A with the following amounts. The master-batch for Examples 28, 29, 31-34 had the composition shown in Table 8.
TABLE 8______________________________________Quantity(grams) Ingredient______________________________________471.2 Mondur ™ M825.0 Formrez ®™ 66-201925.0 PolyG ™ 55-566.16 DMDEE3.3 phosphoric acid______________________________________
Following the addition of the phosphoric acid charge the unfilled master-batch was degassed for 20 minutes at 110° C. and transferred to 750 milliliter aluminum tubes. The unfilled master batch had a thermal conductivity of 0.17 W/m.°C. at 44.2° C.; a ΔH of -22.3 Joules/gram measured according to ASTM E793 using a Perkin-Elmer Series 7 Thermal Analysis System; and a Shore A (10 min.) of 14.4
For Example 30 only, a separate master batch was prepared having the formulation same set forth in Table 8 except that the amount of phosphoric acid was increased to 9.8 grams. This increase was required due to the large amount of sodium lime borosilicate added to the formulation by virtue of the relatively thick-walled glass bubble filler of that run.
Filled adhesives were prepared by adding about 250 grams of the melted master-batch unfilled adhesive to a four (4) neck resin flask equipped with dry nitrogen purge. Sufficient filler to produce a 50% by volume filler loading filled adhesive was added to flask and stirred for 30 minutes at 110° C. and transferred to 750 milliliter aluminum storage tubes. The exact weight of master-batch and filler is shown in Table 9. A description of the particular filler used in each example is indicated in Table 9 and the footnotes.
TABLE 9______________________________________ Qty. Type Qty. of Master- of Filler Filler BatchRun Used (grams) (grams)______________________________________28 K-20 Glass 44.1 243.1 Bubbles29 S-22 Glass 48.4 242.0 Bubbles30 S-60 Glass 139.1 255.1 Bubbles31 Aluminum 633.4 258.0 Spheres32 Calcium 668.9 271.5 Carbonate33 Zeeospheres 460.0 241.034 Macrolite 246.0 258.035 Z-Light 189.8 264.0______________________________________28) Soda-lime-borosilicate glass bubbles (about 60micrometers in average external diameter) having a specificgravity of 0.20 and a thermal conductivity of 0.03 W/m ·°C.designated Scotchlite ™ K-20 Glass Bubbles available from 3MCompany, Saint Paul, MN 55144.29) Soda-lime-borosilicate glass bubbles (about 30micrometers in average external diameter) having a specificgravity of 0.22 designated Scotchlite ™S-22 Glass Bubbles available from 3M Company, Saint Paul, MN55144.30) Soda-lime-borosilicate glass bubbles (about 30micrometer in average external diameter) having a specificgravity of 0.60 grams designated Scotchlite ™S-60 Glass Bubbles available from 3M Company, Saint Paul, MN55144.31) Spherical atomized aluminum (99.5% min.) powder havingan average diameter of 38 micrometers, a specific gravity of2.71, and a thermal conductivity of 237 W/m · °C.designated S-892 Spherical Atomized Powder available from Reynolds MetalsCo., Louisville, KY 40211.32) Calcium carbonate having an average particle size ofabout 10 micrometers and an oil absorption (rub out) in therange of from 5.0 to 9.0 and a thermal conductivity of 3.30W/m · °C.33) Hollow, ceramic (silica-alumina alloy) spheres withthick walls having a median particle size of 17 micrometersand a specific gravity of 2.1 designated Zeeospheres ™ type850 available from Zeelan Industries, Inc. Saint Paul, MN55101.34) Low density ceramic spheres containing a multiplicityof minute, independent, closed air cells surround by a toughouter shell having a median particle size of about 450micrometers, a specific gravity of 1.05, and a thermalconductivity of 0.11 W/m · °C. designated Macrolite ™ML 3050available from 3M Company, Saint Paul, MN 55144.35) Hollow, ceramic (silica-alumina alloy) spheres havingan average particle size of 100 micrometers, a thermalconductivity of 0.09 W/m ·°C., and a specific gravity of0.7grams per cubic centimeter designated Z-Light ™ W-1012available from Zeelan Industries, Inc. Saint Paul, MN 55101.
Example 31 (aluminum powder filler) and Example 32 (calcium carbonate filler) are comparative examples to the present invention, while Examples 28-30 and 33-35 are examples representative of the present invention. The formulations of examples 28-35 were then evaluated as described below for various properties. The results are summarized below in Table 10 for examples 28-35.
TABLE 10______________________________________ Tooled 180° Peel Adh. Therm. Shore A % (10 min..sup.4 / FailureRun Cond..sup.1 ΔH.sup.2 (10 min.) Incr..sup.3 30 min..sup.5) Mode.sup.6______________________________________28 0.16 -18.2 25.8 79% 855/1795 C (44.7)29 0.12 -14.0 27.2 67% 835/820 90% A/ (45.1) 10% C30 0.21 -13.3 35.9 50% 697/452 A (43.8)31 0.88 -6.7 57.1 9% 102/66 A (41.1)32 0.53 -6.5 52.5 28% 430/82 A (40.8)33 0.47 -4.8 50.6 13% 123/52 A (41.6)34 0.29 -7.6 60.0 -12% 685/810 A (43.1)35 0.178 -10.8 45.3 48% 641/263 A (44.6)______________________________________ .sup.1 Thermal Conductivity (Watts/meter per °C.) was measured in accord with ASTM C518 using a PerkinElmer Series 7 Thermal Analysis System. Values in parentheses (....) are temperatures in °C. at which the thermal conductivity was measured. .sup.2 ΔH (Joules/gram) indicates the heat adsorbed (+) or liberate (-) at the crystalline/noncrystalline phase transition of the isocyanate terminated polyester prepolymer component measured in accord with ASTM E793 using a PerkinElmer Series 7 Thermal Analysis System. Heat is absorbed during DSC heating scan and liberated during DSC cooling scan. .sup.3 Percent increase (or decrease (-)) in Shore A hardness after 2 hours .sup.4 180° Peel Adhesion (Newtons/decimeter); adhesive tooled at 10 minutes. .sup.5 180° Peel Adhesion (Newtons/decimeter); adhesive tooled at 30 minutes. .sup.6 A cohesive failure is indicated as "C", and an adhesive failure is indicated as "A".
Further on footnotes 4) and 5) of Table 10, the tooled 180° Peel Adhesion values were measured using a Sintech 6W tensile test system available from MTS Systems Corp., Research Triangle Park, N.C. 22709. Duplicate test specimens were prepared by extruding two, 15 centimeter diameter rounded beads, approximately 20 millimeters apart onto thoroughly degreased, cold-rolled steel panels. The unpolished, 810 micrometer thick, cold rolled steel panels (10×30 centimeters), available under the designated code: APR10161, Batch# 20160216 from Advanced Coating Technologies (ATC) Laboratory, Hillsdale, Mich. 49242, were degreased with 3M General Purpose Adhesive Cleaner designated Part No. 08984 available from 3M Automotive Trades Div., Saint Paul, Minn. 55144. The beads on the first panel were tooled 10 minutes after extrusion, those on the second were tooled 30 minutes after extrusion. The tooled beads were allowed to cure for seven (7) days under ambient room conditions (approximately 25° C./ 50% relative humidity). After cure, the space between the beads was covered with Teflon™ tape and filled-in with Panel Adhesive Compound 30 designated Part Number 08456, which is available from 3M Company, Automotive Trades Division, Saint Paul, Minn. 55144. A strip of cotton cloth (3.8 by 35 centimeters) was placed on the panel adhesive and worked in using a tongue depressor. The specimens were aged under ambient conditions for an additional 3 days to cure the panel adhesive. The steel panel was clamped in the fixed (lower) jaws of the Sintech. The strip of cotton cloth was folded back 180 and the loose end clamped in the movable (upper) jaws of the Sintech. The specimens were pulled at a cross-head speed of 5 centimeters per minute. The maximum peel adhesion value and failure mode were noted and recorded.
Examples 36-41
This example shows the effect of changing the glass bubble volume loading of the filled adhesive. K-20 glass bubbles were added to the master-batch adhesive of Examples 28-35. The results are shown in Table 11. The 180° peel adhesion values are non-tooled peel adhesive values.
TABLE 11______________________________________ (Non-Tooled) 180° Peel % volume Adhesion FailureRun loading (N/dm) Mode______________________________________36 50 1365 C37 40 875 A38 30 610 A39 20 580 A40 10 640 A41 0 630 A______________________________________
The non-tooled 180° peel adhesion values were determined as follows for Examples 36-41. The molten adhesive for each example was uniformly spread on a cold rolled steel test coupon with a tongue depressor. Sufficient adhesive was applied to the coupon to assure that the thickness of the spread layer exceeded 50 micrometers. The test coupons (15×2.5 centimeters) were cut from the same panels used in the tooled 180° Peel Adhesion test for examples 28-35, i.e. Code: APR10161, Batch#: 20160216, from Advanced Coating Technologies (ATC) Laboratory, Hillsdale, Mich. 49242, which were likewise degreased with 3M General Purpose Adhesive Cleaner designated Part No. 08984 available from 3M Automotive Trades Div., Saint Paul, Minn. 55144. The spread adhesive films were allowed to cure for seven (7) days under ambient room conditions (approximately 25° C./50% relative humidity). After cure, the molten master batch adhesive was extruded over the cured adhesive test film and a strip of fine mesh stainless steel screen (3.8 by 35 centimeters) was worked into the molten, unfilled adhesive using a tongue depressor. The fully assembled test specimens were aged under ambient conditions for an additional 7 days to bond the screen to cured adhesive test film. Then, the steel panel was clamped in the fixed (lower) jaws of the Sintech. The strip of stainless steel screen was folded back 180 degrees and the loose end clamped in the movable (upper) jaws of the Sintech. The specimens were "pulled" at a cross-head speed of 5 centimeters per minute. The maximum peel adhesion value was recorded in Newtons per decimeter, as indicated above.
The results in Table 11 show that the non-tooled Peel Adhesion increases directly with % volume loading of K-20 glass bubbles, and when the % volume loading exceeds 50% the adhesive bond fails cohesively.
Various modifications and alterations of this invention will become apparent to those skilled in the art without departing from the scope and spirit of this invention, and it should be understood that this invention is not to be unduly limited to the illustrative embodiments set forth herein. | A reactive hot melt adhesive and/or sealing composition having a heat of crystallization in joules/gram of -2 or lower, comprising a curable heat-flowable adhesive material and a particulate filler, wherein said composition has a thermal conductivity of less than 0.30 W/m.°C. The invention also relates to a method of using the adhesive/sealer composition described herein to fill a cavity or recess in a substrate and the filled substrates formed thereby. | 8 |
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
The present invention relates to a method of activating down and fiber materials, and more particularly to a method of activating down and fiber materials in which ionized air and normal air are alternately brought into contact with materials to be treated continuously so that the surface of the materials is ionized and activated.
DESCRIPTION OF THE PRIOR ART
A conventional method, in which air ionized by corona discharge is blown on down or feathers to neutralize electrostatic charge of the dust attached to the down so that the dust for a down-filled quilt may be removed, is known in Japanese Patent Publication No. 33482/81.
However, the method merely removes dust attached to down, but any further object, operation and effect thereof are not considered.
A quilt filled with cotton shrivels and becomes hard as it is used. The quilt becomes soft and bulky when it is dried in the sun, but when the quilt is used again it becomes thin and hard. The reason why the quilt becomes thin and hard is that cotton fibers are oxidized and lose their original elasticity.
Further, woolen fabrics, silk fabrics, paper or the like also lose their original elasticity and bulkiness as used. It is very difficult to activate such fiber materials which are folded and shriveled.
On the other hand, the feathers and down for down-filled quilts are stuffed into bags imported from South-east Asia. Accordingly, the feathers and down are compressed and intertwined with each other. The feathers and down are further folded in a degreasing process, washing process and drying process. In a process of selecting down from feathers after a dust removel process, the selection ratio of down is as low as about 60% since the shriveled down intertwines about the feathers and fibers. Accordingly, the selection process must be repeated again and again.
The folded and shriveled down can not recover to a sufficiently bulky state. The worn-out down cannot become bulky enough when dried.
SUMMARY OF THE INVENTION
Accordingly, in view of the above problems, it is an object of the present invention to provide a method of activating down and fiber materials through ionization and refreshing folded and shriveled fiber materials. More particularly, it is an object of the present invention to provide a method of activating down and fiber materials, characterized in that a plurality of nozzles for ionized air produced by an air ionizer and nozzles for normal air are alternately disposed at proper intervals in the passage of the materials in order to make said materials go through the passage alternately filled with said ionized air and normal air.
Another method is adopted to achieve the above object. The materials to be treated are accommodated in a chamber, instead of a passage, which is alternately filled with ionized and normal air to repeat the processes where the materials are subjected to ionization and then suspension of the progress of oxydization caused by ozone several times for final activation of the materials.
In accordance with the present invention, a plurality of ionized air nozzles for an air ionizer provided with corona discharging electrodes and normal air nozzles are alternately disposed at proper intervals in the passage of materials to be treated. The passage is filled with ionized air and normal air ejected from the nozzles, and the materials to be treated, for example down, are passed through the passage so that the down is brought into contact with the ionized air for ionization and then brought into contact with the normal air for suspension of the progress of oxydization caused by ozone. This process is repeated so that the surface of the materials is subjected to gradual and intensive ionization to activate the materials deep into the inside of the passage or chamber. More particularly, even if the down is shriveled and folded by degreasing and washing processes, the repeated operations by which the down is ionized in ionized air and then brought into contact with normal to suspend the progress of oxydization caused by ozone several times lead the down to gradual and progressive ionization. The refreshed down turns activated and recovers the original elasticity as if it were covering living fowls. The fiber texture turns into an expanded state. The electrostatic charge is removed.
In this manner, the down recovers its original state such that it can float in the breeze. Thus, such down floats well in the breeze in the selection room to be easily selected from feathers which are difficult to float in the breeze. Likewise, even wornout down can be activated to be soft and bulky in the same manner as reprocessed cotton.
Further, the materials to be treated are placed in a chamber which is alternately filled with ionized air and normal air from nozzles for ionized air and nozzles for normal air, respectively, to refresh and activate the materials.
In accordance with the present invention, such gradually and progressively repeated ionization of the materials prevents the materials from rapid oxidation caused by high concentration of ozone. Thus, the sufficient extent of progress of ionization causes the cellular tissues to be effectively activated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a down activating apparatus for use in a first embodiment of the present invention;
FIG. 2 is a side view of an air ionizer;
FIG. 3 is a cross-sectional view of a nozzle for ionized air of the air ionizer;
FIG. 4 is a plan view of an activating apparatus for use in a method of a second embodiment; and
FIG. 5 is a cross-sectional view of an activating apparatus for use in a method of a third embodiment.
DESCRIPTION OF PREFERRED EMBODIMENTS
A first embodiment of the present invention concerning treatment of down will now be described in detail. FIG. 1 is a cross-sectional view of an apparatus for use in the implementation of the present invention. A down activating apparatus 1 includes a metal box 2 which is divided into a primary treating chamber 3 and a collection chamber 4 by a partition wall 2a.
The primary treating chamber 3 includes a grate 3a which is disposed at a position near the bottom and spaced by a predetermined distance from the bottom. A set of lower rotatable feeding blades 5 are disposed above the grate 3a. Upper rotatable feeding blades 6 are disposed above the lower rotatable feeding blades 5 and the upper rotatable feeding blades 6 are surrounded by a partition wall 2b in the form of a substantial U-shape as viewed from the front direction to form a secondary treating chamber 7.
An inlet 3c is formed at an upper end of a right outer wall 3b of the chamber 3. A down and feathers feeding hose 8a is coupled with the inlet 3c. The outer end of the hose 8a is coupled with the down and feathers feeding device 8. Thus, a predetermined space between the secondary treating chamber 7 and the outer wall 3b forms an incoming path 3d and a predetermined space between the secondary treating chamber 7 and the partition wall 2a forms an upwardly flowing path 3e.
A partition plate 2c is extended above the secondary treating chamber 7 to form a ceiling and also to form an exhaust outlet 2d at a right side of the partition plate 2c. An exhaust path 9 is formed between an upper wall of the box 2 and the partition plate 2c. The partition plate 2c is provided with a vertical wall 2e which hangs down from the partition plate 2c into the secondary treating chamber 7 so that the upper portion of the secondary treating chamber 7 is divided into an incoming path 7a and an outgoing path 7b.
Air ionizers 10 1 and 10 2 are disposed at a lower right corner of the chambers 3 and 7, respectively, so that both nozzles 10a thereof are directed to the chamber 3.
Referring to FIGS. 2 and 3, the air ionizers 10 1 and 10 2 are provided with an air compressor 10b which is coupled with a base end of branched blower pipes 10c. The blower pipes 10c are provided with a plurality of injection pipes 10d. The injection pipe 10d includes a pair of positive and negative corona electrodes 10e and 10f. When a voltage is applied between both the corona electrodes 10e and 10f, a corona discharge is generated therebetween. When air is blown from the air compressor 10b, ionized air is injected into the chamber 3 from the nozzles 10a.
A nozzle 11 1 is disposed in a lower left corner of the chamber 3 in FIG. 1 so that the nozzle 11 1 blows out normal air toward the upper right direction. The base end of the nozzle 11 1 is coupled with an air compressor, not shown, outside of the chamber 3 so that normal air is sent into the chamber 3. Thus, the nozzles 10a for ionized air and the nozzles 11 1 , 11 2 , 11 3 and 11 4 for normal air are alternately disposed in the path of the materials from the chamber 3 to the outlet 2d of the chamber 7 at proper intervals as shown in FIG. 1.
A suction fan 4a is disposed at the lower portion of the collection chamber 4. An exhaust pipe 4b which communicates with the exhaust path 9 is disposed at the upper portion of the partition wall 2a, and a collection bag 4c is attached to an outlet of the exhaust pipe 4b. In FIG. 1 a grate 4d is shown as separating the collection bag 4.
The down feeding device 8 feeds 20 kg of down into the chamber 3 in ten minutes by 12 m 3 per second of air.
The air ionizers 10 1 and 10 2 in the chamber 3 blow out 4 m 3 per second of ionized air into the chamber 3. Other air ionizers 10 3 , 10 4 and 10 5 each possess a capacity of blowing out 1 m 3 per second of ionized air. The nozzles 11 1 to 11 4 for normal air each can blow out 1 to 2 m 3 per second of fresh air.
The suction fan 4a of the collection chamber 4 possesses a suction capacity of about 16 m 3 per second to suck the down in the chamber 7 and collect the down into the collection bag 4c. The collection bag 4c accommodates 20 kg of the down.
In the present apparatus 1 constructed above, the down and feathers sent out from the down feeding device 8 enter the chamber 3 through the hose 8a and the incoming path 3d. The chamber 3 is filled with ionized air generated by the corona discharge of the air ionizers 10 1 and 10 2 . When the down and feathers come into contact with the ionized air, the surface of the down and feathers is ionized. The lower rotatable feeding blades 5 agitate the down and feathers within the chamber 3 and the down with a good floatability goes up into the path 3e while the feathers which are difficult to float stay in the bottom. The down going up into the path 3e is then immediately brought into contact with normal air sent out from the nozzle 11 1 so that the progress of the precipitous oxydization of the down caused by ozone can be suspended. Then the down is blown upward. The down blown upward is brought into contact with ionized air and normal air, alternately, blown out of the nozzles 10a for ionized air and the nozzles 11 2 and 11 3 for normal air to be repeatedly subjected to ionization and immediate subsequent suspension of the progress of oxydization caused by ozone alternately until the down enters the chamber 7. When the down enters the chamber 7, the down is agitated by the upper rotatable feeding blades 6. The down is further ionized by the ionized air blown out of the nozzle 10a and is floated. Then, the down comes into immediate contact with normal air blown out of the nozzle 11 4 and reaches the outlet 2d. The down reaching the outlet 2d is sucked into the exhaust path 9 by the suction fan 4a in the collection chamber 4 and is collected into the bag 4c through exhaust pipe 4b.
Corona discharge by air ionizers 10 1 and 10 5 ionizes air. The ozone O 3 in the ionized air is decomposed into O 2 and O of which two atoms are easily converted into an oxygen molecule O 2 . The surface of the down is subjected to strong oxidization when oxygen atoms generated from ozone become oxygen molecules. Accordingly, the surface of the down once ionized to be activated is subjected to acute oxidization and then immediately prevented from the progress of oxydization by normal air to be further ionized in contact with ionized air. Thus, the down is subjected to progressively repeated ionization and then immediate through gradual ionization instead of one time acute ionization while being kept from oxydization caused by ozone. The down thus ionized is restored to its original shape is activated and then recovers its original elasticity from the state of being shrinked, folded, stretched or entangled. The down which is intertwined with each other is separated from each other when ionized. The down easily floats in the breeze, while the feathres are difficult to float in the breeze and fall down. The selection rate of the down from the feathers becomes 99% according to the present method while the selection rate of the prior art method is about 60%, which necessitates that the selection process be repeated.
In addition, since the activated down, which has shown a phenomenon of age to become shrinked, stretched or folded, recovers its original shape and increases its bulkiness, the collection bag 4c accommodates only 9 kg of down, while the same bag 4c can accommodate 20 kg of down treated by conventional methods. Accordingly, while the down-filled quilt according to conventional methods contains 1.5 kg of down, the quilt which is filled with 1 kg of the activated down according to the present invention is too bulky for the quilt. Therefore 700 to 800 g of the activated down is enough to assure the same bulkiness as the quilt filled with the down according to conventional methods.
The present invention is not limited to the above construction. The materials to be treated may be contained in a bucket to pass through a tunnel and nozzles may be disposed so that ionized air and normal air are alternately blown out.
The present invention is not limited to the treatment of down as described above and can also be utilized to activate cotton, chemical fibers, silk and the like.
FIG. 4 is a plan view of an apparatus used in a method of a second embodiment.
A down activating device 12 includes a conveyor 14 disposed at the bottom of a plane and rectangular housing 13 and moved in the longitudinal direction. A carrying-in conveyor 15 and a carrying-out conveyor 16 are disposed in series before and behind the conveyor 14.
Air curtain units 17 1 , 17 2 . . . , 17 6 are disposed in the housing 13 at predetermined intervals and air curtains 17a are used to define ionized air chambers 18 1 to 18 3 and normal air chambers 19 1 to 19 2 , alternately.
Each of the ionized air chambers 18 1 to 18 3 is provided with an ionized air nozzle 18a of an an ionizer which is identical with that shown in FIG. 3 and described in the first embodiment. In FIG. 4, there is also shown an air pipe 18b and an air pump 8c.
Each of the normal air chambers 19 1 and 19 2 is provided with an air nozzle 19a coupled with an air pump 19c through an air pipe 19b, and an exhaust pipe 20 is further disposed between the normal air chambers 19 1 and 19 2 .
When the materials such as silk thread, woolen yarn, chemical fiber yarn, cotton, blankets, paper and wood are carried into the housing 13 by the carrying-in conveyor 15, the materials are moved in the housing 13 by the conveyor 14 at a predetermined speed. The housing 13 is divided into the ionized air chambers 18 1 to 18 3 and the normal air chambers 19 1 and 19 2 , which are alternately disposed, by the air curtains 17a. The ionized air is blown into the ionized air chambers 18 1 to 18 3 from the nozzles 18a to adjust the quantity of the blown out ionized air to be 4m 3 per second. The materials have their surface ionized while passing through the ionized air chamber 18 1 . Consequently the materials are immediately moved to the normal air chamber 19 1 to have the progress of oxydization caused by ozone suspended temporarily by fresh normal air. The materials are then transferred to the ionized air chamber 18 2 to be ionized therein again. In this manner, the ionized air chambers 18 1 to 18 3 and the normal air chambers 19 1 and 19 2 are alternately disposed within the housing 13 so that the materials passing through the housing 13 are ionized and then immediately have the progress of oxydization caused by ozone suspended with normal air alternately and repeatedly, resulting in gradually intensified ionization. The conveyor 16 carries out the materials. In the above construction, the ionized air was blown into the ionized air chambers 18 1 to 18 3 at the rate of 4 m 3 per second. The conveyor 14 is stationed in each chamber for three minutes to treat 20 kg of silk thread. The treated silk thread was thicker than before treatment and had a feeling like fluffy floss silk. The silk thread seemed to have increased its volume by about 20% or more.
Worn-out neckties each made of silk, polyester fiber and wool recovered their bulkiness as if they had been new ones, when treated under the same conditions, although they had flat folded edges before treatment.
FIG. 5 is a cross-sectional view of an apparatus for use in a method of the third embodiment.
An activating device 21 includes ionized air nozzles 23 1 and 23 2 coupled with an air ionizer and air nozzles 24 1 and 24 2 for feeding normal air which are disposed in a rectangular box 22.
The box 22 is further provided with an exhaust device 25. In FIG. 5, there is also shown air pipes 23a and 24a, air pumps 23b and 24b, a pedestal 26, and a hanger 27. The activating device 21 can interchange the ionized air and the normal air at predetermined intervals alternately. A basket which contains cotton yarn, quilts, paper, books, wood or the like is laid on the pedestal 26 and blankets, clothes, coats, quilts or the like are hung on the hanger 27 for treatment.
Used cotton-filled quilts were hung on the hanger 27. The ionized air nozzles 23 1 and 23 2 blew out the ionized air at the rate of 5 m 3 per second for five minutes and the ionized air was then evacuated by the exhaust device 25. The air pipes 24 1 and 24 2 blow out normal air for four minutes and the normal air was then evacuated. Then again, the nozzles 23 1 and 23 2 blew out the ionized air at the rate of 5 m 3 per second for five minutes and the same conditions as above were thus repeated five times. Consequently, cotton shriveled hard recovered its original elasticity and became bulkier and softer than that dried in the sun for three hours. The cotton was thus activated and refreshed.
Further, when a worsted suit was treated on the same conditions, the hard shriveled worsted cloth was restored to its bulkiness and softness and was activated as if it had been new.
While there has been described what is at present considered to be preferred embodiments of the invention, it will be understood that various modifications may be made therein, and it is intended that the appended claims cover all such modifications as fall within the true spirit and scope of the invention. | A method of activating down and fiber materials uses a plurality of nozzles for ionized air and nozzles for normal air alternately at proper intervals in the passage of the materials to be treated. The materials are subjected to ionization by ionized air ejected from the nozzles for ionized air produced by an air ionizer connected to the ionized air nozzles. Then the materials are subjected to suspension of the progress of oxydization caused by ozone by normal air ejected from the normal air nozzles. This process is repeated several times while the materials are passing through the passage. The repeated processes of such alternate ionization and suspension of the progress of oxydization caused by ozone allow the materials to be gradually and intensively ionized, resulting in producing finally activated materials which are characteristic of restored bulkiness and elasticity. An enclosure can also be adopted instead of the passage. In the enclosure, the stationary materials are subjected to ionization by ionized air injected. After evacuation of the ionized air from the enclosure, normal air is injected which will be evacuated afterward. One of the uses of this method is activation of down to be filled in quilts. But this method is also utilized for activation of other materials such as cotton, silk, chemical fibers, wool, paper, wood etc. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S. Provisional Patent Application No. 61/305,267 filed on Feb. 17, 2010 and U.S. Provisional Patent Application No. 61/419,105 filed on Dec. 2, 2010, the contents of which are incorporated herein by reference in their entirety.
FIELD
[0002] The present invention is related to a device for easily and unobtrusively winding, storing, and protecting cords and/or cables.
BACKGROUND
[0003] Many devices have a cord or cable associated with the device. For example, kitchen appliances such as toasters, coffee makers, and blenders all have a power cable for the transmission of electrical power. In the digital age, most audio-visual devices have a cord or cable. For example, users use headphones or earbuds with their MP3 players and smart phones. Moreover, the cost to replace damaged or broken cords/cables/headphones is increasingly expensive. Although there are a variety of winders available to organize and store cords and cables, these conventional devices fail to be user friendly and/or fail to adequately wind and store the cord or cable. As such, cable management, including organizing, storing, preventing tangling, and protecting cords/cables, remains a continued source of frustration for many people. Accordingly, there is a need for devices that organize and/or make cords easier to use and store.
SUMMARY
[0004] It is to be understood that the present invention includes a variety of different versions or embodiments, and this Summary is not meant to be limiting or all-inclusive. This Summary provides some general descriptions of some of the embodiments, but may also include some more specific descriptions of other embodiments.
[0005] In accordance with one or more embodiments, winders of various size and characteristics are provided to wind and store a variety of cords or cables and to operate “automatically.” As used herein, “automatically” means the winder device in its ready state can operate without turning a crank or handle in order to rotate a winding spool. In use, a folded portion of a cable or cord is engaged around a grasping member, such as a hook. Thereafter, the cord/cable is pulled slightly to disengage a pawl from a spool, and a button is then pushed releasing a spring for winding the cord/cable around the spool. When the two ends of the cord/cable reach the entry point, the refraction stops. To extract the cord/cable, the user pulls the two portions of the cord/cable, either to a desired length or all the way until the cord/cable releases from the winder. Alternatively, a locking hook may be used to lock the cable to the hook so that the cable remains attached to the winder when fully unwound. As the cord/cable is extracted, the spring is re-loaded for the next use. Accidental spin-out is prevented by locking the winder device in its loaded state. Accordingly, a winder device substantially as herein shown and described is provided.
[0006] In at least one embodiment, a device for winding a cord is provided. The cord is bendable to form a looped portion. Accordingly, a device is provided, the device comprising:
[0007] a front housing connected to a back housing and a cord receiving opening positioned therebetween;
[0008] an axle including a first end fixedly connected to the back housing and a spring anchor to operably interconnect the axle to a first end tab of a drive spring;
[0009] a spool including:
an aperture to receive a second end of the axle; a spring engaging member connected to a second end tab of the drive spring; a plurality of grasping members positioned radially around at least a portion of an outer surface of the spool, the plurality of grasping members adapted for engaging the looped portion of the cord; and a plurality of inwardly facing spool teeth positioned radially around at least a portion of an inside perimeter of the spool; and
[0014] a pawl that is selectively moveable from a first position to a second position, the pawl including:
an aperture to receive a mating projection on the front housing; a projection on a front surface of the pawl to operably interconnect the pawl to a spring release mechanism associated with the front housing; and a plurality of pawl teeth on at least a portion of the pawl, wherein the plurality of pawl teeth operably engage the plurality of spool teeth, and wherein, when the pawl is in the first position, the plurality of pawl teeth are engaged with the plurality of spool teeth;
[0018] wherein, when the looped portion of the cord is engaging at least one grasping member of the plurality of grasping members and is pulled in a direction opposite from a winding direction while substantially simultaneously activating the spring release mechanism, the plurality of pawl teeth disengage from the plurality of spool teeth and the pawl is moved to the second position; and
[0019] wherein, when the cord is released, the drive spring at least partially unloads and causes the spool to rotate in a winding direction, which causes the cord to wind onto the spool.
[0020] In at least one embodiment, the cord is wound onto the spool until at least one of three events occurs: (1) the cord is fully wound onto the spool; (2) the cord is pulled again to cause the plurality of pawl teeth to reengage the plurality of spool teeth; or (3) the spring release mechanism is deactivated.
[0021] In at least one embodiment, the plurality of spool teeth are oriented at an angle of about 25 degrees to about 45 degrees with respect to a vertical axis. In at least one embodiment, the device for winding a cord further comprises at least one of a front spool side and a back spool side adapted to connect to a portion of the spool. In at least one embodiment, the drive spring is a coil spring adapted to provide at least about 0.5 inch-pounds of torque. In at least one embodiment, the spring release mechanism is a button. In at least one embodiment, the front housing and back housing are interconnected by at least one of a strut, a pin, a screw, a rivet, a clamp, and a threaded fastener.
[0022] In at least one embodiment, an assembly is provided, the assembly comprising:
[0023] headphones including a cord; and
[0024] a winder for winding the cord, the winder including:
a first housing member connected to a second housing member and a cord receiving opening positioned therebetween; an axle including a first end fixedly connected to the second housing member and means for operably interconnecting the axle to a means for biasing; means for rotating a looped portion of the cord, the means for rotating including:
means for grasping the looped portion of the cord; means for interconnecting to the axle and the means for biasing; and means for preventing rotation in a first direction while allowing rotation in a second direction; and
means for selectively disengaging the means for rotating, the means for selectively disengaging selectively moveable from a first position to a second position, the means for selectively disengaging including:
means for interconnecting to the first housing member; and means for slidably engaging the means for preventing rotation;
wherein, when the looped portion of the cord is operably engaged with the means for grasping, the means for slidably engaging is engaged with the means for preventing rotation and the means for selectively disengaging is in the first position; wherein, when the looped portion of the cord is engaging the means for grasping and is pulled in a direction opposite from a winding direction and substantially simultaneously a bias release mechanism is activated, the means for slidably engaging disengages the means for preventing rotation and the means for selectively disengaging is moved to the second position; and wherein, when the cord is released, the means for biasing at least partially unloads and causes the means for rotating to rotate in a winding direction, which causes the cord to wind onto the means for rotating.
[0037] In at least one embodiment, the means for biasing at least partially unloads and causes the means for rotating to rotate in a winding direction, the cord is wound onto the means for rotating until at least one of three events occurs: (1) the cord is fully wound onto the means for rotating; (2) the cord is pulled again; or (3) the bias release mechanism is deactivated.
[0038] In at least one embodiment, the assembly further includes extracting a desired length of the cord from the winder by exerting a force on the looped portion of the cord such that as the means for rotation rotates the means for preventing rotation slidably engages the means for slidably engaging in a ratchet configuration, and wherein the cord extraction re-loads the means for biasing. In at least one embodiment, the means for preventing rotation are spool teeth oriented at an angle of about 25 degrees to about 45 degrees with respect to a vertical axis. In at least one embodiment, the means for biasing is a coil spring.
[0039] In at least one embodiment, a winder for winding a cord is provided. The cord is separable from the winder. The winder comprising:
[0040] a selectively moveable pawl;
[0041] a spool that selectively rotates relative to the pawl; and
[0042] a biased member connected to the spool, the pawl having at least a first position and a second position operably associated therewith;
[0043] wherein, when in the first position, the biased member is loaded and a plurality of pawl teeth associated with the pawl are engaged with a corresponding plurality of spool teeth associated with the spool, wherein the pawl is moved from the first position to the second position by pulling the cord operably associated with the spool in a direction opposite to a winding direction, and wherein, when in the second position, the plurality of pawl teeth are disengaged from the plurality of spool teeth; and
[0044] wherein, when in the second position, the biased member is at least partially unloaded by activating a spring release mechanism and releasing the cord, which causes the spool to rotate, which causes the cord to wind onto the spool.
[0045] In at least one embodiment, the biased member is a coil spring adapted to provide at least about 0.5 inch-pounds of torque.
[0046] A method for selectively winding a cord is provided, the method comprising: folding the cord; operably engaging a portion of the folded cord with a grasping member of a winder; pulling on the cord to cause at least one pawl tooth of a pawl of the winder to disengage from at least one spool tooth of a spool of the winder; and activating a spring release mechanism operably associated with the pawl to at least partially unload a spring of the winder such that the spool rotates to wind the folded cord around the spool.
[0047] In at least one embodiment, the method further comprises deactivating the spring release mechanism to stop further spool rotation and spring unloading. In at least one embodiment, when the folded cord is fully wound around the spool, two end portions of the folded cord are collocated and substantially adjacent.
[0048] In at least one embodiment, the method further comprises extracting the cord from the winder to a desired length by pulling the folded cord such that as the spool rotates and the cord extraction re-loads the spring. In at least one embodiment, the method further comprises removing the cord entirely from the winder, wherein, when the cord is entirely removed, the spring remains in a loaded state.
[0049] In at least one embodiment, the grasping member is at least one of a hook and a v-shaped, friction engaging member.
[0050] In at least one embodiment, the spring release mechanism is activated by moving a button from a first position to a second position. In at least one embodiment, the button cannot move from the first position to the second position unless the cord has operably engaged a grasping member, and, substantially simultaneously, a tension on the cord is exerted in a direction opposite from a winding direction and activating the button, and thereby preventing accidental spin-out.
[0051] One or more embodiments described herein are directed to a device for winding a cord. Accordingly, a device is provided, comprising:
[0052] a frame having a cord access aperture for receiving the cord, the frame including an inner spool and a concentrically located spring operatively connected to a catch mechanism for engaging the cord; wherein the spring is adapted for winding the cord around the inner spool upon engaging the cord with the catch mechanism and releasing a brake operatively securing a tension in the spring.
[0053] As used herein, “cord” and “cable” refer to components that are capable of being wound and include, but are not limited to, rope, ribbon, a cord of metal wire or chain, an insulated electrical conductor, or a combination of electrical conductors insulated from one another. For example, the terms “cord” and “cable” include, but are not limited to, armored cable, fiber optic cable, flameproof insulated cable, high temperature cable, HV cable, marine cable, mining cable, snake cable, coaxial cables, and patch cables, including microphone cables, headphone cables, telephone cables, and XLR, RCA, and TRS connector cables.
[0054] Various components are referred to herein as “operably associated.” As used herein, “operably associated” refers to components that are linked together in operable fashion, and encompasses embodiments in which components are linked directly, as well as embodiments in which additional components are placed between the two linked components.
[0055] As used herein, “at least one,” “one or more,” and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C,” “at least one of A, B, or C,” “one or more of A, B, and C,” “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.
[0056] Various embodiments of the present inventions are set forth in the attached figures and in the Detailed Description as provided herein and as embodied by the claims. It should be understood, however, that this Summary does not contain all of the aspects and embodiments of the one or more present inventions, is not meant to be limiting or restrictive in any manner, and that the invention(s) as disclosed herein is/are understood by those of ordinary skill in the art to encompass obvious improvements and modifications thereto.
[0057] Additional advantages of the present invention will become readily apparent from the following discussion, particularly when taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0058] To further clarify the above and other advantages and features of the one or more present inventions, a more particular description of the one or more present inventions is rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the one or more present inventions and are therefore not to be considered limiting of its scope. The one or more present inventions are described and explained with additional specificity and detail through the use of the accompanying drawings in which:
[0059] FIG. 1A is an exploded view of a winder device in accordance with at least one embodiment of the one or more present inventions;
[0060] FIG. 1B is an exploded view of the winder device of FIG. 1A , shown without the drive and button springs;
[0061] FIG. 1C is a front elevation view if the winder device of FIG. 1A ;
[0062] FIG. 1D is a left side elevation view of the winder device of FIG. 1A ;
[0063] FIG. 1E is a top plan view of the winder device of FIG. 1A ;
[0064] FIG. 1F is a front perspective view of the winder device of FIG. 1A ;
[0065] FIG. 1G is a side perspective view of the winder device of FIG. 1A ;
[0066] FIG. 2A is a front interior elevation view of the back housing of the winder device illustrated in FIGS. 1A-1G ;
[0067] FIG. 2B is a rear elevation view of the back housing shown in FIG. 2A ;
[0068] FIG. 2C is a top plan view of the back housing shown in FIG. 2A ;
[0069] FIG. 2D is a left elevation view of the back housing shown in FIG. 2A ;
[0070] FIG. 2E is a right elevation view of the back housing shown in FIG. 2A ;
[0071] FIG. 2F is a bottom plan view of the back housing shown in FIG. 2A ;
[0072] FIG. 2G is a front interior perspective view of the back housing shown in FIG. 2A ;
[0073] FIG. 2H is a rear perspective view of the back housing shown in FIG. 2A ;
[0074] FIG. 3A is a front elevation view of the spool of the winder device illustrated in FIGS. 1A-1G ;
[0075] FIG. 3B is a rear elevation view of the spool shown in FIG. 3A ;
[0076] FIG. 3C is a left elevation view of the spool shown in FIG. 3A ;
[0077] FIG. 3D is a right elevation view of the spool shown in FIG. 3A ;
[0078] FIG. 3E is a front perspective view of the spool shown in FIG. 3A ;
[0079] FIG. 3F is a rear perspective view of the spool shown in FIG. 3A ;
[0080] FIG. 4A is a front elevation view of the spool sides of the winder device illustrated in FIGS. 1A-1G ;
[0081] FIG. 4B is a rear elevation view of the spool side shown in FIG. 4A ;
[0082] FIG. 4C is a left elevation view of the spool shown in FIG. 4A ;
[0083] FIG. 4D is a front perspective view of the spool side shown in FIG. 4A ;
[0084] FIG. 4E is a rear perspective view of the spool side shown in FIG. 4A ;
[0085] FIG. 5A is a front elevation view of the drive spring of the winder device illustrated in FIGS. 1A-1G ;
[0086] FIG. 5B is a top plan view of the drive spring shown in FIG. 5A ;
[0087] FIG. 5C is a front perspective view of the drive spring shown in FIG. 5A ;
[0088] FIG. 6A is a front elevation view of the pawl of the winder device illustrated in FIGS. 1A-1G ;
[0089] FIG. 6B is a rear elevation view of the pawl shown in FIG. 6A ;
[0090] FIG. 6C is a top plan view of the pawl shown in FIG. 6A ;
[0091] FIG. 6D is a left elevation view of the pawl shown in FIG. 6A ;
[0092] FIG. 6E is a right elevation view of the pawl shown in FIG. 6A ;
[0093] FIG. 6F is a bottom plan view of the pawl shown in FIG. 6A ;
[0094] FIG. 6G is a front perspective view of the pawl shown in FIG. 6A ;
[0095] FIG. 6H is a rear perspective view of the pawl shown in FIG. 6A ;
[0096] FIG. 7A is a front elevation view of the front housing of the winder device illustrated in FIGS. 1A-1G ;
[0097] FIG. 7B is a rear elevation view of the front housing shown in FIG. 7A ;
[0098] FIG. 7C is a top plan view of the front housing shown in FIG. 7A ;
[0099] FIG. 7D is a left elevation view of the front housing shown in FIG. 7A ;
[0100] FIG. 7E is a right elevation view of the front housing shown in FIG. 7A ;
[0101] FIG. 7F is a bottom plan view of the front housing shown in FIG. 7A ;
[0102] FIG. 7G is a front perspective view of the front housing shown in FIG. 7A ;
[0103] FIG. 7H is a rear perspective view of the front housing shown in FIG. 7A ;
[0104] FIG. 8A is a front elevation view of the button plate of the winder device illustrated in FIGS. 1A-1G ;
[0105] FIG. 8B is a rear elevation view of the button plate shown in FIG. 8A ;
[0106] FIG. 8C is a top plan view of the button plate shown in FIG. 8A ;
[0107] FIG. 8D is a left elevation view of the button plate shown in FIG. 8A ;
[0108] FIG. 8E is a right elevation view of the button plate shown in FIG. 8A ;
[0109] FIG. 8F is a bottom plan view of the button plate shown in FIG. 8A ;
[0110] FIG. 8G is a front perspective view of the button plate shown in FIG. 8A ;
[0111] FIG. 8H is a rear perspective view of the button plate shown in FIG. 8A ;
[0112] FIG. 9A is a front elevation view of the button of the winder device illustrated in FIGS. 1A-1G ;
[0113] FIG. 9B is a rear elevation view of the button shown in FIG. 9A ;
[0114] FIG. 9C is a top plan view of the button shown in FIG. 9A ;
[0115] FIG. 9D is a left elevation view of the button shown in FIG. 9A ;
[0116] FIG. 9E is a right elevation view of the button shown in FIG. 9A ;
[0117] FIG. 9F is a bottom plan view of the button shown in FIG. 9A ;
[0118] FIG. 9G is a front perspective view of the button shown in FIG. 9A ;
[0119] FIG. 9H is a rear perspective view of the button shown in FIG. 9A ;
[0120] FIG. 10A is a front elevation view of the button spring of the winder device illustrated in FIGS. 1A-1G ;
[0121] FIG. 10B is a top plan view of the button spring shown in FIG. 10A ;
[0122] FIG. 10C is a front perspective view of the button spring shown in FIG. 10A ;
[0123] FIG. 11A is a rear perspective view of the winder device illustrated in FIGS. 1A-1G , with the rear housing removed to show the drive spring being loaded as the cord/cable is removed from the winder device;
[0124] FIG. 11B is a front perspective view of the winder device illustrated in FIGS. 1A-1G , with the front housing removed to show the pawl teeth engaged with the teeth on the spool, which maintains the drive spring in a loaded condition;
[0125] FIG. 11C is a front perspective view of the winder device illustrated in FIGS. 1A-1G , with the front housing removed to show the pawl teeth disengaged from the teeth on the spool, and showing the drive spring being unloaded, which causes the cable/cord to be wound into the winder device;
[0126] FIG. 12A is an exploded view of another winder device in accordance with at least one embodiment of the present inventions;
[0127] FIG. 12B is a front elevation view if the winder device of FIG. 12A ;
[0128] FIG. 12C is a left elevation view of the winder device of FIG. 12A ;
[0129] FIG. 12D is a top plan view of the winder device of FIG. 12A ;
[0130] FIG. 13A is a front elevation view of the back cover plate of the winder device illustrated in FIGS. 12A-12D ;
[0131] FIG. 13B is a rear elevation view of the back cover plate shown in FIG. 13A ;
[0132] FIG. 13C is a top plan view of the back cover plate shown in FIG. 13A ;
[0133] FIG. 13D is a left elevation view of the back cover plate shown in FIG. 13 ;
[0134] FIG. 13E is a right elevation view of the back cover plate shown in FIG. 13A ;
[0135] FIG. 13F is a bottom plan view of the back cover plate shown in FIG. 13A ;
[0136] FIG. 13G is a front perspective view of the back cover plate shown in FIG. 13A ;
[0137] FIG. 13H is a rear perspective view of the back cover plate shown in FIG. 13A ;
[0138] FIG. 14A is a front elevation view of the back housing of the winder device illustrated in FIGS. 12A-12D ;
[0139] FIG. 14B is a rear elevation view of the back housing shown in FIG. 14A ;
[0140] FIG. 14C is a top plan view of the back housing shown in FIG. 14A ;
[0141] FIG. 14D is a left elevation view of the back housing shown in FIG. 14A ;
[0142] FIG. 14E is a right elevation view of the back housing shown in FIG. 14A ;
[0143] FIG. 14F is a bottom plan view of the back housing shown in FIG. 14A ;
[0144] FIG. 14G is a front perspective view of the back housing shown in FIG. 14A ;
[0145] FIG. 14H is a rear perspective view of the back housing shown in FIG. 14A ;
[0146] FIG. 15A is a front elevation view of the axle of the winder device illustrated in FIGS. 12A-12D ;
[0147] FIG. 15B is a top plan view of the axle shown in FIG. 15A ;
[0148] FIG. 15C is a right elevation view of the axle shown in FIG. 15A ;
[0149] FIG. 15D is a front perspective view of the axle shown in FIG. 15A ;
[0150] FIG. 16A is a front elevation view of the spool of the winder device illustrated in FIGS. 12A-12D ;
[0151] FIG. 16B is a rear elevation view of the spool shown in FIG. 16A ;
[0152] FIG. 16C is a left elevation view of the spool shown in FIG. 16A ;
[0153] FIG. 16D is a right elevation view of the spool shown in FIG. 16A ;
[0154] FIG. 16E is a front perspective view of the spool shown in FIG. 16A ;
[0155] FIG. 16F is a rear perspective view of the spool shown in FIG. 16A ;
[0156] FIG. 17A is a front elevation view of the spool sides of the winder device illustrated in FIGS. 12A-12D ;
[0157] FIG. 17B is a rear elevation view of the spool side shown in FIG. 17A ;
[0158] FIG. 17C is a left elevation view of the spool side shown in FIG. 17A ;
[0159] FIG. 17D is a front perspective view of the spool side shown in FIG. 17A ;
[0160] FIG. 17E is a rear perspective view of the spool side shown in FIG. 17A ;
[0161] FIG. 18A is a front elevation view of the drive spring of the winder device illustrated in FIGS. 12A-12D ;
[0162] FIG. 18B is a top plan view of the drive spring shown in FIG. 18A ;
[0163] FIG. 18C is a front perspective view of the drive spring shown in FIG. 18A ;
[0164] FIG. 19A is a front elevation view of the pawl of the winder device illustrated in FIGS. 12A-12D ;
[0165] FIG. 19B is a rear elevation view of the pawl shown in FIG. 19A ;
[0166] FIG. 19C is a top plan view of the pawl shown in FIG. 19A ;
[0167] FIG. 19D is a left elevation view of the pawl shown in FIG. 19A ;
[0168] FIG. 19E is a right elevation view of the pawl shown in FIG. 19A ;
[0169] FIG. 19F is a bottom plan view of the pawl shown in FIG. 19A ;
[0170] FIG. 19G is a front perspective view of the pawl shown in FIG. 19A ;
[0171] FIG. 19H is a rear perspective view of the pawl shown in FIG. 19A ;
[0172] FIG. 20A is a front elevation view of the front housing of the winder device illustrated in FIGS. 12A-12D ;
[0173] FIG. 20B is a rear elevation view of the front housing shown in FIG. 20A ;
[0174] FIG. 20C is a top plan view of the front housing shown in FIG. 20A ;
[0175] FIG. 20D is a left elevation view of the front housing shown in FIG. 20A ;
[0176] FIG. 20E is a right elevation view of the front housing shown in FIG. 20A ;
[0177] FIG. 20F is a bottom plan view of the front housing shown in FIG. 20A ;
[0178] FIG. 20G is a front perspective view of the front housing shown in FIG. 20A ;
[0179] FIG. 20H is a rear perspective view of the front housing shown in FIG. 20A ;
[0180] FIG. 21A is a front elevation view of the button of the winder device illustrated in FIGS. 12A-12D ;
[0181] FIG. 21B is a rear elevation view of the button shown in FIG. 21A ;
[0182] FIG. 21C is a top plan view of the button shown in FIG. 21A ;
[0183] FIG. 21D is a left elevation view of the button shown in FIG. 21A ;
[0184] FIG. 21E is a right elevation view of the button shown in FIG. 21A ;
[0185] FIG. 21F is a bottom plan view of the button shown in FIG. 21A ;
[0186] FIG. 21G is a front perspective view of the button shown in FIG. 21A ;
[0187] FIG. 21H is a rear perspective view of the button shown in FIG. 21A ;
[0188] FIG. 22A is a front elevation view of the button spring of the winder device illustrated in FIGS. 12A-12D ;
[0189] FIG. 22B is a top plan view of the button spring shown in FIG. 22A ;
[0190] FIG. 22C is a front perspective view of the button spring shown in FIG. 22A ;
[0191] FIG. 23A is a front elevation view of the front cover plate of the winder device illustrated in FIGS. 12A-12D ;
[0192] FIG. 23B is a rear elevation view of the front cover plate shown in FIG. 23A ;
[0193] FIG. 23C is a top plan view of the front cover plate shown in FIG. 23A ;
[0194] FIG. 23D is a left elevation view of the front cover plate shown in FIG. 23A ;
[0195] FIG. 23E is a right elevation view of the front cover plate shown in FIG. 23A ;
[0196] FIG. 23F is a bottom plan view of the front cover plate shown in FIG. 23A ;
[0197] FIG. 23G is a front perspective view of the front cover plate shown in FIG. 23A ;
[0198] FIG. 23H is a rear perspective view of the front cover plate shown in FIG. 23A ;
[0199] FIG. 24A is a front elevation view of the another embodiment of a spool adapted for use with the winder devices disclosed herein;
[0200] FIG. 24B is a rear elevation view of the spool shown in FIG. 24A ;
[0201] FIG. 24C is a left elevation view of the spool shown in FIG. 24A ;
[0202] FIG. 24D is a right elevation view of the spool shown in FIG. 24A ;
[0203] FIG. 24E is a front perspective view of the spool shown in FIG. 24A ;
[0204] FIG. 24F is a rear perspective view of the spool shown in FIG. 24A ;
[0205] FIG. 25A is a front elevation view of another embodiment of a spool side adapted for use with the spool illustrated in FIGS. 24A-24F ;
[0206] FIG. 25B is a rear elevation view of the spool side shown in FIG. 25A ;
[0207] FIG. 25C is a left elevation view of the spool side shown in FIG. 25A ;
[0208] FIG. 25D is a front perspective view of the spool side shown in FIG. 25A ;
[0209] FIG. 25E is a rear perspective view of the spool side shown in FIG. 25A ;
[0210] FIG. 26A is a front elevation view of yet another embodiment of a spool adapted for use with the winder devices disclosed herein;
[0211] FIG. 26B is a rear elevation view of the spool shown in FIG. 26A ;
[0212] FIG. 26C is a left elevation view of the spool shown in FIG. 26A ;
[0213] FIG. 26D is a right elevation view of the spool shown in FIG. 26A ;
[0214] FIG. 26E is a front perspective view of the spool shown in FIG. 26A ;
[0215] FIG. 26F is a rear perspective view of the spool shown in FIG. 26A ;
[0216] FIG. 27A is an exploded view of another winder device in accordance with at least one embodiment of the one or more present inventions;
[0217] FIG. 27B is a front elevation view of the winder device of FIG. 27A ;
[0218] FIG. 27C is a left elevation view of the winder device of FIG. 27A ;
[0219] FIG. 27D is a top plan view of the winder device of FIG. 27A ;
[0220] FIG. 28A illustrates a user engaging a folded portion of a cable/cord with a winder device in accordance with at least one embodiment of the one or more present inventions, the winder device shown in an un-wound position;
[0221] FIG. 28B illustrates a user pressing a spring release mechanism to wind the cable in the winder device of FIG. 28A ;
[0222] FIG. 28C illustrates a user holding the winder device of FIG. 28A in a wound position;
[0223] FIG. 29 is a cross sectional view of the winder device shown in FIG. 28 ;
[0224] FIG. 30 is a side view of an alternative embodiment of a cord grasping element of a winder device in accordance with at least one embodiment of the one or more present inventions;
[0225] FIG. 31 is an illustration of a plurality of winder devices shown in a stacked configuration;
[0226] FIG. 32A shows a winder device in accordance with embodiments of the one or more present inventions used in connection with a coffee maker;
[0227] FIG. 32B shows the winder device of FIG. 32A also connected to an electrical outlet;
[0228] FIG. 33 shows a winder device in accordance with embodiments of the one or more present inventions used in connection with a blow dryer;
[0229] FIG. 34 shows a winder device in accordance with embodiments of the one or more present inventions used in connection with a hand-held device; and
[0230] FIG. 35 shows a winder device in accordance with embodiments of the one or more present inventions used in connection with a floor lamp.
[0231] The drawings are not necessarily to scale. The dimensions shown are exemplary and for enablement purposes and should not be construed as limiting in any way.
DETAILED DESCRIPTION
[0232] One or more embodiments of the one or more inventions described herein include one or more devices, assemblies and/or methods related to a winder device. A winder device in accordance with at least one embodiment described herein can be used to organize, store, and/or protect cables, such as wire rope, and electrical cords. One or more embodiments of the winder devices described herein have application for audio equipment, such as stereophones, headsets, earphones, earbuds, etc.
[0233] Referring now to FIGS. 1A-10C , one embodiment of the one or more present inventions is shown. In at least the embodiment depicted, the winder device 100 generally includes back and front housings 104 and 108 , back and front spool sides 112 and 116 , a spool 120 , a drive spring 124 , a pawl 128 , a button 132 , button spring 136 , and a button plate 140 .
[0234] With particular reference now to FIGS. 2A-2H , the back housing 104 of at least one embodiment is shown. The back housing 104 generally includes a front interior surface 200 , a back surface 204 , and top and bottom struts 208 and 212 adapted to interconnect the back housing 104 and the front housing 108 . In at least one embodiment, the top and bottom struts 208 and 212 are integrally formed with the back housing 104 . The top and bottom struts 208 and 212 may include at least one bracket 216 and at least one bracket receiving space 220 adapted to mate with corresponding elements on the front housing 108 such that the back and front housings 104 and 108 are interconnected by a press or interference fit. However, any number or combinations of fastening devices may be used to interconnect the back housing 104 and the front housing 108 , including pins, screws, rivets, retaining rings, clamps, threaded fasteners, or glues and other adhesives.
[0235] In at least one embodiment, the front interior surface 200 of the back housing 104 also includes a spool side area 224 adapted to abut at least a portion of the back spool side 112 . In some embodiments, the spool side area 224 is recessed such that at least a portion of the back spool side 112 sits within the spool side area 224 . In at least one embodiment, the spool side area 224 is disc-shaped. Furthermore, in at least one embodiment, the spool side area 224 includes a circular ledge 228 positioned within at least a portion of the spool side area 224 . The ledge 228 is adapted to facilitate movement of the back spool side 112 within the back spool side area 224 . The ledge 228 may also facilitate the placement or positioning of the back spool side 112 in the spool side area 224 .
[0236] In at least one embodiment, the front interior surface 200 of the back housing 104 further includes an axle 232 adapted to receive a portion of the spool 120 . The axle 232 of at least one embodiment is cylindrical in shape and is substantially rigid. Moreover, in at least one embodiment, the axle 232 is formed integral with the back housing 104 . However, in other embodiments, the axle may be formed separately from the back housing and subsequently fastened thereto using a variety of known fastening mechanisms. The axle 232 may also include a spring anchor 236 for securing the drive spring 124 to the axle 232 . In at least one embodiment, the spring anchor 236 is a longitudinal opening that spans the length of the axle 232 and bifurcates at least a portion of the axle 232 . In other embodiments, the spring anchor 236 may be a longitudinal groove (or other receiving portion) that spans at least a portion of the length of the axle 232 . The axle 232 remains fixed (or otherwise non-rotatable) while under loaded and unloaded conditions. In at least one embodiment, the axle 232 is made from Acrylonitrile Butadiene Styrene (“ABS”); however, the axle 232 may be made from a variety of other materials that are durable, low friction, and wear resistant, such as a metal, or other hard plastic.
[0237] In at least one embodiment, the front interior surface 200 of the back housing 104 further includes a plurality of spokes 240 positioned adjacent to the spool side area 224 and the axle 232 . In at least one embodiment, the plurality of spokes 240 extend radially outward from the axle 232 toward the spool side area 224 . The plurality of spokes 240 decrease the surface contact between the drive spring 124 and back housing 104 and further serve as structural reinforcements for the back housing 104 .
[0238] In at least one embodiment, the back surface 204 of the back housing 104 includes a surface treatment or material, such as a non-slip, grippable, traction providing, shock absorbing, drop resistant, or other impact resistant material (not shown) to facilitate a user's handling or manipulation of the winder device 100 and/or to protect the winder device 100 from being damaged. Similarly, in still other embodiments, the back surface 204 includes a decorative or aesthetic decal or design to enhance the marketability of the device.
[0239] In at least one embodiment, the back housing (including the aforementioned features) 104 are formed integrally. For example, the back housing 104 may be formed using an injection molding or other cost effective manufacturing process or processes.
[0240] Referring now to FIGS. 3A-3F , the spool 120 of at least one embodiment of the present inventions is shown. The spool 120 of this embodiment has a substantially cylindrical configuration, an outer surface 300 , a front surface 304 a back surface 308 , and a plate 312 . The plate 312 is generally positioned to separate the front surface 304 from the back surface 308 and\or to prevent the drive spring 124 from interfering with the pawl 128 . In at least one embodiment, the spool 120 has a diameter D.
[0241] Referring specifically now to FIGS. 3A-3B , the plate 312 includes an aperture 316 adapted to receive a portion of the axle 232 associated with the back housing 104 . In one embodiment, the aperture 316 is sized to have at least some clearance such that the spool 120 may easily slide on and rotate about the axle 232 . In other embodiments, ball bearings or other friction reducing materials may be provided at a contact point of the aperture 316 and the axle 232 .
[0242] Referring now to FIGS. 3B and 3F , the back surface 308 of at least one embodiment of the spool 120 includes a back edge 320 and a hollow portion 324 therein. The back edge 320 includes a first set of holes 328 for selectively receiving a plurality of corresponding projections 416 positioned on the back spool side 112 (discussed below). Moreover, any number of fastening means may be included on the back edge 320 to selectively and/or removably interconnect the back surface 308 of the spool 120 to the first face 400 of the back spool side 112 , such as slots or channels.
[0243] The hollow portion 324 is adapted to receive the drive spring 124 . The hollow portion 324 substantially encloses the drive spring 124 ; however, one of skill in the art will appreciate that in other embodiments, the hollow portion 324 may partially enclose the drive spring 124 . The hollow portion 324 helps maintain the shape of the drive spring 124 and also protects the drive spring 124 from distortion and/or damage.
[0244] In addition, in at least one embodiment the back surface 308 of the spool 120 also includes a spring engaging member adapted to engage the drive spring 124 . The spring engaging member of one embodiment is a spring slot 332 that extends from the back edge 320 of the back surface 308 longitudinally along the outer surface 300 to some length or depth. The length of the spring slot 332 may vary depending on the type or size of the drive spring 124 that is used for a particular winder.
[0245] Referring now to FIGS. 3A and 3E , in at least one embodiment, the front surface 304 includes a front edge 336 that has a second set of holes 340 and teeth 344 . The second set of holes 340 are adapted to receive a plurality of projections 416 positioned on the front spool side 116 (discussed below). Any number of interconnecting mechanisms, such as slots or channels, may be included on the front edge 336 to selectively and removably interconnect the front surface 304 of the spool 120 to the first face 400 of the front spool side 116 .
[0246] The teeth 344 generally project radially inward (i.e., toward the center of the spool 120 ) and are sized and shaped to engage at least a portion of the pawl 128 . The teeth 344 are oriented at an angle α in order to reduce and/or prevent winder spin-out. Accidental spin-out is undesirable because a user has to then manually re-load the drive spring 124 before the cord/cable may be wound. As such, the engagement between the spool 120 and the pawl 128 is configured such that the drive spring 124 is maintained in a loaded condition until the user is ready to wind the cord/cable (thereby unloading the drive spring). In order to achieve the desirable spool/pawl engagement, the teeth 344 are properly angled to engage and maintain the engagement (i.e., minimize slip) with the pawl teeth 616 . In at least one embodiment, this engagement is achieved by orienting the teeth 344 at an angle α that ranges from about 25 degrees to about 45 degrees. In a preferred embodiment, the teeth 344 are oriented at an angle α of about 37 degrees.
[0247] Referring back to FIGS. 3A-3F , the outer surface 300 of the spool 120 includes a plurality of grasping members. In at least one embodiment, the grasping members are hooks 348 adapted to selectively engage a portion of a cord, cable, or other object to be wound with the winding device 100 . The number of hooks 348 positioned on the outer surface 300 of the spool 120 may vary depending on a number of variables, such as size and the graspability of the object. Moreover, the grasping members are not limited to hooks and may include a variety of configurations, geometries, and superficial features that are adapted to assist with grasping and/or selectively retaining the cord/cable. Consequently, the height H of the spool 120 may vary depending on the exact configuration of the grasping members. In some embodiments, it may be desirable to include locking hooks to lock the cord/cable to the hook so that the cord/cable remains attached to the winder device when fully unwound.
[0248] In at least one embodiment, the spool 120 is manufactured as an integral piece using any number of conventional manufacturing processes, such as injection molding, and is made at least partially from Delrin, or other similar materials. In other embodiments, the grasping members may be individually and/or selectively interconnected to the outer surface 300 of the spool 120 , depending on the application.
[0249] Referring now to FIGS. 4A-4E , a spool side of one embodiment is shown. In at least one embodiment, the winder device includes two spool sides, adapted for positioning on either side of the spool. In other embodiments, the winder device has no spool sides. In yet other embodiments, the winder device has only one spool side. In still yet other embodiments, the spool sides are formed integrally with the spool.
[0250] In at least one embodiment, the winder device 100 includes a back spool side 112 and a front spool side 116 . The back and front spool sides 112 and 116 may be substantially identical parts. As such, the spool side shown in FIGS. 4A-4E , can be either the back spool side 112 or the front spool side 116 . Because the back and front spool sides 112 and 116 are substantially identical, the number of different component parts that need to be manufactured decreases and the throughput of the manufactured parts increases. However, in some embodiments, it may be desirable to have back and front spool sides 112 and 116 that are not substantially identical parts. For example, the back and front spool sides 112 and 116 may have different interconnecting mechanisms that allow the spool 120 to be selectively removable from the back and front spool sides 112 and 116 .
[0251] In at least one embodiment, the back and front spool sides 112 and 116 are adapted to interconnect with the spool 120 . The back and front spool sides 112 and 116 have a first face 400 , a second face 404 , an outer diameter 408 , an inner diameter 412 , and a substantially planar torus shape. The first face 400 of back spool side 112 is adapted to interconnect to the back surface 308 of the spool 120 and the second face 408 of the back spool side 112 is adapted to abut the spool side area 224 of the back housing 104 . Similarly, the first face 400 of the front spool side 116 is adapted to interconnect to the front surface 304 of the spool 120 and the second face 404 of the front spool side 116 is adapted to abut the spool side area 732 of the front housing 108 .
[0252] In addition, in at least one embodiment, a plurality of projections 416 positioned on the first face 400 of the back and front spool sides 112 and 116 are positioned proximate to the inner diameter 412 . The plurality of projections 416 may be spaced, equidistantly, non-equidistantly, or in any number of other configurations, around the perimeter of the inner diameter 412 . In at least one embodiment, the plurality of projections 416 have a dowel pin or cylindrical rod shape. The plurality of projections 416 are adapted to be received by corresponding fastening means, i.e., in corresponding holes on the front and back surfaces 304 and 308 of the spool 120 . Moreover, the plurality of projections 416 may have various shapes and/or geometry, so long as the spool 120 has corresponding or mating interconnection means.
[0253] The back and front spool sides 112 and 116 may be made from any number of materials, including thermoplastics, such as Delrin having high stiffness, low friction, and good dimensional stability. Moreover, the spool sides 112 and 116 may be manufactured using a number of methods and/or processes, including injection molding.
[0254] Referring now to FIGS. 5A-5C , a biased member is shown. In at least one embodiment, the biased member is a drive spring (mainspring) 124 . However, the biased member may be a coil spring in a biased condition. The drive spring 124 includes a first end tab 500 and a second end tab 504 . The first end tab 500 is adapted to engage the spring anchor 236 on the axle 232 , and the second end tab 504 is adapted to engage the spring slot 332 on the spool 120 . In at least one embodiment, the first end tab 500 further includes an approximately 90 degree bend that interconnects the drive spring 124 to the axle 232 and the second end tab 504 includes a 180 degree or substantially U-shaped bend that interconnects the drive spring 124 to the spool 120 . The width W of the drive spring 124 is designed to fit within at least a portion of the hollow portion 324 of the spool 120 and is made of a strip of metal ribbon. The drive spring 124 may be made of a strip of blue steel, a steel alloy, a carbon steel alloy, other metal alloys, or combinations thereof. Moreover, in at least one embodiment, in a non-compressed (or un-stressed) state, the drive spring 124 includes about ten turns and is adapted to provide at least about 0.5 inch-pounds of torque, and more preferably about 0.8 inch-pounds of torque. As such, the drive spring 124 is the power source for the winder device 100 . In another embodiment, the biased member may be an elastic material such as ‘bungee’ cord.
[0255] Referring now to FIGS. 6A-6H , a pawl 128 of at least one embodiment is shown. The pawl 128 generally includes an outer surface 600 , a front surface 604 , a back surface 608 , and an aperture 612 between the front and back surfaces 604 and 608 . The front surface 604 of the pawl 128 is adapted to abut at least a portion of the button 132 , and the back surface 608 of the pawl 128 is adapted to abut at least a portion of the spool 120 , in at least one embodiment.
[0256] The outer surface 600 has pawl teeth 616 on a portion thereof. The pawl teeth 616 are adapted to selectively and operably engage the teeth 344 on the front edge 336 of the spool 120 . The number of pawl teeth 616 may vary depending on a variety of factors. In at least one embodiment, the outer surface 600 also includes an offset or recessed portion 620 . Incorporation of a recessed portion 620 may be advantageous for winder devices where additional clearance between the pawl 128 and the spool 120 is desired.
[0257] Referring specifically now to FIGS. 6A and 6G , the front surface 604 of at least one embodiment includes a projection 624 adapted to engage a portion of the button 132 (discussed below). As shown in FIG. 6A , the projection 624 is D-shaped. In alternative embodiments, the projection 624 may have a number of different configurations, including cylindrical, conical, polygonal, or an “O” shaped projection. In some embodiments, the front surface 604 has more than one projection. The position of the projection 624 may vary depending on the size of the pawl 128 and the configuration of the front housing 108 , among others. Moreover, in at least one embodiment, the projection 624 has a surface treatment such as a texturizing coating (not shown) on at least a portion thereof to enhance the surface contact between the projection 624 and the button 132 .
[0258] Referring now to FIGS. 6A and 6B , the aperture 612 is adapted to receive a portion of the front housing 108 . More particularly, the aperture 612 is adapted to receive a projection 728 on the back interior surface 704 of the front housing 108 .
[0259] Referring now to FIGS. 7A-7H , the front housing 108 is shown. The front housing 108 of at least one embodiment generally includes a front surface 700 , a back interior surface 704 , an aperture 708 therethrough, and top and bottom struts 712 and 716 adapted to interconnect the front housing 108 and the back housing 104 . In at least one embodiment, the top and bottom struts 712 and 716 are integrally formed with the front housing 108 . The top and bottom struts 712 and 716 may include at least one bracket 720 and at least one bracket receiving space 724 adapted to mate with corresponding elements on the back housing 104 such that the front and back housings 108 and 104 are interconnected by a press or interference fit. In alternative embodiments, various fastening mechanisms are used to interconnect the front and back housings 108 and 104 . In another embodiment, in lieu of the top and bottom struts 712 and 716 , the front and back housings 108 and 104 are connected with a centered bracket (not shown). In still another embodiment, the front housing 108 includes one bracket that is adapted to connect to the back housing 104 . In yet another embodiment, the axle 232 interconnects the front and back housings 108 and 104 and no brackets need be provided.
[0260] In at least one embodiment, the back interior surface 704 of the front housing 108 is adapted to engage the pawl 128 . The back interior surface 704 includes a projection 728 to interconnect with the aperture 612 of the pawl 128 . Depending on the configuration of the pawl 128 , the size, shape, and position of the front housing's projection 728 may vary. In at least one embodiment, the projection 728 is cylindrical and proximate the aperture 708 of the front housing 108 . The back interior surface 704 of the front housing 108 may also include a spool side area 732 adapted to abut at least a portion of the front spool side 116 . In some embodiments, the spool side area 732 is recessed such that at least a portion of the front spool side 116 sits within the spool side area 732 . Moreover, the portion of the back interior surface 704 that is proximate the spool 120 may optionally be recessed to ensure that the spool 120 has sufficient clearance to rotate and/or to make the winder device 100 lighter.
[0261] Referring now to FIGS. 7A-7B and 7 G- 7 H, the aperture 708 of the front housing 108 of at least one embodiment is adapted to allow at least a portion of the pawl 128 to pass at least partially therethrough. The shape of the aperture 708 may vary depending on a variety of factors, such as the size of the winder device, size of the pawl, etc. In at least one embodiment, the aperture 708 has a generally kidney-bean shape. In operation, the position of the pawl 128 in the aperture 708 varies depending on the position of the button 132 .
[0262] Referring specifically now to FIGS. 7A and 7G , in at least one embodiment, the front surface 700 of the front housing 108 generally includes a button receiver 736 . The button receiver 736 is generally adapted to receive the button 132 and the button plate 140 . The button receiver 736 is preferably positioned such that the aperture 708 passes therethrough. In some embodiments, the button receiver 736 is recessed relative to the front surface 700 of the front housing 108 . The size and shape of the button receiver 736 may vary depending on the size and shape of the button 132 and button plate 140 . In at least one embodiment, the button receiver 736 has a clip 740 adapted to interconnect to a portion of the button 132 . The clip 740 in at least one embodiment is sized and shaped to engage the button's spring receiver 916 . The front surface 700 of the front housing 108 may also include a direction indicator 744 . In an exemplary embodiment, the direction indicator 744 is positioned on the button receiver 736 . The direction indicator 744 helps facilitate use of the winder device 100 . Furthermore, the front surface 700 of the front housing 108 may include an ornamental design or feature (not shown), including a product name, brand, logo, design, or decorations such as rhinestones. An ornamental design or feature may be desirable for brand recognition and/or marketing purposes.
[0263] The button plate 140 of at least one embodiment is shown in FIGS. 8A-8H . The button plate 140 generally includes a front face 800 , a back face 804 , and a window 808 therebetween. The back face 804 of the button plate 140 is adapted to interconnect to the front housing 108 . In at least one embodiment, the back face 804 of the button plate 140 is adapted to engage at least a portion of the button receiver 736 . The back face 804 of the button plate 140 may be snap-fit, press-fit, glued, or otherwise positioned at least partially within the button receiver 736 of the front housing 108 . As such, depending on the desired interconnection, the back face 804 of the button plate 140 may include additional fastening means, including screws, pins, and glues, among others. In some embodiments, when the button plate 140 is received within the button receiver 736 , the button plate 140 is substantially flush with the front surface 700 of the front housing 108 , whereas in other embodiments, the button plate 140 is raised relative to the front surface 700 of the front housing 108 .
[0264] In at least one embodiment, the back face 804 of the button pate 140 is also adapted to engage at least a portion of the button 132 . For example, the back face 804 of the button plate 140 may include at least one bracket receiving slot 812 for engaging the button 132 . In at least one embodiment, the back face 804 has two bracket receiving slots 812 , one on each longitudinal side of the button plate 140 . The bracket receiving slots 812 are adapted to receive corresponding brackets 908 on the button 132 . In at least one embodiment, the bracket receiving slots 812 are larger than the button brackets 908 such that the button brackets 908 may slide within the bracket receiving slots 812 so that the button 132 can move in a translational direction within the window 808 .
[0265] In at least one embodiment, the window 808 is positioned such that at least a portion of the front face 900 of the button 132 extends at least partially therethrough. In some embodiments, when the button 132 is aligned in the window 808 , the button 132 is substantially flush with the window 808 of the button plate 140 . In other embodiments, the button 132 extends beyond the front face 800 of the button plate 140 .
[0266] Referring now to FIGS. 9A-9H , the button 132 of at least one embodiment is shown. The button 132 generally includes a front face 900 and a back face 904 and is adapted to interconnect to the button plate 140 and the front housing 108 .
[0267] In at least one embodiment, the back face 904 of the button 132 abuts at least a portion of the button receiver 736 on the front housing 108 . Brackets 908 may be used to at least partially retain the button 132 within the button receiver 736 . In at least one embodiment, the button 132 has two brackets 908 , one on either side of the back face 904 of the button 132 , that are adapted to be received in the bracket receiving slots 812 of the button plate 140 . As such, the button 132 is slidably engaged with the button plate 140 and the button 132 is able to move within the button receiver 736 .
[0268] The back face 904 of the button 132 is also generally adapted to engage at least a portion of the pawl 128 . In at least one embodiment, the back face 904 includes a pawl receiver 912 . The pawl receiver 912 may be shaped to correspond to the shape of the pawl's projection 624 . In at least one embodiment, the pawl receiver 912 is substantially D-shaped (to interconnect to a D-shaped projection 624 on the pawl 128 ). In other embodiments, the pawl receiver 912 is substantially O-shaped, polygonally shaped, or conically shaped to receive a corresponding pawl projection.
[0269] In at least one embodiment, the back face 904 of the button 132 also includes a spring receiver 916 configured as a longitudinal slot. The spring receiver 916 is adapted for receiving the clip 740 on the front surface 700 of the front housing 108 . The spring receiver 916 is also adapted to receive a biased member. An exemplary biased member is illustrated in FIGS. 10A-10C . In at least one embodiment, the biased member is a coil or helical button spring 1000 . The button spring 1000 may be made from a number of materials. The button spring 1000 is adapted for positioning within the spring receiver 916 . As such, the clip 740 is proximate the button spring 1000 . The button spring 1000 of at least one embodiment is adapted to store and release a sufficient amount of energy such that when the button 132 is moved from a first position of use to a second position of use, the button spring 1000 is loaded (i.e., compressed against the clip 740 ) and when the button 132 is moved from the second position of use to the first position of use, the button spring 1000 is unloaded (i.e., expands away from the clip 740 ).
[0270] The front face 900 of the button 132 may include surface features to assist a user's manipulation of the button 132 . For example, in at least one embodiment, the front face 900 has a grippable or textured surface (not shown) such that users of varying age and dexterity may slidably move the button 132 .
[0271] Although an exemplary winder device 100 is depicted in FIGS. 1A-10C , one of skill in the art can appreciate the winder device 100 may be sized up or down depending on the application and the type of cord/cable used. For example, for extension cords, power cords or other larger/longer/thicker cords, the winder device may require a large size whereas, for kitchen appliances and computers, the winder device may require a medium size, and whereas, for headphone and cellular phones, the winder device may require a small size. That is, the size of the winder device may be designed large enough to store and protect the type of cable/cord while also small enough to be non-bulky and unobtrusive.
[0272] Referring now to FIGS. 11A-11C , the operation of at least one embodiment of the winder device 100 is shown. FIGS. 11A and 11B show that as a user pulls the cord/cable 100 associated with the winder out of (or at least partially out of) the winder device 100 , the spool 120 rotates. When the spool 120 rotates, the spool 120 engages the pawl 128 and torque is transmitted to the drive spring 124 . As such, the rotation of the spool 120 causes the drive spring 124 to wind/spiral tighter, which loads the drive spring 124 . In the loaded condition, the drive spring 124 stores a certain amount of energy. Moreover, as the spool 120 rotates, the teeth 344 on the spool 120 selectively engage the pawl teeth 616 such that when the user stops pulling on the cord/cable 1100 , the pawl teeth 616 lock the position of the spool 120 in place. Because of the engagement between the pawl teeth 616 and spool's teeth 344 , the spool 120 is held in place and is maintained in a loaded state, which prevents the drive spring 124 from releasing its energy.
[0273] FIG. 11C shows how the cable/cord 1100 is wound into the winder device 100 . When the user is ready to wind the cable/cord 1100 onto the spool 120 , the user loops the cable/cord 1100 around one of the grasping members (hooks in the embodiment shown) and pulls slightly to exert some force against the cable/cord 1100 to at least partially disengage the pawl teeth 616 from the spool 120 . Once the pawl teeth 616 have disengaged, the user is able to move the button 132 from a first position of use to a second position of use (by moving the button up in the embodiment shown), which moves the pawl teeth 616 away from the spool's teeth 344 . Once the pawl 128 and the spool 120 are disengaged, the drive spring 124 is able to release and return to an unloaded state. Unloading the drive spring 124 causes the spool 120 to spin and wind the cable/cord 1100 into the winder device 100 . One of skill in the art will appreciate that having both ends of the cord/cable at one entry point (rather than each end of the cord/cable coming out of different entry points) is desirable in that both ends of the cord can be quickly accessed.
[0274] It is desirable to be able to keep the drive spring in a loaded state so that the spool is ready to wind the cable/cord when the user is ready. As such, it is desirable to prevent accidental spin-out (or unloading) of the drive spring. In at least one embodiment, accidental spin-out is prevented by preventing the button from moving when a cord/cable is not engaged with the winder device. That is, the button cannot move from a first position of use to a second position of use unless and until a cord is engaged with the spool and the user pulls slightly on the cord while moving the button. A user who completely removes his or her headphones from the winder device is prevented from accidentally unloading the drive spring because he or she may not move the button to a second position of use until the cord/cable has been re-engaged with the spool's grasping members and the user has pulled slightly on the cord/cable. Similarly, a user who partially removes his or her earbuds from the winder device is prevented from accidentally unloading the drive spring because he or she has to pull slightly on the cord/cable before he or she may move the button to a second position of use. Preventing accidental spin-out is highly desirable for the user who, for example, takes his or her earphones out of the winder device and then places the winder device in a backpack, briefcase, or purse while he or she is using the earphones. In this example, the winder device will not accidentally unload while in the backpack, briefcase, or purse and the winder device is ready to wind the cord/cable when the user is ready to. If, however, the drive spring does spin-out or unload accidentally, the user may simply reload the drive spring by manually rotating the spool.
[0275] Referring now to FIGS. 12-23 , another embodiment of the present inventions is illustrated. To draw a few exemplary and non-limiting distinctions between the winder device 100 of at least one embodiment (discussed above) and the winder device 1200 of at least another embodiment (discussed below), one will notice that in the embodiment shown in FIGS. 12-23 , the winder device 1200 includes front and back cover plates. One of skill in the art will appreciate that depending on the application or use of the winder, it may be desirable to have or not have front and back cover plates. For example, when a lower profile winder is desirable, the winder device 100 without cover plates may be advantageous. Alternatively, when a more robust winder is desired, the winder device 1200 having cover plates may be advantageous. To further contrast the at least two embodiments, the winder device 100 has an axle 232 that is integral to the back housing 104 whereas the winder device 1200 has an axle 1220 separate from the back cover plate 1204 and back housing 1212 . Again, depending on the particular application or use of the winder device, it may be desirable for the winder device to have fewer individual components such that the efficiency of the manufacturing and/or assembly processes are increased. In contrast, it may be desirable to have a separate axle if the cable/cord to be wound requires a stronger axle.
[0276] Referring now to FIG. 12 , an exploded view illustrates at least another embodiment of a winder device 1200 . The winder device 1200 of at least this embodiment generally includes back and front cover plates 1204 and 1208 , back and front housings 1212 and 1216 , an axle 1220 , back and front spool sides 1224 and 1228 , a spool 1232 , a drive spring 1236 , a pawl 1240 , a button 1244 , and a button spring 1248 .
[0277] With reference now to FIGS. 13A-13H , the back cover plate 1204 of at least one embodiment is shown. The back cover plate 1204 generally includes front surface 1300 and a back surface 1304 . The front surface 1300 includes a first recessed portion 1308 . In the embodiment shown, the first recessed portion 1308 is disc-shaped (having a flat circular shape). The first recessed portion 1308 is adapted to receive a mating portion on the back housing 1212 . In at least one embodiment, the front surface 1300 also includes a second recessed portion 1312 adapted to cover a portion of the axle 1220 . In the embodiment shown, the second recessed portion 1312 is circular and positioned in substantially the center of the back cover plate 1204 . However, one of skill in the art will appreciate that the shape and position of the second recessed portion 1312 may vary depending on the shape and position of the axle 1220 .
[0278] The back cover plate 1204 also includes top and bottom brackets 1316 and 1320 . In at least one embodiment, the top and bottom brackets 1316 and 1320 are integrally formed with the back cover plate 1204 . For example, in at least one embodiment, the back cover plate 1204 includes integral top and bottom brackets 1316 and 1320 and is manufactured using an injection molding process. The top and bottom brackets 1316 and 1320 are adapted to fasten the back cover plate 1204 to the back housing 1212 . In at least one embodiment, the top and bottom brackets 1316 and 1320 mechanically interconnect to the back housing 1212 by a snap fit. The top and bottom brackets 1316 and 1320 may include a raised lip 1324 to enhance the snap fit design. One of skill in the art will appreciate that any number of fasteners may be used to interconnect the back cover plate 1204 and the back housing 1212 , such as a screws, rivets, pins, retaining rings, clamps, threaded fasteners, or glues and other adhesives. In at least one embodiment, the back surface 1304 of the back cover plate 1204 further includes a non-slip, grippable, traction providing, or other surface treatment or material (not shown) to facilitate a user's handling of the winder device 1200 . Similarly, depending on the application, it is envisioned that the back surface 1304 of the back cover plate 1204 includes shock absorbing, drop resistant, or other impact resistant material (not shown) to further protect the winder device 1200 from being damaged.
[0279] Referring now to FIGS. 14A-14H , the back housing 1212 of at least one embodiment is depicted. The back housing 1212 generally includes a front surface 1400 and a back surface 1404 . The back surface 1404 of the back housing 1212 (see FIGS. 14B and 14H ) is adapted to interconnect with the front surface 1300 of the back cover plate 1204 . In at least one embodiment, the back surface 1404 of the back housing 1212 generally includes a first raised portion 1408 that is shaped to mate with or otherwise engage the first recessed portion 1308 on the front surface 1300 of the back cover plate 1204 . In at least one embodiment, the first raised portion 1408 is disc-shaped (having a flat circular shape). The back surface 1404 of at least one embodiment also includes a second raised portion 1412 having an aperture 1416 adapted to allow the shaft portion 1508 of the axle 1220 to pass therethrough. The second raised portion 1412 may include, among others, an inner diameter 1420 and an outer diameter 1424 . In at least one embodiment, the inner diameter 1420 is substantially “D” shaped (to receive the planar edge 1528 of the substantially circular head portion 1512 of the axle 1220 ), whereas the outer diameter 1424 is substantially circular in shape. One of skill in the art will appreciate that the shape of the inner diameter 1420 may vary depending on the shape and configuration of the axle 1220 . In at least one embodiment, the first and second raised portions 1408 and 1412 (on the back surface 1404 of the back housing 1212 ) are adapted to engage the first and second recessed portions 1308 and 1312 (on the front surface 1300 of the back cover plate 1204 ) and selectively interconnect the back housing 1212 to the back cover plate 1204 .
[0280] Referring specifically to FIGS. 14A and 14G , the front surface 1400 of the back housing 1212 is shown. In at least some embodiments, the front surface 1400 of the back housing 1212 also includes a spool side area 1428 adapted to abut at least a portion of the back spool side 1224 . In some embodiments, the spool side area 1428 is recessed such that at least a portion of the back spool side 1224 sits within the spool side area 1428 . Furthermore, in at least one embodiment, the spool side area 1428 includes a circular ledge 1432 positioned within at least a portion of the spool side area 1428 . The ledge 1432 is adapted to facilitate movement of the back spool side 1224 within the spool side area 1428 . The ledge 1432 may also facilitate the placement or positioning of the back spool side 1224 in the spool side area 1428 .
[0281] In at least one embodiment, the back housing 1212 also includes top and bottom struts 1436 and 1440 . The top and bottom struts 1436 and 1440 may be integrally formed with the back housing 1212 . For example, in at least one embodiment, the back housing 1212 includes integral top and bottom struts 1436 and 1440 and is manufactured using an injection molding process. The top and bottom struts 1436 and 1440 are adapted to fasten the back housing 1212 to the front housing 1216 by a press fit. In at least one embodiment, the top strut 1436 may further include a plurality of pins 1444 and at least one bore 1448 to enhance the interconnection between the back housing 1212 and the front housing 1216 . The bottom strut 1440 of some embodiments includes a bracket receiving space 1452 to receive a portion of the bottom strut 2036 of the front housing 1216 . One of skill in the art will appreciate that any number or combinations of fastening devices may be used to interconnect the back housing 1212 and the front housing 1216 , including screws, rivets, retaining rings, clamps, threaded fasteners, or glues and other adhesives.
[0282] Referring now to FIGS. 15A-15D , an axle 1220 of one embodiment of the present invention is shown. The axle 1220 generally includes a first end 1500 , a second end 1504 , a shaft portion 1508 and a head portion 1512 therebetween. In at least one embodiment, the shaft portion 1508 provides structural support, is cylindrical in shape, and is rigid. In at least one embodiment, the shaft portion 1508 includes a spring anchor 1516 for securing the drive spring 1236 to the axle 1220 . In at least one embodiment, the spring anchor 1516 is a longitudinal cut that spans the length of the shaft portion 1508 and bifurcates the shaft portion 1508 of the axle 1220 . In another embodiment, the spring anchor 1516 is a longitudinal groove that spans at least a portion of the length of the shaft portion 1508 .
[0283] In at least one embodiment, the head portion 1512 includes a surface having a socket 1520 adapted for mating with a screwdriver or other tool. In at least the embodiment shown, the socket includes a slot 1524 and is adapted to engage a flat head screwdriver. One of skill in the art will appreciate that the socket 1520 may include other configurations to engage conventional screwdrivers, such as Phillips or Frearson, or have other geometries, such as a hexagonal socket to engage an Allen wrench.
[0284] The head portion 1512 also supports and maintains the axle's 1220 position when the axle 1220 is under stress. The periphery of the head portion 1512 of at least one embodiment includes a portion having a planar edge 1528 . The planar edge 1528 retains the axle 1220 in a fixed position while under loaded and unloaded conditions. In at least one embodiment, the periphery of the head portion 1512 is “D” shaped (that is, substantially circular while having a planar edge).
[0285] In at least one embodiment, the first end 1500 of the axle 1220 is adapted to be received in the second recessed portion 1312 of the back cover plate 1204 . As such, the back cover plate 1204 covers and protects the head portion 1512 from wear and potential damage. Because the back cover plate 1204 covers the head portion 1512 of the axle 1220 , user's and other objects are also protected from harm or damage. The second end 1504 of the axle 1220 of at least one embodiment is adapted for receiving at least a portion of the spool 1232 thereon.
[0286] In at least one embodiment, the axle 1220 is made from a metal or metal alloy. One of skill in the art will appreciate that the axle 1220 may be made from a variety of materials that are durable, low friction, and wear resistant.
[0287] Referring now to FIGS. 16A-16E , the spool 1232 of at least one embodiment of the present invention is shown. The spool 1232 may have a generally cylindrical configuration and in one embodiment includes an outer surface 1600 , a front surface 1604 , a back surface 1608 , and a plate 1612 positioned therebetween (separating the front surface 1604 from the back surface 1608 ). In at least one embodiment, the spool 1232 has a diameter D.
[0288] In the embodiment shown, the plate 1612 includes an aperture 1616 adapted to receive the shaft portion 1508 of the axle 1220 . In one embodiment, the aperture 1616 is sized to have at least some clearance such that the spool 1232 may easily slide on and rotate about the axle 1220 .
[0289] In at least one embodiment, the back surface 1608 includes a back edge 1620 and a hollow portion 1624 therein. The back edge 1620 includes a first set of holes 1628 for receiving a plurality of projections 1716 that are positioned on the back spool side 1224 (discussed below). One of skill in the art will appreciate that any number of interconnecting means may be included on the back edge 1620 to selectively and/or removably engage and interconnect the back surface 1608 of the spool 1232 to the first face 2408 of the back spool side 1224 .
[0290] In at least one embodiment, the hollow portion 1624 is adapted to receive the drive spring 1236 . The hollow portion 1624 substantially encloses the drive spring 1236 in at least one embodiment; however, one of skill in the art will appreciate that in other embodiments, the hollow portion 1624 may partially enclose the drive spring 1236 . The hollow portion 1624 protects the drive spring 1236 from distortion and/or damage.
[0291] Referring specifically now to FIGS. 16B and 16F , in at least one embodiment the back surface 1608 of the spool 1232 also includes a spring engaging member. The spring engaging member of one embodiment is a spring slot 1632 that extends from the back edge 1620 of the back surface 1608 longitudinally along the cylindrical outer surface 1600 of the spool 1232 to some length. The length of the slot may vary depending on the type or size of the drive spring 1236 that is used for the particular winder embodiment.
[0292] Referring now to FIGS. 16A and 16E , the front surface 1604 includes a front edge 1636 . In at least one embodiment, the front edge 1636 includes a second set of holes 1640 and teeth 1644 . The second set of holes 1640 are adapted to receive a plurality of projections 1716 positioned on the front spool side 1228 (discussed below). Any number of interconnecting mechanisms may be included on the front edge 1636 to selectively and/or removably engage and interconnect the front surface 1604 of the spool 1232 to the first face 1700 of the front spool side 1228 .
[0293] In at least one embodiment, the teeth 1644 project radially inward (i.e., toward the center of the spool) and are sized and shaped to engage at least a portion of the pawl 1240 . The teeth 1644 are oriented at an angle α in order to reduce and/or prevent winder spin-out. Accidental spin-out is undesirable because the user has to manually re-load the drive spring 1236 before the cord/cable may be wound. As such, the engagement between the spool 1232 and the pawl 1240 is configured such that the drive spring 1236 is maintained in a loaded condition until the user is ready to winder the cord/cable (thereby unloading the drive spring). In order to achieve the desirable spool/pawl engagement, the teeth 1644 are properly angled to engage and maintain the engagement (i.e., minimize slip) with the pawl teeth 1916 . In at least one embodiment, this engagement is achieved by orienting the teeth 1644 at an angle α that ranges from about 25 degrees to about 45 degrees. In a preferred embodiment, the teeth are oriented at an angle α of about 37 degrees.
[0294] Referring now to FIGS. 16C and 16D , the outer surface 1600 of the spool includes grasping members. In at least one embodiment, the grasping members are hooks 1648 adapted to selectively engage a portion of a cord, cable, or other object to be used with the winding device 1200 . One of skill in the art will appreciate that the number of hooks 1648 positioned on the outer surface 1600 of the spool 1232 may vary depending on a number of variables, such as size, and the graspability of the object. For example, in at least one embodiment, four hooks are provided. In another embodiment, two hooks are provided. In yet another embodiment, seven hooks are provided. One of skill in the art will appreciate that the grasping members may include a variety of configurations. The grasping element may take on a variety of different forms and is not limited to a hook. By way of example and not limitation, a V-shaped engaging mechanism that uses friction to hold the cord/cable and allows the winder to pull the cord/cable into its frame may be used. In at least another embodiment, a cord engaging mechanism includes texturing for a plurality of superficial features to assist with grabbing and holding the cord/cable. The height H of the spool 1232 may vary depending on the exact configuration of the grasping members.
[0295] In at least one embodiment, the spool 1232 is manufactured as an integral piece using conventional injection molding processes and is made from polyoxymethylene plastic (commonly sold under the trade name “Delrin”). In other embodiments, the grasping members may be individually and selectively interconnected to the outer surface 1600 of the spool 1232 , depending on the application. In another embodiment, the teeth 1644 may be selectively removable from the front surface 1604 such that they may be easily replaced if they get worn or otherwise damaged.
[0296] A spool side of one embodiment is shown in FIGS. 17A-17E . In at least one embodiment, the winder device includes two spool sides, adapted for positioning on either side of the spool. One of skill in the art will appreciate that in at least one embodiment, the winder device has no spool sides, and in other embodiments, the winder device has only one spool side, and in still other embodiments, the spool sides are formed integrally with the spool.
[0297] In at least one embodiment, the winder device 1200 includes a front spool side 1228 and a back spool side 1224 . The front and back spool sides 1228 and 1224 are adapted to interconnect with the spool 1232 . In one embodiment, the front and back spool sides 1228 and 1224 are shaped as a substantially flat or planar torus (doughnut-shaped) and have a first face 1700 , a second face 1704 , an outer diameter 1708 , and an inner diameter 1712 . In at least one embodiment, the second face 1704 of the back spool side 1224 is adapted to abut a front surface 1400 of the back housing 1212 and the second face 1704 of the front spool side 1228 is adapted to abut a back surface 2004 of the front housing 1216 .
[0298] In addition, in at least one embodiment, a plurality of projections 1716 positioned on the first face 1700 of the front and back spool sides 1228 and 1224 are positioned proximate to the inner diameter 1712 . One of skill in the art will appreciate that the plurality of projections 1716 may be spaced equidistantly, non-equidistantly, or other configuration, around the perimeter of the inner diameter 1712 . In at least one embodiment, the plurality of projections 1716 have a dowel pin or cylindrical rod shape. The plurality of projections 1716 are adapted to be received by corresponding fastening means, i.e., in corresponding holes on the front and back surfaces 1604 and 1608 of the spool 1232 . One of skill in the art will appreciate that the plurality of projections 1716 may have various shapes and/or geometry, so long as the spool 1232 has corresponding or mating fastening means. One of skill in the art will appreciate that any number of fastening mechanisms, including screws, rivets, retaining rings, snap fits, or glues and other adhesives, can be used to interconnect the front and back spool sides 1228 and 1224 to the spool 1232 .
[0299] In at least one embodiment, the front and back spool sides 1228 and 1224 are substantially identical parts. One of skill in the art will appreciate that using front and back spool sides 1228 and 1224 that are substantially identical decreases the number of different component parts that need to be manufactured and increases the throughput of manufactured parts. However, one of skill in the art can also appreciate that in some embodiments, it may be desirable to have front and back spool sides that are not substantially identical parts. For example, in other embodiments, the front and back spool sides 1228 and 1224 have different fastening mechanisms, are made from different materials, or have different dimensions. In another embodiment, the front and back spool sides 1228 and 1224 are integrally formed with the spool. In still other embodiments, the winder device only includes one spool side.
[0300] In at least one embodiment, the spool side(s) are made from Delrin. One of skill in the art will appreciate that the spool side may be made from any number of thermoplastics having high stiffness, low friction, and good dimensional stability. Moreover, in at least one embodiment, the spool side(s) are manufactured as an integral piece using an injection molding process.
[0301] Referring now to FIGS. 18A-18C , a biased member is illustrated. The biased member may be a mainspring or a coil spring, in a biased condition. In at least one embodiment, the biased member is a drive spring (mainspring) 1236 . The drive spring 1236 includes a first end tab 1800 and a second end tab 1804 . The first end tab 1800 is adapted to engage the spring anchor 1516 on the axle 1220 . In at least one embodiment, the first end tab 1800 further includes an approximately 90 degree bend that interconnects the drive spring 1236 to the axle 1220 . The second end tab 1804 is adapted to engage the spring slot 1632 on the spool 1232 . In at least one embodiment, the second end tab 1804 includes a 180 degree U-shaped bend that interconnects the drive spring 1236 to the spool 1232 . The width W of the drive spring 1236 in at least one embodiment is designed to fit within the hollow portion 1624 of the spool 1232 . The drive spring 1236 may also include metal ribbon made from a strip of blue steel, steel alloy, carbon steel alloy, or other metal alloys (i.e., iron, nickel and chromium with colbalt, molybdenum, or beryllium). Moreover, in at least one embodiment, in a non-compressed (or un-stressed) state, the drive spring 1236 includes ten or more turns and is adapted to provide at least about 0.5 inch-pounds of torque, and more preferably about 0.8 inch-pounds of torque.
[0302] Turning now to FIGS. 19A-19H , a pawl 1240 of at least one embodiment is shown. The pawl 1240 generally includes an outer surface 1900 , a front surface 1904 , a back surface 1908 , and an aperture 1912 between the front and back surfaces 1904 and 1908 . In at least one embodiment, the front surface 1904 of the pawl 1240 is adapted to abut at least a portion of the button 1244 , and the back surface 1908 of the pawl 1240 is adapted to abut at least a portion of the spool 1232 .
[0303] On at least a portion of the outer surface 1900 pawl teeth 1916 are provided. The pawl teeth 1916 are adapted to selectively and operably engage the teeth 1644 on the front edge 1636 of the spool 1232 . The number of pawl teeth 1916 may vary depending on a variety of factors, such as the size of the winder device 1200 , and the size of the cables/cords to be retained in the winder device 1200 , among others.
[0304] Referring specifically now to FIGS. 19A and 19G , the front surface 1904 of at least one embodiment includes a projection 1920 adapted to engage a complementary portion of the button 1244 (discussed below). As shown in FIG. 19A , the projection 1920 is substantially D-shaped. In alternative embodiments, the projection 1920 may have a number of different configurations, including a cylindrical, conical, or polygonal projection. Moreover, in at least one embodiment, the projection has a surface treatment such as a texturizing coating (not shown) on at least a portion thereof to enhance the surface contact between the projection 1920 and the button 1244 .
[0305] Referring now to FIGS. 19A and 19B , the aperture 1912 is be adapted to interconnect to the front housing 1216 . In at least one embodiment, the aperture 1912 is adapted to receive at least a portion of the back surface 2004 of the front housing 1216 .
[0306] Referring now to FIGS. 20A-20H , the front housing 1216 of at least one embodiment is shown. The front housing 1216 generally includes a front interior surface 2000 , a back surface 2004 , and an aperture 2008 therethrough. The front housing 1216 is generally configured to interconnect to the back housing 1212 and to the front cover plate 1208 .
[0307] Referring specifically to FIGS. 20B and 20H , the back surface 2004 of the front housing 1216 is shown. In at least one embodiment, the back surface 2004 of the front housing 1216 is adapted to engage the pawl 1240 . The back surface 2004 may include a projection or other structure adapted to interconnect to the corresponding aperture 1912 of the pawl 1240 . The size, shape, and position of the projection 2012 may vary depending on the configuration of the pawl 1240 . In the embodiment shown, the projection 2012 is cylindrical. In at least one embodiment, the projection 1212 is proximate the aperture 2008 .
[0308] In at least some embodiments, the back surface 2004 of the front housing 1216 also includes a spool side area 2016 adapted to abut at least a portion of the front spool side 1228 . In some embodiments, the spool side area 2016 is recessed such that at least a portion of the front spool side 1228 sits within the spool side area 2016 .
[0309] Referring specifically now to FIGS. 20A and 20G , in at least one embodiment, the front interior surface 2000 of the front housing 2016 generally includes a first raised portion 2020 that is shaped to mate with or otherwise engage a corresponding portion of the front cover plate 1208 . In at least one embodiment, the first raised portion 2020 is disc-shaped. The front interior surface 2000 of the front housing 1216 of at least one embodiment also includes a button receiver 2024 . The button receiver 2024 is adapted to receive the button 1244 . The button receiver 2024 is preferably positioned such that the aperture 2008 passes therethrough. In some embodiments, the button receiver 2024 is recessed relative to the first raised portion 2020 . The size and shape of the button receiver 2024 may vary depending on the size of shape of the button 1244 . In at least one embodiment, the button receiver 2024 has a clip 2028 adapted to interconnect to at least a portion of the button 1244 .
[0310] Referring now to FIGS. 20A and 20B , the aperture 2008 of at least one embodiment is adapted to allow at least a portion of the pawl 1240 to pass therethrough. The shape of the aperture may vary depending on a variety of factors, such as the size of the winder device, size of the pawl, etc. In at least one embodiment, the aperture 2008 has a generally kidney-bean shape. In operation, the position of the pawl 1240 in the aperture 2008 varies depending on the position of the button 1244 .
[0311] In at least one embodiment, the back surface 2004 of the front housing 1216 is adapted to interconnect with the front surface 1400 of the back housing 1212 . Referring now to FIGS. 20D-20E , the front housing 1216 includes top and bottom struts 2032 and 2036 . In at least some embodiments, the top and bottom struts 2032 and 2036 are integrally formed with the front housing 1216 . For example, in at least one embodiment, the front housing 1216 includes integral top and bottom struts 2032 and 2036 and is manufactured using an injection molding process. In at least one embodiment, the top and bottom struts 2032 and 2036 are adapted to fasten the front housing 1216 to the back housing 1212 by a press fit. In at least one embodiment, the front housing's top strut 2032 has pins 2040 and at least one bore 2044 to mate with the corresponding bores and pins on the back housing's top strut 1436 . The bottom strut 2036 of the front housing 1216 of some embodiments includes a bracket 2048 protruding out therefrom and which is adapted to be received in the bracket receiving space 1452 of the bottom strut 1440 of the back housing 1212 . In alternative embodiments, various fastening devices are used to interconnect the front and back housings 1216 and 1212 .
[0312] Referring now to FIGS. 20A and 20G , in at least one embodiment, the front interior surface 2000 of the front housing 1216 is further adapted to interconnect to the front cover plate 1208 . The front housing 1216 of at least one embodiment includes a screw receiving hole 2052 . One of skill in the art will appreciate the screw receiving hole 2052 may be positioned in numerous locations on the front housing 1216 . In at least one embodiment, the screw receiving hole 2052 is positioned proximate the top strut 2032 .
[0313] Referring now to FIGS. 21A-2H , the button 1244 of at least one embodiment is illustrated. The button 1244 generally includes a front face 2100 and a back face 2104 and is adapted to interconnect to the front housing 1216 and front cover plate 1208 . In at least one embodiment, the back face 2104 of the button 1244 is adapted to abut the button receiver 2024 on the front interior surface 2000 of the front housing 1216 .
[0314] The back face 2104 of the button 1244 is also generally adapted to engage at least a portion of the pawl 1240 . In at least some embodiments, the back face 2104 includes a pawl receiver 2108 . The pawl receiver 2108 may be shaped to correspond to the shape of the pawl's projection 1920 . In at least one embodiment, the pawl receiver 2108 is substantially D-shaped (to interconnect to the D-shaped projection 1920 on the pawl 1240 ). In other embodiments, the pawl receiver 2108 may be substantially O-shaped, polygonally shaped, or conically shaped to receive a corresponding pawl projection.
[0315] In at least one embodiment, the back face 2104 of the button 1244 also includes a spring receiver 2112 . In at least some embodiments, the spring receiver 2112 is configured as a longitudinal slot that is adapted for receiving the clip 2028 (on the front housing 1216 ) and a biased member, such as a button spring 1248 . When assembled, the clip 2028 is proximate the biased member 1248 .
[0316] The front face 2100 of the button 1244 may include additional surface features. For example, in at least one embodiment, the front face 2100 has a direction indicator 2116 and a ornamental design 2120 . One of skill in the art can appreciate that the direction indicator 2116 may help facilitate use of the winder device 1200 and the ornamental design 2120 may be desirable for product branding and brand recognition.
[0317] Referring now to FIGS. 22A-22C , a biased member is illustrated. In at least one embodiment, the biased member is a coil or helical button spring 1248 . The button spring 1248 may be made from a number of materials, including stainless steel. The button spring 1248 is generally adapted for positioning within the button's spring receiver 2112 . The button spring 1248 is designed to store and release a sufficient amount of energy such that when the button 1244 is moved from a first position of use to a second position of use, the button spring 1248 is loaded (i.e., compressed or biased against the clip 2028 ) and when the button 1244 is moved from the second position of use to the first position of use, the button spring 1248 is unloaded (i.e., expands away from the clip 2028 ). After disengaging the pawl teeth 1916 from the teeth 1644 on the spool 1232 (as discussed above, i.e., by pulling slightly on the cord/cable) the movement of the button 1244 rotates the pawl teeth 1916 away from the teeth 1644 on the spool 1232 .
[0318] With reference now to FIGS. 23A-23H , the front cover plate 1208 of at least one embodiment is shown. The front cover plate 1208 generally includes a front surface 2300 , a back surface 2304 , and a window 2308 therebetween. The back surface 2304 may include a first recessed portion 2312 . The first recessed portion 2312 may be adapted to receive a mating portion on the front interior surface 2000 of the front housing 1216 . In at least one embodiment, the first recessed portion 2312 is disc-shaped and adapted to engage the first raised portion 2020 of the front housing 2016 . In at least one embodiment, the back surface 2304 also includes a second recessed portion 2316 that is adapted to engage at least a portion of the front face 2100 of the button 1244 . The window 2308 is positioned such that at least a portion of the front face 2100 of the button 1244 extends at least partially therethrough. In some embodiments, when the button 1244 is aligned in the window 2308 of the front cover plate 1208 , the button 1244 is substantially flush with the front surface 2300 of the front cover plate 1208 . In other embodiments, the button 1244 extends beyond the front surface 2300 of the front cover plate 1208 .
[0319] The front cover plate 1208 also includes top and bottom brackets 2320 and 2324 . In at least one embodiment, the top and bottom brackets 2320 and 2324 are integrally formed with the front cover plate 1208 . For example, in at least one embodiment, the front cover plate 1208 includes integral top and bottom brackets 2320 and 2324 . The top and bottom brackets 2320 and 2324 are adapted to fasten the front cover plate 1208 to the front housing 1216 . In at least one embodiment, the top and bottom brackets 2320 and 2324 mechanically interconnect to the front housing 1216 by a snap fit. The top and bottom brackets 2320 and 2324 may include a raised lip 2328 to enhance the snap fit design. One of skill in the art will appreciate that any number of fasteners may be used to interconnect the front cover plate 1208 and the back housing 1212 , such as a screws, rivets, pins, retaining rings, clamps, threaded fasteners, or glues and other adhesives.
[0320] In at least one embodiment, the back surface 2304 of the front cover plate 1208 further includes a surface treatment or material, such as a non-slip, grippable, or traction providing treatment (not shown) that facilitate a user's handling and manipulation of the winder device 1200 . Similarly, depending on the application, it is envisioned that the front surface 2300 of the front cover plate 1208 includes shock absorbing, drop resistant, or other impact resistant material (not shown) to further protect the winder device 1200 from damage. It is further envisioned, that the front cover plate 1208 include decals or other ornamental features to enhance the marketability of the winder device 1200 .
[0321] It is to be understood that the cord winding devices described herein may be used for a variety of cords and cables for a variety of purposes and industries. Storing headphone cords and kitchen appliance cables are but a few possible applications for utilizing the winder device. Moreover, as one of skill in the art can appreciate that the dimensions of the winder device may be sized up or down depending on the application and the type of cord/cable used.
[0322] Referring now to FIGS. 24A-24F , a spool 2400 of another embodiment is shown. This spool configuration may be particularly desirable and useful for larger winder applications that require a larger spool. Should the particular application or use dictate that the winder device have a larger size (i.e., to accommodate larger cables/cords having a larger radius of curvature), instead of re-sizing and manufacturing all of the component parts for the winder, the spool 2400 may be re-configured to work with a smaller pawl. Unlike the spool's discussed above, the front surface 2404 of the spool 2400 includes a first face 2408 having a first diameter D 1 and a second face 2412 , having a second diameter D 2 . In this configuration, the grasping members are interconnected to the second face 2412 . Like the spools discussed above, the first face 2408 has teeth 2416 to operably engage the pawl teeth. Because the teeth 2416 are positioned on the first face 2408 , the dimensions of the pawl and pawl teeth do not need to be increased, rather the overall size of the spool 2400 may be increased simply by having a second face 2412 with a larger diameter D 2 . The structural stability and/or strength of the spool 2400 may be increased by further including a plurality of radially extending struts (not shown) that interconnect the first and second faces 2408 and 2412 . The second face 2412 may be slotted 2420 to receive mating projections 2500 positioned on the spool sides 2500 . FIGS. 25A-25E show the spool side(s) adapted for use with the spool 2400 . The projections 2504 are sized to selectively interconnect to the second face 2412 of the spool 2400 .
[0323] Referring now to FIGS. 26A-26E a spool 2600 of another embodiment is shown. This spool configuration may be desirable when a low-profile or recessed spool would be useful for the particular winder application. In this embodiment, the grasping members 2604 are integrated into the spool's outer periphery 2608 .
[0324] In still other embodiment of the present inventions, the winder device is configured to mate with an existing device, such as a portable DVD player, an MP3 player, a smartphone, or other commercially popular devices. FIGS. 27A-27D illustrate an exemplary embodiment of a winder device 2700 adapted to work with an APPLE brand IPHONE or IPOD. One of skill in the art will appreciate IPHONE/IPOD users typically carry headphones or earbuds with them so that they may watch television, movies, and to listen to music. The winder device 2700 provides a way to safely store and protect the associated earbuds/headphones unobtrusively.
[0325] One of skill in the art will appreciate that the structure shown in FIGS. 27A-27D is consistent with the embodiments previously described in detail herein. That is, similar in structure to the embodiments discussed herein, the winder device 2700 generally includes back and front housings 2704 and 2708 , back and front spool sides 2712 and 2716 , a spool 2720 , a drive spring (not shown), a pawl 2728 , a button 2732 , and button spring (not shown). The winder device 2700 may also include a spacer 2740 . In at least one embodiment, the spacer 2740 includes an aperture 2744 and the front surface 2748 also includes a projection 2752 . The aperture 2744 and the projection 2752 are adapted to interconnect with the pawl 2728 . The front housing 2708 of the winder device 2700 may also include an aperture 2756 that is configured to allow at least a portion of an axle 2760 to pass therethrough. One of skill in the art will readily recognize the desirability and advantages to storing earphones/earbuds and the desired device (e.g., smartphone) together in a protective housing.
[0326] With reference now to FIGS. 28A-C and 29 , in at least one embodiment a winder device includes a biased member, such as a mainspring or flat coil spring, in a biased condition. A means for grasping an interior region of a folded or overlapped cord, such as a hook (as shown in FIG. 29 ), is operatively associated with the mainspring. Accordingly, the cord can be overlapped and engaged with the hook (see FIGS. 28A and 29 ). Thereafter, a spring release trigger, such as button, is depressed (as shown in FIG. 28B ), thereby causing the cord to be pulled into the winder device and to be wound around an inner spool. Both portions of the cord are adjacent each other and enter the same aperture, thereby allowing the cord plugs to reside adjacent one another (as shown in FIG. 28C ). Alternatively, the fold in the cord can be located closer to one end than the other, and then the fold can be engaged with the hook. Advantageously, in such a configuration cord plugs can be established at different distances from the winder.
[0327] As those skilled in the art will appreciate, in at least one embodiment the winder device is separate from the cord. Accordingly, the winder device may be sold in a separate package. The consumer then uses the winder device with any given cord to wind the cord into the winder device. By way of example, a user could purchase the winder device for use with stereo speaker wiring, and thereafter engage a folded portion of the speaker wire into the winder device to wind excess portions of the speaker wire.
[0328] With reference now to FIG. 30 , the cord grasping element may take on a variety of different forms, and are not limited to a hook. By way of example and not limitation, the V-shaped cord engaging mechanism of FIG. 30 uses friction to hold the cord and allow the winder device to pull the cord into its frame. In at least one embodiment, a cord engaging mechanism includes texturing or a plurality of surficial features to assist with grabbing the cord.
[0329] With reference now to FIG. 31 , a plurality of winder devices are shown in a stacked configuration. In accordance with at least one embodiment, the winder frames include a tongue and groove structure and/or other engaging mechanism for allowing the winder frames to be stacked. The winder frames may further include a releasable lock structure, such as a biased catch that allows a first winder to releasably interlock with a second winder.
[0330] In accordance with one or more embodiments of the present invention, a winder device uses a ratchet and pawl system for releasably securing the spring from unwinding. As shown in FIG. 28B , a button can be depressed that releases the spring and retracts the cord. In at least one embodiment the button is located near the center of one side of the winder. In an alternative embodiment, the winder utilizes a squeeze release, wherein the spring releases when the two halves of the winder are squeezed together. In another embodiment, a cam or other lock-and-release mechanism will be positioned on the outer perimeter of the spool.
[0331] Embodiments of the winder device described herein may be used in connection with a wide variety of electrically operated devices. FIGS. 32A and 32B show a winder device in accordance with at least some of the embodiments described herein used in connection with a coffee maker. FIG. 33 shows a winder device in accordance with the embodiments described herein used in connection with a blow dryer. FIG. 34 shows a winder device in accordance with the embodiments described herein used in connection with a handheld/mobile device. FIG. 35 shows a winder device in accordance with the embodiments described herein used in connection with a lamp. As can be seen in FIG. 35 , the two portions of the cord can be different distance relative to the lamp. That is, the distance between the socket and the winder is a different distance than the distance between the winder and the lamp.
[0332] 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.
[0333] The one or more present inventions, in various embodiments, include components, methods, processes, systems and/or apparatus substantially as depicted and described herein, including various embodiments, subcombinations, and subsets thereof. Those of skill in the art will understand how to make and use the present invention after understanding the present disclosure.
[0334] The present invention, in various embodiments, includes providing devices and processes in the absence of items not depicted and/or described herein or in various embodiments hereof, including in the absence of such items as may have been used in previous devices or processes (e.g., for improving performance, achieving ease and/or reducing cost of implementation).
[0335] The foregoing discussion of the invention has been presented for purposes of illustration and description. The foregoing is not intended to limit the invention to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the invention are grouped together in one or more embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the invention.
[0336] Moreover, though the description of the invention has included description of one or more embodiments and certain variations and modifications, other variations and modifications are within the scope of the invention (e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure). It is intended to obtain rights which include alternative embodiments to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter. | A device for winding, storing, tangle prevention, and protecting cords and/or cables is described. The device for winding a cord includes a frame having a cord access aperture for receiving the cord. The frame also includes an inner spool and a concentrically located spring, such as a flat coil spring, operatively connected to a catch mechanism for engaging the cord. The spring is adapted for winding the cord around the inner spool upon engaging the cord with the catch mechanism and releasing a spring control, such as a ratchet and pawl, that serves to secure tension in the spring. Methods associated with such a device are also described herein. | 1 |
This application is a continuation of prior application Ser. No. 595,647, filed on Oct. 9, 1990, now abandoned, which is a continuation of application Ser. No. 423,744, filed on Oct. 19, 1989, now abandoned, which is a continuation of application Ser. No. 217,923, filed on Jun. 17, 1988, now abandoned.
TECHNICAL FIELD
The present invention relates to an earthquake-proofing device of peripherally restrained type for carrying or supporting a structure while reducing earthquake input and vibration-proofing the structure, and particularly to a vibration-proofing device of peripherally restrained type using an elastic, visco-elastic or viscous body as a load carrier externally surrounded by restraining laminated members to impart a high vertical rigidity to the device while allowing the device to deform horizontally to a great extent, so that the device is capable of earthquake-proofing and vibration-proofing structures and machines.
BACKGROUND ART
As for earthquake-proofing systems for structures including buildings, laminated rubber bearings have come into wide use, and they are classified into three types.
A first type, as shown in FIGS. 29(a) and (b), is a laminated rubber bearing X, wherein rubber plates 1 which are low in compression permanent strain, such as natural rubber, and steel plates 2 are alternately laminated and fixed together. Since this type has a high ratio of vertical compression rigidity to horizontal shear rigidity, it reduces transmission of earthquake energy to a structure while stably supporting the structure, which is a heavy object, against earthquakes.
A second type is a lead-laminated rubber bearing Y (Japanese Patent Publication No. 17984/1986) which is a modification of the laminated construction used for the first type of laminated rubber bearing, incorporating a lead plug 3, as shown in FIGS. 30(a) and (b), vertically inserted therein. Thanks to hysteresis damping provided by plastic strain of the lead inserted in the interior as indicated by a load-displacement curve shown in FIG. 31, this type reduces the amplitude of vibration of a structure produced by an earthquake and quickly damps the vibrations.
A third type is a highly damping laminated rubber bearing Z, which is a modification of the laminated rubber bearing X shown in FIGS. 29(a) and (b), wherein the laminate itself is given a damping property by using highly damping rubber for rubber plates 1.
However, the aforesaid laminated rubber bearings X, Y and Z have the following respective problems.
The first type of laminated rubber bearing X has a vibration damping property which is so low that the direct use of the same will result in an increased amplitude of vibration of a structure during an earthquake; thus, the bearing lacks safety. Therefore, usually, in use it is combined with a separate damper disposed in parallel therewith. In this case, the point of action of restoring force does not coincide with the point of action of damping force, so that there is the danger of giving unnecessary torsional vibrations to the structure.
In the second type of lead-laminated rubber bearing Y, the lead plug 3 develops a high initial shear rigidity for slight vibration, as shown by a characteristic S in FIG. 31; thus, the bearing has poor vibration proofing performance such that it transmits traffic vibrations produced by passage of vehicles. Therefore, it can hardly be applied to a building or floor for installing machines where vibrations are objectionable. Another problem is that the restoration to the original point subsequent to substantial deformation is retarded by the plasticity of the lead.
In the third type of highly damping laminated rubber bearing Z, the amount of creep of the highly damping rubber is high and its restoring force associated with horizontal displacement is low; thus, there is a problem that the reliability for prolonged use is low. Further, the amount of creep differs from one highly damping laminated rubber bearing to another, so that as a result of the earthquake-proofing action, the building shows non-uniform subsidence, causing unnecessary stresses to be produced in the structure.
DISCLOSURE OF THE INVENTION
The present invention has been accomplished with the actual conditions of the laminated rubber bearings X, Y and Z taken into consideration and is intended to propose an earthquake-proofing device which solves the problems on the basis of a construction and principle basically different from those of the rubber bearings.
An earthquake-proofing device of peripherally restrained type newly proposed by the invention is characterized in that it comprises:
a load carrier adapted to be disposed below a structure to support the vertical load therefrom, and
a restrainer including restraining members laminated together in the direction of the height to develop high rigidity against tensile force, said load carrier being inserted in said restrainer, said restrainer restraining the load carrier from bulging outward.
In said earthquake-proofing device, the load carrier formed of an elastic, visco-elastic or viscous material is restrained by the surrounding restrainer, whereby it develops a load support capability due to vertical rigidity while retaining the high deforming capability due to elasticity, visco-elasticity or viscosity. The restrainer and/or load carrier develops a vibration energy absorbing effect mainly by frictional damping. This vibration absorbing effect is also effective for slight vibration.
In addition, in the earthquake-proofing device of the invention, a vertical load is supported mostly by the load carrier, while energy absorption is effected mainly by frictional damping through the restrainer and/or load carrier; in this respect, the mechanism differs essentially from the lead-laminated rubber bearing Y. The reason is that in the lead-laminated rubber bearing Y, a vertical load is supported by the surrounding laminate of steel plates and thin rubber plates while energy absorption is effected by the plastic deformation of the lead.
Further, in the construction of the present inventive device, the point of action of restoring force coincides with the point of action of damping force, so that unnecessary torsional vibrations are not given to structures.
It is seen from the above that the present inventive device serving as a damper-integral type earthquake-proofing device develops the same performance as or higher performance than the conventional laminated rubber bearings X, Y and Z.
Since a columnar load carrier is restrained by the restrainer, it has become possible to utilize those kinds of materials for load carriers that it was not possible to use in the case of laminated construction.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 through 4 are views showing an earthquake-proofing device A according to a first embodiment of the invention; FIG. 1 is a sectional view showing the basic construction; FIGS. 2 and 3 are a plan view and a sectional view, respectively, showing an example of application; and FIG. 4 is a side view showing another example of application.
FIGS. 5 through 9 are views showing an earthquake-proofing device B according to a second embodiment of the invention; FIG. 5 is a sectional view showing the basic construction; FIG. 6 is a plan view; FIG. 7 is a fragmentary enlarged sectional view of FIG. 5; FIG. 8 is a perspective view showing restraining wires; and FIG. 9 is a fragmentary sectional view showing another example of arrangement of the peripheral portion of the load carrier.
FIGS. 10 through 17 are views for explaining an earthquake-proofing device C according to a third embodiment of the invention; FIGS. 10(a) and (b), FIGS. 11(a) and (b) and FIGS. 12(a) and (b) show three examples of the basic construction of the third embodiment, (a)'s being plan views and (b)'s being sectional views. FIG. 13 is a sectional view showing a manufacture example embodying the basic construction example C 1 shown in FIG. 10 and FIG. 14 is a sectional view showing a manufacture example embodying the basic construction example C 2 shown in FIG. 11. FIGS. 15 through 17 are load-displacement curves obtained when the rubber-like material and anti-friction material for the load carrier are changed.
FIGS. 18 through 25 are views showing an earthquake-proofing device D according to a fourth embodiment of the invention; FIGS. 18(a) and (b) are a plan view and a sectional view, respectively, showing a first construction example D 1 . FIGS. 19(a) and (b) show a manufacture example d 1 of the first construction example D 1 shown in FIGS. 18(a) and (b), (a) being a plan view and (b) being a sectional view. FIGS. 20(a) and (b) through FIGS. 25(a) and (b) show second through seventh construction examples of the fourth embodiment, (a)'s being plan views and (b)'s being sectional views.
FIGS. 26 through 28 are views for explaining an earthquake-proofing device E of peripherally restrained type according to a fifth embodiment of the invention; FIGS. 26(a) and (b) and FIGS. 27(a) and (b) show first and second arrangement examples, respectively, (a)'s being plan views and (b)s' being sectional views. FIGS. 28(a), (b) and (c) show a third arrangement example of the fifth embodiment, (a) being a sectional view, (b) being a plan view of an upper pressure receiving plate and (c) being a plan view of an outer plate.
FIGS. 29 and 30 show prior art examples. FIGS. 29(a) and (b) show a laminated rubber bearing X or a highly damping laminated rubber bearing Z, (a) being a plan view and (b) being a sectional view. FIGS. 30(a) and (b) show a lead-laminated rubber bearing Y, (a) being a plan view and (b) being a sectional view. FIG. 31 is a load-displacement curve for the lead-laminated rubber bearing shown in FIG. 30.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present inventive device has a number of embodiments corresponding to different forms of the construction of a restrainer. These will now be described in order.
First of all, a first embodiment which is the most basic type of the invention will be described with reference to FIGS. 1 through 4.
An earthquake-proofing device A according to the first embodiment, as shown in FIG. 1 showing its section, comprises a load carrier 11 using a columnar rubber-like body which develops elasticity or viscoelasticity, and restraining plates 13 disposed therearound as restraining members constituting a restrainer 12.
The rubber-like body forming the load carrier 11 is formed into a column having any desired plan configuration including a cylinder and a prism, and its material includes natural rubber and derivatives thereof, and elastomers developing rubber-like visco-elasticity, such as various synthetic rubbers and rubber-like plastics.
Further, since the rubber-like body, which is the load carrier 11, is singly used, such highly damping rubbers as nitrile-butadiene rubber, isobutylene-isoprene rubber, polynorbornene, and butyl halogenide, whose lamination has heretofore been hampered, can be used if necessary.
Disposed in laminate form around the periphery of the load carrier 11 using a rubber-like body are restraining plates 13 of high rigidity which are restraining members constituting the restrainer 12 for restraining outward bulging. Thereby, the load carrier 11 and the earthquake-proofing device A develop high vertical rigidity and great vertical load support capability and possess low horizontal rigidity and great horizontal deformability.
The restrainer 12 shown in FIG. 1 is constructed by simply stacking the restraining plates 13 in the form of a plurality of steel plates, but as in FIG. 4 showing an example of application of the first embodiment, a single or a plurality of steel plates may be made continuous in spiral form, making it possible to arbitrarily adjust the rigidity and damping performance of the earthquake-proofing device A.
As for the method of treating the restraining plates for lamination, they may be directly laminated or they may be covered or laminated using rubber which is low in compression permanent strain.
Another example of applications of the first embodiment will now be described with reference to FIGS. 2 and 3.
In this example of application, fixing plates 14 adapted to be fixed to a superstructure and a substructure are joined to the upper and lower surfaces of the earthquake-proofing device A of the first embodiment, that is, the upper and lower surfaces of the rubber-like body which is the load carrier 11.
Steel plates are mainly used for the fixing plates 14 as in the case of the restrainer 12.
The example of application shown in FIG. 2 is constructed by stacking a plurality of restraining plates 12 which are a plurality of steel plates to form a restrainer 12, while the example of application shown in FIG. 4 is constructed by spirally forming the restraining plates 13 as described above to form a restrainer 12.
Since the first embodiment is constructed by singly using a rubber-like body and disposing the restraining plates 13 in laminate form therearound to form a restrainer 12, the following effects can be attained.
(1) Particularly in the case where the restraining plates 13 are directly laminated, since the construction is simple, manufacture is easy and hence cost reduction is realized.
(2) When the restraining plates 13 placed one above another are disposed so that they rub each other during earthquake-proofing operation, vibration energy is absorbed by friction, so that a damping effect is obtained; thus, even if the rubber-like body which is the load carrier 11 is natural rubber or the like, the device is a damper-integral type earthquake-proofing device.
(3) Further, in the case of a disposition in which the restraining plates 13 rub each other and also in the case of a disposition in which they do not rub each other, it is possible to use highly damping rubber in order to provide a damping effect to the rubber-like body itself. Further, the rigidity and damping performance of the device can be adjusted at will according to the laminated state of the restraining plates 13. For these reasons, a damper-integral type earthquake-proofing device can be designed in a wide range of characteristics.
(4) The rubber-like body which is the load carrier 11 has high durability and high fire resistance since it is protected around its outer periphery and at its upper and lower portions by steel plates or the like.
(5) Since the amount of material used is small, the device is reduced in weight and is easy to transport.
A second embodiment of the invention will now be described with reference to FIGS. 5 through 9.
An earthquake-proofing device B according to the second embodiment, as shown in FIGS. 5 and 6, is the same as the first embodiment in that a restrainer 12 for restraining outward bulging is disposed around the periphery of a load carrier 11 using a columnar rubber-like body.
The feature of the second embodiment is that the restrainer 12 is constructed of a number of restraining wires 15 which are restraining members wound in laminate form around the load carrier 11 continuously in the direction of the height.
Used for the restraining wires 15 which are restraining members are PC steel wires or wire cords. The restraining wires 15, as shown in FIG. 7 which is a fragmentary enlarged view of the load carrier 11, are disposed in laminate form in the direction of the height and side by side in the horizontal direction. FIG. 8 shows how the restraining wires 15 are assembled. The restraining wires 15 may each be spirally wound so that they are continuous with each other, whereby the rigidity and damping performance of the earthquake-proofing device B can be adjusted at will and the earthquake-proofing device B can be constructed as a damper-integral type, as needed.
The restraining wires 15, as shown in FIG. 7, are protected by being externally covered with an elastic body 16, made of natural rubber or synthetic rubber, which is low in compression permanent strain. The elastic body 16 is integrated with the restraining wires 15 by vulcanization adhesion.
FIG. 9 shows an embodiment wherein groups of restraining wires 15 and an elastic body 16 are disposed in laminate form around a load carrier 11 alternately in the vertical direction.
When the earthquake-proofing device B arranged in the manner described above is used, fixing plates 17 adapted to be fixed to the superstructure and substructure, respectively, are joined to the upper and lower surfaces of the load carrier 11, as shown in FIG. 5.
Since the second embodiment, as described above, is constructed by singly using a rubber-like body as a load carrier and restraining the rubber-like body by a number of restraining wires 15 which are restraining members disposed therearound, the same effect as that of the first embodiment can be obtained.
In the first and second embodiments, when the restraining plates or wires are vertically independent, since vibration energy is absorbed by their frictional energy, the central rubber-like body may be of any kind, though it is preferable that the central rubber-like body has a highly damping property if the restraining plates or wires are fixed by a rubber-like elastic body which is low in compressive permanent strain.
A third embodiment of the invention will now be described with reference to FIGS. 10 through 17.
An earthquake-proofing device C according to the third embodiment of the invention is a developed form of the earthquake-proofing device A according to the first embodiment.
In the earthquake-proofing device A according to the first embodiment, in the case where a horizontal damping effect is provided by dynamic friction between the restraining plates 13 which are restraining members constituting the restrainer 12, vertical minor vibrations attended with noise are produced, a condition undesirable for an earthquake-proofing device. These vibrations become the more severe, the larger the difference between static and dynamic frictions. Thus, the third embodiment provides an arrangement capable of eliminating the vertical vibrations while effectively developing the damping effect due to friction.
First of all, the basic concept of the earthquake-proofing device C according to the third embodiment will be described below.
FIGS. 10 through 12 show three basic arrangement examples C 1 , C 2 and C 3 of the earthquake-proofing device C according to the third embodiment, the examples differing from each other in the construction of a restrainer 12 disposed in laminate form around a load carrier 11 using a columnar rubber-like body. In the case where the columnar rubber-like body which is a load carrier 11 centrally disposed for supporting a vertical load from a structure uses highly damping rubber, it is preferable that the latter be such that the loss (TAN δ) at -10°-40° C. under a dynamic strain of 0.5% at 0.5 Hz is in the range of 0.1-1.5. If the loss (TAN δ) exceeds 1.5, vertical vibration-proofness at above 10 Hz is degraded, while if it is less than 0.1, this does not contribute much to damping performance in a horizontal shear direction.
The respective constructions of the restrainers 12 in the basic arrangement examples C 1 , C 2 and C 3 will now be described in order.
The restrainer 12 in the first arrangement example C 1 shown in FIGS. 10(a) and (b) is in the form of a laminate wherein annular rubber-like elastic bodies 18 which are low in compressive permanent strain and annular restraining plates 19 of steel which are restraining members are fixed together face to face and laminated with anti-friction members 20 interposed therebetween. The term "fixing" includes plying, vulcanization adhesion, etc.
The restrainer 12 in the second arrangement example C 2 shown in FIGS. 11(a) and (b) is constructed such that annular restraining plates 22 of steel which are restraining members are fixed one by one to the front and back surfaces of annular rubber-like elastic plates 21 which are low in compression permanent strain to form assemblies of three-layer construction, which are then laminated with anti-friction members 20 interposed therebetween.
The restrainer 12 in the third arrangement example C 3 shown in FIGS. 12(a) and (b) is constructed such that annular rubber-like elastic plates 24 which are low in compression permanent strain are fixed one by one to the front and back surfaces of annular restraining plates 23 of steel which are restraining members to form assemblies of three-layer construction, which are then laminated with anti-friction members 20 interposed therebetween.
As for the restraining elastic plates 19, 22 and 23 which are restraining members, they have only to have high rigidity and high strength against breakdown, and materials other than steel may be used.
As for the rubber-like elastic plates 18, 21 and 24 which are low in compression permanent strain, any elastic material will do so long as it has the same properties as rubber. The amount of compression permanent strain desirable for causing the strainer 12 to develop its effective function is 35% or less, particularly 20% or less at 70° C.-22 HR heat treatment on the basis of JIS K6301.
As for the anti-friction members 20, any material may be used so long as it reduces the difference between static and dynamic frictions between restraining plates; for example, a member impregnated with such a resin low in friction coefficient as silicone grease or PTFE (Teflon lubricant is used. The mounting of these anti-friction members 20 is effected by applying them, through coating or covering, to the slide surfaces of rubber-like elastic plates or by fixing them to the slide surfaces, depending upon their properties.
In addition, the restrainer 12 is not limited to the above arrangement examples; what is essential is that rubber-like elastic plates having a spacer function are fixed to hard restraining plates which are restraining members and that these are laminated with anti-friction members interposed therebetween. For example, if the rubber-like body which is a load carrier 11 is prismatic, the planar shape of the restrainer 12 will be polygonal correspondingly thereto. Further, the restrainer 12 may be a laminate form constructed by spirally winding restraining plates having rubber-like elastic plate fixed thereto.
Manufacture examples embodying the basic arrangement examples of the third embodiment will be described with reference to FIGS. 13 and 14, and their characteristics will be explained.
An earthquake-proofing device 25 shown in FIG. 13 which is a first manufacture example of the third embodiment corresponds to the basic arrangement example C 1 previously described with reference to FIG. 10, and in which a columnar rubber-like body which is a load carrier 11 and a restrainer 12 which surrounds it are placed between and fixed to fixing plates 26 which are fixed to the superstructure and substructure.
The load carrier 11 using a rubber-like body has pressure receiving plates 27 embedded therein and bonded thereto on its opposite end surfaces, the material being natural rubber or isobutylene-isoprene rubber whose tan δ is about 0.3. The thickness ratio of the restraining plates 19 to rubber-like elastic plates 18 which constitute the restrainer 12 is 2:1, and silicone grease having a viscosity of 300,000 cSc (at 25° C.) or Teflon resin sheets are used as the anti-friction members 20.
An earthquake-proofing device 28 shown in FIG. 14 which is a second manufacture example of the third embodiment corresponds to the basic arrangement example C 2 previously described with reference to FIG. 11, and it differs from what is shown in FIG. 4 in that the restrainer 12 is formed by laminating three-layer assemblies each comprising two restraining plates 22 and a rubber-like elastic body 21 interposed therebetween. In addition, the thickness ratio of each restraining plate 22 to each rubber-like elastic plate 21 is 1:1.
Load-displacement curves obtained by measuring the first manufacture example shown in FIG. 13 are shown in FIGS. 15, 16 and 17. FIG. 15 shows characteristics where the material of the rubber-like body which is the load carrier 11 is natural rubber (NR) and where the anti-friction members 20 are in the form of silicone grease. FIG. 16 shows characteristics where the material of the rubber-like body which is the load carrier 11 is highly damping rubber (IIR) and where the anti-friction members 20 are in the form of silicone grease. FIG. 17 shows characteristics where the material of the rubber-like body which is the load carrier 11 is highly damping rubber and where the anti-friction members 20 are in the form of Teflon resin sheets. In addition, in the earthquake-proofing device 28 which is the second manufacture example, when the materials of the rubber-like body 11 and anti-friction members 20 are selected in the same manner as in the examples described above, the same characteristics as those described above were obtained. When these are compared with the load-displacement curve for the lead-laminated rubber bearing Y, it is seen that the rigidity with respect to slight displacement is low and that a vibration-proofing effect is developed for slight vibration. These comparisons in terms of numerical values are as shown in Table 1.
TABLE 1__________________________________________________________________________ Shear rigidity (amount of displacement) 0.5 HZ ± 100 0.5 HZ ± 2 Damping constant TON/cm TON/cm h (displacement ± 100__________________________________________________________________________ mm) First manufacture example (FIG. 15) 0.33 0.5 0.12 (silicone grease applied + NR parent body) First manufacture example (FIG. 16) 0.34 1.0 0.17 (silicone grease applied + IIR parent body) First manufacture example (FIG. 17) 0.33 0.7 0.11 (Teflon sheet stuck + IIR parent body) Comparative example (FIG. 28) 0.42 3.0 0.19 (lead-laminated rubber bering__________________________________________________________________________
That is, in the earthquake-proofing device C according to the third embodiment, the shear rigidity at 2-mm horizontal displacement is 1/3-1/6 of that in the lead-laminated rubber bearing Y, and it is seen that the device exerts good damping performance when encountering slight vibration. Further, in each example, the damping constant h, which is proportional to the area surrounded by the hysteresis curve, exceeds a value of 0.1 generally demanded of earthquake-proofing devices. Particularly, the manufacture example (FIG. 16) using both silicone grease and highly damping rubber provided good results, its value exceeding 0.17 because of addition of a damping action brought about by the viscosity of the silicone grease.
As for the vertical/shear (horizontal) rigidity ratio, kv/kh, which is a basic characteristic necessary to earthquake-proofness, a comparison between the manufacture example (FIG. 15) using natural rubber and silicone grease and the laminated rubber bearing X shown in FIG. 29 using natural rubber is shown in Table 2.
TABLE 2______________________________________ Vertical Shear rigidity rigidity K.sub.V K.sub.H Ratio TON/cm TON/cm K.sub.V /K.sub.H______________________________________1. Embodiment A 800 0.33 2400 (silicone grease applied + NR parent body)2. Comparative example 820 0.60 1370 (laminated rubber bearing)______________________________________
According to Table 2, the vertical load carrying capacities are approximately equal, and the third embodiment of the invention is lower in horizontal shear rigidity kh and its rigidity ratio kv/kh is about 2 times as high. From this, it can be said that the earthquake-proofing capacity is higher than that of the prior art.
From the above comparison based on the data shown in Tables 1 and 2, it has been clarified that the earthquake-proofing device C according to the third embodiment of the invention has performance equal to or greater than that of the conventional laminated rubber bearing.
A fourth embodiment of the invention will now be described with reference to FIGS. 18 through 25.
An earthquake-proofing device D according to the fourth embodiment of the invention is constructed such that in the case where highly damping rubber, such as isobutyl-isoprene rubber or Polynorbornene, is used for a rubber-like body used as a load carrier 11, the slow rate of restoration of the highly damping rubber is compensated by a restrainer 12, whereby the range of selection of highly damping rubbers is broadened.
First, a typical example of an earthquake-proofing device D according to the fourth embodiment will be referred to as a first construction example D 1 and described in detail.
In the first construction example D 1 , as shown in FIGS. 18(a) and (b), a load carrier 11 of highly damping rubber held between upper and lower pressure receiving plates 30 is inserted in a through-hole 31 vertically formed in a restrainer 12. The restrainer 12 is constructed by alternately sticking rubber-like elastic bodies 32 low in compression permanent strain and annular hard bodies 33 in the form of steel plates or the like which are restraining members and fixing them together in laminate form. In addition, the separate provision of annular pressure receiving plates 34 on the upper and lower surfaces of the restrainer 12 is in consideration of convenience of assembly, and the pressure receiving plates 34 may be integrated with the pressure receiving plates 30 in the form of rubber-like bodies.
A manufacture example d 1 of this first construction example D 1 will now be described with reference to FIGS. 19(a) and (b).
A columnar load carrier 11 using highly damping rubber is held between and fixed to pressure receiving plates 30. Rubber-like elastic bodies 32 in a restrainer 12 are joined at their inner surfaces to and integrated with the outer peripheral surface of the load carrier 11, while hard bodies 33 which are restraining members project only beyond the outer periphery of the restrainer 12.
For this highly damping rubber used for the load carrier 11, use is made of polynorbornene rubber having a tan δ of about 0.8 at a temperature of 25° C. and a frequency of 0.5 Hz, and for the rubber-like elastic bodies 32 low in compression permanent strain constituting the restrainer 12, use is made of natural rubber (NR).
A comparison of the characteristics obtained by example d 1 with those of the conventional laminated rubber bearing X shown in FIG. 29 and of the lead-laminated rubber bearing Y is shown in Table 3.
TABLE 3__________________________________________________________________________ Horizontal shear rigidity Vertical compression vertical load 35 TON rigidity Dynamic Dynamic static load 35 TON displacement ± displacement ± dynamic load ± 5 TON 5 mm 0.5 HZ 100 mm 0.5 HZ Damping constant 10 HZ TON/cm TON/cm at ± 100 mm, 0.5__________________________________________________________________________ HZManufacture example 320 TON/cm 0.44 0.27 0.13d.sub.1Comparative example 270 0.45 0.28 0.022Comparative example 520 1.15 0.50 0.15Y__________________________________________________________________________
In Table 3, a look at the damping performance shows that the damping constant of the earthquake-proofing device D according to the manufacture example d 1 is about 0.13, indicating higher damping performance than that of the laminated rubber bearing X which is a comparative example. This value exceeds a damping constant of 0.10, which is generally required, and is desirable for practical use.
Further, the initial rigidity during shear deformation against slight vibration, which has been a problem inherent in the lead-laminated rubber bearing, is reduced to as low a value as 0.44 in contrast to 1.15 TON/cm provided by the comparative example Y; thus, it is seen that the vibration-proofing characteristic against slight vibration is improved to a great extent.
In addition, in order to check the durability of the highly damping rubber used for the load carrier 11, the earthquake-proofing device D 1 according to the manufacture example d 1 of the fourth embodiment shown in FIG. 19 was subjected to 360 times of deformation under conditions including a frequency of 0.2 Hz and an amplitude of +107 mm, and then the highly damping rubber which was the load carrier 11 was taken out of the restrainer 12 and its surface condition was observed but there was found no change on its surface as compared with what it was before the test.
Besides this, the earthquake-proofing device D of the fourth embodiment has many construction examples, which will be described in order.
Constructions where the highly damping rubber which is a load carrier 11 is vertically extended through the restrainer 12, as in the case of the first construction example D 1 shown in FIG. 18, include a second construction example D 2 shown in FIGS. 20(a) and (b) and a third construction example D 3 shown in FIGS. 21(a) and (b).
These construction examples show that a plurality of highly damping rubber bodies may be inserted as load carriers 11 and that they may take any shape, such as cylinders and prisms.
As for an arrangement in which a plurality of highly damping rubber bodies serving as load carriers 11 are disposed as they are vertically completely divided, there are a fourth construction example D 4 shown in FIGS. 22(a) and (b) and a fifth construction example D 5 shown in FIG. 23. These construction examples D 4 and D 5 use unapertured hard bodies 33a as restraining members, thereby vertically completely dividing the highly damping rubber which is a load carrier 11. The fourth construction example D 4 uses a plurality of highly damping rubber bodies in the form of flat plates as load carriers 11. The fifth construction example D 5 uses a restrainer 12 in the form of a quadrangular prism and four cylindrical highly damping rubber bodies serving as load carriers 11 disposed in each plane. As for an arrangement in which vertically spaced partitions for the load carriers 11 are separate from the hard bodies 33b which are restraining members and are provided by partition plates 33c embedded in the highly damping rubber, there are sixth construction example D 6 shown in FIGS. 24(a) and (b) and a seventh construction example D 7 shown in FIGS. 25(a) and (b). The differences between the sixth and seventh construction examples are in whether the shape is cylindrical or quadrangularly prismatic and in whether the partition plates 33c are at the same levels as the hard bodies 33b which are restraining members or they are disposed at alternate levels. Further, these sixth and seventh construction examples D 6 and D 7 differ from the first through fifth construction examples D 1 through D 5 in that the hard bodies 33b are completely embedded in the restrainer 12.
The first through seventh construction examples D 1 through D 7 which are the fourth embodiment of the invention have so far been described, but it is to be pointed out that the fourth embodiment can be implemented in a wide variety of constructions by combining, in different ways, the features of the various parts appearing in the above construction examples.
For example, in the first through fifth construction examples, the hard bodies 33 and 33a which are restraining members project beyond the restrainer 12, and, in contrast, in the sixth and seventh construction examples they are completely embedded; each of the forms my be employed in the respective construction examples.
In addition, in the fourth embodiment, for example, the desirable amount of compression permanent strain of the rubber-like elastic body 32 used in the restrainer 12 is 35% or less at 70° C.-22HR heat treatment based on JIS-K6301, this value being necessary to impart an appropriate restoring force to the restrainer 12. Particularly, 20% or less provides good results.
As for highly damping rubbers used in load carriers 11, those are preferable whose loss (TAN δ) at 0.5 Hz and at a dynamic strain of 0.5% ranges from 01. to 1.5. The reason is that if the loss (TAN δ) exceeds 1.5, the vertical vibration-proofness at 10 Hz and more is degraded and that if it is less than 0.1, this does not contribute so much to improving damping performance in the horizontal shear direction.
The earthquake-proofing device D of the fourth embodiment has its restrainer 12 integrated and its load carrier 11 made uniform throughout the peripheral surface and elastically restrained in a stabilized state, so that the device is characterized in that highly damping rubber high in compression permanent strain can be used in a stabilized state free from creep phenomena and in that a suitable horizontal restoring force can be imparted to the earthquake-proofing device by the elastic force of the restrainer 12.
The earthquake-proofing device D of the fourth embodiment of the invention essentially differs in mechanism from the conventional lead-laminated rubber bearing Y shown in FIG. 30 in that the vertical load is mostly supported by the highly damping rubber which is the load carrier 11 and in that energy absorption is effected mainly by intermolecular friction in the highly damping rubber. In the lead-laminated rubber bearing Y, the vertical load is supported by the peripherally disposed laminate of steel plates and thin rubber plates and energy absorption is effected by plastic deformation of the lead.
A fifth embodiment of the invention will now be described with reference to FIGS. 26 through 28.
An earthquake-proofing device E according to the fifth embodiment uses viscous fluid as a load carrier 11, wherein high vertical rigidity is imparted to the viscous fluid by restraining outward bulging while a restoring force associated with horizontal deformation is imparted to a rubber-like elastic body which is low in compression permanent strain and which constitutes the restrainer. And a damping action is provided mainly by intermolecular friction in the viscous fluid.
Typical forms of the earthquake-proofing device E of peripherally restrained type according to the fifth embodiment will now be described in order as first through third arrangement examples.
A first arrangement example, as shown in FIGS. 26(a) and (b), has viscous fluid, which is a load carrier 11, enclosed in a cavity 35 defined vertically of a cylindrical restrainer 12 with said viscous fluid placed between upper and lower pressure receiving plates 36. In addition, to ensure perfection of enclosure of the viscous fluid which is a load carrier 11, an elastic bag 37 is used and fixed in position by using bag fixing plates 38. This restrainer 12 is in the form of a laminate formed by fixing, as by vulcanization adhesion or sticking, a rubber-like elastic body 39 low in compression permanent strain and annular or spiral hard restraining members 40. Wires, such as steel wires, may be employed as restraining members. In addition, annular pressure receiving plates 41 are provided on the upper and lower surfaces of the restrainer 12 in consideration of convenience of assembly; said pressure receiving plates 41 may be integrated with the receiving plates 36 for the viscous fluid.
A second arrangement example of the earthquake-proofing device E of peripherally restrained type according to the fifth embodiment of the invention will now be described.
A second arrangement example shown in FIGS. 27(a) and (b) is a modification of the embodiment shown in FIGS. 26(a) and (b), wherein a plurality of viscous fluid shear resistance plates 42 are disposed in parallel to each other to control the flow of the viscous fluid so as to improve damping effect. The viscous fluid shear resistance plates 42 are connected together by a rubber-like elastic body 43 with a predetermined spacing defined between adjacent plates and are supported by a bag fixing flange 38. This embodiment enables the shear resistance force of the viscous fluid shear resistance plates to be effectively transmitted to the upper and lower pressure receiving plates 42 through the rubber-like elastic body 43, thus maintaining the clearances of the viscous fluid shear resistance plates 42 at a constant value to improve the damping effect.
A third arrangement example of the earthquake-proofing device E of peripherally restrained type according to the fifth embodiment of the invention is shown in FIGS. 28(a), (b) and (c). The third arrangement example shows that viscous fluid which is a load carrier 11 may be enclosed in a plurality of chambers and that the viscous fluid shear resistance plates 42 may be integrated with the hard restraining members 40. This third arrangement example has viscous fluid, which is a load carrier 11, enclosed directly in a restrainer 12. This is because if the cavity 35 in the restrainer 12 is made sealable, then the elastic bag 37 is not absolutely necessary.
In addition, in the third arrangement example, outer plates 44 adapted to be joined to a structure and a foundation are fitted on pressure receiving plates 36. The upper pressure receiving plate 36 is formed with enclosing holes 45 for enclosing the viscous fluid which is a load carrier 11. The enclosing holes 45 are closed by bolts 46 screwed thereinto. Further, each viscous fluid shear resistance plate 42 is formed with an unillustrated through-hole to make it possible to inject viscous fluid which is to become a load carrier 11. The arrangement of this third arrangement example is based on the same concept of the second arrangement example. That is, the viscous fluid is sealed in and moreover the viscous fluid shear resistance plates 42 are installed with a small spacing y defined therebetween to enhance the intermolecular motion so as to improve the damping effect. This construction is characterized in that the smaller the spacing y, the greater the damping effect corresponding to the velocity gradient dv/dy between the viscous fluid shear resistance plates 42.
So far, the first through third arrangement examples of the earthquake-proofing device E which is the fifth embodiment have been described, but it is to be pointed out that the fifth embodiment can be implemented in a wide variety of constructions besides the above-described arrangement examples by combining, in different ways, the features of the various parts appearing in the first through third arrangement examples.
For example, in the first and second arrangement examples, the hard restraining members 40 are completely embedded in the restrainer 12, and, in contrast, in the third arrangement example, they project; each of the forms may be employed in the respective embodiments.
In addition, the desirable amount of compression permanent strain of the rubber-like elastic body 39 used in the strainer 12 is 35% or less at 70° C.-22HR heat treatment based on JIS-K6301, this value being necessary to impart an appropriate restoring force to the restrainer 12. Particularly, 20% or less provides good results.
Further, the greater the dynamic viscosity of the viscous fluid used as a load carrier 11, the higher the damping effect, but a viscous fluid having 1,000 st-100,000 st is preferable as it provides suitable damping performance.
INDUSTRIAL APPLICABILITY
The earthquake-proofing device of the present invention uses a non-laminated elastic body, visco-elastic body or viscous body to develop high vertical load support performance, making it possible to eliminate the drawbacks of conventional laminated rubber bearings, and supersedes the latter.
Particularly, since the earthquake-proofing device of the invention does not use a material having high initial rigidity, such as lead, it also has a vibration-proofing property for slight vibration and offers a wide range of selection of restrainers and load carriers, making it possible to design characteristics in a wide range, as desired. Therefore, the invention is suitable for earthquake- and vibration-proofing buildings; for earthquake- and vibration-proofing floors, and for earthquake- and vibration-proofing power transmission equipment and general equipment as well. | The present invention relates to an earthquake-proofing device wherein a superstructure is placed and supported for horizontal movement on a foundation structure so as to increase the natural vibration period of the superstructure, thereby protecting the superstructure against earthquake energy and traffic vibration. More particularly, the outer periphery of an elastic body, visco-elastic body or viscous body which hardly exhibits rigidity by itself is surrounded by a restrainer which restrains it from bulging outward, thereby enabling the body to develop high vertical rigidity while allowing it to retain horizontal deformability, the body being used as a load carrier. The restrainer and/or load carrier absorbs vibration energy by frictional damping action. According to this construction, besides the above-described basic performance essential to earthquake-proofing devices, there are the following advantages: (1) The points of action of the restoring force and damping force coincide with each other, so that the structure is protected against unnecessary torsional vibration; (2) the range of selection of materials for the load carrier is wide, so that characteristics can be designed in a wide range as desired; and (3). The initial shear rigidity at the start of vibration is so low that the structure can also be protected against slight vibration. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of Korean Patent Application No. 2003-89777, filed Dec. 10, 2003 in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates, in general, to a cooking apparatus and, more particularly, to a cooking apparatus that includes a magnetron to generate microwaves and convection modules to supply hot air into a cooking cavity.
[0004] 2. Description of the Related Art
[0005] A cooking apparatus disclosed in Japanese Unexamined Pat. Publication No. 8-247473 includes a body in which an inner casing forming a cooking cavity is placed inside an outer casing. An open front of the cooking cavity is selectively opened and closed by a door, and an air-blowing chamber is recessed behind the cooking cavity in the inner casing. A convection fan to compulsorily circulate air in the cooking cavity and a heater to heat the circulated air are placed in the air-blowing chamber. A cover is placed in front of the convection fan and the heater, that is, in front of the air-blowing chamber.
[0006] However, since the conventional cooking apparatus has a structure, in which hot air which is discharged through a hot air outlet formed at a back of the cooking cavity, is blown onto food placed on a food rack in the cooking cavity, and the hot air concentrically heats a specific portion of the food, so that the specific portion of the food is overcooked or burned, and a portion of the food opposite to the specific portion is left uncooked, thus the food is not uniformly cooked.
SUMMARY OF THE INVENTION
[0007] Accordingly, an aspect of the present invention provides a cooking apparatus that allows a temperature distribution of hot air to be uniform in a cooking cavity. As a result, food in the cooking cavity is uniformly cooked. The present invention also enables initial heating of air in the cooking cavity to be rapidly accomplished so that a cooking time is reduced.
[0008] Additional and/or other aspects and advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
[0009] The above and/or other aspects are achieved by providing a cooking apparatus, including a cooking cavity, and first and second convection modules. The cooking cavity cooks food contained therein. The first convection module heats air in the cooking cavity and then circulates the heated air. The second convection module is placed opposite to the first convection module to heat the air in the cooking cavity and then circulate the heated air.
[0010] The above and/or other aspects are achieved by providing a cooking apparatus, including a cooking cavity, and first and second convection modules. The cooking cavity cooks food contained therein. The first convection module heats air in the cooking cavity and circulates the heated air. The second convection module is opposite to the first convection module and is vertically offset from the first convection module to heat the air and then circulate the heated air.
[0011] The above and/or other aspects are achieved by providing a cooking apparatus, including a cooking cavity, and first and second convection modules. The cooking cavity cooks food contained therein. The first convection module heats air in the cooking cavity and circulates the heated air. The second convection module is opposite to the first convection module and is horizontally offset from the first convection module so as to heat the air and then circulate the heated air.
[0012] The above and/or other aspects are achieved by providing a method of controlling a cooking apparatus, including heating air in a cooking cavity and circulating the heated air using first and second convection modules in a convection-cooking mode, and stopping the first and second convection modules if a predetermined first cooking time has elapsed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] These and/or other aspects and advantages of the invention will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings, of which:
[0014] FIGS. 1 to 3 are views showing constructions of cooking apparatuses, according to embodiments of the present invention;
[0015] FIG. 4 is a block diagram showing a control system of a cooking apparatus of the present invention; and
[0016] FIGS. 5 to 7 are flowcharts showing methods of controlling the cooking apparatus, according to embodiments of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] Reference will now be made in detail to the embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below to explain the present invention by referring to the figures.
[0018] Cooking apparatuses and methods of controlling the cooking apparatuses according to embodiments of the present invention are described with reference to FIGS. 1 to 6 below. FIGS. 1 to 3 are cross sections showing constructions of convection microwave ovens according to embodiments of the present invention. FIG. 1 is a cross section showing a convection microwave oven 100 of the present invention, in which first and second convection modules 102 and 104 located on both sides of a cooking cavity 114 , respectively, to be opposite to each other.
[0019] As shown in FIG. 1 , the first convection module 102 includes a first convection fan 102 a, a first fan motor 102 c to operate the first convection fan 102 a, and a first heater 102 b to heat circulated air. The first convection fan 102 a is a centrifugal fan, so that, when the first convection fan 102 a rotates, air in the cooking cavity 114 is drawn through a center portion of the convection fan 102 a and air heated by the first heater 102 b is discharged through an outer portion of the convection fan 102 a. A first cover member 106 is provided between the first convection module 102 and the cooking cavity 114 . An air inlet 106 a is formed along a center portion of the first cover member 106 to draw air from the cooking cavity 114 , and a hot air outlet 106 b is formed along an outer portion of the first cover member 106 to discharge hot air.
[0020] Accordingly, when the first convection module 102 is operated, air is drawn from the cooking cavity 114 to the center portion of the first convection fan 102 a, heated by the first heater 102 b, and then supplied back into the cooking cavity 114 through the outer portion of the first convection fan 102 a. In other words convection of the hot air, in which the air is drawn into the center portion of the first cover member 106 and the hot air is discharged from the outer portion of the first cover member 106 , as indicated by arrows in a left side of FIG. 1 , is performed.
[0021] The second convection module 104 includes a second convection fan 104 a, a second fan motor 104 c to operate the second convection fan 104 a, and a second heater 104 b to heat circulated air. The second convection fan 104 a is an axial-flow fan, so that, when the second convection fan 104 a rotates, air in the cooking cavity 114 is drawn through an outer portion of the second convection fan 104 a, and air heated by the heater 104 b is discharged through a center portion of the second convection fan 104 a. That is, the first and second convection fans 102 a and 104 a have opposite draw and discharge directions. A second cover member 108 is provided between the second convection module 104 and the cooking cavity 114 . An air inlet 108 b is formed along an outer portion of the second cover member 108 to draw the air from the cooking cavity 114 , and a hot air outlet 108 a is formed along a center portion of the second cover member 108 to discharge heated air.
[0022] Accordingly, when the second convection module 104 is operated, the air in the cooking cavity 114 is drawn through an outer portion of the second convection fan 104 a, heated by the heater 104 b, and then supplied back into the cooking cavity 114 through a center portion of the second convection fan 104 a. Convection of the hot air, in which the air is drawn into the outer portion of the second cover member 108 and the hot air is discharged from the center portion of the second cover member 108 , as indicated by arrows in a left side of FIG. 1 , is performed.
[0023] If the first and second convection modules 102 and 104 are both operated, the first convection module 102 draws air from a center part of the cooking cavity 114 , heats the air, and then discharges the heated air to front, back, upper, and lower parts of the cooking cavity 114 . The second convection module 104 draws in the heated air, which was discharged into the outer parts of the cooking cavity 114 , heats the drawn air again, and then discharges the heated air to the center part of the cooking cavity 114 .
[0024] Similarly, heated air, which was discharged from the second convection module 104 into the center part of the cooking cavity 114 , is drawn back into the first convection module by the first convection module 102 . The redrawn air is reheated and then discharged. Supplementary draws and discharges of the first and second convection modules 102 and 104 allow the convection of the hot air to be effectively performed all through the cooking cavity 114 , to distribute temperature uniformly throughout the cooking cavity 114 . As a result, hot air with a uniform temperature distribution is applied to the entire food, thereby uniformly cooking the entire food.
[0025] FIG. 2 is a cross section showing a convection microwave oven 200 , according to another embodiment of the present invention, which shows a cross section of the convection microwave oven 200 in which first and second convection modules 202 and 204 are provided on both sides of a cooking cavity 214 at, respectively, different heights. As shown in FIG. 2 , the first convection module 202 includes a first convection fan 202 a, a first fan motor 202 c to operate the first convection fan 202 a and a first heater 202 b to heat circulated air. The first convection module 202 is provided on a lower part of a first side of the cooking cavity 214 . The first convection fan 202 a is a centrifugal fan, so that, when the first convection fan 202 a rotates, a center portion of the first convection fan 202 a draws air from the cooking cavity 214 , and an outer portion of the cooking cavity 214 discharges air heated by the first heater 202 b. A first cover member 206 is provided between the first convection module 202 and the cooking cavity 214 . An air inlet 206 a is formed in a center portion of the first cover member 206 to draw air, and a hot air outlet 206 b is formed along an outer portion of the first cover member 206 to discharge the heated air.
[0026] Accordingly, when the first convection module 202 is operated, the air in the cooking cavity 214 is drawn through the center portion of the first convection fan 202 a, heated by the first heater 202 b, and then supplied back into the cooking cavity 214 through the outer portion of the first convection fan 202 a. In other words, convection of the hot air in which the air is drawn into the center portion of the first cover member 206 and the hot air is discharged from the outer portion of the first cover member 206 , as indicated by arrows in a left side of FIG. 2 , is performed.
[0027] A second convection module 204 includes a second convection fan 204 b, a second fan motor 204 c to operate the second convection fan 204 a, and a second heater 204 b to heat circulated air. The second convection module 204 is provided on an upper part of a second side of the cooking cavity 214 to be opposite to the first convection module 202 . The second convection module 204 is placed on the second side of the cooking cavity 214 at a height higher than that of the first convection module 202 . The height of the second convection module 204 is such that a height of a lower part of the second hot air outlet 208 b of a second cover member 208 is similar to that of the first air inlet 206 a formed in a center portion of the first cover member 206 . The second convection fan 204 a is also a centrifugal fan, so that, when the second convection fan 204 a rotates, air in the cooking cavity 214 is drawn through a center portion of the second convection fan 204 a, and the air heated by the second heater 204 is discharged through an outer portion of the second convection fan 204 a. That is, the first and second convection fans 202 a and 204 a have opposite draw and discharge directions. The second cover member 208 is provided between the second convection module 204 and the cooking cavity 214 . An air inlet 208 a is formed along a center portion of the second cover member 208 to draw air in the cooking cavity 214 , and a hot air outlet 208 b is formed along an outer portion of the second cover member 208 to discharge the heated air.
[0028] Accordingly, when the second convection module 204 is operated, the air in the cooking cavity 214 is drawn through the center portion of the second convection fan 204 a, heated by the second heater 204 b, and then directed back into the cooking cavity 214 through the outer portion of the second convection fan 204 a. As a result, convection of the hot air, in which the air is drawn into the center portion of the second cover member 208 and the hot air is discharged from the outer portion of the second cover member 208 , as indicated by arrows in a right side of FIG. 2 , is performed.
[0029] If the first and second convection modules 202 and 204 are operated simultaneously, the first convection module 202 draws air from the cooking cavity 214 , heats the air, and discharges the heated air into an upper half of the cooking cavity 214 . As with the first convection module 202 , the second convection module 204 draws air through the center portion of the second convection module 204 and discharges hot air through the outer portion of the second convection module 204 Therefore, the second convection module 204 draws air into the second convection module, heats the drawn air, and then discharges the heated air into a lower half of the cooking cavity 214 . Although the first and second convection modules 202 and 204 draw and discharge air in opposite directions, a lower part of the second hot air outlet 208 b of the second convection module 204 and the first air inlet 206 a formed in the center portion of the second cover member 206 are located at equal heights. Thus, the second convection module 204 draws hot air, which was discharged back into the cooking cavity 214 , through the first convection module 202 , reheats the drawn air, and then discharges the heated air.
[0030] As described above, the first and second convection modules 202 and 204 are located at different heights, but the air inlets and hot air outlets of the first and second convection modules 202 and 204 are partially overlapped. Accordingly, convection of the hot air in the cooking cavity 214 is effectively performed, and a temperature distribution in the cooking cavity 214 is made uniform. As a result, hot air with a uniform temperature distribution is applied to the entire food in the cooking cavity 214 , so that entire food is uniformly cooked.
[0031] FIG. 3 is a transverse section showing a convection microwave oven 300 , according to still another embodiment of the present invention, in which first and second convection modules 302 and 304 are provided on both sides of a cooking cavity 314 , respectively, at substantially similar heights. However, the first convection module 302 is provided on a front portion of a first side of the cooking cavity 314 , and the second convection module 304 is provided on a back portion of a second side of the cooking cavity 314 . That is, locations of an air inlet 306 a and a hot air outlet 306 b of the first convection module 302 are offset from locations of an air inlet 308 a and a hot air outlet 308 b of the second convection module 304 . However, the air inlet and the hot air outlet 306 a and 306 b are partially overlapped, so that convection of the hot air in the cooking cavity 314 is effectively performed and a temperature distribution in the cooking cavity 314 is made uniform. As a result, the hot air with a uniform temperature distribution is applied to entire food in the cooking cavity 314 uniformly cook the entire food.
[0032] FIG. 4 is a block diagram showing a control system of a convection microwave oven 100 , according to an embodiment of the present invention. As shown in FIG. 4 , an input 404 , to input a cooking mode or a set value for cooking, is connected to an input terminal of a controller to control an overall operation of the convection microwave oven 100 . A magnetron driver 406 , a tray motor driver 408 , and first and second convection module drivers 410 and 412 are connected to an output terminal of the controller 402 to operate a magnetron 110 , a tray motor 112 , and first and second convection modules 102 and 104 , respectively.
[0033] FIGS. 5 to 7 are flowcharts showing methods of controlling a cooking apparatus, according to embodiments of the present invention.
[0034] FIG. 5 is a flowchart showing a method of controlling a convection-cooking mode using only the first and second convection modules 102 and 104 . As shown in FIG. 5 , when a user selects the convection-cooking mode in operation 502 , the first and second convection modules 102 and 104 are operated simultaneously in operation 504 . Food is cooked by hot air generated by the first and second convection modules 102 and 104 . If a predetermined cooking time has elapsed in operation 506 , the first and second convection modules 102 and 104 are stopped. Thus, the convection-cooking mode ends in operation 508 . Since the first and second convection modules 102 and 104 are operated simultaneously, a smooth convection of hot air is performed in the cooking cavity 114 , and a temperature of the air is rapidly increased.
[0035] FIG. 6 is a flowchart showing a method of controlling a complex cooking mode using the first and second convection modules 102 and 104 and the magnetron 110 . As shown in FIG. 6 , when a convection-cooking mode is selected by a user in operation 602 , the first and second convection modules 102 and 104 are all operated in operation 604 . Food is cooked by hot air generated by the first and second convection modules 102 and 104 . If a predetermined cooking time (that is, cooking time based on only convection) has elapsed in operation 606 , one (for example, the second convection module 104 ) of the first and second convection modules 102 and 104 is stopped in operation 608 . The magnetron 110 is operated while the first convection module 102 is continuously operated, so as to perform complex cooking using convection and microwaves in operation 610 . If a predetermined second cooking time to perform the complex cooking has elapsed in operation 612 , the first convection module 102 and the magnetron 110 are both stopped. Thus, the convection-cooking mode ends in operation 614 .
[0036] FIG. 7 is a flowchart showing a method of controlling a cooking mode using the first and second convection modules 102 and 104 , including alternately operating the first and second convection modules 102 and 104 rather than operating the first and second convection modules 102 and 104 simultaneously. As shown in FIG. 7 , when a convection-cooking mode is selected by a user in operation 702 , the first and second convection modules 102 and 104 are alternately operated in operation 704 . That is, the first and second convection modules 102 and 104 are operated in an alternate manner. Food is cooked by hot air, which is generated by alternately operating the first and second convection modules 102 and 104 . If a predetermined cooking time has elapsed in operation 706 , the first and second convection modules 102 and 104 are both stopped, and thus the convection-cooking mode ends in operation 708 . A heating speed of the air in the cooking cavity 114 may be controlled by alternately operating the first and second convection modules 102 and 104 , as described above. Since the cooking apparatus of the present invention generates convection of hot air in a cooking cavity using two convection modules, a temperature distribution in the cooking cavity is uniformly maintained, so that the food may have a uniform cooking quality.
[0037] Furthermore, since the hot air is generated by using the two convection modules, a heating speed of air surrounding the food is improved, one or all of convection modules may be operated according to need, and the two convection modules may be alternately operated according to need, so that a temperature of the hot air may be controlled even though a heating temperature of a heater is fixed.
[0038] This invention may be understood to include alternate configurations of first and second modules which have not been explicitly discussed above. With regard to these additional configurations, the modules may be placed at various positions in the cooking cavity as long as a first module discharges air into a convenient area of the cooking cavity for a second module to draw the discharged air in. Similarly, the second module should be positioned so as to discharge air in an area of the cooking cavity that is convenient for the first module to draw the air, which the first module originally discharged, back in.
[0039] Furthermore, this invention may be understood to include additional modules beyond first and second modules. In such a case, additional modules would be in convenient draw and discharge positions relative to the first and second modules as well as with respect to any other additional modules.
[0040] Although a few embodiments of the present invention have been shown and described, it would be appreciated by those skilled in the art that changes may be made in this embodiment without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents. | A cooking apparatus and a method of controlling the cooking apparatus allow a temperature distribution of hot air to be uniform in a cooking cavity so that food in the cooking cavity is uniformly cooked, and enables initial heating of the air in the cooking cavity to be rapidly accomplished so that a cooking time is reduced. The cooking apparatus includes a cooking cavity, and first and second convection modules. The cooking cavity cooks food contained therein. The first convection module heats air in the cooking cavity and circulates the heated air. The second convection module is placed to be opposite to the first convection module so as to heat the air and circulate the heated air. | 5 |
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